New Holland F4HFA413AE002 F4HFA613BE002 F4HFA613CE002 F4HFA613DE002 Tier 2 Engine Service Manual

SERVICE MANUAL F4HFA413A*E002 / F4HFA613B*E002 / F4HFA613C*E002 / F4HFA613D*E002 / F4HFA613F*E003 Tier 2 Engine

Part number 47441596 1st edition English October 2012 Printed in U.S.A. Copyright © 2012 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

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

Electrical systems ....................................................................... 55 Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012 Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013 Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015 Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201 Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

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Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301

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INTRODUCTION

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

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

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

•

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

•

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

Helpful hints •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

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

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

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

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

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

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

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

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Torque Component Cylinder Head and Components Plug

Grid Heater Intake Manifold Engine Lifting Bracket Rear Front Cylinder Head First Phase Second Phase Third Phase Cylinder Head First Phase Second Phase Third Phase Rocker Bracket Rocker Arm Jam Nuts Exhaust Manifold Valve Cover Turbocharger 6 Cylinder 4 Cylinder

Size

Specification

¼" ½" ¾" M6 Nut M8 Screw

10 - 14 Nm (7.4 - 10.3 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 31 - 41 Nm (22.9 - 30.2 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M12 M8 M12x1.75x130 mm

65 - 89 Nm (47.9 - 65.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 85 - 95 ° 85 - 95 °

M12x1.75x150 mm

M8 Nut

50 - 60 Nm (36.9 - 44.3 lb ft) 85 - 95 ° 85 - 95 ° 31 - 41 Nm (22.9 - 30.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 48 - 58 Nm (35.4 - 42.8 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 M8 M8 M8

Screw Nut Screw Nut

6 - 8 Nm (4.4 - 5.9 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 6 - 8 Nm (4.4 - 5.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

M12 Screw M10 Screw M8 Screw M10 M12

65 - 89 Nm (47.9 - 65.6 lb ft) 42 - 52 Nm (31.0 - 38.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft)

Front Case Front Cover

Rear Case Gear Case

Flywheel Housing

Cylinder Block and Crankshaft Components Camshaft Retaining Plate Camshaft Gear Crankcase Plate Vibration Damper and Adapter First Phase Second Phase Drive Pulley Engine Flywheel First Phase Second Phase Main Caps First Phase Second Phase Third Phase Connecting Rod Caps First Phase Second Phase

M8 Screw M8 Screw M10 Screw M12

20 - 28 Nm (14.8 - 20.7 lb ft) 32 - 40 Nm (23.6 - 29.5 lb ft) 38 - 48 Nm (28.0 - 35.4 lb ft) 45 - 55 Nm (33.2 - 40.6 lb ft) 90 ° 61 - 75 Nm (45.0 - 55.3 lb ft)

M10 M12

26 - 34 Nm (19.2 - 25.1 lb ft) 55 - 65 ° M12 44 - 56 Nm (32.5 - 41.3 lb ft) 74 - 86 Nm (54.6 - 63.4 lb ft) 85 - 95 ° 55 - 65 Nm (40.6 - 47.9 lb ft) 55 - 65 °

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INTRODUCTION

Component Lubrication System and Components Oil Pump First Phase Second Phase Oil Pressure Relief Valve Oil Cooler and Oil Filter Base Oil Filter Connection on Filter Base for Turbo Oil Supply Turbo Lubrication Pipe Turbo Lubrication Pipe Adapter Oil Pan Piston Spray Nozzles

Size

M8 M8 M22 M8 Screw

Specification

7 - 9 Nm (5.2 - 6.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 72 - 88 Nm (53.1 - 64.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn 20 - 28 Nm (14.8 - 20.7 lb ft)

1 ⅛" M12 Nut M12

8 - 12 Nm (5.9 - 8.9 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 12 - 18 Nm (8.9 - 13.3 lb ft)

M8

Electrical Components Camshaft Sensor

Wiring Bulkhead Support Bracket for Injector Wiring Injector Wiring ECU Cooling Plate Fuel Outlet Fuel Inlet Crankshaft Speed Sensor Coolant Temperature Sensor Oil Pressure / Temperature Sensor Fuel Pressure Sensor Fuel Temperature Sensor Air Pressure / Temperature Sensor Engine Oil Level Sensor Alternator Support Bracket Alternator Tension Bracket Starter

M6 M6 M6 M6 M8

Studs Nut Screw Screw Screw

6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 1.25 - 1.75 Nm (0.92 - 1.29 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M6 Screw M8 Screw M12 M12 M6 Screw M14 Screw M5 Screw M14 M12 M10 Screw M10 Screw

Fuel System and Components Feed Pump High Pressure Pump Gear Fuel Pump Injector First Phase Second Phase Injector Feed Connector Common Rail High Pressure Fuel Line High Pressure Pipe Connector Fuel Filter Bracket Fuel Filter Holder Fuel Filter

M8 Studs M18 Nut M8 Nut

10 - 14 Nm (7.4 - 10.3 lb ft) 100 - 110 Nm (73.8 - 81.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M6 Screw M6 Screw

8.15 - 8.85 Nm (6.0 - 6.5 lb ft) 70 - 80 ° 45 - 55 Nm (33.2 - 40.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 18 - 22 Nm (13.3 - 16.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 71 - 85 Nm (52.4 - 62.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn

M8 Screw M14 Fitting M8 Screw M12 Screw M8 Screw

Cooling System and Components

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INTRODUCTION

Component Engine Coolant Inlet Fitting on Coolant Inlet Compressor Cooling Pipe Engine Coolant Drain Collector Water Pump Belt Tensioner Idler Pulleys

Size M10 Screw 90 ° Elbow

Specification 37 - 49 Nm (27.3 - 36.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 24 Nm (14.8 - 17.7 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M6 Screw M8 Screw M10 M10

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

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

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

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

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

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

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INTRODUCTION

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

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

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

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

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

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

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

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

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METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

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

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

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

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

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED

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

1.

Manufacturer's Identification

2.

Property Class

1

Metric Hex nuts and locknuts, classes 05 and up

20083681

2

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LOCKNUT CL.10 W/CL10.9 BOLT

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

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

PLATED W/ZnCr

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

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

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

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

INTRODUCTION

1.

Manufacturer's Identification

2.

Property Class

3.

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

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

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

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

SAE GRADE 8 BOLT and NUT

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

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

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

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

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

8.5 N·m (75 lb in)

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

111 N·m (82 lb ft)

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

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INTRODUCTION

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

9 N·m (80 lb in)

5/16

19 N·m (168 lb in)

3/8

33 N·m (25 lb ft)

7/16

53 N·m (39 lb ft)

1/2

81 N·m (60 lb ft)

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

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

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

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

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

LOCKNUT GrF W/ Gr5 BOLT

8 N·m (71 lb in) 17 N·m (150 lb in)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in)

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

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

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

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

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

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

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

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

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

INTRODUCTION

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

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

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

•

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

•

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

•

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

•

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

•

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

•

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

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

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

remove any incrustations using a metal brush.

•

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

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

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

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

machine model (commercial name) and serial number

•

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

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INTRODUCTION

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

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

2.

Never short any of the charging components to ground.

3.

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

4.

•

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

•

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

•

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

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

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

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

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

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

84-110

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

specifically researched and designed for use with CNH machines

•

essential for reliable repair operations

•

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

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

operating in optimal technical conditions

•

obtaining the best results

•

saving time and effort

•

working in safe conditions

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

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INTRODUCTION

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SERVICE MANUAL Engine

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

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Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

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Engine - 10 Engine and crankcase - 001

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Engine and crankcase - 001

FUNCTIONAL DATA Engine Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Engine and crankcase

Engine - Component localisation Location of main electrical components

CRIL04D081G01

(1) Coolant Temperature Sensor (2) Electro-Injector (3) Rail Pressure Sensor (4) Air Temperature/Pressure Sensor (5) Engine Starter (6) Timing Sensor (7) Solenoid Valve for Pressure Regulator

1

(8) Fuel Temperature Sensor (9) EDC7 UC31 (10) Crankshaft Sensor (11) Oil Level Sensor (12) Engine Oil Temperature/Pressure Sensor (13) Heating Element for Pre-Post Heating

The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by the engine.

Through the engine control module it is possible to verify the correct working of the engine.

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Engine - Service instruction Maintenance procedures WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

Engine oil level check The check can be made using the dipstick (1) placed on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool.

Draw off the rod from it's slot and check that the level is within the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no contamination and put it back in it's slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

Add oil through the upper top or through the lateral top (2).

During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

OILFILLH

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1

Engine - Engine and crankcase

Combustion system inspection The check must be executed both when the engine off and when it is running.

The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head.

Special attention must be paid to the connections on the high pressure pipelines.

Cooling system inspection The check must be executed both when the engine is off and when it is running.

Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips.

Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years.

NOTE: In case of new filling, proceed bleeding the system, through the bleeds on the engine.

If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine's head.

Lubricating system inspection The check must be executed both when the engine is off and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

Inspection of water presence within the fuel filter or pre-filter The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

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Engine - Engine and crankcase

Inspection / replacement of blow-by filter The filter in subject has been developed and equipped for the collection , filtering and condense of the lubricating oil vapors.

Within the filter unit (1) two cartridge filters are included (2).

The check of the filtering element is carried out by removing the cover and drawing off the cartridges (2).

86070785_RESIZE

2

VALVEADJUST

3

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.

Inspection and setting of tappet clearance Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Valve clearance •

Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)

Engine oil and filter replacement Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.

We recommend to carry out the oil drainage when the engine is hot.

Place a proper container for the oil collecting under the pan connected with drain plug.

Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil.

After the complete drainage, screw the plug and carry out the clean oil filling.

NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don't mix oils having different features. If you don't comply with these rules, the service warranty is no more valid.

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Engine - Engine and crankcase

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.

NOTE: The engine oil filter has an internal volume of about 1 l (0.3 US gal).

Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support.

Tighten by means of the tool 380000670 of three fourth turn.

Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change.

However the following operations are valid for all applications.

Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities.

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

Screw manually the new filtering cartridge until the gasket is completely on its seat.

Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11 lb ft) torque.

Alternator belt replacement Due to several applications the belt run can change very much.

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure.

Remove the control belt (2) from the driven and intermediate pulleys.

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

Place the automatic tightener in order to key the belt in the functioning position.

