48076871-Linked PDF 2

SERVICE MANUAL
NEF
Tier 4B (final) and Stage IV
Engine
See the following page for engine model numbers
Part number 48076871

Printed in U.S.A. 1st edition English
© 2016 CNH Industrial America LLC. All Rights Reserved.
Case, Case IH, New Holland, and Steyr are trademarks registered in the United States and many other countries,
November 2016
owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Replaces part numbers 47606092, 47606102,
47606112, 47606122
SERVICE MANUAL
F4DFE4131*B001, F4DFE4131*B002, F4DFE4131*B007, F4DFE4131*B008,

F4DFE4132*B001, F4DFE4132*B002, F4DFE4132*B005 , F4DFE4132*B006,
F4DFE413R*B001, F4DFE413S*B001, F4DFE413T*B001, F4DFE413U*B001,
F4DFE414B*B001 , F4DFE414C*B001 , F4DFE414D*B001 , F4DFE414E*B001 ,
F4DFE6132*B001, F4DFE6132*B007 , F4DFE613B*B001, F4DFE613B*B002,
F4DFE613B*B003, F4DFE613B*B005, F4DFE613B*B006, F4DFE613H*B001,
F4DFE613H*B002, F4DFE613H*B003, F4DFE613J*B001, F4DFE613J*B002,
F4DFE613J*B003, F4DFE613J*B005, F4DFE613J*B006, F4DFE613K*B001,
F4DFE613K*B002, F4DFE613K*B003, F4DFE613K*B004, F4DFE613K*B006,
F4DFE613K*B007, F4DFE613K*B008, F4DFE613L*B001, F4DFE613M*B001,
F4DFE613M*B002, F4DFE613M*B003, F4DFE613N*B001, F4DFE613N*B002,
F4DFE613N*B003, F4DFE613N*B005, F4DFE613N*B006, F4DFE613P*B001,
F4DFE613P*B002, F4DFE613P*B003, F4DFE617L*B002, F4DFE617M*B001,
F4HFE413H*B001, F4HFE413H*B002 , F4HFE413L*B001, F4HFE413M*B001,
F4HFE413N*B001, F4HFE413P*B001, F4HFE413V*B001, F4HFE413W*B001,
F4HFE413X*B001, F4HFE413Y*B001, F4HFE6133*B001, F4HFE6133*B003,
F4HFE6135*B001, F4HFE6136*B003, F4HFE6137*B003, F4HFE613A*B001,
F4HFE613A*B002, F4HFE613B*B001, F4HFE613B*B002, F4HFE613B*B003,
F4HFE613B*B005, F4HFE613B*B006, F4HFE613C*B001, F4HFE613C*B002,
F4HFE613C*B004, F4HFE613C*B006, F4HFE613D*B001, F4HFE613D*B006,
F4HFE613D*B007, F4HFE613E*B001, F4HFE613E*B005, F4HFE613F*B001,
F4HFE613F*B002, F4HFE613F*B004, F4HFE613G*B001, F4HFE613G*B002,
F4HFE613H*B001, F4HFE613H*B003, F4HFE613J*B001, F4HFE613J*B002,
F4HFE613J*B004, F4HFE613J*B005, F4HFE613K*B001, F4HFE613K*B002,
F4HFE613R*B001, F4HFE613R*B002, F4HFE613R*B005, F4HFE613R*B006,
F4HFE613S*B001, F4HFE613S*B002, F4HFE613S*B003, F4HFE613S*B004,
F4HFE613T*B001, F4HFE613T*B002, F4HFE613T*B005, F4HFE613T*B006,
F4HFE613U*B001, F4HFE613U*B002, F4HFE613W*B001, F4HFE613W*B002,
F4HFE613W*B003, F4HFE613W*B005, F4HFE613W*B006, F4HFE613X*B001,
F4HFE613Y*B001, F4HFE613Y*B002, F4HFE613Y*B003, F4HFE613Z*B001,
F4HFE613Z*B002
48076871 15/11/2016
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
48076871 15/11/2016
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
48076871 15/11/2016
48076871 15/11/2016
INTRODUCTION
48076871 15/11/2016
1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
48076871 15/11/2016
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INTRODUCTION
Foreword - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CNH Sales and Service Networks.
48076871 15/11/2016
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INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Safety rules - Ecology and the environment

Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the
treatment of some of the substances that advanced technology requires, sound judgment should govern the use and
disposal of products of a chemical and petrochemical nature.
Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this
legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze,
cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use,
and dispose of these substances.
Helpful hints
• Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems
may cause considerable spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances
that may be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid,
etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of
the fluids in a proper way that complies with all local legislation and available resources.
• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.
• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-condi-
tioning specialist or use a special extractor to recharge the system properly.
• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils,
coolant, etc.
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful
effect on the environment if the batteries are not properly recycled after use. Improper
disposal of batteries can contaminate the soil, groundwater, and waterways. CNH strongly
recommends that you return all used batteries to a CNH dealer, who will dispose of the
used batteries or recycle the used batteries properly. In some countries, this is a legal
requirement.
Mandatory battery recycling

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

• Accept the return of your used batteries
• Store the returned batteries in a suitable location
• Send the returned batteries to the battery manufacturer for recycling
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INTRODUCTION
Torque
Component Size Specification
Cylinder head and components
Plug ¼" 10 - 14 Nm (7.4 - 10.3 lb ft)
½" 20 - 28 Nm (14.8 - 20.7 lb ft)
¾" 31 - 41 Nm (22.9 - 30.2 lb ft)
Grid heater M6 Nut 6 - 10 Nm (4.4 - 7.4 lb ft)
Intake manifold M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Engine lifting bracket
Rear M12 65 - 89 Nm (47.9 - 65.6 lb ft)
Front M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder head M12x1.75x130 mm
First phase 30 - 40 Nm (22.1 - 29.5 lb ft)
Second phase 85 - 95 °
Third phase 85 - 95 °
Cylinder head M12x1.75x150 mm
Rocker bracket 31 - 41 Nm (22.9 - 30.2 lb ft)
Rocker arm jam nuts 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust manifold 48 - 58 Nm (35.4 - 42.8 lb ft)
Valve cover M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Turbocharger
6 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 37 - 49 Nm (27.3 - 36.1 lb ft)
4 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Front case
Front cover M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear case
Gear case M12 Screw 65 - 89 Nm (47.9 - 65.6 lb ft)
M10 Screw 42 - 52 Nm (31.0 - 38.4 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Flywheel housing M10 75 - 95 Nm (55.3 - 70.1 lb ft)
M12 44 - 54 Nm (32.5 - 39.8 lb ft)
Cylinder block and crankshaft components
Camshaft retaining plate M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft gear M8 Screw 32 - 40 Nm (23.6 - 29.5 lb ft)
Crankcase plate M10 Screw 38 - 48 Nm (28.0 - 35.4 lb ft)
Vibration damper and adapter M12
Second phase 90 °
Drive pulley M10 70.0 - 75.0 N·m (51.6 - 55.3 lb ft)
Engine flywheel M12
Main caps M12
Second phase 74 - 86 Nm (54.6 - 63.4 lb ft)
Connecting rod caps
First phase 45.0 - 55.0 N·m (33.2 - 40.6 lb ft)
Lubrication system and components
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INTRODUCTION

Oil pump
First phase M8 7 - 9 Nm (5.2 - 6.6 lb ft)
Second phase M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil pressure relief valve M22 72 - 88 Nm (53.1 - 64.9 lb ft)
Oil cooler and oil filter base M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Filter Contact + ¾ Turn
Connection on filter base for turbo oil 1 ⅛" 20 - 28 Nm (14.8 - 20.7 lb ft)
supply
Turbo lubrication pipe M12 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
Turbo lubrication pipe adapter M12 30 - 40 Nm (22.1 - 29.5 lb ft)
Oil pan 20 - 28 Nm (14.8 - 20.7 lb ft)
Piston spray nozzles M8 12 - 18 Nm (8.9 - 13.3 lb ft)
Electrical components
Camshaft sensor M6 Studs 6 - 10 Nm (4.4 - 7.4 lb ft)
M6 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Wiring bulkhead M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Support bracket for injector wiring M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector wiring 1.25 - 1.75 Nm (0.92 - 1.29 lb ft)
ECU cooling plate M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel outlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Fuel inlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Crankshaft speed sensor M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Coolant temperature sensor M14 Screw 17 - 23 Nm (12.5 - 17.0 lb ft)
Oil pressure / Temperature sensor M5 Screw 5 - 7 Nm (3.7 - 5.2 lb ft)
Fuel pressure sensor 30 - 40 Nm (22.1 - 29.5 lb ft)
Fuel temperature sensor M14 17 - 23 Nm (12.5 - 17.0 lb ft)
Air pressure / Temperature sensor 5 - 7 Nm (3.7 - 5.2 lb ft)
Engine oil level sensor M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Alternator support bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator tension bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Starter 37 - 49 Nm (27.3 - 36.1 lb ft)
Fuel system and components
Feed pump M8 Studs 10 - 14 Nm (7.4 - 10.3 lb ft)
High pressure pump gear M18 Nut 100 - 110 Nm (73.8 - 81.1 lb ft)
Fuel pump M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector
First phase M6x1x35 3.5 N·m (31 lb in)
Second phase M6x1x35 25 °
Third phase M6x1x35 25 °
Fourth phase M6x1x35 25 °
Injector feed connector 45 - 55 Nm (33.2 - 40.6 lb ft)
Common rail M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
High pressure fuel line M14 Fitting 18 - 22 Nm (13.3 - 16.2 lb ft)
High pressure pipe connector M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel filter bracket M12 Screw 71 - 85 Nm (52.4 - 62.7 lb ft)
Fuel filter holder M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel filter Contact + ¾ Turn
Cooling system and components
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INTRODUCTION

