CNH LS Series L3AL L3BL Tier 3 Engine Service Manual 47731080 - PDF DOWNLOAD

SERVICE MANUAL LS Series L3AL / L3BL Tier 3 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 47731080 English August 2015 Replaces part number 47528913

SERVICE MANUAL L3AL L3BL

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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 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

Electrical systems ....................................................................... 55 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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INTRODUCTION

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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INTRODUCTION

Foreword This publication contains data, features instructions and methods for performing repair operations on the assembly and its components and is addressed to qualified, specialized personnel.

Check to make sure you have the right publication related to the component you are about to work on before you start.

Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.

Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to ensure correct repair procedures and safety of operators.

NOTE: This manual applies to multiple applications, therefore images may not all be accurate.

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

In case of questions, refer to your CNH Industrial 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 Industrial strongly recommends that you return all used batteries to a CNH Industrial 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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SERVICE MANUAL Engine L3AL L3BL

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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 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

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Engine - 10 Engine and crankcase - 001

L3AL L3BL

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Crankcase Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FUNCTIONAL DATA Engine and crankcase Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dynamic description ventillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE Engine and crankcase Check cylinder bores (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check cylinder bores (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47731080 04/08/2015

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Engine - Engine and crankcase

Engine - General specification L3AL

Engine model Number of cylinders Bore x stroke Displacement Compression ratio Engine speed (Low idle no load) Engine speed (High idle no load) PTO engine horsepower Firing order Cylinder arrangement Valve arrangement Compression pressure at 150 RPM (cylinder speed) to 200 RPM Minimum compression pressure at 150 RPM (cylinder speed) to 200 RPM Variation between cylinders

L3AL 3 90 mm x 105 mm ( 3.54 in x 4.13 in) 2003 cm³ (122 in³) 810 - 850 RPM 2790 - 2830 RPM 28 kW (38 Hp) 1-3-2 In-Line vertical Overhead 2940 kPa (426 psi) 2550 kPa (370 psi) 345 kPa (50 psi)

Engine - General specification L3BL

Engine specifications Engine model Number of cylinders Bore x stroke Displacement Compression ratio Engine speed (Low idle no load) Engine speed (High idle no load) PTO engine horsepower Firing order Cylinder arrangement Valve arrangement Compression pressure at 150 RPM (cylinder speed) to 200 RPM Minimum compression pressure at 150 RPM (cylinder speed) to 200 RPM Variation between cylinders

L3BL 3 88 mm x 105 mm ( 3.5 in x 4.13 in) 1915 cm³ (117 in³) 810 - 850 RPM 2790 - 2830 RPM 24 kW (33 Hp) 1-3-2 In-Line vertical Overhead 2940 kPa (426 psi) 2550 kPa (370 psi) 345 kPa (50 psi)

Engine - Torque Component Cylinder head bolts Rocker cover bolts Rocker arm assembly (Long bolts) Rocker arm assembly (Short bolts) Main bearing retaining bolts Connecting rod cap bolts Flywheel retaining bolts Camshaft thrust plate Crankshaft main bearing bolts Front end plate

Bolt size and thread M12 x 1.75 M8 x 1.25 M8 x 1.25 x 62 M8 x 1.25 x 25 M12 x 1.75 M10 x 1 M12 x 1.25 M8 x 1.25 M12 x 1.75 M8 x 1.25

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Torque 113 - 123 N·m (83 - 91 lb ft) 11 - 14 N·m (8 - 10 lb ft) 13 - 0.0 N·m (10 - 12.4 lb ft) 11 - 13 N·m (8 - 9 lb ft) 77 - 88 N·m (57 - 65 lb ft) 49 - 60 N·m (36 - 44 lb ft) 77 - 88 N·m (57 - 65 lb ft) 11 - 14 N·m (8 - 10 lb ft) 77 - 88 N·m (57 - 65 lb ft) 11 - 14 N·m (8 - 10 lb ft)

Engine - Engine and crankcase

Component Engine rear mounting plate Engine timing gear case and cover Crankshaft pulley nut Rear housing Oil pan Oil pan drain plug Oil filter shaft Cooling fan bolts Fuel injection nozzle Fuel leak - off pipe Fuel injection gear pump (distributor type) “B” terminal of the starter Glow plug (body terminal) Pressure relief valve Coolant drain plug Fuel injection pipe Fuel return pipe Oil pump set bolt Overheat warning unit (thermo switch) Drain plug

Bolt size and thread M10 x 1.25 M8 x 1.25 x 50 M8 x 1.25 x 55 M24 x 1.25 M10 x 1.25 M8 x 1.25 M14 x 1.5 M20 x 1.5 M8 x 1.25 x 104 M20 x 1.5 M12 x 1.5 M14 x 1.5 M8 x 1.25 M10 x 1.25 M4 x 0.7

Torque 31 - 37 N·m (23 - 27 lb ft) 11 - 14 N·m (8 - 10 lb ft) 382 - 401 N·m (282 - 296 lb ft) 54 - 66 N·m (40 - 48 lb ft) 15 - 0.0 N·m (11 - 13 lb ft) 35 - 43 N·m (26 - 32 lb ft) 43 - 54 N·m (32 - 40 lb ft) 9 - 13 N·m (7 - 9 lb ft) 53 - 64 N·m (39 - 47 lb ft) 22 - 24 N·m (16 - 18 lb ft) 76 - 87 N·m (56 - 64 lb ft) 11 - 12 N·m (8 - 9 lb ft) 16 - 19 N·m (12 - 14 lb ft) 4 - 5 N (1 - 1 lb) 43 - 54 N·m (32 - 40 lb ft) 35 - 43 N·m (26 - 32 lb ft) 27 - 33 N·m (20 - 24 lb ft) 18 - 20 N·m (13 - 15 lb ft) 30 - 0.0 N·m (22 - 28 lb ft)

M22 x 1.5 M12 x 1.5 M10 x 1.25 M12 x 1.75 M16 x 1.5

2 - 2 N·m (16 - 18 lb in)

M16 x 1.5

39 - 50 N·m (29 - 37 lb ft)

Engine - Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

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

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

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

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

CLASS 10.9 BOLT and CLASS 10 NUT

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

LOCKNUT CL.10 W/CL10.9 BOLT

PLATED W/ZnCr

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

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

Engine - Engine and crankcase

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

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Engine - Engine and crankcase

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

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

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

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

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

CLASS 10.9 BOLT and CLASS 10 NUT

57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

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

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

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(1) Manufacturer's Identification (2) Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

LOCKNUT CL.10 W/CL10.9 BOLT

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

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

PLATED W/ZnCr

UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in)

LOCKNUT CL.8 W/CL8.8 BOLT

2

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37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb 226 N·m (167 lb ft) ft) 318 N·m (235 lb 440 N·m (325 lb ft) ft) 552 N·m (407 lb ft)

Engine - Engine and crankcase

(1) Manufacturer's Identification (2) Property Class (3) Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

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

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 30 N·m (22 lb 43 N·m (31 lb 57 N·m (42 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)

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

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)

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

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Engine - Engine and crankcase

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

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

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

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

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

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Engine - Engine and crankcase

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

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

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

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

Engine - Special tools Tool number

Description Injector tester Adapter - Compression tester Injector adapter set Compression test gauge assembly Injector cleaning kit Oil pressure test fitting Seal installer set 0 - 25 mm (0 - 1 in) 25 - 51 mm (1 - 2 in) 76.2 - 101.6 mm (3 - 4 in) 19 - 25 mm (0.75 - 1 in) 76.2 - 101.6 mm (3 - 4 in) 25 - 51 mm (1 - 2 in)

OEM1064 FNH00120 FNH01728 OEM1074 FNH01720 FNH00011 294165 Micrometer, outside Micrometer, outside Micrometer, outside Small hole gauge Cylinder bore gauge Cylinder bore gauge

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Engine - Engine and crankcase

Crankcase - Dimension Bore Standard

84 - 84.019 mm (3.3071 - 3.3078 in) Head surface warp

Standard Maximum

0.05 mm (0.002 in) 0.20 mm (0.0079 in)

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Engine - Engine and crankcase

Engine and crankcase - Component localization

NHIL14ENG0184FA

1

Left side components (1) Water pump (2) Water temperature sensor (3) Exhaust manifold

(4) Engine number (5) Oil filter (6) Starter solenoid

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(7) Starter motor (8) Alternator (9) Crankshaft pulley

Engine - Engine and crankcase

NHIL14ENG0186FA

2

Right side components (1) (2) (3) (4)

Fuel filter Thermostat Water outlet Cooling fan

(5) Oil filler (6) Oil pan (7) Oil drain plug

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(8) Flywheel (9) Oil pressure sensor (10) Injection pump

Engine - Engine and crankcase

Engine and crankcase - Dynamic description ventillation

NHIL14ENG0186FA

1

When the gas (created by combustion) passes through the piston ring, the gas is called "blow-by-gas".

The blow-by-gas flows into the valve cover (1).

Natural aspiration allows blow-by-gas to pass into the intake manifold (3) through the breather hose (2) and be burned with the aspirated air.

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Engine - Engine and crankcase

Engine - Identification NOTE: Engine - Identification is located by the oil filter and oil pressure relief valve on the left side of the engine.

The L3B (1) in the engine cast indicates : LS engine, 3 cylinder, (B) 33 horse power.

The L3A in the engine cast indicates : LS engine, 3 cylinder, (A) 38 horse power. (Not shown) Numeric value (2) under the engine code (1) indicates the engine serial number.

NHIL14ENG0340AA

1

NHIL14ENG0339AA

2

NOTE: The emission plate (1) is located on the valve cover.

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Engine - Engine and crankcase

Engine - Exploded view L3AL

NHIL14ENG0270FA

1

Three cylinder engine (Single cylinder shown) (1) First ring (OD 90 mm (3.54 in) (2) Second ring (OD 90 mm (3.54 in) (3) Oil ring assembly (4) Piston pin (5) Snap ring (6) Connecting rod bolt (7) Connecting rod bushing

(8) Connecting rod (9) Connecting rod bearing (10) Connecting rod bearing (11) Connecting rod cap (12) Connecting rod nut (13) Key (14) Crankshaft washer

(15) Nut (16) Crankshaft pulley (17) Baffle plate (18) Ring gear (19) Flywheel assembly (20) Ball bearing (21) Hex bolt, M12 x 36mm (22) Lock washer, M12

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

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

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Engine - Engine and crankcase

Engine - Exploded view L3BL

NHIL14ENG0270FA

1

Three cylinder engine (Single cylinder shown) (1) First ring (OD 88 mm (3.46 in) (2) Second ring (OD 88 mm (3.46 in) (3) Oil ring assembly (4) Piston pin (5) Snap ring (6) Connecting rod bolt (7) Connecting rod bushing

(8) Connecting rod (9) Connecting rod bearing (10) Connecting rod bearing (11) Connecting rod cap (12) Connecting rod nut (13) Key (14) Crankshaft washer

(15) Nut (16) Crankshaft pulley (17) Baffle plate (18) Ring gear (19) Flywheel assembly (20) Ball bearing (21) Hex bolt, M12 x 36mm (22) Lock washer, M12

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

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

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Engine - Engine and crankcase

Engine and crankcase - Check cylinder bores L3AL

1. Measure the engine bore with a cylinder bore gauge having a dial indicator.

2. Take measurements at A, B, and C positions in the bore on axis 90 ° apart as shown in the illustration to check the diameter, out-of-round and taper.

NOTE: If the bores exceed the service limit for diameter, out of round and taper, increase the bore for oversized pistons.

NHIL14ENG0302AA

L3AL Standard Cylinder internal measurement

0.25 mm (0.0098 in) 0.50 mm (0.0196 in)

Out-of-round and taper of bores

Assembly standard 90 mm (3.543 in) + 0.035 mm (0.00138 in) 90.25 mm (3.5531 in) + 0.035 mm (0.00138 in) 90.50 mm (3.5629 in) + 0.035 mm (0.00138 in) Maximum

1

Service Limit Standard + 0.2 mm (0.0078 in)

0.015 mm (0.0006 in)

Boring and honing 1. Determine an oversize to which the bores are to be increased by boring and honing on the basis of the maximum measurement taken on the bores.

2. Bore, then finish honing the bores to the oversize determined in instruction one.

NHIL14ENG0303AA

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2

Engine - Engine and crankcase

Engine and crankcase - Check cylinder bores L3BL

Checking bores 1. Measure the engine bore with a cylinder bore gauge having a dial indicator.

2. Take measurements at A, B, and C positions in the bore on axis 90 ° apart as shown in the illustration to check the diameter, out-of-round and taper.

NOTE: If the bores exceed the service limit for diameter, out of round and taper, increase the bore for oversized pistons.

NHIL14ENG0302AA

L3BL Standard Cylinder internal measurement

0.25 mm (0.0098 in) 0.50 mm (0.0196 in)

Out-of-round and taper of bores

Assembly standard 88 mm (3.464 in) + 0.035 mm (0.00138 in) 88.25 mm (3.474 in) + 0.035 mm (0.00138 in) 88.50 mm (3.484 in) + 0.035 mm (0.00138 in) Maximum

1

Service Limit Standard + 0.2 mm (0.0078 in)

0.015 mm (0.0006 in)

Boring and honing 1. Determine an oversize to which the bores are to be increased by boring and honing on the basis of the maximum measurement taken on the bores.

2. Bore, then finish honing the bores to the oversize determined in instruction one.

NHIL14ENG0303AA

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2

Engine - Engine and crankcase

Engine - Test Test • An engine should be tested on a dynamometer. This test is also for “break in” of the major running parts of the engine.

Start-up procedure • Check the fluid levels in the radiator, oil pan and fuel tank. Bleed the fuel and cooling system.

• Crank the engine with the starter for 5 s to permit lube oil to circulate through the engine. For this cranking, do not supply fuel to the engine.

• Slightly move the speed control lever in the direction of increasing the injection quantity and turn the starter switch to the START position. (Do not move the speed control lever to the full injection position).

• After the engine starts, allow it to idle by operating the speed control lever.

Inspection after starting the engine • After starting the engine, check the following items.

Upon discovery of any faulty condition, immediately stop the engine and investigate for this cause.

• Lube oil pressure – should be 2 - 4 bar (28 - 57 psi) when the engine is running at the rated speed. It should be 1 bar (14 psi) when the engine is running at low idle speed.

• Coolant temperature – should be 75 - 85 °C (167 185 °F).

• Lube oil temperature – Should be 70 - 90 °C (158 194 °F).

• Oil, coolant or fuel leaks.

• Knocking – Should die away as the coolant temperature increases. No other defects should be noted.

• Abnormal exhaust smoke and smell.

Test condition • Follow the table shown below : Step 1 2 3 4 5 6

Speed (rpm) 1000 RPM Rated (varies according to specifications)

Inspection after break-in • Check under and around the engine for loose bolts or nuts.

• Check and adjust the valve clearance.

• Check and adjust the injection timing.

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Load - % No load 25 % 25 % 50 % 75 % 100 %

Time / minutes 30 min 30 min 10 min 10 min 30 min 20 min

Engine - Engine and crankcase

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

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

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

3. Remove all of the glow plugs.

4. Install the adapter FNH00120 (2).

5. Install the hose and gauge assembly OEM1074 (1), in each port and crank the engine until pressure stabilizes.

NOTE: There should not be more than 3 bar (50 psi) variation between the cylinders.

SECT10C01PG17_1

1

SECT10C01PG17_2

2

NOTE: The gauge (2) should read 29 bar (427 psi +/- ) 3 bar (50 psi).

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

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

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Engine - Engine and crankcase

Engine - Troubleshooting Problem Possible Cause Engine does not develop Clogged air cleaner full power Fuel line obstructed

Low oil pressure

Engine will not stop Low cylinder compression

Correction Inspect and replace air cleaner if necessary

Check for crimped fuel line. Inspect fuel lifter for cleanliness Improper injection timing Repair/replace components as required Improper nozzle injection pressure and an- Check injection timing, inspect for proper gle injection pressure and angle Low cylinder compression Check engine compression Repair at authorized shop Insufficient fuel injection Improper valve lash adjustment Adjust valves to correct tolerances Burned, worn or sticking valves Inspect and replace as necessary Blown head gasket Replace head gasket Worn or sticking piston rings Overhaul as necessary Faulty engine stop solenoid Replace stop solenoid Engine oil level low Fill to proper level Replace with correct grade oil Wrong grade of oil Clogged oil pump filter Change oil and filter Faulty oil pressure relief valve Replace relief valve Worn oil pump drive shaft gears, or broken Inspect oil system and components. Replace defective components oil pipe 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 engine stop solenoid Replace the stop solenoid Faulty starter switch Replace starter switch Burned, worn or sticking valves Replace valves

Bent valve stem Replace valves Broken or weak valve spring Replace valve spring Blown cylinder head gasket Replace head gasket Worn or sticking piston rings Replace piston rings Replace piston Scored piston Poor engine idling Improper injection timing Correct the injection timing Air in injection pump Purge air from the system Improper governor adjustment Adjust the governor Replace the bulb Oil pressure warning light Bulb burnt out fails to operate Replace oil pressure sensor Oil pressure sensor is faulty Replace warning light circuit Warning light circuit faulty Engine knocks Diluted or thin oil Change engine oil and filter Insufficient oil supply Check engine oil level Low oil pressure Inspect lube system for restrictions Replace thrust bearing Worn crankshaft thrust bearing Excessive flywheel runout Replace flywheel Excessive connecting rod or main bearing Replace bearings clearance Seized bearing Replace bearing and affected component if necessary Clogged oil passage Clean out oil passages Bent or twisted connecting rod Replace connecting rod Crankshaft journals out of round Rework or replace crankshaft Excessive piston to cylinder bore clearance Replace piston with correct oversized piston Excessive piston ring side clearance Replace piston rings Broken or damaged ring Replace piston ring Excessive piston pin clearance Replace piston pin or bushing

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Engine - Engine and crankcase

Problem

Excessive oil consumption

Engine overheats

Possible Cause Seized piston Piston pin retainer loose or missing Improper valve lash adjustment Worn valve lifter Excessive timing gear backlash Engine oil level too high Leakage in cylinder head gasket Oil loss past the pistons and rings Worn, broken, or sticking piston rings Clogged return hole of oil ring Worn valves, guides, or seals Leakage past oil seals and gaskets External oil leaks from engine Insufficient amount of coolant in the radiator Hose connection leaking or collapsed hose Radiator leakage Loose, worn, or broken V-belt Radiator fins bent or clogged Radiator cap not sealing Thermostat operating improperly Insufficient amount of oil Water pump operating improperly Improper valve clearance Restriction in exhaust system Improperly installed cylinder head gasket Rust and/or scale clogged water ports Extended engine idling