Check proper position in the races of the pulleys.

ALTBELT

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Engine - Engine and crankcase

Crankcase Bore - Check Prior operation: Connecting rod and piston - Remove (10.105) Once engine is disassembled, clean accurately the cylinder block assembly.

Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

Inspect cylinder bore surfaces; they shall be free from seizing, scores, ovalization, taper, or excessive wear.

Inspection of cylinder bore to check ovalization, taper, and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder bore diameter.

NOTE: Should a ring gauge not be available, use a micrometer for zero-setting.

BACD04APH104ASA

1

BAIL07APH372AMA

2

Measurements shall be performed on each cylinder at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B).

Maximum wear is usually found on plane (B) in correspondence with the first measurement.

Should ovalization, taper, or wear be found, bore and grind the cylinder bores. Cylinder bore regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm (0.016 in) and to the specified assembling clearance.

NOTE: In case of regrinding, all bores shall have the same oversize 0.4 mm (0.016 in).

Next operation: Crankcase - Check (10.001)

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Engine - Engine and crankcase

Crankcase - Check Prior operation: Crankshaft - Remove (10.103)

Main Bearing Housings Check main bearing housings as follows: •

fit the main bearing caps on the supports without bearings

•

tighten the fastening screws to the specified torque

•

use the proper internal gauge to check whether the housing diameter is falling within the specified value.

Replace if a higher value is found.

Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit.

Planarity error shall not exceed 0.075 mm (0.003 in) Check cylinder unit operating plug (1) conditions, replace them in case of uncertain seal or if rusted.

CRIL04J058A01

Next operation: Crankshaft Journal - Clearance (10.103)

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1

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 47441596 09/10/2012

10.001 / 11

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 - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Cylinder heads - 101

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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10.101 / 1

Contents Engine - 10 Cylinder heads - 101

SERVICE Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Valve guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Valve seat Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Cylinder heads

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

Unscrew the nuts (3) from the top of the electro-injectors (4) and disconnect the electrical wires.

2.

Unscrew the bolts (1) securing the rocker housing (2).

3.

Remove the rocker housing (2) and gasket from the cylinder head.

ROCKERHOUSING

Next operation: Valve cover Rocker housing - Install (10.101)

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1

Engine - Cylinder heads

Valve cover Rocker housing - Install Prior operation: Rocker arm - Install (10.106) 1.

Check the condition of the electrical cables (5) and connectors (3), replace if damaged by removing the screw (4).

2.

Install a new gasket (1) on the support (2).

3.

VALVEBASEDH

1

VALVEBASEDH2

2

VALVEBASEDH3

3

Install the housing (2) and tighten the screws (1) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

4.

Connect the electrical cables (1) to the injectors (3) and use the torque wrench (4) to tighten the fastening nuts (2) to the specified torque.

Next operation: Valve cover - Install (10.101)

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Engine - Cylinder heads

Valve cover - Remove 1.

Remove the nuts securing the valve cover to base.

2.

Remove valve cover and gasket.

BACD04APH004ASA

Next operation: Valve cover - Install (10.101)

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1

Engine - Cylinder heads

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

Install a new gasket (2) on the valve cover (1).

2.

Place the valve cover (1) on its seat, and install the mounting bolts.

VALVECOVER

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1

Engine - Cylinder heads

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

Remove the fastening screws (1) from the cylinder head (2).

NOTE: The highlighted screws are shorter.

2.

CYLHEADF4DF4HE

1

CYLHEADREMOVE

2

Hook brackets (1) with suitable lifting chains and remove the cylinder head (2) from the cylinder block using a hoist.

Next operation: Cylinder head - Check (10.101)

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Engine - Cylinder heads

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

Checking cylinder head wet seal This check shall be performed using the proper tools.

1.

Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure.

2.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

NOTE: Before refitting, smear the plug surfaces with water repellent sealant.

3.

Replace the cylinder head if leaks are found.

80709

1

70325

2

Checking cylinder head supporting surface 4.

Distortion found along the whole cylinder head shall not exceed 0.20 mm (0.008 in).

If higher values are found, grind the cylinder head according to values and indications shown in the following figure.

5.

The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal shall not exceed thickness (B) by 1 mm (0.039 in).

NOTE: After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

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

Check the cleanliness of the cylinder head and engine block coupling surface.

2.

Taking care not to foul the cylinder head gasket, set the gasket (1) with the marking "TOP" facing the head.

3.

The arrow shows the point where the gasket thickness is given.

4.

5.

80714

1

PROTRUSION

2

BACD04APH224ASA

3

There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B).

To determine the correct head gasket to use, piston protrusion must be measured.

•

For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in) from the center of the piston S1 and S2.

Then calculate the average:

•

Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

•

If S is > 0.40 mm (0.016 in) use seal type A.

•

If S is < 0.40 mm (0.016 in) use seal type B.

Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0.1 mm (0.004 in) the screw can be utilized again; If D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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Engine - Cylinder heads

6.

7.

Using a suitable hoist (1), set the cylinder head (2) on the engine block.

CYLHEADREMOVE

4

CYLINDERHEADDH

5

Tighten the cylinder head bolts (2) in the following order using tool 380000304 for the angle tightening procedure.

1.

Tighten with a torque wrench.

•

12x1.75x130 are torqued to 30 - 40 Nm (22 - 30 lb ft).

•

12x1.75x150 are torqued to 50 - 60 Nm (37 - 44 lb ft).

2.

Turn the bolt clockwise 85 - 95 °.

3.

Turn the bolt clockwise an additional 85 - 95 °.

70476

6

Tightening sequence for the 6 cylinder engine.

A = Front of engine Next operation: Fuel injectors - Install (10.218)

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Engine - Cylinder heads

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

Intake (1) and exhaust (2) valves heads with the same diameter. The central notch of the exhaust valve (2) head distinguishes it from the intake valve.

NOTE: Should cylinder head valves not be replaced, number them before removing in order to refit them in the same position.

A = intake side - S = exhaust side

2.

Valve removal shall be performed using tool 380000302 (1) and pressing the cap (3) so that when compressing the springs (4) the keepers (2) can be removed. Then remove the cap (3) and the springs (4).

3.

Repeat this operation for all the valves.

4.

Overturn the cylinder head and withdraw the valves (5).

5.

BACD04APH145ASA

1

BACD04APH146ASA

2

BACD04APH147ASA

3

Remove the sealing rings (1) and (2) from the valve guide.

NOTE: Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

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

VALVE

1

INTAKE AND EXHAUST VALVE MAIN DATA 1.

Check the valve stem (1) using a micrometer (2), it shall be 6.970 - 6.990 mm (0.274 - 0.275 in).

BAPH04APH152ASA

Next operation: Valves - Install (10.101)

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2

Engine - Cylinder heads

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

Remove carbon deposits from valves using the proper metal brush.

2.

Check that the valves show no signs of seizing, scoring, or cracking.

3.

If necessary, rectify the valve seats, taking away the least amount of material possible.

BAPH04APH151ASA

Next operation: Valves - Measure (10.101)

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1

Engine - Cylinder heads

Valves Spring - Check Prior operation: Valves - Remove (10.101) Before installing the valve springs use tool to check the springs flexibility. Compare load and elastic deformation data with those of the new springs in the following table:

50676

Height (H) - 47.75 mm (1.880 in) (H1) - 35.33 mm (1.391 in) (H2) - 25.2 mm (0.992 in)

Weight applied None (P) - 320.8 - 358.8 N (72.1 - 80.7 lb) (P1) - 702 - 780 mm (27.6 - 30.7 in)

Next operation: Valves - Install (10.101)

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1

Engine - Cylinder heads

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

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

2.

Fit the sealing rings (2) and (3) on the valve guide.

NOTE: Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.

3.

80713

1

BACD04APH146ASA

2

Position on the cylinder head: the springs (4) the upper cap (3) use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (5) by the keepers (2).

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Valve guide - Clearance Prior operation: Valves - Remove (10.101) 1.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 0.092 mm (0.002 - 0.004 in).

2.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm (0.001 in).

3.

80710

1

0B0O200405BACD0

2

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valve seat - Regrind Prior operation: Valves - Remove (10.101) Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated as follows:

80711

70331

2

VALVE SEAT MAIN DATA (4 CYL.) Should valve seats be not reset just by regrinding, replace them with spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

1.

Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F) and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head.

2.

Therefore, with an adequate tool, go over the valve seats according to the values stated in the previous figure.

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1

Engine - Cylinder heads

70332

3

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD 3.

After regrinding, check that the valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

80712

Next operation: Valves - Install (10.101)

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4

Index Engine - 10 Cylinder heads - 101 Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve cover Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - 10 Pan and covers - 102

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Pan and covers - 102

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

Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Engine - Pan and covers

Engine oil pan - Remove 1.

Remove the bolts (2) surrounding the oil sump (1).

2.

Remove the plate (2).

3.

Disconnect the oil sump (1) from the engine block.

NOTE: The shape and dimensions of the oil pan and of the suction tube may vary according to the application of the engine. However, the procedures described are still applicable.

4.

OILPANH

1

OILPICKUPTUBEH

2

Remove the screws (4) and (1) and disassemble the oil suction tube (5). Remove the screws (2) and disassemble the stiffening plate (3).

Next operation: Engine oil pan - Install (10.102)

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Engine - Pan and covers

Engine oil pan - Install Prior operation: Engine oil pan - Remove (10.102) 1.

2.

Fit the plate (3), the oil pick up tube (5) and tighten the fastening screws (1), (2) and (4) to the specified torque.

OILPICKUPTUBEH

1

OILPANH2

2

OILPANH

3

Set the gasket on the oil sump.

NOTE: The pictures of the instructions relating to the oil pan and to the suction pipe may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

3.

Fit the oil sump (1) on the engine block and apply the mounting plate (3). Tighten the bolts (2) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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Engine - Pan and covers

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

Remove the screws (1) from the front cover. Be sure to remove the two screws (3) underneath the cover.

NOTE: Take note of screw (1) assembling positions since they have different lengths.

2.

Remove the front cover from the cylinder block.

FRONTCOVERH

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

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1

Engine - Pan and covers

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

2.

Remove the sealing ring (2) from the front cover (1).

FRONTCOVERH2

1

FRONTCOVERG

2

Clean the sealing surfaces and apply LOCTITE 5205.