Engine coolant inlet M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Fitting on coolant inlet 90 ° Elbow 20 - 28 Nm (14.8 - 20.7 lb ft)
Compressor cooling pipe 20 - 24 Nm (14.8 - 17.7 lb ft)
Engine coolant drain collector M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Water pump M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Belt tensioner M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Idler pulleys M10 37 - 49 Nm (27.3 - 36.1 lb ft)
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, 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.
48076871 15/11/2016
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE
NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m 225 N·m (166 lb 301 N·m (222 lb 143 N·m (106 lb 205 N·m (151 lb
M16
ft) (155 lb ft) ft) ft) ft) ft)
319 N·m (235 lb 425 N·m 440 N·m (325 lb 587 N·m (433 lb 290 N·m (214 lb 400 N·m (295 lb
M20
ft) (313 lb ft) ft) ft) ft) ft)
551 N·m (410 lb 735 N·m 762 N·m (560 lb 1016 N·m 501 N·m (370 lb 693 N·m (510 lb
M24
ft) (500 lb ft) ft) (750 lb ft) ft) ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
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INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
ft) ft) ft) ft) ft) ft)
M20
ft) ft) ft) ft) ft) ft)
607 N·m (447 lb 809 N·m (597 lb 838 N·m (618 lb 1118 N·m 552 N·m (407 lb
M24
ft) ft) ft) (824 lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
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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

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m 16 N·m 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) (106 lb in) (142 lb in) in)
17 N·m 23 N·m 24 N·m 32 N·m 17.5 N·m (155 lb 25 N·m (220 lb
5/16
(150 lb in) (204 lb in) (212 lb in) (283 lb in) in) in)
30 N·m (22 lb 40 N·m 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) (30 lb ft) ft) ft)
48 N·m (36 lb 65 N·m 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) (48 lb ft) ft) ft)
74 N·m (54 lb 98 N·m 104 N·m 139 N·m 108 N·m (80 lb
1/2 76 N·m (56 lb ft)
ft) (73 lb ft) (77 lb ft) (103 lb ft) ft)
107 N·m 142 N·m 150 N·m 201 N·m 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
(79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) ft)
147 N·m 196 N·m 208 N·m 277 N·m 153 N·m (113 lb 215 N·m (159 lb
5/8
(108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) ft) ft)
3/4
7/8
1
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

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
3/8 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft) ft)
7/16 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft) ft)
81 N·m (60 lb 108 N·m (80 lb 115 N·m (85 lb 153 N·m 104 N·m (77 lb
1/2 74 N·m (55 lb ft)
ft) ft) ft) (113 lb ft) ft)
117 N·m (86 lb 156 N·m 165 N·m 221 N·m 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) (115 lb ft) (122 lb ft) (163 lb ft) ft)
162 N·m (119 lb 216 N·m 228 N·m 304 N·m 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) (159 lb ft) (168 lb ft) (225 lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120 ° Apart
3 Grade 8 - Five Marks 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 Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
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INTRODUCTION
Basic instructions - Shop and Assembly

Shimming
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up
the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value
indicated on each shim.
Rotating shaft seals

For correct rotating shaft seal installation, proceed as follows:
• before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
• thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
• position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction
and position the grooves so that they will deviate the fluid towards the inner side of the seal.
• coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
• insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
• whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact
with the thrust element, if required.
• to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O-Ring seals
Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting,
which would jeopardise sealing efficiency.
Sealing compounds
Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or
LOCTITE® RTV 598™ or LOCTITE® INSTANT GASKET 587™ BLUE. Before applying the sealing compound, prepare
the surfaces as directed on product container or as follows:
• remove any incrustations using a metal brush.
• thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts
cleaner.
Spare parts
Only use "CNH Original Parts" or " CNH Parts".
Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same
parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this
guarantee.
When ordering spare parts, always provide the following information:
• machine model (commercial name) and serial number
• part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for
order processing
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INTRODUCTION
Protecting the electronic/electrical system 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.
• 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
4. 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 burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
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
Basic instructions - Shop and assembly

Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals

For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CNH Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CNH Original Parts can offer this
guarantee.
When ordering spare parts, always provide the following information:

• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
W0111A
Special tools
The special tools that CNH suggests and illustrate in this manual have been specifically researched and designed for
use with CNH machines. The special tools are essential for reliable repair operations. The special tools are accurately
built and rigorously tested to offer efficient and long-lasting operation.
By using these tools, repair personnel will benefit from:

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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CONSUMABLES INDEX
Consumable Reference PAGE

Loctite® RTV 598™ Basic instructions - Shop and Assembly 15
Loctite® Instant Gasket 587™ Basic instructions - Shop and Assembly 15
Blue
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SERVICE MANUAL
Engine

F4HFE613Z*B002
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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
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CONSUMABLES INDEX

Loctite® 5205 Engine block cover Front - Cleaning 10.2 / 13
Loctite® 5205 Engine block cover Front - Install 10.2 / 14
Loctite® 5205 Engine block cover Rear - Cleaning 10.2 / 18
Loctite® 518™ Gasket Engine block cover Rear - Cleaning 10.2 / 23
Eliminator®
Loctite® 5205 Timing gear housing - Cleaning 10.2 / 27
Molykote® G-N Metal Cylinder head - Install 10.4 / 11
assembly paste
Mobilux® EP 023 Common rail Relief valve - Install 10.11 / 39
DEF/AdBlue® Diesel Exhaust Fluid 10.14 / 32
Diesel Exhaust Fluid Diesel Exhaust Fluid 10.14 / 35
(DEF)/AdBlue®
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Engine - 10
Engine and crankcase - 001

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F4HFE613Z*B002
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Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Engine
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankcase
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSTIC
Engine
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Testing - Engine oil in air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
(*) See content for specific models
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Engine - Engine and crankcase
Engine - General specification

General specifications
Engine type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel feed
Injection type Bosch high pressure common rail
Control EDC17 CV41
Injector CRIN 2
Nozzle type DLLA
Injection sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure 250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger type Honeywell GT25 Holset HX35
Lubrication
Oil pressure @ low idle 2.0 bar (29.0 psi)
Oil pressure @ fast idle 4.0 bar (58.0 psi)
Oil pan capacity 15 l (15.85 US qt)
Oil filter capacity 1 l (1.06 US qt)
Cooling
Water pump Belt driven
Thermostat 79 - 83 °C (174 - 181 °F)
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Clearance data
Cylinder block and crankshaft components
Cylinder barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
Pistons 103.739 - 103.757 mm (4.084 - 4.085 in) (*)
Skirt height 49.5 mm (1.949 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Piston (oversize) 0.4 mm (0.016 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston pin - Pin housing 0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Intermediate 2.420 - 2.440 mm (0.095 - 0.096 in) (*)
Oil control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Intermediate 2.350 - 2.380 mm (0.093 - 0.094 in)
Oil control 3.970 - 3.990 mm (0.156 - 0.157 in)
Piston ring and ring landing clearance
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Intermediate 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*)
Oil control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston ring end gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Intermediate 0.60 - 0.80 mm (0.024 - 0.031 in)
Oil control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting rod
Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in)
Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in)
Small end bushing inside
38.019 - 38.033 mm (1.497 - 1.497 in)
diameter
Big end bearing shell
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
Piston pin and bushing
0.019 - 0.039 mm (0.001 - 0.002 in)
clearance
Oversize big end bearing
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
shells
Crankshaft
Main journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Main bearing shell thickness 2.456 - 2.464 mm (0.097 - 0.098 in)
Big end bearing shell
1.955 - 1.968 mm (0.077 - 0.078 in)
thickness
Main bearing bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Bearing shell and journal clearance
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
Bearing shell and crankpin
0.033 - 0.041 mm (0.001 - 0.002 in)
clearance
Thrust journal 37.475 - 37.545 mm (1.475 - 1.478 in)
Thrust bearing bore 32.180 - 32.280 mm (1.267 - 1.271 in)
Thrust bearing 37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)
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Clearance data
Cylinder head and components
Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 59.75 - 60.25 °
Exhaust valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 44.75 - 44.25 °
Valve stem and guide clearance 0.052 - 0.092 mm (0.002 - 0.004 in)
Valve seat bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Valve seat outside diameter:
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve seat angle
Intake 60 °
Exhaust 45 °
Valve sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Interference between valve seat and cylinder head
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve spring height
Free 47.75 mm (1.880 in)
Under a load equal to:
330.8 - 348.8 N (74.4 -
35.33 mm (1.391 in)
78.4 lb)
Under a load equal to:
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft bore
No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in)
Bushing and journal clearance 0.038 - 0.162 mm (0.001 - 0.006 in)
Cam lift
Intake 6.045 mm (0.238 in)
Exhaust 7.582 mm (0.299 in)
Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Tappet outside diameter
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Tappets and bore clearance 0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Rockers and shaft clearance 0.024 - 0.162 mm (0.001 - 0.006 in)
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Engine - Dynamic description
NHIL13ENG0290FA 1
The NEF F4HFA engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4
valves per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by Fiat Power Train (FPT).
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
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Engine - Component localization