Temperature gauge fails Faulty temperature sender to reach normal operating temperature Faulty thermostat Faulty temperature gauge Engine does not start Faulty starter switch Insufficient charging or complete discharge of battery Lack of fuel Air mixed in fuel system Clogged fuel filter Irregular or faulty fuel supply Glow plug not heating Improper lubricating oil viscosity Clogged air cleaner Faulty engine stop solenoid Burned out fuse Excessive Exhaust Smoke Air cleaner dirty or restricted Excessive fuel delivery Engine stops while Lack of fuel in fuel tank operating Clogged fuel filter Air mixed in fuel system Faulty engine stop solenoid Burned out fuse Undesirable exhaust color Unsuitable fuel (black or light grey) Excess injection Faulty engine component 47731080 04/08/2015

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Correction Replace piston and, if necessary, engine block Replace retainer Adjust valve lash to specification Replace valve lifter Replace all timing gears Remove excess oil Replace head gasket Replace piston rings Replace piston rings Unclog return oil hole and replace rings Replace valves, guides, or seals Replace leaking seals and gaskets Locate leaks and repair Fill coolant to proper level Tighten hose connection or replace hose Locate leak and repair or replace radiator Adjust V-belt tension or replace belt Straighten out and clean fins Replace radiator cap Replace thermostat cap Fill to proper level Replace water pump Adjust valve clearance to specification Remove restriction Reinstall head gasket in proper position Backflush cooling system Shutdown engine during extended idling periods Replace temperature switch

Replace thermostat Replace temperature gauge Replace switch Check battery and charging system Fill fuel tank Inspect fuel system for tightness Replace fuel filter Replace fuel supply Replace glow plug Replace lube oil Replace air cleaner Replace solenoid Replace fuse Replace air cleaner Adjust fuel delivery Fill fuel tank Replace filter Inspect for air leaks Replace solenoid Replace fuse Replace fuel Replace injection pump Replace as required

Engine - Engine and crankcase

Problem

Undesirable exhaust smoke (white or pale)

Possible Cause Over loading Clogged air filter Excess engine oil

Correction Decrease load Replace filter Drain oil to proper oil level

Improper lubricating oil viscosity Faulty injection timing

Replace oil with specified viscosity Replace injection pump

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Index Engine - 10 Engine and crankcase - 001 Crankcase - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Engine and crankcase - Check cylinder bores (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine and crankcase - Check cylinder bores (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine and crankcase - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine and crankcase - Dynamic description ventillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

(*) See content for specific models 47731080 04/08/2015

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Engine - 10 Cylinder heads - 101

L3AL L3BL

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Cylinder heads Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Valves Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dimension - Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Valve guide Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Cylinder head Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble and valve removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble and valve install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install and head gasket install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjust valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Valve guide Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Valve seat Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 47731080 04/08/2015

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Engine - Cylinder heads

Cylinder heads - Dimension Engine model

L3AL, L3BL

Standard Maximum

0.05 mm (0.002 in) 0.20 mm (0.00787 in)

Standard Maximum Service limit (Clearance)

1.04 - 1.32 mm (0.041 - 0.052 in) 1.18 mm (0.0464 in) 1.6 mm (0.063 in)

Standard (Recess) Maximum Service limit (Clearance)

0.7 - 0.9 mm (0.03 - 0.035 in) 0.8 mm (0.0314 in) 1.3 mm (0.0512 in) 30 °

Head warp

Valve seat width

Valve seat sink

Valve angle

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Engine - Cylinder heads

Valves - Dimension L3AL , L3BL Valve stem thickness Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust) Valve head gasket thickness (Compressed) Standard Maximum

7.94 - 7.955 mm (0.312 - 0.313 in) 8.0 mm (0.314 in) 7.920 - 7.940 mm (0.311 - 0.312 in) 8.0 mm (0.314 in) 1.3 mm (0.0511 in) 1.27 - 1.35 mm (0.05 - 0.0531 in)

Valves - Dimension - Valve springs L3AL , L3BL Out of square Standard Maximum

1.5 mm (0.05905 in) 1.5 mm (0.05905 in)

Free length Standard Maximum Service limit clearance Spring force when compressed to 30.4 mm (1.20 in) Standard assembled load Maximum assembled load Service limit assembled load

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48.85 mm (1.923 in) 48.85 mm (1.923 in) 47.6 mm (1.874 in) 177 - 196 N (40 - 44 lb) 196 N (44 lb) 147 N (33 lb)

Engine - Cylinder heads

Valve guide - Dimension L3AL, L3BL Valve stem to valve guide clearance Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust)

0.065 - 0.095 mm (0.0025 - 0.0037 in) 0.200 mm (0.00787 in) 0.080 - 0.115 mm (0.0031 - 0.0045 in) 0.200 mm (0.00787 in)

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Engine - Cylinder heads

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

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

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

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Engine - Cylinder heads

Cylinder head - Exploded view

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

1

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

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

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Engine - Cylinder heads

Valve cover - Remove 1. Remove the air breather hose (1).

2. Remove the five M8 x 1.25 x 40mm bolts (2) and five washers (3).

3. Remove the valve cover (4).

4. Remove the gasket (5).

NOTICE: Install a new gasket (5) at assembly.

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1

Engine - Cylinder heads

Valve cover - Install 1. Install a new gasket (5).

2. Install the valve cover (4).

3. Install the five M8 x 1.25 x 40mm bolts (2) and the five washers (3).

4. Torque these bolts to 15 - 18 N·m (11 - 13 lb ft) 5. Install the air breather hose (1).

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Engine - Cylinder heads

Cylinder head - Remove Prior operation: Rocker support - Remove rocker shaft assemblies (10.106) 1. Remove the cylinder head bolts (1).

NOTICE: Remove the cylinder head bolts (1) by alternately loosening a half turn at a time to prevent warping the head (2).

2. Remove the cylinder head (2).

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3. Remove the gasket (3).

NOTE: Remove all gasket material from the cylinder head and the engine block.

NOTE: Keep all valve components in separately marked containers for reassembly in their original location.

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

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

3. Use a valve spring compressor (6) to compress the spring (4).

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

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

6. Remove the valve guide seals (Not shown).

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

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Engine - Cylinder heads

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

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

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

4.

Inspect the head for cracks or damage in the following areas: • Valve ports • Water jackets (1).

• Valve seats (2).

• Prechamber (3).

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5. Inspect the gasket surfaces for scratches or nicks, which could cause leakage.

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

7. Inspect the prechamber for carbon deposits and looseness. Remove any carbon deposits found. If prechamber is found to be loose, cylinder head may be warped.

8.

Inspect the cylinder head for warpage : • Use a straight edge (1) and a feeler gauge (2) and check the cylinder head (3) for warp lengthwise (4) , crosswise (5), and diagonally (6).

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

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Engine - Cylinder heads

Cylinder head - Assemble and valve install 1. Insert each valve (5) in the guide (Not shown) from which it was removed and lightly lap the valve to be sure of an even seat around the valve face.

NOTICE: Remove the valve and remove all traces of lapping compound.

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

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

3. Use a spring compressor (6) to assemble the valves (5), springs (4), spring cap (3), keepers (2).

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1

NOTICE: Compressing the valve spring excessively will cause the retainer to make contact with and damage the stem seal.

4. Install the valve stem cap (1).

5. Tap the top of the valve (1) with a soft-faced hammer (2) several times to make sure the valve spring and valve cotters are properly installed.

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Engine - Cylinder heads

Cylinder head - Install and head gasket install 1. Install a new head gasket (1).

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2. Install the cylinder head (1).

3. Install the fourteen cylinder head bolts (1).

4. Torque the cylinder head bolts to 112.5 - 123.4 N·m (83.0 - 91.0 lb ft), following the sequence shown.

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Engine - Cylinder heads

Valves - Remove 1. Refer to Cylinder head - Disassemble and valve removal (10.101)

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Engine - Cylinder heads

Valves - Inspect Clean all deposits from the valves using a soft wire brush. Inspect the condition of the valves and discard any that are badly burned, cracked, or bent.

Prior operation: Cylinder head - Disassemble and valve removal (10.101) 1. Use a micrometer to measure the valve stem at points (A), (B), and (C).

2. If the valve stem is less than 7.940 mm (0.313 in) (intake), 7.920 mm (0.312 in) (exhaust), it must be replaced.

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3. If the valve head is less than 0.500 mm (0.020 in) it must be replaced.

4. If inspection indicates that the valve may be reused, the valve should be ground: (1) 30 ° Angle Seat (2) Minimum valve margin 5. After grinding the valve and seat, check to ensure the seat contacts the center of the valve face. Using PERMATEX ™ PRUSSIAN BLUE, lightly coat the valve seat, place the valve in position and rotate the valve slightly while holding a light pressure against the valve.

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

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

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Engine - Cylinder heads

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

2. Measure the free length (3) of the spring (1).

3. Check the spring to be square by using a square (2).

NOTE: If the spring exceeds 1.5 mm (0.06 in) out of square, replace springs.

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

5. Compress the spring to 43 mm (1.692 in). If the spring exerts less than 15 kgf (33 lbf) of force, replace the springs.

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Engine - Cylinder heads

Valves - Install 1. Refer to Cylinder head - Assemble and valve install (10.101)

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Engine - Cylinder heads

Valves - Adjust valve clearance 1. Find the top dead center on the compression stroke No.1 piston as outlined below : A. Put turning handle (1) on the crankshaft pulley nut (2).

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B. Turn the crankshaft in the normal direction (as seen from the front end) until the “0” mark scribed on the crankshaft pulley is aligned with the pointer on the timing gear case as shown in the illustration.

NOTE: The No 1 piston is at the top dead center on the compression stroke when the rocker arms are not being pushed up by push rods. If the rocker arms are being pushed up, turn the crankshaft one turn.

C. Try to move up and down the inlet and exhaust valve rocker arms of the No.1 cylinder to make sure they are not being pushed up by the push rods.

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2

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Engine - Cylinder heads

2. Insert a 0.25 mm (0..0098 in) feeler gauge into between the rocker arm and valve cap (2).

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3

3. Loosen the lock nut (1) for the adjusting screw (3) and turn the adjusting screw (3) in either direction until the feeler gauge is slightly gripped between the rocker arm and valve cap.

Valve clearance (cold setting)

Item Inlet valves Exhaust valves

Assembly standard 0.25 mm (0.0098 in)

NOTICE: After adjusting , tighten the lock nut and recheck the clearance.

NOTE: Adjust the valve clearance on the remaining cylinders by turning the crankshaft 120 ° at a time in the firing order.

Turning angle 120 °

Sequence (cylinder No.) 1-3-2 120 ° mark (1).

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4

NOTICE: After adjusting the valve clearance on cylinders turn the crankshaft two or three turns and recheck the clearance

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Valve guide - Inspect Thoroughly clean the valve guides before attempting to check internal wear.

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

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

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

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Engine - Cylinder heads

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

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1

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

Intake 1.04 - 1.32 mm (0.0409 - 0.052 in) 1.6 mm (0.063 in)

Exhaust 1.04 - 1.32 mm (0.0409 - 0.052 in) 1.6 mm (0.063 in)

0.7 - 0.9 mm (0.028 - 0.035 in) 1.3 mm (0.051 in)

0.7 - 0.9 mm (0.028 - 0.035 in) 1.3 mm (0.051 in)

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Engine - Cylinder heads

1. Check the seat for surface defects. Use a 30 ° stone to reface if needed.

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

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

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

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

Lower seat location - 15 ° stone Seat angle - 30 ° stone Raise seat location - 75 ° stone Contact width Standard assembling value Service limit

3

Intake 1.04 - 1.32 mm (0.0409 - 0.052 in) 1.6 mm (0.063 in)

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Exhaust 1.04 - 1.32 mm (0.0409 - 0.052 in) 1.6 mm (0.063 in)

Engine - Cylinder heads

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

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

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

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4

Index Engine - 10 Cylinder heads - 101 Cylinder head - Assemble and valve install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cylinder head - Disassemble and valve removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cylinder head - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinder head - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cylinder head - Install and head gasket install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cylinder head - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder heads - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Valve guide - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve guide - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Valve seat - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Valves - Adjust valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Valves - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves - Dimension - Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Valves Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - 10 Pan and covers - 102

L3AL L3BL

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Contents Engine - 10 Pan and covers - 102

FUNCTIONAL DATA Engine oil pan Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Timing gear housing Exploded view timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Engine - Pan and covers

Engine oil pan - Dynamic description

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Engine oil pan The engine oil pan stores lubricating oil for the engine.

The capacity of the engine oil pan is 6 L (2 US gal).

Use AMBRA SUPER GOLD 10W-30/AKCELA ENGINE OIL 10W-30 in cold climates.

Use AMBRA SUPER GOLD 15W-40/AKCELA ENGINE OIL 15W-40 in warm climates.

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Engine - Pan and covers

Engine oil pan - Exploded view

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Oil pan components (1) (2) (3) (4)

Oil level gauge “U” seal Oil pan gasket Oil pan gasket

(5) Dowel pin (6) Oil pan (7) Gasket

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(8) Drain plug (9) Washer, M8 (10) Hex bolt, M8 x 1.25 x 155

Engine - Pan and covers

Timing gear housing - Exploded view timing gears

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1

Timing gears and housing components

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Engine - Pan and covers

Timing gears and housing components (Refer to figure 1 .

(1) Filler cap (2) Gasket

(12) Oil seal (13) O - ring

(23) Front plate gasket (24) Bearing case gasket

(3) Hex bolt, M8 x 1.25 x 55mm (4) Washer, M8 (5) Gear case gasket

(14) Bearing case

(25) Ball bearing

(15) Washer, M8 (16) Hex bolt, M8 x 1.25 x 16mm (17) Washer, M8 (18) Hex bolt, M8 x 1.25 x 60mm (19) Injector pump gear

(26) Ball bearing (27) Bearing case

(6) Ball bearing (7) Ball bearing (8) Ball bearing (9) Timing gear case

(20) Hex bolt, M8 x 1.25 x 16mm (10) Stud bolt, M8 x 1.25 x (21) Washer, M8 25mm (11) Hex bolt, M8 x 1.25 x (22) Front PTO plate 50mm

(28) Dowel pin (29) Washer, M8 (30) Hex bolt, M8 x 1.25 x 20mm (31) Pump drive gear (32) PTO idler gear (33) Camshaft gear

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(34) Idler assembly (35) Hex bolt, M10 x 1.25 x 20mm (36) Washer, M10 (37) Thrust plate

Engine - Pan and covers

Engine oil pan - Remove NOTE: Drain the engine oil into a suitably sized container. The engine oil pan capacity is 6 L (2 US gal).

1. Remove the oil drain plug (7) and gasket (6),and drain the oil.

2. Remove the sixteen M8 x 1.25 x 155mm oil pan retainer bolts (8) and sixteen M8 washers (9).

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3. Remove the five M10 x 1.25 x 50 bolts and lock washers (1).

NOTICE: The five M10 x 1.25 x 50 bolts in instruction two pass through threaded holes both in the back plate and oil pan, therefore should be installed last at assembly.

4. Remove the oil pan (5) and discard four gaskets (1), (2) and (3).

NOTICE: Replace these gaskets at assembly.

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Engine - Pan and covers

Engine oil pan - Install 1. Apply a thin coat of PERMATEX ® FORM-A-GASKET® NO. 2 SEALANT to the oil pan sealing and crankcase area at gaskets (1) and (3).

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NOTE: Refer to figure 1 throughout this instruction for an overview.

2. Install a new gasket (1), “U” seals (2) and gasket (3).

NOTICE: Make sure gaskets (1) and (3) are installed properly. They must lie flat after being tucked in at each end (A).

3. Apply PERMATEX ® FORM-A-GASKET® NO. 2 SEALANT to the seats (1) formed by the No.1 and No.5 main bearing caps just enough to be forced out of the seats slightly when the “U” seals (2) are installed.

4. Install the U - seals (2) to the bottom of the crankcase by fitting them into the grooves in the main bearing caps while forcing their ends into the seats as shown in illustration.

5. Install the oil pan (5).

6. Install the sixteen M8 x 1.25 x 155mm bolts (8) and washers (9).

NOTICE: Torque the M8 x 1.25 x 155mm bolts to 16 N·m (12 lb ft) in a criss cross pattern.

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Engine - Pan and covers

7. Install the five M10 x 1.25 x 50 bolts and lock washers (1).

NOTICE: The five M10 x 1.25 x 50 bolts in instruction number eight pass through threaded holes both in the back plate and oil pan, therefore should be installed last at assembly.

8. Torque these bolts to 44 - 0.0 N·m (32 - 41.2 lb ft) 9. Install the oil pan drain plug (7) and gasket (6)..

10. Torque the drain plug (7) to 35 - 43 N·m (26 - 32 lb ft).

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4

Engine - Pan and covers

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

NOTICE: Be prepared to collect the fluid with a suitable container before opening or disassembling any component containing fluids.

1. Remove the one M8 x 1.25 x 55 retaining bolt (2) and the thirteen M8 x 1.25 x 50 bolts (3) from the timing cover (1).

NOTICE: The front plate is bolted inside the gear case. Do not attempt to remove the plate with the case by tapping.

2. Remove the timing cover (2) off the locating dowels.

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

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

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Engine - Pan and covers

Timing gear housing - Inspect 1. The timing gear housing (4) contains the front oil seal (3), power steering seal (2), and the governor linkage assembly (1).

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2. Inspect the timing gear housing (1) for cracks or defects on the gasket mating surfaces. If any defects are present, replace the timing gear housing.

3. Inspect the oil seals (2) and make sure all seals are in good condition. If any of the seals show signs of wear or tears, replace the seals.

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Engine - Pan and covers

Timing gear housing - Install seal 1. Using a seal installer set (1),tool number 294165 install a new oil seal (2) in the timing gear case (3) until it is flush with the end face of the case as shown in the illustration. The lip of the seal must be toward the inside of the gear case.

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1

Engine - Pan and covers

Timing gear housing - Install NOTICE: Never rotate the engine with the timing cover removed.

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

1. Install new cover gasket (1).

2. Install the oil pump drive gear and idler gear to timing gear case.

3. Install the baffle plate to the crankshaft.

4. Install the timing gear case and gasket to the front face of the crankcase. Make sure the locating dowels enter their holes in the case and gasket.