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

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Engine - Pan and covers

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

Install the front cover (2) and tighten the mounting bolts (1) to the specified torque.

FRONTCOVERD3

Next operation: Crankshaft damper - Install (10.110)

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1

Engine - Pan and covers

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

Remove the retaining bolts (2) from the rear cover (1) and withdrawal the cover.

NOTE: Take note of the bolt location due to the different lengths. This will aid in ease of assembly.

REARCOVERH3

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

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1

Engine - Pan and covers

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

Clean the rear cover and it's mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERH

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

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1

Engine - Pan and covers

Engine block cover Rear - Install Prior operation: Engine block cover Rear - Cleaning (10.102) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt.

1.

Install the cover (1) onto the timing gear housing and install the bolts in same location that they were removed.

2.

Tighten them to the prescribed torque.

REARCOVERH2

Next operation: Engine flywheel - Install (10.103)

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1

Engine - Pan and covers

Timing gear housing - Remove 1.

Remove the screws (2) and disconnect the timing gear case (1) from the engine block.

NOTE: Mark locations of mounting screws (2) since they are different sizes. This will make assembly much easier.

TIMINGGEARHOUSI

Next operation: Timing gear housing - Cleaning (10.102)

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1

Engine - Pan and covers

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

Clean the timing gear housing (1) and it's mating surface on the engine block.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (2), a few millimeters thick, to the sealing surface of the housing.

NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes.

GEARCASESEAL

Next operation: Timing gear housing - Install (10.102)

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1

Engine - Pan and covers

Timing gear housing - Install Prior operation: Timing gear housing - Cleaning (10.102) NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.

1.

Install the housing (1) on the engine block.

2.

Insert the fastening bolts in the same position found upon disassembly and tighten them to the prescribed torque.

GEARCASEINSTALL

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1

Index Engine - 10 Pan and covers - 102 Engine block cover Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - 10 Crankshaft and flywheel - 103

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Crankshaft and flywheel - 103

SERVICE Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Crankshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Crankshaft gears Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Main bearings Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Crankshaft and flywheel

Engine flywheel - Remove 1.

Insert tool 380000988 (2) into flywheel housing (1) to keep the flywheel (3) from rotating.

2.

Loosen two bolts opposite each other and place two guide pins (2) in place of the bolts.

3.

Remove the remaining bolts (4) figure 1 securing the flywheel (1) to the crankshaft.

4.

Remove the flywheel locking tool from the flywheel housing.

5.

Insert two bolts of medium length into the threaded holes (4) at the top of the flywheel to sling the flywheel with a hoist.

6.

Remove the flywheel (1) from it's housing.

Next operation: Engine flywheel - Check (10.103)

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FLYWHEELH

1

FLYWHEEL2H

2

Engine - Crankshaft and flywheel

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

Check the supporting surface of the clutch plate (1) and if it is scratched, it is necessary to carry out turning.

2.

Check ring gear teeth (2), if breakage or excessive wear is found, remove the ring gear from the engine flywheel using a suitable hammer.

3.

Heat the ring gear to 150 °C (302 °F)for 15 to 20 minutes.

4.

Install the ring gear with the chamfering on the inside diameter facing the flywheel.

FLYWHEELH3

Next operation: Engine flywheel - Install (10.103)

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1

Engine - Crankshaft and flywheel

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

Install two guide pins (2) having suitable length into crankshaft (3) holes.

2.

Using the proper sling and hoist, install the flywheel (1).

3.

Apply tool 380000988 (2) to the flywheel housing to stop rotation of the flywheel (3).

4.

Tighten the bolts (1) securing the flywheel (3) to the crankshaft (4).

5.

FLYWHEELH4

1

FLYWHEELH5

2

FLYWHEELH6

3

Tighten the flywheel bolts (1) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Engine - Crankshaft and flywheel

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

2.

Remove the ring sealing the engine's driving shaft from the front cover (6). Use the tool (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

Fix the tool to the ring tightening the six screws (5) provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).

MAINSEALDH

1

EXHOLDRINGDH

2

Using the specific tie rod (3) of the tool 380000669 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

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

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Engine - Crankshaft and flywheel

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

Apply tool (4) to the front crankshaft tang (6) and secure it by screws (5) and install the new sealing ring (7). Position part (2) on part (4), tighten nut (3) until completing installation of the sealing ring (7) into the front cover (1).

BACD04APH074ASA

Next operation: Crankshaft damper - Install (10.110)

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1

Engine - Crankshaft and flywheel

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

Remove the holding ring of the flywheel cover box using the tool (3) to operate on the driving shaft's back bar hold (5).

2.

Through the steering holes of the tool, perforate the inside holding ring with a straight way drill bit with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

3.

Fix the tool (3) to the ring tighten the six screws (4) provided with the equipment.

4.

Then proceed removing the ring (1) by tightening the screw (2).

5.

REARMAINSEALDH

1

EXHOLDRINGDH

2

Using a specific tie rod (3) of the tool 380000669 and an ancillary lever (4), remove the external holding ring (2)from the rear cover (1).

Next operation: Engine flywheel - Remove (10.103)

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Engine - Crankshaft and flywheel

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

Apply tool (6), to the rear crankshaft tang (5), secure it by screws (4) and install the new sealing ring (3).

Position part (1) on part (5), tighten nut (2) until completing installation of the sealing ring (3) into the flywheel housing (7).

BACD04APH219ASA

Next operation: Engine flywheel - Install (10.103)

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1

Engine - Crankshaft and flywheel

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

Use tool 380000362 (2) and hoist to remove the crankshaft (1) from the block.

BACD04APH057ASA

Next operation: Main bearings - Install (10.103)

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1

Engine - Crankshaft and flywheel

Crankshaft - Measure Prior operation: Crankshaft - Remove (10.103) Grind journals and crank pins if seizing, scoring or excessive ovalization are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

NOTE: It is recommended to insert the found values in the table below.

NOTICE: Journals and crank pins shall always be ground to the same undersize class.

Journals and crank pins undersize shall be marked on the side of the crank arm No.1.

For undersized crank pins: letter M For undersized journals: letter B For undersized crank pins and journals: letters MB.

BACD04APH108ASA

Measuring journals and crank pins

BACD04APH186FSA

2

Fill this table with crankshaft journal and crank pin measured values * Rated value

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1

Engine - Crankshaft and flywheel

ZEIL06EN0183F0B

3

Crankshaft tolerances * Measured on a radius greater than 45.5 mm (1.791 in) ** 0.500 mm (0.020 in) between adjacent main journals Tolerances Shape

Direction Position Oscillation

Tolerance Characteristic

Graphic Symbol

Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation Levels of importance for product characteristics

Critical Important Secondary Next operation: Crankshaft Journal - Clearance (10.103)

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Graphic Symbol

Engine - Crankshaft and flywheel

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

Install the crankshaft (1).

2.

Check the backlash between crankshaft main journals and the relevant bearings as follows:

3.

Clean accurately the parts and remove any trace of oil.

4.

Position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis;

5.

Fit caps (1), including the half bearings (2) on the relevant supports.

BACD04APH057ASA

1

BACD04APH112ASA

2

80621

3

NOTE: Before using the fixing screws again, measure them twice as indicated in the picture, checking (D1) and (D2) diameters: if (D1)- (D2) < 0.1 mm (0.004 in) the screw can be utilized again; if (D1)- (D2) > 0.1 mm (0.004 in) the screw must be replaced.

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Engine - Crankshaft and flywheel

6.

7.

Tighten the pre-lubricated screws (1) in the following three successive stages: STAGE 1: with torque wrench to 44 - 56 Nm (32.5 41.3 lb ft).

STAGE 2: with torque wrench to 74 - 86 Nm (54.6 63.4 lb ft).

BACD04APH058ASA

4

BACD04APH113ASA

5

BACD04APH114ASA

6

BACD04APH115ASA

7

STAGE 3: with tool 380001001 (1) set as shown, tighten the screws (2) with 85 - 95 ° angle.

8.

Remove the caps from the supports.

9.

The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire.

The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

Checking crankshaft end play 10.

This check is performed by setting a magnetic base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 - 0.41 mm (0.003 0.016 in).

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings.

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Engine - Crankshaft and flywheel

Crankshaft gears - Replace Check that gear toothing (1) is not damaged or worn, otherwise remove it from the crankshaft (2) using the proper puller (3).

When installing the new gear, heat it to 180 °C (356 °F) for 10 minutes in an oven and then key it to the crankshaft.

CRIL04J068A01

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1

Engine - Crankshaft and flywheel

Main bearings - Remove Prior operation: Engine oil pan - Remove (10.102) 1.

2.

Remove the screws (1) and the main bearing caps (2).

BACD04APH043ASA

1

BACD04APH044ASA

2

The second to last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

NOTE: Take note of the lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

Next operation: Main bearings - Install (10.103)

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Engine - Crankshaft and flywheel

Main bearings - Install Prior operation: Main bearings - Remove (10.103) NOTE: Refit the main bearings that have not been replaced, in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 - 0.500 mm (0.010 - 0.020 in) undersize on the internal diameter.

Clean accurately the main half bearings (1) having the lubricating and fit them into their housings.

The second last main half bearing (1) is fitted with shoulder half rings.

BACD04APH056ASA

NOTICE: Do not try to adapt the bearings.

Next operation: Engine oil pan - Install (10.102)

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10.103 / 17

1

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - 10 Connecting rods and pistons - 105

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Connecting rods and pistons - 105

FUNCTIONAL DATA Connecting rod and piston Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Piston Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connecting rod bearing Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Piston pin bushings Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - Connecting rods and pistons

Connecting rod and piston - Overview

1

BAPH04APH144ASA

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

Stop rings Pin Piston Split rings

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

Bolts Half bearings Connecting rod Bushing

NOTE: The pistons are supplied spare with the following sizes: - Standard - 0.4 mm (0.016 in) oversize.

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Engine - Connecting rods and pistons

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

Loosen the fixing screws (1) and remove the rod caps (2).

2.

Withdraw the piston including the connecting rod from the top of the engine block.

3.

Repeat these steps for the remaining cylinders.

NOTE: Keep the half bearings into their housing since in case of use they shall be fitted in the same position found at removal.

BACD04APH042ASA

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

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1

Engine - Connecting rods and pistons

Connecting rod and piston Connecting rod - Measure

BACD04APH131BSA

1

* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.

NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recommended not to smooth the knurls.

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Engine - Connecting rods and pistons

CRIL04D023F

2

NOTE: Every connecting rod is marked as follows: (1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

(2) - On the body with a letter showing the weight of the connecting rod assembled at production: - V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking) - W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking) - X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking) Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.

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Engine - Connecting rods and pistons

Connecting rod and piston - Assemble Prior operation: Piston Pin - Remove (10.105) 1.

2.

3.

The piston crown is marked as follows: 1.

Part number and design modification number.

2.

Arrow showing piston assembling direction into cylinder.

3.

Manufacturing date.

4.

Stamp indicating the ring carrier US inspection.

BACD04APH136ASA

1

BACD04APH137ASA

2

BACD04APH138ASA

3

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (4) are read as shown in the figure.

Position the piston (3) on the connecting rod according to the diagram shown in the figure and fit the pin (1) and stop at the stop rings (2).

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

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Engine - Connecting rods and pistons

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

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside.

2.

Use band 380000325 (1) to fit the connecting rod - piston assembly (2) into the cylinder barrels and checking the following:

MID0332A

1

BACD04APH061ASA

2

The number of each connecting rod shall correspond to the cap coupling number.

Split ring openings shall be displaced with each other by 120 °.

Connecting rod - piston assemblies shall have the same weight.

The arrow (1) marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

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

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Engine - Connecting rods and pistons

Piston - Measure Prior operation: Piston - Remove (10.105) 1.

2.

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

BAPH04APH123ASA

1

BACD04APH124ASA

2

The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.

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

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Engine - Connecting rods and pistons

Piston Ring - Measure Prior operation: Piston - Remove (10.105) 1.

2.

3.

4.

Use a micrometer (1) to check split ring (2) thickness.

BAPH04APH127ASA

1

BAPH04APH128ASA

2

BAPH04APH129ASA

3

BACD04APH130ASA

4

Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).

Since the first sealing ring is trapezoidal, the clearance between the slot and the ring shall be measured as follows: Make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot.

Found value shall be the specified one.

Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).

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Engine - Connecting rods and pistons

Next operation: Piston - Install (10.105)

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Engine - Connecting rods and pistons

Piston Ring - Install Prior operation: Piston - Remove (10.105) 1.

Use pliers 380000221 (3) to fit the split rings (1) on the piston (2).

NOTICE: Split rings shall be fitted with the marking "TOP" (4) facing upwards and their openings shall be displaced with each other by 120 °.

NOTE: Split Rings are supplied spare with the following sizes: - standard - 0.4 mm (0.016 in) oversize.

MID0330A

Next operation: Piston - Install (10.105)

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1

Engine - Connecting rods and pistons

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

Remove the piston pin (1) by extracting the stop rings (2) using a scriber (3).

BACD04APH121ASA

Next operation: Piston Pin - Measure (10.105)

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1

Engine - Connecting rods and pistons

Piston Pin - Measure Prior operation: Piston Pin - Remove (10.105) 1.

2.

To measure the piston pin (1) diameter, use a micrometer (2).

BAPH04APH125ASA

1

BAPH04APH126ASA

2

Lubricate the pin (1) and its seat on the piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.

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

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Engine - Connecting rods and pistons

Piston - Check 1.

Once connecting rod - piston assemblies installation is completed, use dial gauge 380000228 (1) fitted with base 380000364 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block.

Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.020 in).

BACD04APH143ASA

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1

Engine - Connecting rods and pistons

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

Fit the half-bearings (1) on the connecting rod and cap.

NOTE: Refit the bearings that have not been replaced in the same position found at removal. Do not relocate the half-bearings.

BAPH04APH059ASA

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

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1

Engine - Connecting rods and pistons

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

Clean the parts accurately and remove any trace of oil.

2.

Set a piece of calibrated wire (2) on the crank pins (1).

3.

Fit the connecting rod caps (3) with the relevant half bearings (4).

NOTE: Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the center of the thread length is not < 0.1 mm (0.004 in) than the diameter measured at approximately 10 mm (0.394 in) from the screw end.

4.

5.

BAPH04APH139ASA

1

BACD04APH140ASA

2

0B00200405BACD0

3

BACD04APH141ASA

4

Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2).

Apply tool 380001001 (1) to the socket wrench and tighten screws (2) to 60 °.

6.

Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).

7.

If a different clearance value is found, replace the half bearings and repeat the check.

8.

Once the specified clearance has been obtained, lubricate the half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

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Engine - Connecting rods and pistons

9.

Check manually that the connecting rods (1) are sliding axially on the crank pins and that their end float, measured with a feeler gauge (2) is 0.10 - 0.33 mm (0.004 - 0.013 in).

BACD04APH142ASA

Next operation: Piston - Check (10.105)

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5

Engine - Connecting rods and pistons

Piston pin bushings - Service instruction Prior operation: Piston Pin - Remove (10.105) 1.

Check that the bushing in the connecting rod small end is free from scoring or seizing and that it is not loose. Otherwise replace.

2.

Removal and refitting shall be performed using the proper beater.

3.

When refitting take care to make the oil holes in the bushing coincide with the holes in the connecting rod small end.

4.

Grind the bushing to obtain the specified diameter.

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

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Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connecting rod bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Connecting rod bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Piston pin bushings - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - 10 Valve drive and gears - 106

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Valve drive and gears - 106

FUNCTIONAL DATA Valve drive and gears Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Rocker arm Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Rocker shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Camshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Camshaft bushings Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Camshaft gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - Valve drive and gears

Valve drive and gears - Overview Rocker Assembly Components

ROCKERCOMPONENT

(1) Bolts

(2) Bracket

1

(3) Shafts

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(4) Rockers

Engine - Valve drive and gears

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

Loosen tappet adjustment jam nuts (1) and unscrew the adjusting screws.

2.

Remove the rocker shaft mounting bolts (2).

3.

Remove the rocker assembly (3), which consists of the pedestal (6), rockers (4), and shaft (5).

4.

Remove the valve bridges (7).

5.

Remove the push rods (8).

BACD04APH020ASA

Next operation: Rocker shaft - Clearance (10.106)

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1

Engine - Valve drive and gears

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

Check that the tappet adjusters (1) are loose to prevent their binding on the rods when fitting the rocker assembly

2.

Install the rocker assembly consisting of:

3.

•

Bracket (5).

•

rockers (3).

•

shafts (4).

Secure them to the cylinder head by tightening the fastening screws (2) to a torque of 36 Nm (27 lb ft).

ROCKERASSEMDH

Next operation: Rocker arm - Adjust (10.106)

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1

Engine - Valve drive and gears

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

Adjust the clearance between the rockers and valves using a set screw wrench (1), box wrench (3), and feeler gauge (2).

2.

Set the clearance to the following specifications.

•

Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in)

BACD04APH162ASA

Next operation: Valve cover - Install (10.101)

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1

Engine - Valve drive and gears

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

Check that the shaft/rocker coupling surfaces are not showing excessive wear or damage.

SHAFTMEASURE

Next operation: Rocker arm - Install (10.106)

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1

Engine - Valve drive and gears

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

Remove the bolts (1)and disconnect camshaft (3)retaining plate (2).

NOTE: Take note of the retaining plate (2) assembly position.

2.

BACD04APH047ASA

1

BACD04APH048ASA

2

Carefully extract the camshaft (1) from the cylinder block.

Next operation: Camshaft - Measure (10.106)

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Engine - Valve drive and gears

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

Set the camshaft on the tailstock using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm (0.002 in), otherwise replace the camshaft.

2.

Check cam lift; found values shall be: 6.045 mm (0.238 in) for exhaust cams and 7.582 mm (0.299 in) for intake cams, in case of different values replace the camshaft.

3.

Check the camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

BACD04APH117ASA

BAIL07APH360FSA

1

2

NOTE: Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and the bush.

Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

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

2.

Lubricate the camshaft bushings and fit the camshaft (1) taking care not to damage the bushings or the housings.

CRIL04J056A01

1

CRIL04J064A01

2

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.

Next operation: Camshaft - End play (10.106)

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Engine - Valve drive and gears

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

Check camshaft end play (1). It shall be 0.10 - 0.36 mm (0.004 - 0.014 in).

CRIL04J065A01

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

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1

Engine - Valve drive and gears

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

Before installation be sure to check that there is no signs of wear or distortion. Intake and exhaust rods are identical and therefore interchangeable.

2.

Install the push rods (2).

3.

Install the valve bridges (1) with the marks facing the exhaust manifold

Next operation: Rocker arm - Install (10.106)

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PUSHROD

1

BACD04APH093ASA

2

Engine - Valve drive and gears

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

Withdraw the tappets (1) from the engine block.

BACD04APH049ASA

Next operation: Camshaft Tappets - Measure (10.106)

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1

Engine - Valve drive and gears

Camshaft Tappets - Measure Prior operation: Camshaft Tappets - Remove (10.106)

BAIL07APH361FSA

1

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Install Prior operation: Camshaft Tappets - Measure (10.106) Lubricate the tappets (1) and fit them into the relevant housings on the engine block.

CRIL04J063A01

Next operation: Camshaft - Install (10.106)

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1

Engine - Valve drive and gears

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

Camshaft bushing (2) shall be pressed into its housing. Internal surface must not show seizing or wear.

Use bore dial gauge (3) to measure camshaft bushings (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axis'.

CRIL04J060A01

BAIL07APH367FMA

2

*Height to be obtained after installing the bushing.

Next operation: Camshaft - Replace (10.106)

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1

Engine - Valve drive and gears

Camshaft bushings - Replace Prior operation: Camshaft - Measure (10.106) Remove and install the bushing (1) using the beater (2) and the hand-grip 380000145 (3).

NOTICE: When installing the bushing , take note of orientation to make sure the lubricating holes coincide with the holes on the block housing.

ZEIL06EN0048A0B

Next operation: Camshaft - Install (10.106)

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1

Engine - Valve drive and gears

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

Remove the screws (1) securing the camshaft gear (3) to the camshaft (2).

2.

Withdrawal the camshaft gear (3).

CAMGEARH

Next operation: Camshaft gear - Install (10.106)

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1

Engine - Valve drive and gears

Camshaft gear - Install Prior operation: Camshaft gear - Remove (10.106) NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.

1.

2.

3.

Highlight the timing mark on the crankshaft gear (1) with a felt tip pen so it's easier to see.

BACD04APH064ASA

1

BACD04APH065ASA

2

BACD04APH066ASA

3

Turn the crankshaft (4) and the camshaft (2) so that by mounting the drive gear (1) on the camshaft (2), both timing marks (3) will align properly.

Tighten the bolts (1) that secure the gear (2) to camshaft (3) to the specified torque.

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

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Index Engine - 10 Valve drive and gears - 106 Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rocker arm - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rocker shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve drive and gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Balancer and damper - 110

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Balancer and damper - 110

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

Crankshaft damper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Balancer and damper

Balancer - Remove Prior operation: Engine oil pan - Remove (10.102) 1.

Remove the bolts (1) and withdraw the oil pickup tube.

2.

By means of pin (2) lock the dynamic balancer (3) in the Top Dead Center (TDC) position.

3.

Loosen the bolts (4) and remove the dynamic balancer (3).

DYNAMICBALANCER

Next operation: Balancer - Install (10.110)

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1

Engine - Balancer and damper

Balancer - Install 1.

Place the balancer on the engine, install and tighten the mounting bolts.

2.

Install and tighten the oil sump.

3.

Remove the retaining bolt previously installed during the timing adjustment.

4.

Install the oil pan on the engine, fill the engine with oil.

5.

Pull the timing lock pin from the cam gear.

6.

Start and run engine, check for excessive vibration and oil leaks.

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RCPH10TLB003BAL

1

RCPH10TLB004BAL

2

Engine - Balancer and damper

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

Remove the bolts (3) securing the vibration dampener (2) and withdrawal the damper (2) and pulley (1).

VIBDAMPENERH

Next operation: Crankshaft damper - Install (10.110)

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1

Engine - Balancer and damper

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

Attach the vibration damper (2) and the pulley (1) to the crankshaft, and torque the mounting bolts (3) to 45 - 55 N·m (33 - 41 lb ft) then, 90 ° .

VIBDAMPENERH

Next operation: Belt - Install (10.414)

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1

Index Engine - 10 Balancer and damper - 110 Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Pump drives - 114

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Pump drives - 114

SERVICE Pump drives Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Pump drives

Pump drives - Remove 1.

Unscrew the cover bolts (3) and remove the cover (1). Save the cover gasket (4).

2.

Remove the power take-off adapter (2). Save the gasket (4).

AUXDRIVEH

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1

Engine - Pump drives

Pump drives - Install 1.

Insert the power take-off adapter (2) with gaskets (4) and cover (1).

2.

Tighten the bolts (3) to the specified torque.

AUXDRIVEH

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1

Index Engine - 10 Pump drives - 114 Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Fuel filters - 206

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Fuel filters - 206

FUNCTIONAL DATA Fuel heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fuel filters Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuel filters Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel filters

Fuel heater - Overview The ECU drives the filter heater at fuel temperature less than our equal to 5 °C (41 °F).

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Engine - Fuel filters

Fuel filters - Remove Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1.

Using the tool disassemble the fuel filter (1) and remove it from the support (5).

2.

Disconnect the electrical connections (2) from the support (5) including the one for the fuel heater.

3.

Disconnect the fuel low pressure pipelines (3) from the support (5).

4.

Disconnect pipeline (4) from the support (5).

5.

Remove the sustaining support bracket (5) from the block.

4442596398GHDC

Next operation: Fuel filters - Install (10.206)

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1

Engine - Fuel filters

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

Assemble the bracket and support (1) of the fuel filter (6).

2.

Proceed connecting in sequence the pipelines (9) (3) (4) (5) of the support (1) to the high pressure pump (8).

3.

Connect the pipeline (7) from the high pressure pump to the common rail.

NOTE: Refer to Common rail lines - Connect (10.218) for the proper operation of the clamps on the low pressure fuel lines.

FUELSYSTEMD

Next operation: Fuel supply lines Low pressure - Connect (10.210)

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1

Engine - Fuel filters

Fuel filters - Install 1.

Install the bracket and the base of the fuel filter.

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Index Engine - 10 Fuel filters - 206 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Lift pump and lines - 210

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Lift pump and lines - 210

FUNCTIONAL DATA Fuel lift pump Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Lift pump and lines

Fuel lift pump - Sectional view Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump's shaft.

Normal operating condition

BACD04APH163ASA

(A) Fuel supply from the primary filter (B) Fuel supply to the secondary filter

1

(1) Fuel supply relief valve 5 bar (73 psi) (2) Supply pump bypass valve (for bleeding)

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Engine - Lift pump and lines

Overpressure condition

BACD04APH164ASA

2

The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the resistance of the valve's spring (1), connects the exhaust with the entry through the gallery (2).

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Engine - Lift pump and lines

Jettison condition

BACD04APH165ASA

3

The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).

NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.

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Engine - Lift pump and lines

Fuel supply lines Low pressure - Connect 1.

Connect the pipeline to the pressure limiter.

2.

Connect all the fuel lines between the fuel filter base and the high pressure pump.

3.

Connect the pipeline from the high pressure pump to the engine control module cooling plate.

4.

Connect the pipeline from the high pressure pump to high pressure common rail.

LPFUELCONNECT

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1

Engine - Lift pump and lines

Fuel supply lines Low pressure - Disconnect 1.

Disconnect the fuel return pressure limiter (1). Refer to Common rail lines - Disconnect (10.218).

RETURNLINEF4DEF

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1

Index Engine - 10 Lift pump and lines - 210 Fuel lift pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10 Fuel injection system - 218

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Fuel injection system - 218

FUNCTIONAL DATA Fuel injection system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

High pressure pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure regulating valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE High pressure pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Common rail Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Common rail lines Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuel injectors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Injector fuel lines Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fuel fillers Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Engine - Fuel injection system

Fuel injection system - Dynamic description

1

4C0O200406CRILH

(1) Electro-injector (2) Common rail (3) Pressure limiting device for fuel return (4) Common rail pressure relief valve

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

Pre-filter mounted on the frame High-pressure pump Mechanical vane pump Fuel filter

The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

The hydraulic system is implemented by a low pressure circuit and a high pressure circuit The high pressure circuit is composed of the following pipings: •

piping connecting high pressure pump outlet to rail

•

pipings supplying injectors from rail

The low pressure circuit is composed of the following pipings: •

fuel suction piping from tank to pre-filter

•

pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter

•

pipings supplying the high pressure pump through the fuel filter

The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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Engine - Fuel injection system

Fuel injection system - Plumbing schema The fuel system is a Common Rail injection system with a CP3 high pressure pump.

The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.

The pressure relief valve (2) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain piping (16) from piping (8).

The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).

Two bypass valves are placed in parallel with the mechanical supply pump.

The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it's inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.

The bypass valve (17) allows filling the supply system through the manual priming pump (10).

FUELSYSTEMSCHEM

(1) High-pressure pump (2) Low pressure relief valve (3) Return fuel relief valve (4) Common rail relief valve (5) Common rail (6) Common rail pressure sensor

1

(7) Electro-injector (8) Return fuel line (9) ECU cooling plate (10) Priming pump (11) Pre-filter (12) Fuel tank

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(13) Mechanical supply pump (14) Fuel filter (15) Pressure regulator (16) High pressure pump cooling passage (17) By-pass valve (18) Charge pressure relief valve

Engine - Fuel injection system

High pressure pump - Overview Fuel system operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements at about 2 bar (29 psi).

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

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

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

The pumping element compresses the fuel till top dead center of the delivery stroke, is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed.

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

The delivery valves must always be free in their movements, free from impurities and oxidation.

The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

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

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

Rail

COMMONRAILOVERV

(1) Rail

(2) Fuel inlet from high-pressure pump

1

(3) Overpressure valve

(4) Pressure sensor

The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.

It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback information, where the rail pressure value is checked and if necessary, corrected.

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Engine - Fuel injection system

High pressure pump - External view Introduction Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

The CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi).

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

HARNESS

(1) Fuel pressure sensor (2) Coolant temperature sensor (3) Oil temperature/pressure sensor (4) Driving shaft sensor

1

(5) Connection to electro-injectors (6) Air temperature/pressure sensor (7) Camshaft sensor (8) Fuel heater cable and fuel temperature sensor

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(9) Pressure gauge cabling (10) EDC7 UC31 Control unit (11) Electro-injector

Engine - Fuel injection system

High pressure pump - Dynamic description CP3 high pressure pump Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical feeding pump driven by the high pressure pump's shaft is assembled to the rear side of the high pressure pump.

NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with the retaining bolts.

The only serviceable components are the control gear and pressure regulator.

80719

(1) Outlet to common rail (2) High pressure pump (3) Pressure regulator valve

1

(4) Drive gear (5) Supply fuel inlet from filter (6) Return to filter

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(7) Inlet from primary filter (8) Outlet to secondary filter (9) Transfer pump

Engine - Fuel injection system

Inside structure

80720

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

Pumping element Rotary coupling Inlet valve Outlet valve

2

(5) Piston (6) Eccentric pump shaft (7) Low pressure fuel inlet (8) Fuel supply ducts to pumping elements

Every pumping unit is composed of: •

A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset part of the shaft, uses the highest part of the element to actuate the three pistons alternately.

•

Cap intake valve.

•

Ball delivery valve.

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Engine - Fuel injection system

Working principle

80721

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

Fuel to common rail Outlet valve Pumping element Eccentric pump shaft

3

(5) Pulse Width Modulated (PWM) metered fuel (6) Low pressure fuel supply (7) PWM pressure regulator valve

The pumping element is oriented towards the pump's camshaft. During the intake phase, the pumping element is fed through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge. The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust unit.

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Engine - Fuel injection system

80722

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

Pumping element inlet passage Pump lubrication passage Pumping element inlet passgae Main supply passage PWM pressure regulator valve

4

(6) Pumping element inlet passage (7) Relief valve outlet passage (8)Relief valve 5 bar (73 psi) (9) Fuel supply to relief valve and regulator

The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue The pump shaft is lubricated by the fuel from the feeding and recovery lines.

The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the exhaust gallery.

The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the pressure at a constant 5 bar (73 psi) limit at gauge entry.