5. Install the thirteen M8 x 1.25 x 50 bolts (2) and the one M8 x 1.25 x 55 cover retaining bolts (2).

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

6. Evenly torque the retaining bolts to 11 - 13 N·m (8 9.4 lb ft).

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Index Engine - 10 Pan and covers - 102 Engine oil pan - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil pan - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Timing gear housing - Exploded view timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Timing gear housing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Timing gear housing - Install seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Crankshaft and flywheel - 103

L3AL L3BL

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine flywheel Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect the flywheel surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check face run - out and pilot bearing bore run - out of flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Crankshaft oil seal Remove rear seal and rear end plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Check oil seal running surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install rear seal and rear end plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Crankshaft Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Main bearings Check oil clearance of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Crankshaft - Dimension Journal diameter Standard Maximum

69.840 - 69.855 mm (2.7496 - 2.7501 in) 70 mm (3 in)

Standard Maximum

57.955 - 57.970 mm (2.2816 - 2.2822 in) 58 mm (2.2834 in)

Standard Maximum

0.02 mm (0.0007 in) 0.05 mm (0.0019 in)

Crankpin diameter

Runout

Endplay Standard 0.100 - 0..204 mm (0.0039 - 0.080 in) Maximum 0.300 mm (0.0118 in) Thrust washer thickness Standard Minimum Cylinder block bearing diameter Standard 69.840 - 69.855 mm (2.749 - 2.7501 in) Clearance between camshaft journal and bore in crank -case (or bushing) for camshaft) Standard 0.07 - 0.11 mm (0.0028 - 0.0043 in) Maximum 0.15 mm (0.0059 in) Center bearing to crankshaft clearance Standard 0.02 mm (0.0008 in) Maximum 0.05 mm (0.0020 in)

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Engine - Crankshaft and flywheel

Engine flywheel - Dynamic description

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Flywheel A flywheel (1) is a rotating mechanical device that is used to store rotational energy. Flywheels have a significant moment of inertia and thus resist changes in rotational speed. The amount of energy stored in a flywheel is proportional to the square of its rotational speed.

Its ring gear (2) provides a toothed component (3) where the starter motor (4) can engage (5) to roll the engine over to start.

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Engine flywheel - Remove 1. Secure the crankshaft pulley (1) with a wrench (2) to prevent the flywheel (3) from turning during removal.

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2. Remove the four M12 x 1.25 x 36mm flywheel retaining bolts (1) and M12 lock washers (2).

3. Use a dead blow hammer to tap the end (arrow) of the crankshaft (1) and loosen the flywheel (2) from the shaft.

4. Remove the flywheel (2).

Next operation: Engine flywheel - Inspect the flywheel surface (10.103) Next operation: Engine flywheel - Inspect - Ring gear (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Inspect the flywheel surface 1. Place the flywheel (1) on a flat surface (2).

2. Install a dial indicator (3) at one side of the friction surface (4).

3. Move the dial indicator (3) across the surface (4) to the opposite side.

4. Observe the dial indicator (3).

NOTICE: If the friction surface is not flat and exceeds the repair limit, turn the flywheel on a lathe. Refer to the table below.

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Item Flatness of the flywheel

Assembly standard 0.15 mm (0.0059 in) (Maximum)

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Repair limit 0.50 mm (0.0020 in)

1

Engine - Crankshaft and flywheel

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

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Engine - Crankshaft and flywheel

Engine flywheel - Replace - Ring gear Prior operation: Engine flywheel - Inspect - Ring gear (10.103) Prior operation: Engine flywheel - Inspect the flywheel surface (10.103)

Removal 1. Remove the starter ring gear (3) using a hammer (1) and chisel (2) to crack the ring gear.

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Installation 1. Heat the new ring gear up to 150 °C (302 °F) from the inside only.

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

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

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

Next operation: Engine flywheel - Install (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Install Prior operation: Engine flywheel - Remove (10.103) Prior operation: Engine flywheel - Inspect the flywheel surface (10.103) Prior operation: Engine flywheel - Inspect - Ring gear (10.103) Prior operation: Engine flywheel - Replace — Ring gear (10.103) 1. Locate the dowel pins (1).

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2. Install the flywheel (1) on the crankshaft (2).

NOTE: Use the dowel pins as guides for installation.

NOTE: Use a dead blow hammer to assist in the installation.

3. Secure the crankshaft pulley (1) with a wrench (2) to prevent the flywheel (3) from turning during removal.

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Engine - Crankshaft and flywheel

4. Install the four M12 x 1.25 x 36mm flywheel retaining bolts (1) and M12 lock washers (2).

5. Torque the M12 x 1.25 x 36mm bolts to 77 - 88 N·m (57 - 65 lb ft).

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4

Engine - Crankshaft and flywheel

Engine flywheel - Check face run - out and pilot bearing bore run out of flywheel NOTICE: Excessive run-out of the flywheel in either position will probably be caused by dirt in the mounting face or improper tightening of the bolts.

1. Set a dial indicator at the friction (vertical) surface (1) and turn the flywheel one full revolution to check the face run out (axial eccentricity).

2. Set a dial indicator at the horizontal surface (2) of the pilot bearing bore and turn the flywheel one full revolution to check the bore run-out.

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Item Face and pilot bearing bore run-out

Assembly Standard 0.25 mm (0.0098 in)

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Repair limit 0.50 mm (0.0197 in)

1

Engine - Crankshaft and flywheel

Crankshaft oil seal - Remove rear seal and rear end plate 1. Remove the flywheel (1). (Refer to Engine flywheel Remove (10.103) )

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2. Remove the twelve M10 x 1.25 x 50mm bolts (2).

3. Remove the rear housing (1).

4. Remove the seal (2) from the rear housing (1).

5. Remove the gasket (1).

NOTICE: Replace the gasket (1) at assembly.

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Crankshaft oil seal - Check oil seal running surface Checking oil seal running surface 1. Check the oil seal running surface (1) of the balancer shaft drive gear for wear at the rear end of the crankshaft.

NOTICE: If the drive gear is badly worn, replace the oil seal (2) with replacement oil seal and oil seal sleeve.

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Engine - Crankshaft and flywheel

Crankshaft oil seal - Remove Removing oil seal sleeve 1. Hold a flat cold chisel (1) at right angles to the sleeve (2) and cut the sleeve at three places to loosen it, as shown in the illustration.

NOTE: If it is impossible to remove the sleeve in this method, hold the chisel in the axial direction and lightly tap the sleeve to loosen it.

NOTICE: Be extra careful not to cause damage to the drive gear when removing the sleeve.

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Engine - Crankshaft and flywheel

Crankshaft oil seal - Install Installing oil seal and sleeve 1. Heat an oil seal sleeve (1) in an oven to a temperature of 100.0 - 150 °C (212.0 - 302 °F) and install it by tapping uniformly with a hammer.

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2. When the oil seal sleeve is worn after the engine has been operated, replace both oil sea l (1) and oil seal sleeve (2).

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Engine - Crankshaft and flywheel

Crankshaft oil seal - Install rear seal and rear end plate Prior operation: Crankshaft oil seal - Remove rear seal and rear end plate (10.103) 1. Install the seal (2) into the rear housing, from the chamfered side of the housing (1).

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2. Install the new gasket (1).

3. Install the rear housing (1).

NOTICE: Apply engine oil to the lip of the seal.

NOTE: Make sure the locating dowels enter their holes in the gasket and the housing.

4. Install the twelve M10 x 1.25 x 50mm bolts (2).

5. Torque the twelve M10 x 1.25 x 50mm bolts to 31 37 N·m (23 - 27 lb ft).

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Engine - Crankshaft and flywheel

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

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

3. Remove and retain the key (3).

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1

Engine - Crankshaft and flywheel

Crankshaft - Install pulley Installing crankshaft pulley 1. Install the key (1) on the crankshaft (2).

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2. Install two M12 x 1.25 bolts (3) to the flywheel end of the crankshaft (4).

3. Install a bar between the two bolts (3).

4. Install the pulley (1).

5. Install the crankshaft nut (2).

6. Torque the crankshaft nut to 382 - 401 N·m (282 296 lb ft).

7. Remove the two M12 x 1.25 (3) bolts from the flywheel end.

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Engine - Crankshaft and flywheel

Crankshaft - Remove gear Removing crankshaft gear 1. Remove the crankshaft gear (1) with a gear puller (2) as shown in the illustration.

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NOTICE: Do not remove the gear unless it requires replacement.

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1

Engine - Crankshaft and flywheel

Crankshaft - Install gear Installing crankshaft gear 1. Heat the gear (1) in an oven to a temperature of 100 150 °C (212 - 302 °F).

2. Install the key (2) to the crankshaft (3).

3. Install the gear (1) by fitting the key (2) into the keyway (4) in the in gear.

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1

Engine - Crankshaft and flywheel

Crankshaft - Remove the crankshaft Prior operation: Engine oil pan - Remove (10.102)

Checking thrust clearance of connecting rod big end 1. Lay the crankcase (1) on it’s side.

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2. Check the clearance between the connecting rod big end and the crankpin (1) with a feeler gauge (2),as shown.

NOTE: If the thrust clearance exceeds the service limit, replace the connecting rod.

Item Thrust clearance of connecting rod big end

Assembly standard 0.15 - 0.35 mm (0.0059 - 0.0138 in)

Service limit 0.50 mm (0.0197 in)

NOTICE: When replacing the connecting rods, select new connecting rods (1) and connecting rod caps (2) having the same weight rank marks (3) so that the difference between average weight of all connecting rod assemblies in one engine does not exceed the maximum permissible limit.

NOTE: Maximum permissible difference between average weight of all connecting rod assemblies in one engine is 10 g (0.35 oz)

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3

Engine - Crankshaft and flywheel

Removing connecting rod caps 1. Put a mark on each cap so it can be installed in same position from which it was removed.

2. Remove the caps and the lower halves (1) of the connecting rod bearings 3. Put a mark on each connecting rod bearing (lower half) so it can be installed in the same position from which it was removed.

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NOTICE: Be careful not to cause damage to the bearings.

Removing pistons 1. Remove carbon from the inner surface of the cylinders with a rag and sandpaper.

2. Turn the crankshaft to bring the piston to the top dead center.

3. Push the piston (1) and connecting rod (2) away from the crankshaft with the handle of a hammer (3) until the piston rings are above the cylinder. Then remove the piston and connecting rod from the crankcase.

Removing piston rings 1. Remove the piston rings (1) with piston ring pliers (2).

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Engine - Crankshaft and flywheel

Removing piston pins 1. Remove the snap rings (1) with a snap ring pliers (2)

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2. Remove the piston pin (1) to separate the connecting rod (3) from the piston (2).

NOTICE: When it is difficult to remove the piston pin, heat piston in an oven or in hot water.

Checking end play of crankshaft 1. Turn the crankcase (1) upside down with the oil pan side (2) up.

2. With a dial indicator (1) at the end of the crankshaft (2), check the end play as shown in the illustration. .

NOTICE: If the end play exceeds the service limit, replace the thrust bearings.

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10

Engine - Crankshaft and flywheel

Item Crankshaft end play

Assembly standard 0.100 - 0.204 mm (0.00394 0.00803 in)

Service limit 0.300 mm (0.01181 in)

Removing main bearing caps 1. Remove the main bearing caps (1) with lower halves of the main bearings.

NOTICE: Be careful not to cause damage to the main bearings. Put a mark on each bearing cap so it can be installed in the same position from which it was removed.

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Removing crankshaft 1. Carefully remove the crankshaft (1).

NOTICE: Be careful not to cause damage to the main journals and crank pins. Put a mark on each bearing.

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Engine - Crankshaft and flywheel

Crankshaft - Check run-out Checking run-out 1. Support the crankshaft (3) on its front and rear journals in V-blocks (4).

2. Install the dial indicator (1) set at 0.0 mm (0.0 in) at the center journal (2).

3. Turn the crankshaft (3) one full revolution and read the indicator as shown in the illustration.

NOTE: Repeat this procedure for the remaining journals.

NOTICE: Replace the crankshaft if run-out exceeds repair limit.

NHIL14ENG0299AA

Item Crankshaft run-out

Assembly standard 0.02 mm (0.0008 in)

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Repair limit 0.05 mm (0.0020 in)

1

Engine - Crankshaft and flywheel

Crankshaft - Install crankshaft Installing the crankshaft 1. Install the lower halves of the main bearings in the main bearing caps.

2. Install the upper halves of the main bearings (1) in the crankcase (2).

NOTICE: Make sure the upper and lower halves of the main bearings are installed so the bearing tabs (3) fit into the notch in the crankcase and main bearing caps (4).

NOTE: Only the upper halves of the main bearings to be installed in the crankcase has an oil groove.

NOTE: Apply engine oil at (A).

3. Install the upper and lower halves of the main bearing having flanges in both the crankcase and main bearing cap for number four journal of the crankshaft.

NOTE: Apply a small amount of engine oil to the inside of the main bearings.

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4. Wash the crankshaft with cleaning solvent and blow dry with compressed air.

• Make sure all oil holes in the crankshaft are clean.

• Check the oil holes to be in excellent condition.

5. Lift the crankcase (1) into place carefully.

6. Apply a small amount of engine oil to the journals of the crankshaft (A).

7. Install the main bearing caps in position so the “Front” mark (arrow) on the cap (1) is toward the front of the engine and the number on the cap (2) is the same as the number on the crankcase on the left side of each main bearing cap.

NOTICE: The end faces of number one and number four bearing caps must be flush with the end faces of the crankcase.

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Engine - Crankshaft and flywheel

8. Tighten the main bearing cap bolts (1) evenly to the specified torque. Torque to 77 - 88 N·m (57 - 65 lb ft).

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9. Make sure the crankshaft (1) rotates smoothly.

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Engine - Crankshaft and flywheel

10. Use a dial indicator (1) to check the crankshaft end play with a dial indicator as shown in the illustration.

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Item Crankshaft end play

6

Assembly standard Repair limit 0.100 - 0.204 mm (0.0039 - 0.0118 in) 0.300 mm (0.0118 in)

NOTICE: If the end play is less than the assembly standard, retighten the main bearing cap bolts. If it exceeds the service limit, replace the flanged bearings.

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Engine - Crankshaft and flywheel

Main bearings - Check oil clearance of main bearings Checking oil clearance of main bearings 1. Install the upper and lower halves of the bearings and the cap to the crankcase and tighten the cap nuts to the specified torque. Torque the cap nuts to 77 - 88 N·m (57 - 65 lb ft).

2. Measure the inside diameter of bearing (2) as shown in the illustration.

3. Take several measurements (1).

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4. Measure the diameter of the journal (1) of the crankshaft (2) as shown in the illustration and subtract the diameter of the journal from the inside diameter of the bearing in the previous step.

NOTE: The difference is the oil clearance of the main bearing.

Item Diameter of crankpin (standard) Oil clearance

Normal size 65 mm (2.56 in) N/A

Assembly standard Service limit 69.840 - 69.855 mm (2.55777 - 2.5585 in) 0.035 - 0.100 mm (0.0014 - 0.200 mm (0.0079 in) 0.0039 in)

NOTICE: If the oil clearance exceeds the repair limit, replace the bearing and recheck the oil clearance.

NOTICE: If the oil clearance still exceeds the repair limit, use 0.25 mm (0.0098 in), 0.50 mm (0.0197 in) or 0.75 mm (0.0295 in) undersize bearings. When using undersize bearings, refinish the crankpins to any of the undersize listed below.

0.25 mm (0.0098 in)

Undersize of journal

0.50 mm (0.0197 in)

0.75 mm (0.0295 in)

NOTICE: Grind all crankpins to the same undersize.

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Finishing dimension 64..75 mm (2.5492 in) - 0.015 mm (0.00058 in) - 0.035 mm (0.000138 in) 64..50 mm (2.5394 in) - 0.015 mm (0.00058 in) - 0.035 mm (0.000138 in) 64.25 mm (2.5295 in) - 0.015 mm (0.00058 in) - 0.035 mm (0.000138 in)

Engine - Crankshaft and flywheel

5. Finish the fillet radius (1) to 3.0 mm (0.12 in).

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3

Engine - Crankshaft and flywheel

Main bearings - Install main bearings 1. Install the lower halves of the main bearings in the main bearing caps.

2. Install the upper halves of the main bearings (1) in the crankcase (2).

NOTICE: Make sure the upper and lower halves of the main bearings are installed so the bearing tabs (3) fit into the notch in the crankcase and main bearing caps (4).

NOTE: Only the upper halves of the main bearings to be installed in the crankcase has an oil groove.

NOTE: Apply engine oil at (A).

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3. Install the upper and lower halves of the main bearing having flanges in the crankcase and main bearing cap for number four journal of the crankshaft.

NOTE: Apply a small amount of engine oil to the inside of the main bearings.

4. Wash the crankshaft with cleaning solvent and blow dry with compressed air.

• Make sure all oil holes in the crankshaft are clean.

• Check the oil holes to be in excellent condition.

5. Lift the crankcase (1) into place carefully.

6. Apply a small amount of engine oil to the journals of the crankshaft (A).

7. Install the main bearing caps in position so the “Front” mark (arrow) on the cap (1) is toward the front of the engine and the number on the cap (2) is the same as the number on the crankcase on the left side of each main bearing cap.

NOTICE: The end faces No.1 and No.5 bearing caps must be flush with the end faces of the crankcase.

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Engine - Crankshaft and flywheel

8. Tighten the main bearing cap bolts (1) evenly to the specified torque. Torque to 77 - 88 N·m (57 - 65 lb ft).

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9. Make sure the crankshaft (1) rotates smoothly.

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Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Check run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Crankshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft - Install crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Crankshaft - Install gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Crankshaft - Install pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankshaft - Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Crankshaft - Remove gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crankshaft - Remove the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Crankshaft oil seal - Check oil seal running surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankshaft oil seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft oil seal - Install rear seal and rear end plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankshaft oil seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Crankshaft oil seal - Remove rear seal and rear end plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine flywheel - Check face run - out and pilot bearing bore run - out of flywheel . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine flywheel - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine flywheel - Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine flywheel - Inspect the flywheel surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine flywheel - Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main bearings - Check oil clearance of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Main bearings - Install main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Engine - 10 Connecting rods and pistons - 105

L3AL L3BL

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rod and piston Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Piston Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Connecting rods and pistons Detailed view inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Piston Remove piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check gap between piston ring and groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check clearance between ends of piston rings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Check clearance between ends of piston rings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Check clearance between piston pin and bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Connecting rod bearing Check oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Piston pin bushings (*) See content for specific models 47731080 04/08/2015

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Check clearance between connecting rod bushing and piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Replace connecting rod bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Engine - Connecting rods and pistons

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

0.05 mm (0.0019685 in) 0.15 mm (0.00590551 in) 0.05 mm (0.002 in) 0.1 mm (0.003937 in) 0.15 - 0.35 mm (0.0059 - 0.01377 in) 0.20 mm (0.0787 in) 0.03 - 0.09 mm (0.00118 - 0.00327 in) 0.2 mm (0.008 in)

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Engine - Connecting rods and pistons

Piston - Dimension L3AL

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

89.955 - 89.985 mm (3.541 - 3.543 in) 89.770 mm (3.5342 in) 0.13 - 0.60 mm (0.00511 - 0.002362 in) 27.994 - 28.000 mm (1.1021 - 1.10236 in) 28.00 mm (1.10236 in) 0.000 - 0.0016 mm (0.00000 - 0.0006 in) 0.050 mm (0.00196 in)

Piston - Dimension L3BL

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

88.220 - 88.470 mm (3.4724 - 3.543 in) 87.970 mm (3.44830 in) 0.13 - 0.60 mm (0.00511 - 0.002362 in) 27.994 - 28.000 mm (1.1021 - 1.10236 in) 28.00 mm (1.10236 in) 0.000 - 0.0016 mm (0.00000 - 0.0006 in) 0.050 mm (0.00196 in)

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

27.994 - 28.0 mm (1.1021 - 1.10236 in) 27.98 mm (1.1016 in) 0.020 - 0.051 mm (0.00787 - 0.02007 in) 0.50 mm (0.0019 in)

Piston Ring - Dimension Engine Model

L3Al, L3BL

End Gap 1st Ring Maximum 2nd Ring Maximum Oil Ring Maximum Compression ring-to-groove clearance Standard (1st Ring) 2nd Ring Maximum

0.2 - 0.35 mm (0.008 - 0.0138 in) 1.5 mm (0.0590 in) 0.2 - 0.35 mm (0.008 - 0.0138 in) 1.5 mm (0.0590 in) 0.20 - 0.40 mm (0.0079 - 0.0157 in) 1.5 mm (0.0590 in) 0.60 - 0.10 mm (0.0024 - 0.0040 in) 0.045 - 0.085 mm (0.002 - 0.0033 in) !st ring 0.20 mm (0.008 in) 2nd ring 0.150 mm (0.0059 in) Oil, ring, 0.150 mm (0.0059 in) 47731080 04/08/2015

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Engine - Connecting rods and pistons

Engine Model

L3Al, L3BL

Ring diameter 1st Compression 2nd Compression Oil Compression

90 mm (3.54 in) 90 mm (3.54 in) 90 mm (3.54 in)

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Engine - Connecting rods and pistons

Connecting rods and pistons - Detailed view inspection

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Inspection points for typical wear NOTE: See table on next page.

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Engine - Connecting rods and pistons

Inspect the following items: • Check for damage to the snap rings (1).

• Check for wear at the piston pin bushing (2).

• Check for wear or damage to the piston rings (3).

• Check for scale deposits or other defects to the cylinder bore (4).

• Check for nicks, chipping or abnormal tooth contact to the flywheel ring gear (5).

• Check for cracks at the main bearing cap (6).

• Typical failures for which main bearings (7) are to be checked for are: ○ scratches embedded into bearing material because of dirt embedded, due to lack of oil ○ craters or pockets due to fatigue failure ○ failure due to poor seating, radius ride, etc.

• Check for cracks at the connecting rod caps (8).

• Typical failures for which connecting rod bearings (9) are to be checked for are: ○ scratches embedded into bearing material because of dirt embedded, due to lack of oil ○ craters or pockets due to fatigue failure ○ failure due to poor seating, radius ride, etc.

• Check connecting rod serrated portions for wear or cracks (10).

• Check for wear or clogged oil hole in connecting rod busings (11).

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Connecting rod and piston - Remove Prior operation: Engine oil pan - Remove (10.102) Prior operation: Valve cover - Remove (10.101) Prior operation: Cylinder head - Remove (10.101) NOTICE: Maximum permissible difference between average weight of all connecting rods in one engine is 10 g (4 oz) 1. Remove the two nuts (1), retaining the connecting rod caps (2).

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

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

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4. Push the piston (1) and connecting rod (2) out of the cylinder block (3).

NOTE: Install the connecting rod cap onto the piston assembly it was removed from. Keep together in cylinder sequence.

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Connecting rod and piston - Remove piston pins 1. Remove the snap rings (1) with a snap ring pliers (2).

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2. Remove the piston pin to separate the connecting rod from the piston.

NOTICE: Use a hammer (1) and a soft metal punch (2) as shown.

NOTICE: When it is difficult to remove the piston pin, heat the piston in an oven or in hot water only.

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Connecting rod and piston Connecting rod - Inspect 1. Check the connecting rods for damage and alignment.

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

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

• Twist (B) 0.15 mm (0.0059 in) per 100 mm (3.94 in).

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

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(A) Bent rod (B) Twisted rod

1

Engine - Connecting rods and pistons

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

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

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2. Install the piston pin (1) through the piston and connecting rod (3) and secure with retaining clips (2).

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Engine - Connecting rods and pistons

Connecting rod and piston - Install 1. Lay the crankcase (1) on its side.

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2. Clean the bores with a clean rag and apply engine oil (1) to the bores.

3. Install the connecting rod cap bolts (1) in the big end of the connecting rod (2) so the flats of their heads fit on the connecting rod properly.

4. Install the upper half of the connecting rod bearing (3) in the big end of the connecting rod. Make sure the tab on the back of the bearing is in the notch of the connecting rod (4).

NOTICE: Coat the bearing faces, pistons, and piston rings with clean engine oil. Slide the piston rings to permit a sufficient amount of oil to be applied in the grooves.

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Engine - Connecting rods and pistons

5. Make sure the piston ring end gaps are arranged on the piston as shown in the illustration.

6.

Arrangement of piston ring end gaps on piston : • Thrust direction (A).

• End gap of No.1 ring (1).

• Piston pin (B).

• End gap of Oil ring (2).

• Anti-thrust direction (C).

• End gap of No.2 ring (3).

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NOTICE: Set the piston ring gaps 120 ° apart from each other. Do not position these gaps toward the piston pin or the right angle of the pin.

7. Turn the crankshaft to bring the No.1 crankpin to the center.

8. Put a piston ring compressor (1) on the top of the crankcase in alignment with the bore center. Hold the installer in position by one hand.

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

NOTE: Make sure the big end of the connecting rod on the crankpin properly.

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

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10. Lightly tap the top of the piston (1) with the handle of a hammer to put the big end of the connecting rod on the crankpin (2).

NOTE: Ensure that the front mark on the piston (A) is towards the front of the engine (B).

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11. Install the lower half of the connecting rod bearing in the connecting rod cap.

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NOTICE: Make sure the tab on the back of the bearing is in the notch of the connecting rod cap.

12. Apply engine oil to the inside of the bearing.

13. Install the connecting rod cap (with the bearing) to the connecting rod (over the crankpin) with the matching mark of the cap on the same side as the mark of the rod.

NOTE: Tighten the connecting rod cap nuts finger tight NOTE: Do steps (1) through (13) for the installation of the piston assemblies in the No.1 cylinder Turn the crankshaft 180˚ and install the piston assemblies in the No.2 and No.3 cylinders.

14. Install the connecting rod caps (1) making sure the rod and cap matching marks (2), Figure 7 align. Tighten the connecting rod nuts (2) to 49 - 54 N·m (36 - 40 lb ft).

NOTE: After installation, ensure the crankshaft moves freely. Ensure the axial play of 0.15 - 0.35 mm (0.0059 - 0.0138 in) is provided between the connecting rod and crank pin (1).

NOTICE: Replace the connecting rod if axial play of the connecting rod on the crank pin is more then 0.50 mm (0.0197 in).

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15. Raise up the crankcase (1) with the oil pan side (2) up.

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16. Make sure the crankshaft (1) rotates smoothly.

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17. Check the crankshaft end play with a dial indicator (1) as shown. (Refer to figure 11

Item End play of crankshaft

Assembly standard 0.100 - 0.204 mm (0.0039 0.0080 in)

Repair limit 0.300 mm (0.0118 in)

NOTICE: If the end play is less than the assembly standard, retighten the main bearing cap bolts. If it exceeds the service limit, replace the flanged bearings.

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Engine - Connecting rods and pistons

Piston - Remove piston rings 1. Remove the piston rings (1) with piston ring pliers (2).

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Engine - Connecting rods and pistons

Piston - Inspect L3AL

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

2. Use a groove cleaner (1) to remove the carbon deposits from the ring grooves (2).

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

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Checking diameter of pistons 1. Measure the diameter of the piston at skirt (1) in the direction transverse to the piston pin (2) with a micrometer (3) as shown in the illustration.

NOTICE: If the piston is worn beyond service limit, replace it.

NOTICE: When replacing the piston select new piston so that the difference between average weight of all pistons in one engine does not exceeds the maximum permissible limit.

Diameter of piston, L3AL Item Standard 0.25 mm (0.0098 in) oversize 0.50 mm (0.0197 in) Maximum permissible difference between average weight of all pistons in one engine.

Normal size 89.970 mm (3.4634 in) 90.220 mm (3.4732 in) 90.470 mm (3.4831 in)

Assembly standard 89.955 - 89.985 mm (3.4628 - 3.4640 in) 90.205 - 88.235 mm (3.4726 - 3.4738 in) 90.445 - 88.485 mm (3.4825 - 3.4837 in) 5 g (0.2 oz)

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Service limit 89.770 mm (3.4555 in) 90.020 mm (3.4654 in) 90.270 mm (3.4752 in)

Engine - Connecting rods and pistons

Identification on top of piston 1. The “Front mark” (1), weight identification (2), and size identification (3).

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Engine - Connecting rods and pistons

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

2. Use a groove cleaner (1) to remove the carbon deposits from the ring grooves (2).

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

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Checking diameter of pistons 1. Measure the diameter of the piston at skirt (1) in the direction transverse to the piston pin (2) with a micrometer (3) as shown in the illustration.

NOTICE: If the piston is worn beyond service limit, replace it.

NOTICE: When replacing the piston select new piston so that the difference between average weight of all pistons in one engine does not exceeds the maximum permissible limit.

Diameter of piston, L3BL Item Standard 0.25 mm (0.0098 in) oversize 0.50 mm (0.0197 in) Maximum permissible difference between average weight of all pistons in one engine.

Normal size 87.970 mm (3.4633 in) 88.220 mm (3.47322 in) 88.470 mm (3.4830 in)

Assembly standard Service limit 87.955 - 87.98 mm (3.4627 87.770 mm (3.4555 in) - 3.4637 in) 88.205 - 88.23 mm (3.4726 88.020 mm (3.4653 in) - 3.4736 in) 88.445 - 88.48 mm (3.4820 88.270 mm (3.4751 in) - 3.4834 in) 5 g (0.2 oz)

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Engine - Connecting rods and pistons

Identification on top of piston 1. The “Front mark” (1), weight identification (2), and size identification (3).

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3

Engine - Connecting rods and pistons

Piston - Check gap between piston ring and groove 1. Check the clearance between the groove and the piston ring with a feeler gauge as shown in the illustration.

If the clearance exceeds the service limit, replace the piston ring.

NOTE: Number one ring (1), number two ring (2).

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Item Clearance between groove Number one ring and piston ring Clearance between groove Number two ring and piston ring Clearance between groove Oil ring and piston ring

1

Assembly standard Service limit 0.060 - 0.100 mm (0.00024 0.200 mm (0.0079 in) - 0.0040 in) 0.045 - 0.085 mm (0.0018 - 0.150 mm (0.0059 in) 0.0032 in) 0.025 - 0.065 mm (0.0010 - 0.150 mm (0.0059 in) 0.0026 in)

NOTICE: Install a new piston rings and recheck the clearance If the clearance still exceeds the service limit, replace the piston.

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Engine - Connecting rods and pistons

Piston - Check clearance between ends of piston rings L3AL

1. Install the piston ring in a new cylinder or a gauge and measure the clearance between the ends of the ring with a feeler gauge. If the clearance at (1) exceeds the service limit, replace all piston rings.

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Inside diameter of gauges Item Standard Inside diameter of crankcase

0.25 mm (0.009845 in) O.S 0.50 mm (0.01968 in) O.S

L3AL 90.0 mm (3.5433 in) + 0.35 mm (0.01377 in) 90.25 mm (3.5531 in) + 0.35 mm (0.01377 in) 90.50 mm (3.5629 in) + 0.35 mm (0.01377 in)

2. Install the piston ring (4) in the cylinder squarely with a piston (1).

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

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Item Clearance between ends of No.1, No. 2 ring piston ring Oil ring

Assembly standard 0.20 - 0.35 mm (0.0099 0.0158 in) 0.20 - 0.40 mm (0.00118 0.0197 in)

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Service Limit 1.50 mm (0.0591 in)

2

Engine - Connecting rods and pistons

Piston - Check clearance between ends of piston rings L3BL

1. Install the piston ring in a new cylinder or a gauge and measure the clearance between the ends of the ring with a feeler gauge. If the clearance at (1) exceeds the service limit, replace all piston rings.

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Inside diameter of gauges Item Standard Inside diameter of crankcase

0.25 mm (0.009845 in) O.S 0.50 mm (0.01968 in) O.S

L3BL 88.0 mm (3.4645 in) + 0.35 mm (0.01377 in) 88.25 mm (3.4744 in) + 0.35 mm (0.01377 in) 88.50 mm (3.4842 in) + 0.35 mm (0.01377 in)

2. Install the piston ring (4) in the cylinder squarely with a piston (1).

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

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Item Clearance between ends of No.1, No. 2 ring piston ring Oil ring

Assembly standard 0.20 - 0.35 mm (0.0099 0.0158 in) 0.20 - 0.40 mm (0.00118 0.0197 in)

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Service Limit 1.50 mm (0.0591 in)

2

Engine - Connecting rods and pistons

Piston - Check clearance between piston pin and bore 1. Measure the inside diameter of the pin bore of the piston (1) and the diameter of the pin (2) as shown in the illustration, to check the clearance.

NOTICE: If the clearance exceeds the service limit, replace the parts.

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Item Diameter of piston pin

Normal size 28 mm (1.10 in)

Clearance between piston pin and bore

N/A

Assembly standard 27.994 - 28.000 mm (1.1021 - 1.10234 in) 0.000 - 0.016 mm (0.000 0.0006 in)

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Service limit N/A 0.050 mm (0.0020 in)

1

Engine - Connecting rods and pistons

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

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

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

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Engine - Connecting rods and pistons

Connecting rod bearing - Check oil clearance Checking oil clearance of connecting rod bearings 1. Install the upper (1) and lower (2) halves of the bearings and the cap to the connecting rod and tighten the cap nuts (3) to the specified torque. ( Torque the cap nuts to 49 - 60 N·m (36 - 44 lb ft) .)

2. Measure the inside diameter of bearing as shown in the illustration (A)

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3. Measure the diameter of the crankpin of the crankshaft (1) as shown in the illustration and subtract the diameter of crankpin from the inside diameter of the bearing as measured in the pervious step.

NOTE: The difference is the oil clearance of the connecting rod bearing NOTE: Take two measurements of the crankpin diameter (B).

Item Diameter of crankpin (standard) Oil clearance

Normal size 58 mm (2.28 in) N/A

Assembly standard 57.955 - 57.970 mm (0.02.2817 - 2.2823 in) 0.03 - 0.09 mm (0.0012 0.0035 in)

Service limit

0.20 mm (0.0079 in)

NOTICE: If the oil clearance exceeds the repair limit, replace the bearing and recheck the oil clearance.

NOTICE: If the oil clearance still exceeds the repair limit, use 0.25 mm (0.0098 in), 0.50 mm (0.0197 in) or 0.75 mm (0.0295 in) undersize bearings. When using undersize bearings, refinish the crankpins to any of the undersize listed below.

0.25 mm (0.0098 in) Undersize of crankpin

0.50 mm (0.0197 in) 0.75 mm (0.0295 in)

NOTICE: Grind all crankpins to the same undersize.

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Finishing dimension 57.75 mm (2.2736 in) - 0.030 mm (0.00118 in) - 0.045 mm (0.00177 in) 57.50 mm (2.2638 in) - 0.030 mm (0.00118 in) - 0.045 mm (0.00177 in) 57.25 mm (0.02.2539 in) - 0.030 mm (0.00118 in) - 0.045 mm (0.00177 in)

Engine - Connecting rods and pistons

4. Finish the fillet radius (1) to 3.0 mm (0.12 in).

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3

Engine - Connecting rods and pistons

Piston pin bushings - Check clearance between connecting rod bushing and piston pin 1. Measure the inside diameter of the connecting rod bushing bore (1) and the diameter of the piston pin (2) as shown in the illustration to check the clearance.

NOTICE: If the clearance exceeds the service limit, replace the parts.

NOTE: Take several measurements (3).

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Item Inside diameter of bushing

Normal size 28 mm (1.10 in)

Clearance between bushing N/A and piston pin

Assembly standard Service limit 28.020 - 28.045 mm N/A (1.1032 - 1.1041 in) 0.020 - 0.051 mm (0.0008 - 0.080 mm (0.0032 in) 0.0020 in)

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Engine - Connecting rods and pistons

Piston pin bushings - Replace connecting rod bushings Replacing connecting rod bushings NOTE: Use a connecting rod bushing puller to replace the connecting rod bushings.

1. When installing a new bushing, align the oil holes in the bushing and connecting rod (1).

2. Position the ends of the bushing (2) at the location shown in the illustration.

NOTE: After installing the bushing, insert the piston pin into position and make sure it rotates smoothly.