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Engine - Fuel injection system

80723

(1) Fuel exhaust galley

5

(2) Fuel exhaust galley

(3) Fuel outlet to rail

This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

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Engine - Fuel injection system

Pressure regulating valve - Overview Pressure Regulator The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the pressure regulator is managed by the EDC7 control unit.

Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by controlling the pressure regulator solenoid valve.

This component is a N.O. solenoid valve.

The solenoid valve impedance is approximately 3.2 Ω.

Pressure Limiter for Fuel Return It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of 1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

BACD04APH176ASA

1

(A) - To Tank (B) - From Injectors

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Engine - Fuel injection system

Common rail Relief valve - Overview

93101562

1

Mounted on the end of the rail, it has the function of protecting the system's components in case the failure of the rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high pressure plant.

When the rail pressure reaches 2000 bar (29000 psi), the valve initially opens in order to allow the fuel to flow and subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to approximately 1000 bar (14500 psi).

This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to tank.

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Engine - Fuel injection system

Fuel injectors - Overview On NEF TIER IV engines, BOSCH - CRIN2 electro-injectors with 8 hole DLLA type jets with a flow rate of 550 CCM / 30 SEC @ 100 bar (1450 psi).

The injector is similar as construction to the tier 3 injectors, apart from the absence of the plunger return springs.

The injector is composed of two main parts: •

Actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.

•

Control solenoid valve composed of a coil, and pilot valve.

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

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

Pressure Rod Plunger Nozzle Coil Pilot Valve

1

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

Engine - Fuel injection system

Injection Start

93095367

2

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process.

NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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Engine - Fuel injection system

Electro-Injector Solenoid Valves Each injector is connected to the EDC control unit on connector A. The Impedance of the coil of each injector is 0.56 - 0.57 Ω.

COVERBASE

Description

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

3

EDC pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

11A 6A 13A 4A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

14A 3A 12A 5A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

15A 2A 1A 16A

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Engine - Fuel injection system

High pressure pump - Remove Prior operation: Injector fuel lines - Disconnect (10.218) Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1.

Disconnect all fuel lines (4) on the high pressure pump (2).

2.

Remove the mounting nuts (1) and remove the high pressure pump (2) and feed pump (3) together as one unit.

HPPUMPDH

Next operation: High pressure pump - Install (10.218)

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1

Engine - Fuel injection system

High pressure pump - Install Prior operation: High pressure pump - Remove (10.218) Prior operation: Fuel supply lines Low pressure - Connect (10.210) 1.

Slide the high pressure pump (2) including the feed pump (3) into place on the rear cover.

2.

Install the nuts (1) securing the pump to the rear cover and tighten to the specified torque.

3.

Hook up all fuel lines (4).

HPPUMPDH

Next operation: Injector fuel lines - Connect (10.218)

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1

Engine - Fuel injection system

Common rail - Install Prior operation: Injector fuel lines - Disconnect (10.218) 1.

Install the high pressure fuel rail (2) on the cylinder head.

2.

Tighten the mounting screws (1) to the specified torque.

3.

Connect new fuel pipes (6) to the rail (2) and to the manifold for electro-injectors (5).

4.

Tighten the pipe joints (3) to 20 Nm (14.8 lb ft).

5.

Install the low pressure fuel line (4) to the rail (2).

Refer to Common rail lines - Connect (10.218) for the proper procedure.

RAIL

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1

Engine - Fuel injection system

Common rail lines - Disconnect Low Pressure 1.

Hold down the clasp (1) and release the quick fitting joint.

80628

Next operation: Common rail lines - Connect (10.218)

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1

Engine - Fuel injection system

Common rail lines - Connect Low Pressure Prior operation: Common rail lines - Disconnect (10.218) 1.

Connect low pressure lines to the fuel rail by inserting the rapid fitting joint into the connection joint and press until the clip (1) fastens securely.

2.

Check proper fuel connection.

80628

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1

Engine - Fuel injection system

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

Remove the bolts securing the injector to the cylinder head.

2.

Use tool 380001099 (1) to remove the injectors (2) from the cylinder head.

INJECTORREMOVE

Next operation: Fuel injectors - Install (10.218)

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1

Engine - Fuel injection system

Injector fuel lines - Connect 1.

2.

Connect new fuel pipes (1) between high pressure rail (3) and fuel manifolds (2).

HPFUELCONNECT

1

HPFUELTORQUE

2

Pipe connection (1) should be torqued to 20 Nm (15 lb ft) using the proper wrench (4) and torque wrench (3).

Connections should be tighten by holding the flow limiting valve hexagon with the proper wrench.

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Engine - Fuel injection system

Injector fuel lines - Disconnect 1.

Disconnect the fuel pipe (4) from the cylinder head Common rail lines - Disconnect Low Pressure (10.218). Disconnect the fuel pipes (5) from the rail (2) and injector manifolds (6).

NOTICE: When releasing pipe (5) connections (6) to rail (2), use the proper wrench to avoid rotation of flow limiters (3).

2.

Remove the screws (1) and disconnect the rail (2).

COMMONRAILF4HE

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1

Engine - Fuel injection system

Fuel fillers - Remove Prior operation: Injector fuel lines - Disconnect (10.218) NOTICE: Make sure the area around the fuel manifold is clean. Once they are removed, there is a greater risk of contaminating the internal components.

1.

Remove the nuts (1) and remove the fuel manifolds (2).

NOTE: Disassembled fuel manifolds must not be used again. Replace them with new ones during reassembly.

FUELMANIFOLD

Next operation: Fuel fillers - Install (10.218)

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1

Engine - Fuel injection system

Fuel fillers - Install Prior operation: Fuel fillers - Remove (10.218) 1.

Fit a sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2).

2.

Install the fuel manifold (2) into the cylinder head so that the positioning ball (5) is coinciding with the relevant housing (4).

NOTE: After removing fuel manifolds they cannot be used again. Replace them with new ones.

3.

Screw the fastening nuts on without tightening them.

NOTE: During this operation, the injector (1) can be moved so that the manifold (2)can be properly inserted into the inlet hole.

4.

FUELMANIFOLDDH

1

INJMANIFOLDDH

2

After everything is in place, tighten the fuel manifold nuts (2) to 50 Nm (37 lb ft).

NOTICE: Be sure to tighten the screws (1) securing the injector to the specified torque. Refer to Fuel injectors Install (10.218) for the proper procedure.

Next operation: Injector fuel lines - Connect (10.218)

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Index Engine - 10 Fuel injection system - 218 Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Common rail lines - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Common rail lines - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fuel fillers - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fuel fillers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel injection system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 High pressure pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Injector fuel lines - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - 10 Turbocharger and lines - 250

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Turbocharger oil supply line Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Turbocharger and lines

Turbocharger Turbine - Remove 1.

Remove the turbo oil supply line (3) from the oil filter base and from the pipe fitting (4) to the turbine.

2.

Remove the nuts securing the turbocharger (1) to the exhaust manifold (2)and remove it from its seat.

TURBOF4HE

Next operation: Turbocharger Turbine - Install (10.250)

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1

Engine - Turbocharger and lines

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

With a suitable sling, place the turbocharger (1) on the exhaust manifold (2) with a new gasket.

2.

Tighten the mounting screws (3) to the specified torque.

TURBOF4DE

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1

Engine - Turbocharger and lines

Turbocharger - Install 1.

Set the turbocharger (1) on the exhaust manifold (2).

2.

Torque the nuts (3) to 35 N·m (26 lb ft) then torque to 46 N·m (34 lb ft).

TURBOF4DE

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1

Engine - Turbocharger and lines

Turbocharger oil supply line - Install Oil Fill Tube 1.

Install a new O-ring on the oil fill tube (1).

2.

Attach the oil fill tube (1) to the engine block using the three M12x25 bolts.

OILFILLH2

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Engine - Turbocharger and lines

Turbocharger oil supply line - Install Turbo oil lines 1.

Connect the oil supply line (2) between the turbine (1) and the oil filter base.

2.

Install the oil drain pipe (1) onto the turbo and tighten the fixing screws.

3.

Connect the pipe to the block (2) also.

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OILLINEDH

1

OILLINEDH2

2

Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Turbocharger Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10 Intake and exhaust manifolds and muffler - 254

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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

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

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

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

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Overview The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure, one main body and one compressor.

During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk wheel's rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the drawn air is then cooled by the radiator and flown through the piston collector.

The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector before the turbine and connected by piping to the induction collector. It's function is to restrict the exhaust of the emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed pressure.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

BOOSTDIAGRAM

1

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove 1.

Loosen the retaining bolts (2) of the intake manifold (1) and disassemble the intake air heater (3) for the cold start aid.

INTAKEF4HE

Next operation: Intake manifold - Install (10.254)

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1

Engine - Intake and exhaust manifolds and muffler

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

Apply LOCTITE 5999to the mounting surface of the air intake heater (3) on the intake manifold (1).

2.

Install the heater (3) and tighten bolts.

3.

Assemble the manifold and fasten it to the cylinder head using screws (2).

INTAKEF4HE

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1

Engine - Intake and exhaust manifolds and muffler

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

Loosen the bolts (1) and remove the exhaust manifold (2) from the cylinder head.

BAIL06CCM055ASA

Next operation: Exhaust manifold - Install (10.254)

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1

Engine - Intake and exhaust manifolds and muffler

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

Connect the exhaust manifold (2) with new gasket.

Tighten the mounting bolts (1) to the specified torque.

EXHAUSTMANIFOLD

Next operation: Turbocharger Turbine - Install (10.250)

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1

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

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Engine - 10 Engine lubrication system - 304

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Engine lubrication system - 304

FUNCTIONAL DATA Engine lubrication system Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Blowby re-circulation system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Blowby re-circulation system Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Engine - Engine lubrication system

Engine lubrication system - Exploded view Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the crankshaft, camshaft and to the valve drive.

4C0O200406CRIL0

1

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Engine - Engine lubrication system

Blowby re-circulation system - Dynamic description

93101561

1

Version with blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and return to the oil sump. The remaining vapors are put back into circulation.

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Engine - Engine lubrication system

93101560

2

Version without blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are conveyed, collected and discharged into the open air through a bleeder.

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Engine - Engine lubrication system

Engine oil filter - Remove 1.

Use the tool 380000670 to remove the oil filter.

OILFILTERF4HE

Next operation: Engine oil filter - Install (10.304)

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1

Engine - Engine lubrication system

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

Lubricate the oil filter O-ring (2) with clean engine oil.