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1

Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Connecting rod and piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connecting rod and piston - Remove piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting rod and piston Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Connecting rod bearing - Check oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Connecting rods and pistons - Detailed view inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Piston - Check clearance between ends of piston rings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Piston - Check clearance between ends of piston rings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Piston - Check clearance between piston pin and bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Piston - Check gap between piston ring and groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Piston - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Piston - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Piston - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Piston - Remove piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Piston Ring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Piston pin bushings - Check clearance between connecting rod bushing and piston pin . . . . . . . . . . . . . . . . . . . . . 29 Piston pin bushings - Replace connecting rod bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

(*) See content for specific models 47731080 04/08/2015

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Engine - 10 Valve drive and gears - 106

L3AL L3BL

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Rocker arm Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Camshaft Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Push rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rocker arm Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Valve drive and gears Inspect – Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replace valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace combustion jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rocker support Remove rocker shaft assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install rocker shaft assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Camshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Check tappets for wear and clearance between tappet and bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Camshaft gear Remove camshaft and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install camshaft and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Rocker arm - Dimension Engine model

L3AL, L3BL Shaft diameter

Standard Minimum Standard Maximum

18.980 - 19 mm (0.7472 - 0.75 in) Not available Shaft-to-rocker clearance 0.010 - 0.050 mm (00.00039 - 0.00197 in) 0.050 mm (0.00197 in)

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

L3AL, L3BL Inlet valves 46.916 mm (1.84708 in) , Exhaust valves 45.944 mm (1.80882 in) 34.1 mm (1.3425 in) More than 0.02 mm (0.0007 in) 0.05 mm (0.0020 in) 0.05 - 0.15 mm (0.0019 - 0.0059 in) 0.25 mm (0.0098 in)

Camshaft Push rod - Dimension Engine model Length Diameter

L3AL, L3BL 210 mm (8 in) 8 mm (0.3149 in)

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Rocker arm - Dynamic description The rocker shaft (1) and rocker arms (2) work in conjunction to operate the three sets of intake and exhaust valves.

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The energy from the camshaft travels up the push rod (3) and rocks over the rocker (1) to the valves (2).

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Camshaft - Dynamic description The camshaft (1) is driven by the crankshaft (2) through an idler gear (3).

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The camshaft (1) has lobes (2) .

Through tappets (3) and push rods (4), the camshaft (1) operates intake and exhaust valves (5).

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

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(1) Correct valve seat width and location.

(2) Correct valve head margin LS: L3AL, L3BL 1.20 - 1.70 mm (0.05 0.07 in)

1

(3) Correct valve sinkage : Normal (4) 30 ° Valve seat angle. size 0.8 mm (0.032 in) Correct valve sinkage : Assembly standard, 0.7 - 0.9 mm (0.028 0.035 in) Correct valve sinkage : Service limit, 1.3 mm (0.051 in)

1. Check the seat for surface defects. Use a 30 ° stone if necessary to reface. Grind away only enough material to provide a smooth even seat.

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

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

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Valve drive and gears - Replace valve seats Removal 1. Weld (1) a stud (4) to the valve seat (3) Insert a bar (2) through the valve guide from the upper side of the cylinder head put its end on the stud (4) as shown in the illustration.

2. Drive the seat off the head.

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NOTICE: When welding the stud to the valve seat, avoid contact of any spatter with the machined surface of the cylinder head.

NOTE: Before installing a replacement valve seat, measure the bores in the cylinder head for the valve seats to make sure they are correct in dimension.

Install 1. Chill the valve seat in liquid Nitrogen.

2. The temperature will be -170 °C (-274 °F) for more than four minutes.

3. Heat the cylinder head to 80 - 100 °C (176 - 212 °F) with the valve seat chilled in ether or alcohol containing dry ice.

4. Use a installation tool (1) to drive the seat (2) into the head (3).

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Valve drive and gears - Replace combustion jets Removal NOTE: Replace the combustion jets when they are cracked otherwise faulty.

NOTE: The glow plugs should be removed.

1. Remove the combustion jet (3) by tapping the jet from the cylinder head with a 6 mm (0.24 in) diameter bar (1).

2. Insert the bar (1) through the glow plug hole (2), tap the combustion jet (3) out of the head.

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Installation NOTICE: Drive the combustion jet into place with a plastic hammer.

1. Install the combustion jet (1), positioned so the orifice is toward the center of the cylinder.

NOTE: The center of the orifice (A) is 15 °, (2) to the right of the center line (3) of the cylinder (4).

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Rocker support - Remove rocker shaft assemblies Removal 1. Loosen the adjusting screw (1) one turn.

2. Remove the bolts, long and short, (2) that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first.

NOTICE: If the long bolt is loosened first the rocker shaft bracket might suffer damage.

3. Remove the rocker shaft (3) assembly from cylinder head (4).

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Rocker support - Disassemble 1. Remove the snap ring (1).

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NOTICE: Before removing the rocker arms, mark them for their rocker shaft position to insure the original clearance between the arm and shaft at time of assembly.

2. Slide the rocker arms (1) and springs (2) off of the rocker shaft (3).

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Rocker support - Assemble NOTICE: Install as marked during disassembly.

NOTE: When installing the rocker arms to the rocker shaft, position the arms with their assembly marks pointing forward.

NOTE: After installing the arms, make sure they move smoothly.

1. Install the rockers (1) and springs (2) on the rail (3).

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2. Install the snap ring (1).

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Rocker support - Install rocker shaft assemblies 1. Install the rocker shaft (2) onto the cylinder head (3).

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2. Install the three long M8 x 62mm bolts (2).

3. Install the three short M8 x 25mm bolts (3).

4. Turn the rocker screw (1) inward one turn. and lock with nut. (Refer to figure 1 for an exploded view.)

NOTICE: Tighten these bolts from the center of the rocker arm assembly outwards. Torque the M8 x 62mm bolts to 13 - 17 N·m (10 - 12 lb ft). Torque the M8 x 25mm bolts to 11 - 13 N·m (8 - 9 lb ft).

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Camshaft - Remove 1. Remove the camshaft (1), by removing two M8 x 1.25 x 16 hex bolts and two M8 lock washers.

2. Remove the camshaft and gear as a unit.

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Camshaft - Remove tappets 1. Remove the tappets (1) from the bores (2) of the crankcase (3).

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Engine - Valve drive and gears

Camshaft - Check tappets for wear and clearance between tappet and bore Contact 1. Check the cam contact face of each tappet for wear.

Replace badly worn tappets if any.

• (A) Good • (B) Bad • (C) Bad

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Checking clearance between tappet and bore 2. Measure the diameter of the tappet (1) and the inside diameter the bore (2) in the crankcase for the tappet as shown in illustration, to check the clearance.

NOTE: Take several measurements (A).

NOTICE: If the clearance exceeds the service limit, replace the tappets. If the bores are worn beyond the service limit, replace the crankcase.

Item Inside diameter of bore for tappet Clearance between tappet and bore

Normal size 14 mm (0.55 in) N/A

Assembly standard Service limit 14.000 - 14.018 mm 14.100 mm (0.5551 in) (0.5512 - 0.5519 in) 0.016 - 0.052 mm (0.0006 - 0.080 mm (0.0032 in) 0.0021 in)

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Camshaft - Install tappets 1. Apply engine oil to the tappets (1) and install them in the bores (2) in the crankcase (3).

NOTICE: Make sure the tappets rotate smoothly.

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Camshaft - Install 1. Install the key (3) and the thrust plate (2) on the camshaft (4).

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2. Install the camshaft gear (1) by heating the gear to 250 °C (482 °F).

NOTE: The thrust plate (2) must go on the camshaft before the camshaft gear.

3. Drive the camshaft gear (1) onto the camshaft (4).

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Camshaft gear - Remove camshaft and gear 1. Remove the camshaft (1), by removing two M8 x 1.25 x 16 hex bolts and two M8 lock washers.

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2. Remove the camshaft gear (1) and thrust plate (2) from the camshaft (4) by using a hydraulic press.

NOTE: Do not remove the camshaft, thrust place or gear unless it requires replacement.

3. Remove the key (3) from the camshaft (4).

Remove front end plate and gasket 1. Remove the front end plate by removing two M8 x 1.25 x 16 hex bolts and washers (4).

2. Remove the front end plate (1) and gasket (2) from the front face of the crankcase (3).

NOTICE: Make sure the locating dowels stay in their place.

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Camshaft gear - Install camshaft and gear 1. Install the key (3) and the thrust plate (2) on the camshaft (4).

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2. Install the camshaft gear (1) by heating the gear to 250 °C (482 °F).

NOTE: The thrust plate (2) must go on the camshaft before the camshaft gear.

3. Drive the camshaft gear (1) onto the camshaft (4).

Installing front end plate 1. Put the front end plate (1) and gasket (2) on the front face of the crankcase (3).

NOTICE: Make sure the locating dowels enter their holes in the plate and gasket.

2. Secure the front end plate by installing two M8 x 1.25 x 16 hex bolts and washers (4).

3. Torque the two bolts (4) to 11 - 13 N·m (8 - 9 lb ft).

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Installing camshaft 1. Apply engine oil to the camshaft (1).

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2. Install the camshaft (with gear) in the crankcase.

NOTICE: Do not cause damage to the journals and lobes.

3. Secure the camshaft (1), by installing two M8 x 1.25 x 16 hex bolts and two M8 lock washers.

4. Torque the bolts to 11 - 13 N·m (8 - 9 lb ft).

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Index Engine - 10 Valve drive and gears - 106 Camshaft - Check tappets for wear and clearance between tappet and bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Camshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Camshaft - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Camshaft - Install tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Camshaft - Remove tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Camshaft Push rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Camshaft gear - Install camshaft and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Camshaft gear - Remove camshaft and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rocker arm - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rocker arm - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rocker support - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rocker support - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rocker support - Install rocker shaft assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rocker support - Remove rocker shaft assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Valve drive and gears - Inspect – Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve drive and gears - Replace combustion jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Valve drive and gears - Replace valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - 10 Pump drives - 114

L3AL L3BL

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Contents Engine - 10 Pump drives - 114

FUNCTIONAL DATA Crankcase gears Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Crankcase gears Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Backlash measurement between the gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 End play of idler gear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 End play of camshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install Idler gear, Oil pump, and Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Crankcase gears - Exploded view

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Crankcase gears (1) Injection pump drive gear (2) Idler gear (3) Camshaft

(4) Idler gear (5) Hydraulic pump drive gear (6) Crankshaft gear

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Crankcase gears - Remove 1. Remove the camshaft (1), by removing two M8 x 1.25 x 16 hex bolts and two M8 lock washers.

2. Remove the camshaft and gear as a unit.

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Engine - Pump drives

Crankcase gears - Backlash measurement between the gears 1. Measure the backlash between the gears (1) and make a record of the measurements to be referred to at the time of assembly.

NOTICE: If the backlash exceeds the service limit, replace the gears.

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Item Backlash between crankshaft gear and idler gear Backlash between idler gear and camshaft gear Backlash between injection pump drive gear and idler gear

Assembly standard

Service limit

0.05 - 0.15 mm (0.0020 - 0.0059 in)

0.25 mm (0.0098 in)

0.04 - 0.16 mm (0.0016 - 0.0063 in)

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Engine - Pump drives

Crankcase gears - End play of idler gear check 1. Check the end play with a feeler gauge (1) or a dial indicator.

NOTICE: If the end play exceeds the service limit, replace the thrust plate.

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Item End play of gear

Assembly standard 0.05 - 0.0020 mm (0.20 - 0.0079 in)

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Service limit 0.35 mm (0.0138 in)

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Engine - Pump drives

Crankcase gears - End play of camshaft check 1. Check the end play with a dial indicator (1), as shown in the illustration.

NOTICE: If the end play exceeds the service limit, replace the thrust plate.

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Item End play of camshaft

Assembly standard 0.10 - 0.25 mm (0.0039 - 0.0098 in)

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Service limit 0.30 mm (0.0118 in)

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Engine - Pump drives

Crankcase gears - Install 1. Install the key (3) and the thrust plate (2) on the camshaft (4).

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2. Install the camshaft gear (1) by heating the gear to 250 °C (482 °F).

NOTE: The thrust plate (2) must go on the camshaft before the camshaft gear.

3. Drive the camshaft gear (1) onto the camshaft (4).

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Crankcase gears - Install Idler gear, Oil pump, and Injection timing 1. Install the thrust washer, on the idler gear shaft.

2. Align the timing marks (2) on the idler gear (4), crankshaft gear (3), and the camshaft gear (1).

3. Complete the installation of the oil pump and adjust axial clearance. See Engine oil pump - Install - oil pump, suction pipe and suction strainer (10.304) NOTE: Do not turn the crankshaft until the timing gear cover is installed.

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Index Engine - 10 Pump drives - 114 Crankcase gears - Backlash measurement between the gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crankcase gears - End play of camshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Crankcase gears - End play of idler gear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crankcase gears - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankcase gears - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crankcase gears - Install Idler gear, Oil pump, and Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankcase gears - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fuel injection system - 218

L3AL L3BL

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Injection pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Fuel injection system Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view ;Sensor, and injection system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel fillers Exploded view and water sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Injection pump Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Fuel injection system

Injection pump - General specification Fuel system specifications Engine model Fuel injection pump type Fuel injection timing Injector opening pressure Fuel

L3AL, L3BL Bosch VE ATDC 3 ° 157 bar (2276 psi) Diesel

Injection pump - General specification Item Number of cylinders Direction of rotation Maximum allowable speed (pump) Plunger diameters Injection timing control

Speed governing

Speed drop Weight Lubrication system Control lever position Stop lever position Maximum allowable in-pipe pressure Engine reverse rotation prevention

Additional devices

Specification 2, 3, 4, 5 or 6 Clockwise/counterclockwise (viewed from the operator’s side) 3000 RPM (2. 4. 5 cylinders) 2500 RPM (3. 6 cylinders) 8.0 mm (0.2149 in), 9.0 mm (0.3543 in), 10 mm (0.3937 in), 11.0 mm (0.4330 in), 12.0 mm (0.4724 in) Speed timer 2, 4, 5 cylinders: 110 ° Maximum 3, 6 cylinders: 7 ° Maximum Load Timer Maximum: 3 - 4 ° (3 - 4 °) Speed-load timer 2, 4. 5 cylinders: 11 ° Maximum 3, 6 cylinders: 7 ° Maximum Variable speed governor (All speed governor) Minimum-maximum speed governor (limited speed governor) Combination governor(Half- all speed governor) 4 % 750 RPM Approximately 6 kg (12 lb) Fuel oil lubrication Right or Left side of governor cover (viewed from the drive side) Right or Left side of governor cover (viewed from the drive side) 540 bar (7823 psi) Because the inlet port opens during the compression stroke if the engine rotates in the reverse direction, fuel cannot be delivered and injection cannot occur.

Installation of boost compensator, pump speed sensor, cold start device etc. is possible.

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Fuel injection system - Static description Fuel Delivery The drive shaft, rotated by the engine’s timing belt (or gear), rotates the cam disk through a cross coupling. The cam disk’s press-fitted pin fits into a groove in the plunger to rotate the plunger.

To reciprocate the plunger, the cam disk is also equipped with raised face cams, arranged uniformly around the circumference of the cam disk. The cam disk’s face cams are always in contact with the roller holder assembly’s rollers because the cam disk and the plunger are pressed against the roller holder assembly by the set force of the two plunger springs.

Because of this the plunger can follow cam disk movement. Therefore, as the cam disk is rotated on the roller holder assembly by the drive shaft. simultaneous plunger rotation and reciprocating movement is possible.

The roller holder assembly construction is such that it can only rotate in a certain angle range in accordance with timer operation.

Because the plunger rotates and reciprocates simultaneously, suction of the fuel oil into the pressure chamber, pressurization in the pressure chamber delivery into the engine cylinder are possible.

Speed Governing The governor is located in the upper part of the injection pump chamber. Four flyweights and a governor sleeve are held in the flyweight holder, which is mounted on the governor shaft.

The flyweight holder is rotated and accelerated by the drive shaft gear, through rubber dampers.

The governor lever assembly is supported by pivot bolts in the pump housing, and the ball joint at the bottom of the lever assembly is inserted into the control sleeve, which slides over the outside surface of the plunger The top of the lever assembly (the tension lever) is connected to the governor spring by a retaining pin, while the opposite end of the governor spring is connected to the control lever shaft. The control lever shaft is inserted into the governor cover and a control lever is attached to the control lever shaft. The accelerator pedal is connected directly to the control lever by a linkage, and the governor spring set force changes in response to the control lever position (i.e. accelerator pedal position).

Injection quantity control is governed by the mutually opposing forces of the flyweights’ centrifugal force and the governor spring’s set force.

The flyweights’ centrifugal force, which changes in response to engine speed, acts on the governor lever through the governor sleeve.

The governor spring’s set force, which is dependant on control lever position, i.e. accelerator pedal position, acts on the governor lever through the retaining pin.

Injection Timing Control In the lower part of the injection pump is the timer, in the centre of which the timer piston is positioned.

On the low pressure side of the timer piston is a timer spring with a predetermined set force; the pump chamber fuel oil pressure acts on the opposite side (high pressure side). The timer piston position changes in accordance with the balance of these two forces, to rotate the roller holder via the roller holder pin. When the timer piston compresses the timer spring, the injection timing is advanced (the roller holder rotates in the reverse rotation direction), and through timer piston movement in the opposite direction the injection timing is retarded. Injection timing is controlled by the above.

Feed Pump The feed pump comprises a rotor, blades and liner. Drive shaft rotation is transmitted through a key to the rotor to rotate the rotor.

The inside circumference of the liner is eccentric to the center of rotor rotation. Four blades are installed in the rotor.

Centrifugal force forces the blades outwards during rotation to contact the inside surface of the liner and form four fuel oil chambers. Therefore, the volume of these four chambers increases through rotor rotation to suck fuel oil from the fuel tank. Conversely, when the volume of these four chambers decreases fuel oil is pressurized.

Regulating Valve Feed pump fuel oil delivery pressure increases proportionately with an increase in injection pump speed.

However, the total fuel oil injection quantity necessary for the engine is considerably less than that delivered by the feed pump. Therefore, in order to prevent an excessive increase in the pump chamber pressure caused by the excess fuel oil, and to adjust the pump chamber pressure so that it is usually within the specified limit, a regulating valve is 47731080 04/08/2015

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installed near the feed pump outlet. The timer performs timing control using the pump chamber pressure, which is regulated by the regulating valve.

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Fuel injection system - Exploded view ;Sensor, and injection system components

NHIL14ENG0688GA

1

Fuel injection system components (1) Fuel pump and filter (2) Bolt, M8

(7) Pipe clamp

(13) O - ring

(8) Nut, M8 x 1.25

(3) Hose clamp

(9) Lock washer

(14) Injector pump gasket (15) Injection pump

(4) Fuel hose (ID 7mm (10) Upper retainer x 250mm Length) (5) Fuel return pipe (11) Stud bolt, M8 x 1.25 x 35mm (6) Hose clamp (12) Injector pump flange

(16) Number one injector pipe (17) Hex bolt, M6 x 25mm with washer (18) Pipe clamp

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(19) Number two (25) Gasket holder injector pipe (20) Fuel leakoff pipe (21) Number three injector pipe (22) Nozzle nut (23) Fuel gasket (24) Injector pump nozzle

Engine - Fuel injection system

Fuel injection system - Dynamic description

NHIL14ENG0327FA

1

Fuel system (1) Fuel pump (2) Fuel filter (3) Overflow pipe

(4) Injector nozzle (5) Fuel cutoff solenoid (6) VE type injection pump

(7) Fuel tank (8) Moisture separator

The illustration shows an example of a fuel system. The injection pump drive shaft is turned by the engine’s timing gear, and fuel is drawn by the fuel pump through the moisture separator. The fuel will pass through a fuel filter, into the injection pump’s fuel inlet. The fuel filter will filter out any fuel contamination, and the moisture separator removes moisture from the fuel system.

The drive shaft rotation will supply fuel into the injection pump. Fuel pressure will increase as it enters the injection pump’s chamber. Fuel pressure is proportional to the speed of the injection pump’s drive shaft. When the fuel pressure exceeds a specified pressure, the excess fuel will return to the inlet side through a regulating valve. The regulating valve is located at the injection pump’s fuel outlet.

The fuel in the injection pump chamber flows through the distributor head inlet, and into the pressure chamber. The plunger rotation and reciprocating motion inside the chamber increase the fuel pressure. Fuel is then delivered through the injection pipe to the nozzle, and nozzle holder. An overflow valve located at the top of the injection pump, helps to maintain a constant fuel temperature in the pump chamber by returning excess fuel to the fuel tank.

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Fuel fillers - Exploded view and water sensor

NHIL14ENG0399BA

1

Fuel filter and water sensor (1) Bolt, M8 x 1.25 x 25mm

(4) O - ring

(2) Body assembly

(5) Sensor assembly

(3) Air vent plug

(6) Electrical connection

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(7) Fuel hose, OD 8MM, ID 5mm x 300mm (8) Cartridge assembly (9) Body assembly

Engine - Fuel injection system

Injection pump - Timing adjust 1. Remove the engine valve cover (1).

NHIL13CT00757AA

1

NHIL13CT00752AA

2

NHIL13CT00766AA

3

2. Remove the oil fill cover (2) from the timing gear housing to gain access to the injection pump gear (3).

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3. Rotate the engine crankshaft clockwise until both #1 cylinder valve rockers (1) and push rods (2) are loose.

This indicates compression stroke of #1 cylinder.

4. Remove rocker arm assembly (3) from the engine cylinder head.

NHIL13CT00761AA

4

NHIL13CT00758AA

5

NHIL13CT00760AA

6

NHIL13CT00767AA

7

5. Remove the valve keepers and spring from one of the #1 cylinder valves.

6. Push valve (1) downwards until valve contacts the top of the piston.

7. Install a dial indicator (2) of top of the valve stem.

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NOTICE: Read the following procedure before removing the injection pump from the engine.

8. Rotate the crankshaft clockwise until the “B B” timing marks (1) on the injection pump gear are at approximately 4 o’clock position and are in full tooth engagement with the idler gear (2). Mark the idler gear tooth (A) with a paint pen at this time.

NHIL13CT00786AA

8

NHIL13CT00761AA

9

9. Rotate the crankshaft clockwise until the valve travel shown on the dial indicator (1) reverses direction. The point at when the valve direction reverses is top dead center or “TDC” of the #1 piston travel.

NHIL13CT00767AA

10

NHIL13CT00753AA

11

10. Remove injector lines (1) and head bolt (2) from the rear of the fuel injection pump.

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11. Install special adapter with dial indicator (1) tool # CAS1745 into the rear of the injection pump.

12. Pre load the dial indicator approximately 2.5 mm (0.098 in) .

NHIL13CT00763AA

12

NHIL13CT00787AA

13

NHIL13CT00761AA

14

NHIL13CT00787AA

15

13. Rotate the crankshaft counter-clockwise approximately 30 ° until the dial indicator on the injection pump STOPS moving. Stop rotating the crankshaft at this point.

14. Adjust the dial indicator to ZERO at this time.

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15. Rotate the crankshaft pulley clockwise until the until top dead center (TDC) of #1 cylinder is obtained.

NHIL13CT00761AA

16

NHIL13CT00769AA

17

NHIL13CT00787AA

18

16. Loosen the injection pump mounting bolts and rotate the pump to adjust pump timing until total dial indicator movement (A) from the ZERO setting reads the following:

Engine model L3BL (33 HP) L3BA (38 HP)

Tractor model Workmaster 35 Workmaster 40

Dial indicator total movement (A) 1.175mm ((0.046in) 1.175mm ((0.046in)

Engine model L3BL (33 HP) L3BA (38 HP)

Tractor model Workmaster 35 Workmaster 40

Injection pump timing specification After top dead center 3° (ATDC3) After top dead center 3° (ATDC3)

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17. Tighten the injection pump mounting bolts and reassemble engine.

NHIL13CT00769AA

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19

Index Engine - 10 Fuel injection system - 218 Fuel fillers - Exploded view and water sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel injection system - Exploded view ;Sensor, and injection system components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel injection system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Injection pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Injection pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - 10 Intake and exhaust manifolds and muffler - 254

L3AL L3BL

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

FUNCTIONAL DATA Intake and exhaust manifolds and muffler Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Intake manifold Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exhaust manifold Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Dynamic description

NHIL14ENG0188FA

1

Air flow NOTE: The dark arrows in figure 1 show the up and down motion of the piston (5) and intake and exhaust valves (2).The outlined arrows show air travel.

Air flow (1) through natural aspiration, is drawn through the intake manifold (6). The piston (5) and the valves (2) are timed with timing gears. During this process air is drawn into the combustion cylinder through the intake valve (2) by the piston (5) on a downward travel. The piston will complete it’s stroke, the intake valve (2) will close as the piston (5) starts it’s upward travel. At some point combustion takes place near top dead center and the exhaust valve opens.

The timed combustion actually drives the piston (5) downward . Exhaust gasses (3) leave the engine through the exhaust manifold (4), exhaust piping and muffler (Not shown).

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Intake manifold - Exploded view

NHIL14ENG0404FA

1

Intake manifold and components (1) Bolt, M8 x 1.25 x 20mm (2) Bolt, M8 x 1.25 x 60mm (3) Intake manifold (Qty. seven) (Qty. one)

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(4) Gasket

Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Exploded view

NHIL14ENG0405FA

1

Exhaust manifold and components (1) Gasket

(2) Exhaust manifold

(3) Hex bolt, M8 x 1.25 x 23mm (Qty. six)

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Intake manifold - Remove 1. Remove the seven M8 x 1.25 x 20mm bolts (1).

2. Remove the one M8 x 1.25 x 60mm bolt (2).

3. Remove the intake manifold (3).

4. Remove the gasket (4).

NOTICE: Replace the gasket (4) at assembly.

NHIL14ENG0404AA

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1

Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install 1. Install the gasket (4).

NOTICE: Replace the gasket (4) at assembly.

2. Install the intake manifold (3).

3. Install the seven M8 x 1.25 x 20mm bolts (1).

4. Install the one M8 x 1.25 x 60mm bolt (2).

NHIL14ENG0404AA

NOTE: Torque these eight bolts 12 - 14 N·m (9 - 10 lb ft).

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1

Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove 1. Remove the six M8 x 1.25 x 23mm bolts (3).

2. Remove the exhaust manifold (2).

3. Remove the gasket (1).

NOTICE: Replace the gasket (1) at assembly.

NHIL14ENG0405AA

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1

Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install 1. Install the gasket (1).

2. Install the exhaust manifold (2).

3. Install the six M8 x 1.25 x 23mm bolts (3).

NOTICE: Torque the six bolts to 15 - 19 N·m (11 - 14 lb ft).

NHIL14ENG0405AA

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1

Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust manifold - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Intake and exhaust manifolds and muffler - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intake manifold - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - 10 Engine lubrication system - 304

L3AL L3BL

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Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Engine lubrication system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Engine lubrication system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine oil filter Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Oil pressure valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine oil pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Engine lubrication system Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine oil filter Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Oil pressure valve Remove the oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install the oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine oil pump Remove oil pump, - suction pipe and strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install - oil pump, suction pipe and suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Crankcase ventilation system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Engine - Engine lubrication system

Engine lubrication system - General specification Lubrication system Engine model Minimum oil pressure Relief pressure Oil capacity (High / low level) Lubrication oil Maximum oil temperature

L3AL, L3BL 1 bar (14 psi) 3 bar (50 psi) +/- 0.5 bar (7 psi) 6 L (2 US gal) / 5 L (1 US gal) AMBRA SUPER GOLD 15W-40/AKCELA ENGINE OIL 15W-40 130 °C (266 °F)

Engine lubrication system - General specification Engine model Pressure relief valve Opening pressure Fully open at 2600 RPM Rotor-to-vane clearance Standard Maximum Rotor-to-cover clearance Standard Maximum Oil pump volume

L3AL, L3BL 3 - 4 bar (43 - 57 psi) 4 bar (57 psi) 0.13 - 0.15 mm (0.0051 - 0.0059 in) 0.20 mm (0.0078 in) 0.04 - 0.09 mm (0.0015 - 0.0035 in) 0.15 mm (0.0059 in) 5 - 6 L/min (1 - 2 US gpm)

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Engine - Engine lubrication system

Engine lubrication system - Dynamic description The oil pump assembly is located within the idler gear at the front of the block, below and to the left of the crankshaft as viewed from the front of the engine. The oil pump is driven by the crankshaft gear.

Oil is picked up from the sump through the suction strainer and intake tube and drawn into the lower side drilling in the block to the oil pump. Oil from the pump flows through passages in the block, past the relief valve, through the oil filter and returns to the main oil gallery in the area of the drilled bolt located on the side of the block. Oil flow in the main oil gallery extends to the four main bearings. Oil flow to the main bearings passes through drilled passages in the crankshaft to the three connecting rod bearings. The remaining portion of the oil flow is directed through the external tube to the rocker arm assembly. Oil flows from the external tube into a passage in the rocker arm bracket to the rocker arm shaft. Oil leakage from clearance between the rocker arms and the shaft overflows in the valve cover and lubricates the valve stems, push rods, and tappets. The relief valve is mounted on the side of the engine block and intersects the main oil passage. When the oil pressure exceeds the rated pressure, oil is bypassed through the relief valve directly to the sump. The cylinder walls, pistons, and piston pins are splash lubricated by the crankshaft.

NHIL14ENG0199FA

1

Lubrication oil flow (1) Oil pressure switch (2) Relief valve (3) Oil filter

(4) Suction strainer (5) Oil pump

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Engine oil filter - Component localization The engine oil filter (1) is located on the left side of the engine.

NHIL14ENG0203AA

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Engine - Engine lubrication system

Engine oil filter - Dynamic description Oil from the engine oil sump is pumped through the oil filter (1) where dirt is taken out of the oil.

The lubrication system and the oil filter are protected from over pressurization by the oil relief valve (2).

NHIL14ENG0206AA

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Engine - Engine lubrication system

Engine oil filter - Overview When installing a filter, wet the seal (1) with clean engine oil.

NHIL14ENG0204AA

1

NHIL14ENG0205AA

2

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3

Directions to turn the filter : (1) Counter clockwise (Off) (2) Clockwise (On)

Engine oil filter installed.

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Engine - Engine lubrication system

Oil pressure valve - Dynamic description The oil pressure relief valve (1) is designed to protect the engine lubrication system fro over pressurization. When it senses extreme pressure, it relieves internally.

Item Valve opening pressure

Assembly standard 3 - 4 Kg/cm² (43 - 57 psi)

NHIL14ENG0206AA

1

NHIL14ENG0206AA

2

Relief pressure is adjusted up or down by adding or subtracting shims (1).

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Engine - Engine lubrication system

Engine oil pump - Exploded view

NHIL14ENG0394BA

1

Engine oil pump components (1) Gear and case assembly (2) Outer rotor (3) Oil pump cover (4) Oil pump strainer gasket

(5) Oil strainer

(9) Oil filter shaft

(6) Hex bolt, M6 x 20 (10) Oil filter assembly (7) Gasket (11) Oil pump set bolt (8) Relief valve (12) Gasket assembly (13) Oil pressure switch

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Engine - Engine lubrication system

Engine oil pump - Dynamic description

NHIL14ENG0199FA

1

The oil pump (1) receives it’s power from the camshaft (2).

The pump receives oil from the oil sump (3).

Oil is sucked into the pump (1) through the strainer (4).

From there the pump discharges to the main gallery (5) for oil distribution.

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Engine - Engine lubrication system

NHIL14ENG0564FA

Oil pump (1)

2

Rail bolt (2)

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Engine - Engine lubrication system

Engine lubrication system - Pressure test - Engine oil Check 1. Disconnect the sending lead (1) and remove the oil pressure sending unit (2).

NHIL14ENG0556AA

1

NHIL14ENG0685AA

2

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3

NOTE: The main gallery access port (1) is located next to the oil filter (2).

2. Install the oil pressure test fitting FNH00011 (1) and test gauge (2). Start the engine and observe gauge indicator. Gauge should indicate between 3.0 bar (43.0 psi) at low idle and 3.9 bar (57.0 psi) at high idle.

NOTE: Pressure test should be with engine at normal operating temperature.

3. If the gauge did not indicate the oil pressure within specified tolerances at low and high idle, troubleshoot the lube oil system. See Engine - Troubleshooting (10.001).

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Engine - Engine lubrication system

Engine oil filter - Service instruction Construction and Function 1. These engines utilize a cartridge type filter. Pressurized oil flows from the pump enters from (1) and is filtered by a full flow filter before discharge through (2).

When the full flow filter is clogged, the safety valve (3) opens to bypass the oil.

NHIL14ENG0952AA

1

NHIL12CT00696AA

2

NHIL12CT00694

3

Replacement 1. Replace the oil filter every 300 hours of operation.

NOTE: Initial 50 hours.

2. Coat the filter mounting surface with oil and tighten the filter by hand.

3. Do not reuse the filter if it was removed once.

NOTE: Change the engine oil and filter after the first 50 hours of operation, then every 300 hours thereafter. If the tractor is operated for extended periods of time at maximum rated power and speed, or under other types of continuous, severe operating conditions, the engine oil and filter should be changed at 200 hour intervals following the initial oil change.

To change the engine oil: 4. Place a suitable container beneath the drain opening to catch the used oil. With the tractor engine off but at normal operating temperature, remove the drain plugs, (1). Reinstall the plugs after all of the oil has been drained.

NOTE: There are two drain plugs in the oil pan, one on each side of the engine.

5. Next, place a container below the oil filter, (2), to catch the used oil and unscrew the oil filter. Discard the used oil and filter.

6. Coat the gasket on the new filter with a film of clean oil.

Screw the filter into place until the gasket contacts its mating surface, then turn the filter approximately threequarters of a turn by hand. Do not overtighten.

7. Add the proper type and level of new oil, then start the engine and check the filter for leaks.

NOTE: Oil Capacity, with filter 6.5 l (6.9 US qt)

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Engine - Engine lubrication system

Recommended Oils Ambient Temp (°F) -12 - 49 °C (10 - 120 °F)

Recommended Oil AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15W-40/AKCELA NO. 1™ ENGINE OIL SAE 15W-40 AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 10W-30/AKCELA NO. 1™ ENGINE OIL SAE 10W-30 AMBRA MASTERGOLD HSP SAE 5W-30/ENGINE OIL SAE 5W-30

-23.3 - 49 °C (-10 - 120 °F) -29 - 16 °C (-20 - 60 °F) Oil Specification API CF-4 or CH-4 NOTE: Tractors are originally shipped with (15W40) oil.

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Engine - Engine lubrication system

Oil pressure valve - Remove the oil pressure relief valve 1. Remove the oil pressure relief valve (1) from the block.

NHIL14ENG0556AA

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Engine - Engine lubrication system

Oil pressure valve - Inspect 1. Disassemble the oil relief valve (1) and inspect the components (2) for cracks and wear.

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NHIL14ENG0540AA

1

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Engine - Engine lubrication system

Oil pressure valve - Install the oil pressure relief valve 1. Install a new copper seal (1) on the oil pressure relief valve (2).

NHIL14ENG0540AA

1

NHIL14ENG0556AA

2

2. Install the oil pressure relief (1) valve into the block.

3. Torque the oil pressure relief valve to 43 - 54 N·m (32 40 lb ft).

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Engine - Engine lubrication system

Engine oil pump - Remove oil pump, - suction pipe and strainer Prior operation: Engine oil pan - Remove (10.102) 1. Remove the rail bolt (1).

NHIL14ENG0563AA

1

NHIL14ENG0562AA

2

2. Grasp the oil pump pickup tube (1) and remove the oil pump (2).

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Engine - Engine lubrication system

Engine oil pump - Inspect - Pick-up tube 1. Clean the filter mesh (1), remove any debris or foreign objects.

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Engine - Engine lubrication system

Engine oil pump - Install - oil pump, suction pipe and suction strainer 1. Install the oil pump, suction pipe and strainer with the gear down.

NOTE: Ensure the pick up tube (1) strainer is facing to the rear of the engine.

NHIL14ENG0562AA

1

NHIL14ENG0563AA

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2. Install the rail bolt (1).

3. Torque the rail bolt (1) to 30 - 38 N·m (22 - 28 lb ft).

Next operation: Engine oil pan - Install (10.102)

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Engine - Engine lubrication system

Engine oil pump - Inspect Prior operation: Engine oil pump - Remove (10.304) 1. Remove the four M6 x 20 hex bolts (1).

NHIL14ENG0564AA

1

NHIL14ENG0200AA

2

Clearance between outer rotor and inner rotor.

1. Check the clearance with a feeler gauge (1), as shown in the illustration.

NOTICE: If the clearance exceeds the service limit, replace the pump assembly.

Item Clearance between outer and inner rotor

Assembly standard 0.13 - 0.15 mm (0.0051 - 0.0059 in)

Service limit 0.20 mm (0.0078 in)

Clearance between rotors and cover.

1. Check the clearance with a feeler gauge (1) and straight edge (2), as shown in the illustration.

NOTICE: If the clearance exceeds the service limit, replace the pump assembly.

NHIL14ENG0201AA

Item Assembly standard Clearance between rotors and cover 0.04 - 0.09 mm (0.0015 - 0.0035 in)

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Service limit 0.15 mm (0.0059 in)

3

Engine - Engine lubrication system

Clearance between outer rotor and case.

1. Check the clearance with a feeler gauge, (1) as shown in the illustration.

NOTICE: If the clearance exceeds the service limit, replace the pump assembly.

NHIL14ENG0200AA

Item Clearance between outer rotor and case

4

Assembly standard Service limit 0.20 - 0.275 mm (0.0078 - 0.0108 in) 0.50 mm (0.1968 in)

Assembly NOTICE: Be sure to match the mark (1) both on the upper case and low case of the oil pump when assembling.