2.

Screw the filter (3) onto the base (1) until contact is made with sealing surface.

3.

Tighten the oil filter an additional 3/4 of a turn.

4.

Apply a new sealing ring on the oil temperature/pressure sensor (4).

5.

Install the sensor (4) onto the filter base (1) and tighten the screws (5) to the specified torque.

OILFILTERH2

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1

Engine - Engine lubrication system

Engine oil pump Gear driven - Remove Prior operation: Engine block cover Front - Remove (10.102) 1.

Remove the retaining bolts (1) and disconnect the oil pump (2) from the engine block.

OILPUMPH

Next operation: Engine oil pump Gear driven - Install (10.304)

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Engine - Engine lubrication system

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

Install the oil pump (1) into the engine block.

2.

Tighten the bolts (2) to the specified torque.

OILPUMPH2

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

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1

Engine - Engine lubrication system

Blowby re-circulation system - Remove - External filter 1.

Loosen the clamp (1)holding the blow-by tube and remove the pipe.

2.

Remove the screws (2)and remove the blow-by filter, if applicable.

86070784_RESIZE

Next operation: Blowby re-circulation system - Install (10.304)

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Engine - Engine lubrication system

Blowby re-circulation system - Install - External filter Prior operation: Blowby re-circulation system - Remove (10.304) 1.

2.

3.

Insert the blow-by filter (1) and tighten the bolts (2).

86070785_RESIZE

1

86070784_RESIZE

2

86070784_RESIZE

3

Install the cover (1) on the blow-by filter housing (2) and tighten the mounting screws (3).

Connect the pipelines (1) and fix the oil vapor pipes with the clamps (2).

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Engine - Engine lubrication system

Blowby re-circulation system - Remove - Internal filter 1.

Pull the plastic fitting (1) out of the top of the valve cover.

NOTE: The fitting is held in place by a rubber O-ring.

2.

Remove the valve cover.

3.

Lift the valve cover off of the cylinder head.

4.

Remove the plastic retaining nut (2) from the top of the valve cover.

5.

93110964

1

93110965

2

Pull the filter (3) out of the bottom side of the valve cover.

NOTE: There may be a slight resistance when pulling the filter from the valve cover due to the O-ring seal.

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Engine - Engine lubrication system

Blowby re-circulation system - Install - Internal filter 1.

Lubricate the O-ring seal on the filter.

2.

Install the filter (1) into the bottom side of the valve cover.

NOTE: Be sure to connect the hose (2) between the filter (1) and pressure regulator (3).

3.

93110965

1

93110964

2

Install the retaining nut (4) on the top side of the valve cover.

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Engine - Engine lubrication system

Piston cooling Spray nozzle - Remove 1.

Remove the main half bearing (1) to avoid damaging them.

2.

Remove the screws (2) and remove the oil nozzles (3).

BACD04APH046ASA

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

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1

Engine - Engine lubrication system

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

Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.

CRIL04J066A01

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1

Index Engine - 10 Engine lubrication system - 304 Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Blowby re-circulation system - Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Blowby re-circulation system - Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Blowby re-circulation system - Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blowby re-circulation system - Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - 10 Engine cooling system - 400

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Engine cooling system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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Engine - Engine cooling system

Engine cooling system - Dynamic description The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: •

Expansion Tank - Placement, shape and dimension are subject to change according to the engine's equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator. Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

ZEIL06EN0105G0B

1

6 cylinder version

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Engine - Engine cooling system

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

Remove the retaining bolts and withdrawal the water pump.

BVE0294A

Next operation: Water pump - Install (10.400)

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1

Engine - Engine cooling system

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

2.

3.

Apply a new sealing ring (2) on the water pump (1).

BACD04APH220ASA

1

ZEIL06CS0245A0B

2

BACD04APH070ASA

3

Install the water pump (1) into the engine block (2) using the two mounting bolts (3).

Tighten the water pump (1) mounting bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

Next operation: Belt - Install (10.414)

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Engine - Engine cooling system

Water pump Water manifold - Remove Prior operation: Alternator - Remove (55.301) 1.

Remove the screws (2) and disconnect the water manifold (1).

WATERMANIFOLDH

Next operation: Water pump Water manifold - Install (10.400)

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1

Engine - Engine cooling system

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

Position the water manifold/alternator support (1) so that the pins (3) and (4) are set against the engine block.

2.

Tighten the mounting bolts (2) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

WATERMANIFOLDH2

Next operation: Alternator - Install (55.301)

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1

Engine - Engine cooling system

Coolant thermostat - Remove 1.

Remove the three screws securing the thermostat housing (1) to the top of the cylinder head.

2.

Remove the thermostat (2) and the seal (3) from the housing (1).

86082981

Next operation: Coolant thermostat - Install (10.400)

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1

Engine - Engine cooling system

Coolant thermostat - Install Prior operation: Coolant thermostat - Remove (10.400) 1.

Install the seal (3) around the flange of the thermostat (2).

2.

Install the thermostat (2) into the housing (1) and secure the assembly to the cylinder head using the three mounting screws.

86082981

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1

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

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Engine - 10 Oil cooler and lines - 408

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Oil cooler and lines - 408

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

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Engine - Oil cooler and lines

Engine oil cooler - Remove Prior operation: Engine oil filter - Remove (10.304) 1.

Unscrew the mounting bolts (1).

2.

Remove the oil filter base (2)oil cooler (3), and all gaskets.

OILCOOLERH

Next operation: Engine oil cooler - Install (10.408)

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1

Engine - Oil cooler and lines

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

Place a new gasket (1) on the engine block.

2.

Install the oil cooler (2).

3.

Place a new gasket (3) on the oil cooler.

4.

Install the oil filter base (4).

5.

Tighten the mounting bolts (5) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt

OILCOOLERH2

Next operation: Engine oil filter - Install (10.304)

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1

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

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Engine - 10 Fan and drive - 414

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Engine - 10 Fan and drive - 414

SERVICE Fan and drive Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Belt tensioner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Idler pulley Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Fan and drive

Fan and drive - Remove Support - Remove Prior operation: Belt - Remove (10.414) 1.

Loosen the fastening screws (3) and remove the pulley controlling the fan (2).

2.

Proceed detaching the support (1).

FANDRIVEC

Next operation: Fan and drive - Install (10.414)

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1

Engine - Fan and drive

Fan and drive - Install Support - Install Prior operation: Fan and drive - Remove (10.414) 1.

Re-attach the support, tightening the screws to the prescribed torque.

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Belt - Remove 1.

Release tension on the belt (1) by pulling back on the belt tensioner (2).

2.

Extract the belt (1) from all the pulleys.

BELT

Next operation: Belt - Install (10.414)

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1

Engine - Fan and drive

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

Turn the belt tensioner and fit the belt on the pulleys.

66070776

1

Belt Configuration (1) - Crankshaft (2) - Fixed Idler Pulley

(3) - Fan (4) - Water Pump

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(5) - Alternator (6) - Tensioner

Engine - Fan and drive

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

Remove the bolt from the center of the belt tensioner and remove the tensioner.

Next operation: Belt tensioner - Install (10.414)

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Engine - Fan and drive

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

Install the belt tensioner. Tighten the mounting bolt to the specified torque.

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

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

Remove the retaining bolt from the center of the idler pulley.

2.

Remove the idler pulley.

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

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

Install the idler pulley and tighten the retaining bolt in the center to the specified torque.

Next operation: Belt - Install (10.414)

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Index Engine - 10 Fan and drive - 414 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

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

47441596 09/10/2012 EN

SERVICE MANUAL Electrical systems

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Electrical systems - 55

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301 F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003

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Electrical systems - 55 Fuel injection system - 010

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Electrical systems - 55 Fuel injection system - 010

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

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

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Electrical systems - Fuel injection system

Fuel temperature sensor - Overview

FUELTEMPH

(1) Fuel Temperature Sensor

1

(2) Filter heating resistance

This sensor is identical to the coolant temp sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.

The fuel temperature sensor is connected to the control unit on pins 35C - 18C. The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω.

Reference 1 2

Description Ground Temperature signal

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EDC pin 35C 18C

Electrical systems - Fuel injection system

Fuel pressure sensor - Overview

FUELPRESS

1

Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command.

The power supply is 5 Volt.

Description

Reference 1 2 3

Ground Signal Power supply

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

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

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

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview

COOLANTTEMP

1

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine.

The same signal is utilized by the control unit to drive an instrument panel gauge, if present.

The sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

Reference 1 2

Description Ground Temperature signal

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EDC pin 15C 26C

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

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Electrical systems - 55 Engine oil system - 013

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Contents Electrical systems - 55 Engine oil system - 013

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

SERVICE Engine oil pressure/temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Engine oil system

Engine oil pressure/temperature sensor - Overview

OILPRESSTEMP

1

This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.

The sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.

The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 24C 28C 32C 27C

Electrical systems - Engine oil system

Engine oil pressure/temperature sensor - Remove 1.

Disconnect the wiring harness from the sensor.

OILPRESSTEMPH

2.

Remove the mounting screws and remove the sensor and O-ring from the oil filter base.

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1

Electrical systems - Engine oil system

Engine oil pressure/temperature sensor - Install 1.

Install a new O-ring on the oil temperature/pressure sensor.

2.

Install the sensor on the oil filter base and tighten the mounting bolts to the specified torque.

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure/temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pressure/temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil pressure/temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine intake and exhaust system - 014

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

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

SERVICE Intake air pressure and temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Overview

AIRPRESSTEMP

1

This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure.

The power supply is 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 25C 36C 33C 34C

Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Remove 1.

Disconnect the wiring harness from the sensor.

2.

Remove the retaining bolt.

3.

Remove the sensor and O-ring.

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine control system - 015

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Contents Electrical systems - 55 Engine control system - 015

FUNCTIONAL DATA Engine control unit Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine wire harness Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Engine control unit Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine wire harness Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine speed/RPM sensor Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Engine timing sensors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Electrical systems - Engine control system

Engine control unit - Detailed view EDC7 UC31

CONTROLMODULE

(A) Injector connector

1

(B) Vehicle connector

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(C) Sensor connector

Electrical systems - Engine control system

Engine control unit - Overview EDC7 UC31 OPERATION Engine preheating element control Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors detect a temperature less than or equal to 5 °C (41 °F).

Phase recognition Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time of starting.

Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.

Injection pressure closed loop control On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control unit administrates the regulator to maintain injection pressure at constantly optimal values.

Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping.

Idle speed control The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected.

It also controls the pressure regulator and modulates injection duration of the electro-injectors.

Within specific limits, the control unit also monitors battery voltage.

Overheating protection If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance.

When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature).

Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors.

In some applications the maximum limiting response consists in stopping the engine.

Cut Off Fuel cut off in release phases is managed by the control unit with the following logical interventions: •

Deactivation of the electro-injectors.

•

Reactivation of electro-injectors immediately prior to reaching idle speed.

•

Control of fuel pressure regulator.

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Electrical systems - Engine control system

Smoke control under acceleration With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust.

After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started.

Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions.

If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in order to restore the engine to maximum power.

Recovery strategies Recovery strategies are characterized by certain differences as application varies: •

Control of fuel leaks In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained with a low number of RPMs and high torque values in order to inject the maximum quantity of fuel.

•

Control of pressure in the rail When the pressure in the rail exceeds the safety values, the engine reduces power.

•

Synchronism problems In the case of synchronism problems, faulty RPM sensors, the system controls the engine by increasing the number of RPMs in order to improve interpretation of the signals.

•

Power restrictions as operating temperature increases When the temperature of the charge air rises above 88 °C (190 °F), power reduction is started. When a temperature of 120 °C (248 °F) is reached, performance is further reduced and is comparable to a naturally aspirated engine.

•

Reduction of power as reference temperature varies In normal operating conditions, the system knows the charge air, oil and water temperatures.

If the temperature of the engine water is not available, the system takes the temperature of the oil as a reference and when this reaches the threshold of 103 °C (217 °F), it starts to reduce the power available. Upon reaching 113 °C (235 °F), power is reduced to 50 %.

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Electrical systems - Engine control system

Engine wire harness - Electrical schema

ELECSCHEMH

(1) Injectors cylinders 1 and 2 (2) Injectors cylinders 3 and 4 (3) Injectors cylinders 5 and 6 (4) Engine RPM sensor (5) Timing sensor

1

(6) Engine oil pressure/temperature (7) Fuel temperature (8) Coolant temperature (9) Air pressure/temperature (10) Fuel pressure

(11) Pressure regulator (12) Connector C - Sensors (13) Connector A - Injectors

Connector A - Injectors Function

EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure Regulator Pressure Regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector

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Electrical systems - Engine control system

Connector C - Sensors EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Function Timing sensor Timing sensor Negative for rail temperature and pressure sensor Positive for rail temperature and pressure sensor Signal from rail temperature and pressure sensor Coolant temperature sensor signal from fuel temperature sensor Engine RPM sensor Engine RPM sensor Negative for engine oil pressure and temperature sensor Negative for air temperature and pressure sensor Coolant temperature sensor Signal from engine oil pressure sensor Signal from engine oil temperature Positive for engine oil pressure and temperature sensor Positive for air temperature and pressure sensor Signal from air pressure sensor Negative for fuel temperature sensor Signal from air temperature sensor

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Electrical systems - Engine control system

Engine speed/RPM sensor Camshaft - Overview

CAMSENSOR

1

This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal.

Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external shape.

The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ~900 Ω.

Description

Reference 1 2 3

Signal Signal Shield

EDC pin 10C 9C -

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Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Overview

CRANKSENSOR

1

This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone wheel fitted on the crankshaft.

The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.

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Electrical systems - Engine control system

Engine control unit - Remove Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1.

Disconnect the main wiring harness from the electronic control module (2).

2.

Disconnect the low pressure fuel lines that are attached to the control module cooling plate.

3.

Remove the three mounting bolts (1) that secure the control module and the cooling plate to the engine block.

4.

Remove the control module and cooling plate as one unit.

EDC7H

Next operation: Engine control unit - Install (55.015)

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1

Electrical systems - Engine control system

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

Install the electronic control module (2) and cooling plate on the side of the engine block.

2.

Install the mounting bolts (1) and rubber isolators and tighten to the specified torque.

NOTE: If the rubber isolators are cracked or excessively deformed, replace them before installation.

EDC7H

Next operation: Fuel supply lines Low pressure - Connect (10.210)

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1

Electrical systems - Engine control system

Engine wire harness - Disconnect

HARNESS

(1) Fuel pressure Sensor (2) Coolant temperature sensor (3) Engine oil temperature sensor (4) Crankshaft speed sensor 1.

1

(5) Electro-injector (6) Air pressure/temperature sensor (7) Timing sensor (8) Fuel temperature sensor

(9) Fuel pressure regulator (10) EDC 7 UC31 (11) Connectors for electro-injectors

Disconnect the engine's cable from the connectors wiring harness to Electro-Injectors (11); Air Pressure/Temperature Sensor; (6) Fuel Pressure Sensor (1); Engine Control Module (10); Timing Sensor (7); Coolant Temperature Sensor (2); Crankshaft Speed Sensor (4).

HARNESS

Next operation: Engine wire harness - Connect (55.015)

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2

Electrical systems - Engine control system

Engine wire harness - Connect Prior operation: Engine wire harness - Disconnect (55.015) 1.

Reconnect the engine wiring harness to all the sensors, the engine control module and the common rail. Refer to Engine wire harness - Disconnect (55.015) for the harness routing and connections.

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Electrical systems - Engine control system

Engine speed/RPM sensor - Install 1.

Install a new O-ring on the speed sensor (3).

2.

Install the speed sensor (3) on the front cover (1).

3.

Tighten the screw (2) to the specified torque.

SPEEDSENSORH

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1

Electrical systems - Engine control system

Engine timing sensors - Remove 1.

Remove the mounting nut and slide the timing sensor out of the timing gear housing.

Next operation: Engine timing sensors - Install (55.015)

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Electrical systems - Engine control system

Engine timing sensors - Install Prior operation: Engine timing sensors - Remove (55.015) 1.

Install a new O-ring on the timing sensor.

2.

Slide the sensor over the mounting stud and install the nut. Tighten to the specified torque.

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Index Electrical systems - 55 Engine control system - 015 Engine control unit - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine control unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine control unit - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine control unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine timing sensors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine timing sensors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine wire harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine starting system

Engine starter - Remove 1.

Disconnect the starter cables from the solenoid and the starter body (2).

2.

Remove the three mounting bolts (3) securing the starter (2) to the flywheel housing (1). Withdraw the starter (2).

STARTERDH

Next operation: Engine starter - Install (55.201)

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1

Electrical systems - Engine starting system

Engine starter - Install Prior operation: Engine starter - Remove (55.201) 1.

Install the starter (2) on the flywheel housing (1) using the three mounting bolts (3).

NOTE: Before any assembly operation verify that the hole and bolt threads have no evidence of wear or dirt.

STARTERDH

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1

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

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Electrical systems - 55 Cold start aid - 202

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Contents Electrical systems - 55 Cold start aid - 202

FUNCTIONAL DATA Grid heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Cold start aid

Grid heater - Overview

GRIDHEATER

1

The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.

The resistance impedance is approximately 0.5 Ω.

The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).

The contactor impedance is approximately 15 Ω.

WARNING This engine is equipped with an intake air (grid) heater. DO NOT use starting fluid on this engine. Use of starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in death or serious injury.

M836

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Index Electrical systems - 55 Cold start aid - 202 Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Alternator - 301

F4HFA413A*E002 F4HFA613B*E002 F4HFA613C*E002 F4HFA613D*E002 F4HFA613F*E003

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Contents Electrical systems - 55 Alternator - 301

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Alternator

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

Remove the cables from the back of the alternator.

2.

Remove the retaining bolts (2) securing the alternator (1) to the support.

3.

Remove the alternator (1).

ALTERNATOR

Next operation: Alternator - Install (55.301)

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1

Electrical systems - Alternator

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

Install the alternator (1) and tighten the bolts (2) to the specified torque.

2.

Connect the positive and negative cables onto the back of the alternator.

ALTERNATOR

Next operation: Belt - Install (10.414)

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1

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

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

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

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

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

47441596 09/10/2012 EN

SPECIAL TOOL INDEX Genuine 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000304 [Angle Torque Thightening Screw Tool] 380000302 [Cylinder Head Valve Spring Compressor] 380000302 [Cylinder Head Valve Spring Compressor] 380000364 [Comparator Holder Base For Different Surveys] 380000228 [Dial Gauge (0 - 5 mm)] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000304 [Angle Torque Thightening Screw Tool] 380000669 [Seal Extraction Tool] 380000669 [Seal Extraction Tool] 380000362 [Crankshaft Lifting Hook] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000325 [90 - 175mm Diameter Piston Assembly Band Clamp] 380000221 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000228 [Dial Gauge (0 - 5 mm)] 380000364 [Comparator Holder Base For Different Surveys] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000145 [Camshaft Bushing Remover And Installer] 380001099 [Fuel Injector Extractor] 380000670 [Oil Filter Wrench]

Reference

PAGE

Engine - Service instruction Maintenance procedures Engine - Service instruction Maintenance procedures Engine - Service instruction Maintenance procedures Engine - Service instruction Maintenance procedures Cylinder head - Install

10.001 / 7 10.001 / 7 10.001 / 7 10.001 / 7 10.101 / 10

Valves - Remove

10.101 / 11

Valves - Install

10.101 / 15

Valve seat - Regrind

10.101 / 18

Valve seat - Regrind

10.101 / 18

Engine flywheel - Remove

10.103 / 3

Engine flywheel - Install

10.103 / 5

Engine flywheel - Install

10.103 / 5

Crankshaft oil seal Front seal - Remove

10.103 / 6

Crankshaft oil seal Rear seal - Remove

10.103 / 8

Crankshaft - Remove

10.103 / 10

Crankshaft Journal - Clearance

10.103 / 14

Connecting rod and piston - Install

10.105 / 8

Piston Ring - Install

10.105 / 12

Piston - Check

10.105 / 15

Piston - Check

10.105 / 15

Connecting rod bearing - Clearance

10.105 / 17

Camshaft bushings - Replace

10.106 / 17

Fuel injectors - Remove

10.218 / 22

Engine oil filter - Remove

10.304 / 6

09/10/2012

7

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

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

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

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

47441596 09/10/2012 EN