NHIL14ENG0202AA

5

NHIL14ENG0564AA

6

1. Install and tighten the four M6 x 20 bolts (1).

2. Torque the four M6 x 20 bolts to 8 - 11 N·m (6 - 8 lb ft).

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Engine - Engine lubrication system

Crankcase ventilation system - Troubleshooting Problem Engine seals leaking oil

Engine emitting a bluish smoke

Possible Cause Correction Excessive crankcase pressure. High pres- Inspect breather hose for damage or consure caused by breather hose clogged. tamination. Replace breather hose if necessary.

Excessive blow by gases of engine. Pos- Replace piston rings, hone cylinder walls to sible worn piston rings or scored cylinder seat new rings. walls.

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Index Engine - 10 Engine lubrication system - 304 Crankcase ventilation system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine lubrication system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine lubrication system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine lubrication system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine lubrication system - Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine oil filter - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil filter - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine oil filter - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine oil pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine oil pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine oil pump - Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine oil pump - Install - oil pump, suction pipe and suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Engine oil pump - Remove oil pump, - suction pipe and strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Oil pressure valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Oil pressure valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Oil pressure valve - Install the oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil pressure valve - Remove the oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - 10 Engine cooling system - 400

L3AL L3BL

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Contents Engine - 10 Engine cooling system - 400

TECHNICAL DATA Engine cooling system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine cooling system Exploded view L3BL (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view L3AL (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Coolant thermostat Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Engine cooling system Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water pump Remove L3AL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove L3BL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install L3AL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install L3BL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47731080 04/08/2015

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Engine - Engine cooling system

Engine cooling system - General specification L3AL

Engine model Type of system Water pump Drive belt deflection (Tension) Thermostat Starts to open Fully open Radiator cap pressure rating Coolant

L3AL Pressurized liquid with recirculating by-pass Centrifugal 10 - 12 mm (0.394 - 0.472 in) when 98 N (22 lb) force is applied midway between pulleys.

77 °C (170 °F) 90 °C (194 °F) 0.90 bar (13 psi)

77 °C (170 °F) 90 °C (194 °F) 0.90 bar (13 psi)

Ethylene glycol and water in a 50/50% mixture.

Engine cooling system - General specification L3BL

Engine model Type of system Water pump Drive belt deflection (Tension) Thermostat Starts to open Fully open Radiator cap pressure rating Coolant

L3BL Pressurized liquid with recirculating by-pass Centrifugal 10 - 12 mm (0.394 - 0.472 in) when 98 N (22 lb) force is applied midway between pulleys.

77 °C (170 °F) 90 °C (194 °F) 0.90 bar (13 psi)

77 °C (170 °F) 90 °C (194 °F) 0.90 bar (13 psi)

Ethylene glycol and water in a 50/50% mixture.

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Engine - Engine cooling system

Engine cooling system - Exploded view L3BL L3BL

NHIL14ENG0968FA

1

L3BL engine cooling components (1) Hex bolt, M8 x 1.25 x 80mm (2) Cooling fan (3) Fan spacer (4) Fan spacer

(5) Low edge belt (6) Hex bolt, M8 x 1.25 x 60mm (7) Hex bolt, M8 x 1.25 x 25mm (8) Water pump assembly

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(9) Pump cover gasket (10) Hex bolt, M8 x 1.25 x 40mm (11) Water pump pulley

Engine - Engine cooling system

NHIL14ENG0964FA

2

Thermostat (1) Hex bolt, M8 x 1.25 x 25mm (2) Thermostat cover (3) Thermostat gasket (4) Thermostat

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

Hose clamp By - pass hose Hose clamp Thermostat gasket

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(9) Thermostat housing (10) Water temperature sending unit (11) Hex bolt, M8 x 1.25 x 25mm (12) Hex bolt, M8 x 1.25 x 75mm

Engine - Engine cooling system

Engine cooling system - Exploded view L3AL L3AL

NHIL14ENG0965FA

1

L3AL engine cooling components (1) Hex bolt, M8 x 1.25 x 80mm (2) Cooling fan (3) Fan spacer (4) Fan spacer

(5) Low edge belt (6) Water pump assembly (7) Pump cover gasket

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(8) Hex bolt, M8 x 1.25 x 40mm (9) Hex bolt, M8 x 1.25 x 60mm (10) Water pump pulley

Engine - Engine cooling system

NHIL14ENG0964FA

2

Thermostat (1) Hex bolt, M8 x 1.25 x 25mm (2) Thermostat cover (3) Thermostat gasket (4) Thermostat

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

Hose clamp By - pass hose Hose clamp Thermostat gasket

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(9) Thermostat housing (10) Water temperature sending unit (11) Hex bolt, M8 x 1.25 x 25mm (12) Hex bolt, M8 x 1.25 x 75mm

Engine - Engine cooling system

Engine cooling system - Dynamic description

NHIL14ENG0190FA

1

Cooling system A supply of engine coolant, a 50/50% mixture of Ethylene glycol is used throughout the engine and is stored predominantly in the radiator (7).

The coolant is circulated through the engine by the water pump (5) with the aid of the by - pass valve (4).

When the engine is running, it produces heat.

This heat must be addressed, and is by use of a thermostat (2).When the coolant temperature increases to 77 °C (171 °F), the thermostat (2) starts to open, and will be open fully at 90 °C (194 °F) .

The thermostat (2) allows the engine coolant to flow through the radiator (7) where air drawn through the radiator by the cooling fan (6) causes a heat exchange there by cooling the engine coolant.

The temperature of the coolant will drop below 77 °C (171 °F) and the thermostat will close.

The water pump will continue to pump engine coolant through the water jacket (3) keeping the engine cool.

The radiator cap (1) is designed as a safety relief in case the internal pressure of the engine coolant rises above 13.0 bar (188.5 psi).

The radiator cap (1) will relieve externally of the engine and radiator.

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Engine - Engine cooling system

Water flow when cold (A) Water flow when not cold (B)

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2

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Engine - Engine cooling system

Coolant thermostat - Dynamic description The thermostat (1), is located between the coolant outlet on the engine and the radiator. In this position the thermostat is able to sense the coolant temperature in the engine and regulate the flow of coolant to the radiator. When the engine is cold, only a small amount of coolant flows to the radiator through the thermostat bypass. As the engine warms up, the thermostat opens to allow sufficient coolant flow to the radiator to maintain a constant engine temperature.

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Engine - Engine cooling system

Engine cooling system - Service instruction 1. Clean the cooling system to remove rust, sludge, and other foreign material by using a coolant system cleaning solvent. In severe cases, pressure flushing may be required. A pulsating or reverse flow flushing will more effectively loosen and remove foreign material than a steady flushing in normal direction of coolant flow. If pressure flushing is to be used, always remove the thermostat and make sure the head bolts are tightened properly.

2. Coolant: • The coolant is a permanent type ethylene-glycol base antifreeze and should be used all year.

• Drain and flush the cooling system every twelve months and replace the coolant with fresh antifreeze and pure water.

• After the coolant has been drained, flush the system.

With the drain open and the system full of water, start the engine and run it until the water flowing from the drain is clear. Replace the coolant with new 50/50 mixture antifreeze and pure water.

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Engine - Engine cooling system

Water pump - Remove L3AL engine L3AL

1. Loosen the alternator and remove the fan belt (9).

2. Remove the four M8 x 1.25 x 104mm bolts (1).

3. Remove the fan (2).

4. Remove the two spacers (3) and (4).

5. Remove the water pump pulley (5).

6. Remove four bolts. Two M8 x 1.25 x 40mm (8) and two M8 x 1.25 x 60mm not shown.

7. Remove the water pump assembly (6).

8. Remove the gasket (7).

NHIL14ENG0965AA

NOTICE: Ensure that the mating surface on the engine and the water pump (If reused) are free of gasket material.

Install a new gasket at assembly.

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Engine - Engine cooling system

Water pump - Remove L3BL engine L3BL

1. Loosen the alternator and remove the fan belt (11).

2. Remove the four M8 x 1.25 x 80mm bolts (1).

3. Remove the fan (2).

4. Remove the spacers (3) and (4).

5. Remove the water pump pulley (10).

6. Remove the one M8 x 1.25 x 25mm bolt (6).

7. Remove the two M8 x 1.25 x 60mm bolts (5).

8. Remove the two M8 x 1.25 x 40mm bolts (9).

9. Remove the water pump assembly (7).

NHIL14ENG0968AA

10. Remove the gasket (8).

NOTICE: Ensure that the mating surface on the engine and the water pump (If reused) are free of gasket material.

Install a new gasket at assembly.

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1

Engine - Engine cooling system

Water pump - Inspect 1. Inspect the water pump for indications of coolant leakage from around the pump shaft (1). If coolant leakage is evident, or if the water pump is noisy when running, replace the water pump.

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Engine - Engine cooling system

Water pump - Install L3AL engine L3AL

1. Install the gasket (7).

NOTICE: Ensure that the mating surfaces of the engine and the water pump are clean.

2. Install the water pump assembly (6).

3. Secure the water pump (6) to the engine with four bolts.

Two M8 x 1.25 x 40mm (8) and two M8 x 1.25 x 60mm (Not Shown).

4. Torque the bolts to 23 - 28 N·m (17 - 21 lb ft) 5. Install the water pump pulley (5).

6. Install the two spacers (3) and (4).

NHIL14ENG0965AA

7. Install the fan (2).

8. Secure the fan (2), spacers (3) and (4) and the water pump pulley (5) with four M8 x 1.25 x 104mm bolts (1).

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

10. Install the fan belt (9).

NOTICE: Adjust the belt to the following specification : 10 - 12 mm (0.394 - 0.472 in) of deflection when 98 N (22 lb) force is applied midway between pulleys.

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Engine - Engine cooling system

Water pump - Install L3BL engine L3BL

1. Install the gasket (8).

NOTICE: Ensure that the mating surfaces of the engine and the water pump are clean.

2. Install the water pump assembly (7).

3. Install the two M8 x 1.25 x 40mm bolts (9).

4. Install the two M8 x 1.25 x 60mm bolts (5).

5. Install the one M8 x 1.25 x 25mm bolt (6).

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

7. Install the water pump pulley (10).

NHIL14ENG0410AA

8. Install the spacers (3) and (4).

9. Install the fan (2).

10. Secure the fan (2) with four M8 x 1.25 x 80mm bolts (1).

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

12. Install the fan belt (11) and tighten the alternator NOTICE: Adjust the belt to the following specification : 10 - 12 mm (0.394 - 0.472 in) of deflection when 98 N (22 lb) force is applied midway between pulleys.

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Engine - Engine cooling system

Coolant thermostat - Remove 1. Remove two M8 x 1.25 x 25mm bolts (1).

2. Remove the thermostat cover (2).

3. Remove the gasket (3).

NOTICE: Clean the mating surfaces . Replace this gasket at assembly.

4. Remove the thermostat (4).

5. Remove the two hose clamps (10).

6. Remove the hose (11).

7. Remove the M8 x 1.25 x 25mm bolt (6).

NHIL14ENG0964AA

8. Remove the M8 x 1.25 x 75mm bolt (8).

9. Remove the thermostat housing (9).

10. Remove the gasket (5).

NOTICE: Clean the mating surfaces . Replace this gasket at assembly.

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Engine - Engine cooling system

Coolant thermostat - Test 1. Place the thermostat (3) in a container filled with a 50/50% mixture of antifreeze and water. Isolate the thermostat from the bottom of the container.

2. Place a high temperature thermometer (2), in the coolant mixture and heat the container.

3. Use a 0.08 mm (0.003 in) feeler gauge (1), to determine when the thermostat begins to open.

4. Note the coolant temperature at which the thermostat starts to open and when it is fully opened.

5. Replace the thermostat if it fails to open at the specified temperature.

NHIL14ENG0956AA

L3AL - L3BL Thermostat opening temperature: • Start to open: 77 °C (171 °F) • Fully open: 90 °C (194 °F) 6. Thoroughly clean the gasket mating surfaces before installing thermostat.

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Engine - Engine cooling system

Coolant thermostat - Install 1. Install the thermostat housing (9).

2. Install the gasket (5).

NOTICE: Clean the mating surfaces . Replace this gasket at assembly.

3. Install the M8 x 1.25 x 75mm bolt (8).

4. Install the M8 x 1.25 x 25mm bolt (6).

5. Install the thermostat (4).

6. Install the gasket (3).

NOTICE: Clean the mating surfaces . Replace this gasket at assembly.

7. Install the thermostat cover (2).

8. Install two M8 x 1.25 x 25mm bolts (1).

9. Install the hose (11).

10. Install the two hose clamps (10).

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1

Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Coolant thermostat - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine cooling system - Exploded view L3AL (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine cooling system - Exploded view L3BL (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine cooling system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Water pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Water pump - Install L3AL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Water pump - Install L3BL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Water pump - Remove L3AL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Water pump - Remove L3BL engine (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

(*) See content for specific models 47731080 04/08/2015

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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 Industrial 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 Industrial Dealer.

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SERVICE MANUAL Electrical systems L3AL L3BL

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Contents Electrical systems - 55

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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Electrical systems - 55 Fuel injection system - 010

L3AL L3BL

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Contents Electrical systems - 55 Fuel injection system - 010

FUNCTIONAL DATA Fuel shutoff solenoid Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fuel shutoff solenoid Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Dynamic description The fuel shutoff solenoid (1) is located on the right side of the engine, threaded into the top of the fuel injection pump (2). The fuel shutoff solenoid contains a spring-loaded plunger that pushes the injection pump control rack to the closed (shut-off) position when the solenoid is not energized. When the key switch is turned to the "ACC/RUN" or "START" position, the safety stop relay closes completing the circuit that energizes the solenoid. This retracts the plunger from the injection pump, and the injection pump control rack moves into the position that allows the engine to start.

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Remove 1. Disconnect the wiring harness lead from the fuel shutoff solenoid (1).

2. Use a pair of pliers to carefully remove the fuel shutoff solenoid (1) from the fuel injection pump (2).

NHIL14ENG0554AA

1

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2

3. Remove and discard the sealing washer (1) which seals the solenoid (2) to the fuel injection pump.

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Test 1. Use a suitable measuring device to measure the actuating pin (1) protrusion distance (A) on the solenoid.

The distance should measure between 25.5 - 26.4 mm (1.004 - 1.039 in). If the distance is not within these specifications, the solenoid is defective and needs replaced.

NHIL14ENG0957AA

1

NHIL14ENG0958AA

2

2. Use jumper wires to connect the positive (+) terminal of a 12 V power supply (A), to the solenoid lead (2).

Connect the negative terminal of the 12 V power supply to the solenoid body (3). The plunger should retract into the solenoid body.

NOTE: When connecting the 12 V power supply to the solenoid body, be sure paint is the removed from the body.

Otherwise, the power will not be transferred to the solenoid.

3. Use a suitable measuring device to measure the actuating pin (1) protrusion distance (B) on the solenoid.

The distance should measure between 11.5 - 14.5 mm (0.453 - 0.571 in). If the distance is not within these specifications or the plunger does not retract, the solenoid is defective and needs replaced.

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Install 1. Install a new sealing washer (1) on the solenoid (2).

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1

20000885

2

NHIL14ENG0554AA

3

2. Thread the fuel shutoff solenoid (2) into the fuel injection pump (3). Use pliers to tighten the solenoid into the injection pump.

3. Connect the wiring harness lead (1) into the fuel shutoff solenoid (2).

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Index Electrical systems - 55 Fuel injection system - 010 Fuel shutoff solenoid - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel shutoff solenoid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel shutoff solenoid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel shutoff solenoid - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Engine cooling system - 012

L3AL L3BL

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Contents Electrical systems - 55 Engine cooling system - 012

FUNCTIONAL DATA Engine cooling system Static description - Engine coolant temperature sending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine cooling system Test - Engine coolant temperature sending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine coolant temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Engine cooling system

Engine cooling system - Static description - Engine coolant temperature sending unit The coolant temperature sender (1) is located at the left front side of the engine inside the thermostat housing. resistance.

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1

NHIL14ENG0549AA

2

This sender (1) regulates a variable to ground, which translates into the movement of the temperature gauge.

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Electrical systems - Engine cooling system

Engine cooling system - Test - Engine coolant temperature sending unit NOTE: Engine paint must be removed from sending unit body or the ohmmeter will indicate a false reading when the ohmmeter test lead is touched to sending unit body.

1. Disconnect the main wiring harness terminal (1) from the coolant temperature sending unit.

NHIL14ENG0548AA

1

NHIL14ENG0960AA

2

20097580

3

2. Use an ohmmeter (A) and touch one test lead to the sending unit terminal (1). Touch the other test lead to the sending unit body (2).

3. Observe the ohmmeter for resistance readings at different engine operating temperatures. If resistance is too high, the sending unit us defective and needs replaced.

Coolant temperature 50 °C (122 °F) 80 °C (176 °F) 100 °C (212 °F) 120 °C (248 °F)

Sending unit Ohms reading 153.9 Ω 51.9 Ω + 4.9 Ω - 4.4 Ω 27.4 Ω + 1.9 Ω - 1.2 Ω 16.1 Ω

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Remove 1. Disconnect wiring harness connector (1) from temperature sending switch.

2. Remove the temperature sending switch (2) by unscrewing from the coolant passage in the front of the cylinder head.

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Install 1. Thread the temperature sender (1) into the coolant passage on the front of the cylinder head.

NOTE: Use teflon tape as a sealant on the sending unit threads.

2. Torque the temperature sender to 22 - 24 N·m (16 18 lb ft) .

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1

Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine cooling system - Static description - Engine coolant temperature sending unit . . . . . . . . . . . . . . . . . . . . . . . 3 Engine cooling system - Test - Engine coolant temperature sending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine oil system - 013

L3AL L3BL

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil system Dynamic description - Engine oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine oil system Test - Engine oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine oil pressure sensor and switch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Engine oil system

Engine oil system - Dynamic description - Engine oil pressure switch Engine Oil Pressure Warning Light - Illuminates with the key switch in the "ON" position and remains lit for a short period of time after the engine is started. The light indicates oil pressure only and goes out when sufficient oil pressure is present at the oil sender. If the bulb becomes lit during operation, stop the tractor engine immediately and investigate the cause.

The oil pressure sender (1) is located below the oil filter on the left side of the engine. The switch opens under normal oil pressure 4.6 - 6.0 bar (66.7 - 87.0 psi) and closes when oil pressure is less than 4.6 - 6.0 bar (66.7 - 87.0 psi), to complete the ground circuit of the oil pressure warning light.

When the ground circuit is completed, the oil pressure warning light illuminates on the instrument panel when the key switch is turned to the "ON" position and goes out when the engine is started. If the light does not go out after the engine has started, first check the engine oil level. If oil level is correct, check for a malfunctioning sender or engine oil pump.

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1

Electrical systems - Engine oil system

Engine oil system - Test - Engine oil pressure switch 1. Use an ohmmeter and touch one test lead to the pressure switch terminal (1) and the other test lead to the switch body (2).

2. Observe the ohmmeter. There should be little or no resistance, indicating continuity in the switch. If there is no continuity, the switch is defective and needs replaced.

NOTE: The following test is not a calibrated test. The purpose of the test is to see if the switch opens at pressure.

1. While the test leads are connected to the switch, pressurize the switch oil pressure port (1) with low pressure, 10.0 - 30.0 bar (145.0 - 435.0 psi) compressed air.

2. Observe the ohmmeter. While air pressure is being supplied to the oil pressure port, the ohmmeter should indicate high resistance, or no continuity. If there is continuity, the switch is defective and needs replaced.

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NHIL14ENG0550AA

1

Electrical systems - Engine oil system

Engine oil pressure sensor and switch - Remove 1. Remove the wire from the spade connector (1).

2. Remove the oil pressure switch, by unscrewing switch from oil passage on the engine (2).

NHIL14ENG0556AA

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1

Electrical systems - Engine oil system

Engine oil pressure sensor and switch - Install 1. Thread oil pressure switch (1) into oil passage port in the engine (2).

2. Attach wiring spade connector (3) to oil pressure switch.

NHIL14ENG0556AA

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1

Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure sensor and switch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil pressure sensor and switch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil system - Dynamic description - Engine oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil system - Test - Engine oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter General specification Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Engine starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Engine starting system

Engine starter - General specification Starter motor Manufacturer

Sam Hyune, E.N.G Co LTD

Model

40006954

No load RPM HP Current, A No load voltage Mica undercut

3750 RPM 2 kW (3 Hp) 130 A (130 A) max 11 V

Wear limit

0.4 - 0.6 mm (0.0157 - 0.0236 in) 0.2 mm (0.0078 in)

New Wear limit

18 mm (0.7086 in) 11 mm (0.4330 in)

Brush length

Brush spring tension

3 - 4 kgf (7 - 9 lbf)

Commutator diameter New Wear limit Commutator insulation depth

32 mm (1.2598 in) 31.4 mm (1.2362 in) 0.4 - 0.6 mm (0.0157 - 0.0236 in)

Armature runout Commutator Ratings time Weight

0.03 - 0.05 mm (0.0011 - 0.0019 in) 30 Sec 4.6 kg

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Electrical systems - Engine starting system

Engine starting system - Dynamic description The starting system consists of a starter motor equipped with an electromagnetic starter solenoid, a key switch, a start relay, several safety switches, and heavy-duty wiring.

Starter components

NHIL14ENG0938FA

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

Idler gear Idler gear roller bearing Reduction uni cover Armature drive gear Motor/Field coil housing (Yoke) Permanent magnet Field coil Armature

1

(9) Brush spring (10) Brush (11) Plunger (12) Solenoid (13) Return spring (14) Pinion clutch (15) Pinion

Starter motor assembly The starter motor features a high-speed motor that utilizes a gear reduction unit, an overrunning pinion clutch (14) and permanent magnets (6) in a field coil (7) for magnetic field induction. The reduction unit consists of a small drive gear (4) on the motor armature (8) which drives an idler gear (1) in the reduction unit. The idler gear is splined to the gear on the pinion clutch housing (14). When the starter solenoid (12) is energized, the solenoid plunger (11) pushes the pinion gear (15) out, engaging with the engine flywheel. The starter motor then is turning the flywheel, which rotates the engine. The use of the gear reduction unit allows use of the compact, high-speed motor and provides more torque and power to turn the engine flywheel. The sliding pinion mechanism is enclosed, resulting in a more durable mechanism.

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Electrical systems - Engine starting system

Starter solenoid The starter solenoid is an electromagnetic type solenoid that is located on the bottom of the starter motor assembly. The solenoid contains two coils, a pull-in coil (1) and a hold-in coil (2). When the key switch is turned to the "START" position and the safety start relay is closed (safety switches closed), current from the battery will energize the solenoid's two coils. With the coils energized, the solenoid plunger (4) pushes a spring (5) which will then push the pinion gear out to engage the flywheel. At the same time, a set of contacts (3) on the solenoid become closed, allowing current to flow to the starter motor.

Closing the contacts also supplies current to both ends of the solenoid pull in coil which makes the coil become non-energized. The hold-in coil continues to engage the pinion gear with the flywheel. .

NHIL14ENG0992AAB

2

Pinion clutch To prevent the engine from driving the starter motor once the engine is running, the pinion gear is equipped with an overrunning clutch. The clutch will disengage the pinion gear from the rest of the starter components once the engine has been started and the key switch is in the "START" position. The clutch consists of an outer gear/shell (2) a cam with tapered notches (1), rollers (3), roller springs (4), a splined pinion collar/tube that acts as a clutch hub (5), and the pinion shaft (6). As the starter motor engages and rotates, the rollers are locked against the pinion collar with the tension provided by the roller springs. While the rollers are locked, the clutch assembly is locked, allowing the pinion gear to rotate the flywheel. When the engine starts, the flywheel moves faster than the starter motor and this causes the rollers to become unlocked. With the rollers unlocked, the clutch assembly is unlocked, allowing the pinion gear and shaft to turn independently of the starter motor.

NHIL14ENG0940AA

(A)

Engaged (B)

The clutch is not serviceable and is replaced as a complete assembly.

Once the engine is started and the key switch is released from the "START" position, the solenoid's pull in coil becomes energized, pulling the solenoid plunger in, which disengages the pinion from the flywheel.

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3

Disengaged

Electrical systems - Engine starting system

Engine starter - Remove 1. Disconnect the wiring harness connections (1) from the starter motor (2).

NHIL14ENG0543AA

1

NHIL14ENG0544AA

2

2. Remove the M10 x 30 bolt (2) and the M10 nut (1) and lock washers which secure the starter assembly (3) to the engine.

3. Remove the starter assembly (3).

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Electrical systems - Engine starting system

Engine starter - Install 1. Install the starter assembly (3).

2. Install the M10 nut (1) and the M10 x 30 bolt (2) and lock washers which secure the starter assembly (3) to the engine.

NHIL14ENG0544AA

1

NHIL14ENG0543AA

2

3. Torque the M10 x 30 bolt (1) and the M10 nut (2) to 54 N·m (40 lb ft).

4. Connect the wiring harness connections (1) to the starter motor (2).

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Electrical systems - Engine starting system

Engine starter - Troubleshooting Problem Pinion shaft fails to advance

Pinion motor rotates but no rotation transmitted to engine

Motor rotates before pinion meshes with ring gear

Pinion meshes with ring gear but starting motor fails to turn

Motor fails to stop after engine starts and key switch is turned off

Possible Cause Wiring: Open circuit battery, and switch terminal connections.

Wiring: Open circuit, fuse.

Key switch: No contact.

Starter motor: Sleeve bearing burnt out.

Starter motor: Lever broken.

Solenoid: Plunger movement defective or coil open or shorted.

Starting motor: Clutch defective.

Correction Repair or replace.

Replace fuse.

Repair or replace.

Repair or replace.

Replace.

Repair or replace.

Replace.

Starting motor: Orbital gear or planetary Replace. gears damaged.

Replace.

Starter motor: Shift lever damaged.

Starter motor: :Shift lever damaged Starter motor: Slip ring defective.

Starter motor: Pinion teeth worn.

Starter motor: Pinion push out position defective.

Engine: Ring gear worn.

Solenoid defective Wiring: Line connecting solenoid to battery broken or defective ground.

Replace.

Replace.

Replace.

Adjust.

Wiring: Lead wire connecting solenoid to motor tightened improperly.

Starting motor: Ball bearing locked.

Starting motor: Brush worn.

Starting motor: Improper installation.

Starting motor: Brush spring defective.

Starting motor: Commutator dirty.

Starting motor: Armature of field coil defective.

Starting motor: Field coil-to-brush connection defective.

Solenoid: Contact not touching properly.

Solenoid: Contact contacting surface roughened.

Battery: In discharge state.

Key switch: defective.

Repair or replace.

Replace.

Replace.

Repair or replace.

Replace.

Replace.

Reinstall.

Replace.

Clean.

Repair or replace.

Replace.

Replace.

Replace.

Recharge or replace.

Replace.

Replace.

Defective solenoid.

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - General specification Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine starter - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starting system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Cold start aid - 202

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Contents Electrical systems - 55 Cold start aid - 202

TECHNICAL DATA Cold start aid General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Cold start aid Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview glow plugs, hardware and connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Cold start aid Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Cold start aid

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

22 mm +/- 0.8661 mm 5 mm +/- 0.1968 mm Less than 5 s 950 - 1010 °C Less than 19 A 5 A +/- 1.0 A 0.5 mm

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Electrical systems - Cold start aid

Cold start aid - Overview

NHIL12ENG0173AA

1

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

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Electrical systems - Cold start aid

Cold start aid - Overview glow plugs, hardware and connection plate

NHIL14ENG0648FA

(1) Nut, M4

(2) Washer, M4

1

(3) Glow plug

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(4) Connection plate

Electrical systems - Cold start aid

Cold start aid - Remove - Glow plug 1. Disconnect the wiring harness (1).

NHIL14ENG0552AA

1

NHIL14ENG0552AA

2

NHIL14ENG0551AA

3

2. Remove glow plug bus connector (1) by removing the three M4 nuts (2).

3. Remove glow plugs (2).

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Electrical systems - Cold start aid

Cold start aid - Test 1. Clean the carbon from the sheath end of the glow plug.

NOTE: Do not test resistance using the glow plug sheath.

2. Use an ohmmeter and touch one test probe to the glow plug electrode.

3. Touch the other test probe to the glow plug body.

4. A resistance reading of 1 Ω is normal for the standard glow plug. If the resistance is too high, the glow plug is defective and needs replaced.

NHIL13ENG0027AA

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Electrical systems - Cold start aid

Cold start aid - Install - Glow plug 1. Install the glow plugs (1).

NHIL14ENG0551AA

1

NHIL14ENG0681AA

2

NHIL14ENG0552AA

3

NHIL14ENG0552AA

4

NOTICE: Install and torque the glow plug body (1) to 16 N·m (12 lb ft), torque the glow plug terminal to 0.1274 N·m (0.94 lb ft).

2. Install the connector plate (1).

3. Attach the glow plug connector (3) to the terminal on the glow plug.

4. Tighten the M4 nuts (1) on the glow plugs until the connector is tight on all glow plugs.

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Index Electrical systems - 55 Cold start aid - 202 Cold start aid - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cold start aid - Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cold start aid - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cold start aid - Overview glow plugs, hardware and connection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cold start aid - Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cold start aid - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Alternator

Alternator - General specification Manufacturer

Korea Delphi

Model

Q1750007

Polarity

Negative ground

Rotational direction (viewed from pulley side)

Clockwise

Drive belt tension

10 - 12 mm (0.39 - 0.47 in) deflection @ 9 - 11 kg (20 - 25 lb) of force

Load characteristics Terminal voltage Current Brush length Wear limit (min. length) Original Rotor coil resistance

12 V 50 A minimum at 2700 RPM 5 mm (0.20 in) 18.5 mm (0.73 in) 3.4 Ω

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Electrical systems - Alternator

Alternator - Static description

NHIL14ENG0936FA

1

Alternator The 12 V, 50 A output alternator is equipped with an integrated circuit (IC) regulator, meaning voltage is regulated internally and electronically within the alternator.

The principle components of the alternator are the stator (5), the rotor (2), the rectifier assembly (7), and the IC regulator (1).

The rectifier assembly (7) consist of two heat sinks, one positive (+) and one negative (-) and a diode trio.

The diode trio is used as a field supply diode and is connected to terminal 'L' on the alternator.

The IC regulator (1) is a solid state unit and can only be serviced as an assembly.

The internal components of the alternator are housed in a two-piece frame, which is divided into a drive end (front) frame (4) and a rear frame (6) The frame contains open slots to allow for cooling of the alternator.

The alternator is rotated in the frame by using a belt-driven pulley (3) which is powered off of the engine crankshaft pulley by a belt.

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Electrical systems - Alternator

NHIL14ENG0937FA

2

Charging circuit The charging circuit and internal connections are shown. The charging system consists of an IC voltage regulator (6) (enclosed with dotted lines), a battery (5) and connecting wires. Because of the use of IC, the voltage regulator is very compact and is built into the alternator.

The IC voltage regulator (6) limits the field current to flow directly from the diode trio (2) to the field coil (7) without passing through the external circuit. Consequently, there are no voltage drops caused by the key switch or the external wiring as with conventional vibrating-contact regulators mounted separately from the alternator. To aid in initial voltage buildup when the engine is started the field current is supplied through the indicator lamp (3) from the battery (5).

Since the frequency pulse output of 1/10 the alternator speed develops on the 'P' terminal, this terminal is used for speed detection.

Principle of IC regulator The basic function of the IC voltage regulator is to make the terminal voltage constant by detecting the generated voltage and increasing/decreasing the field current.

As indicated, the regulator consists of two basic sections: a voltage control device and an output device to handle the field current. The voltage control device includes the voltage divider network, R1 and R2, a zener diode, DZ, for voltage reference, and a single amplifying transistor, Tr1. The output device is a darlington-type amplifier which is called power transistor, Tr2. The power transistor, Tr2, is placed in series with the alternator field coil and ground.

The signal amplifying transistor, Tr1, senses the generated voltage and turns the power transistor, Tr2, on and off many times per second most of the time the engine is in operation.

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Electrical systems - Alternator

The basic operating principles are explained as follows, refer to Figure 1 : 1. When the key switch (4) is closed current from the battery (5) flows through the indicator lamp (3) and resistor R6, which are in parallel to the field coil (7). From here it continues to flow on through the field coil (7) to the ground completing the circuit back to the battery (5).

2. When the alternator begins to rotate, AC voltages are generated by the stator coil (1). The diodes in the rectifier assembly change the stator AC voltages to DC voltage which appears between ground and the 'B' terminal.

3. The stator also supplies DC field current through the diode trio (2), the field coil (7), the power transistor, Tr2, and then through the diodes in the rectifier assembly back to the stator.

4. When the generated voltage is low, no current flows in the zener diode, DZ, since the voltage at point 'A' is lower than the zener voltage.

5. As the speed and voltage increase, the voltage at point 'A' also increases until it reaches the limiting value set at the factory. As the zener diode, DZ, breaks down, current flows through R1, DZ, and the base-emitter circuit of Tr1 to ground. This renders Tr1 conductive, so that much of the current flows through the collector emitter circuit of Tr1. This reduces the base current of Tr2 thereby reducing the field current. This means that Tr1 turns on and Tr2 turns off.

6. When the generated voltage decreases, the zener diode, DZ, again turns off and Tr1 also turns off. This cycle repeats many times per second, and the alternator output voltage is, therefore, regulated within a narrow limit.

In other words, the action is similar to the conventional vibrating-contact regulator, in that current to the field coil (7) is varied to limit the output voltage, but in place of the voltage coil and spring system there is a voltage divider network, R1and R2, and a zener diode, DZ

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Electrical systems - Alternator

Alternator - Remove 1. Disconnect the negative (-) battery cable from the negative battery terminal.

2. Disconnect all wiring (2) from the rear of the alternator.

3. Loosen the M10 x 66 alternator mounting bolt (1) and the M8 x 25 bolt (3) and lock washers and remove the V-belt (4) from the alternator drive pulley.

4. Remove the alternator mounting bolts (1) and (3) and remove the alternator from the engine.

NHIL14ENG0545AA

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1

Electrical systems - Alternator

Alternator - Install 1. Align the alternator with the alternator mounting holes located on the engine block and brackets.

2. Use the M10 x 66 alternator mounting bolt (1) and the M8 x 25 bolt (3) to secure the alternator to the mounting brackets.

NHIL14ENG0545AA

1

NOTICE: Be sure to install the v-belt (4) into the drive pulley.

NOTE: Check the condition of the fan belt after every 50 hours of operation. Check fan belt tension after every 300 hours of operation.

3. A belt-driven fan located at the front of the engine draws air through the fins of the radiator to lower the temperature of the radiator coolant.

4. When 10 kg (22 lb) of pressure is applied midway (A) between the belt pulleys, a correctly tightened belt will deflect 10 - 12 mm (0.4 - 0.5 in).

5. If the fan belt is slipping, fan efficiency is lowered, resulting in the engine running too hot. If the belt is too tight, the life of the alternator bearing will be shortened.

If the fan belt shows signs of cracking or fraying, install a new one.

6. Tighten the hardware M10 x 66 alternator mounting bolt (1) and the M8 x 25 bolt (3).(Refer to figure 1) 7. Connect all wire terminals (2) rear of the alternator.(Refer to figure 1)

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NHIL12CT00890AA

2

Index Electrical systems - 55 Alternator - 301 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Industrial 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 Industrial Dealer.

47731080 04/08/2015 EN

SPECIAL TOOL INDEX Genuine FNH00120 [Oil Pump Port Block Installer Adapter] FNH01728 [Injector Adapter Set - use with FNH01721 (Ford Engines)] FNH01720 [Injector Cleaning Kit] FNH00011 [Engine Oil Pressure Test Fitting - 1/8 BSPT x 7/16-20 UNF] 294165 [Seal Installer Set] FNH00120 [Oil Pump Port Block Installer Adapter] 294165 [Seal Installer Set] CAS1745 [Injection Pump Timing Kit, Dial Indicator Assembly for CDC 3.9L And 5.9L]

Reference

10.1 / 9

Engine - Special tools

10.1 / 9

Engine - Special tools

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Engine - Special tools

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Engine - Special tools Engine - Compression test

10.1 / 9 10.1 / 20

Timing gear housing - Install seal Injection pump - Timing adjust

10.3 / 12 10.8 / 12

OEM OEM1064 [Injector Nozzle Tester] OEM1074 [Compression Gauge] OEM1074 [Compression Gauge]

PAGE

Engine - Special tools

Reference

PAGE

Engine - Special tools

10.1 / 9

Engine - Special tools

10.1 / 9

Engine - Compression test

10.1 / 20

47731080 04/08/2015

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 Industrial 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 Industrial Dealer.

47731080 04/08/2015 EN