Location of main electrical components
CRIL04D081G01 1
(1) Coolant temperature sensor (8) Fuel temperature sensor

(2) Electro injector (9) EDC17 CV41
(3) Rail pressure sensor (10) Crankshaft sensor
(4) Air temperature/Pressure sensor (11) Oil level sensor
(5) Engine starter (12) Engine oil temperature/Pressure sensor
(6) Timing sensor (13) Heating element for pre-post heating
(7) Solenoid valve for pressure regulator
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 - Dynamic description

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
48076871 15/11/2016
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NHIL13ENG0291FA 1
The NEF F4DFE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4
valves per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by Fiat Power Train (FPT).
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
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Engine - Component localization

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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Location of main electrical components
NHIL13ENG0294GA 1
(1) Coolant temperature sensor (7) fuel temperature sensor

(2) Electro-injector (8) EDC17 CV41 electronic control module
(3) Starter (9) Crankshaft speed sensor
(4) Fuel pressure sensor (10) Engine oil pressure/temperature sensor
(5) Air pressure/temperature sensor (11) Pre-post heating resistor
(6) Timing sensor
The NEF F4DFE engines are fully driven by the electronic engine control module, which is mounted remotely on the
unit 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 - Compression test

1. Select the DATAR application (1) in the Electronic Ser-
vice Tool (EST).
NHIL15ENG0249AA 1
2. Once the DATAR screen is open, select the ‘Datar Di-

agnostics’ (1).
NHIL15ENG0250AA 2
3. Select ‘Help’ from the tool bar (1).

4. Select ‘Contents’ or press “F1” (2).
NHIL15ENG0254AA 3
5. Select ‘Tests’ (1).

6. Select ‘Compression Test’ (2).
7. Follow the instructions for “Relative Compression’.
NHIL15ENG0255AA 4
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Engine - Service instruction - Finding Top Dead Center (TDC)

1. Remove the starter from the flywheel housing (1).
2. Install tools 380003372 (2) and 380003373 (3) to rotate
the flywheel.
3. Remove the valve cover.
FLYWHEELROTATEG 1
4. Rotate the crankshaft until the blank space on the tone

wheel (1) aligns with the crankshaft sensor (2).
5. Check to make sure the intake and exhaust valves for
cylinder number 1 are closed and the push rods are
loose.
NOTE: Rotate the engine 360 ° if the push rods are tight.
NHVM13ENG0691AA 2
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Crankcase Bore - Check

Prior operation:
Connecting rod and piston - Remove (10.105)
Once engine is disassembled, perform the following:

Clean the engine block assembly
Use the proper rings to handle the cylinder unit.
Inspect engine block for cracks.
Check operating plug conditions and replace them in
case of uncertain seal or if rusted.
Inspect cylinder bore surfaces for seizing and scoring.
Inspect cylinder bores for ovalization, taper, and wear
by using a bore dial gauge OEM1032 (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 mi-
crometer for zero-setting. NHIL13ENG0270AA 1
Measurements should be performed on each cylinder at

three different heights in the cylinder and on two planes
perpendicular with each other: one parallel to the lon-
gitudinal axis of the engine (A), and the other perpen-
dicular (B).
Maximum wear is usually found on plane (B) in corre-
spondence with the first measurement.
Should ovalization, taper, or wear be found, bore and
hone the cylinder bores. Cylinder boring should be per-
formed according to the new piston diameter oversize
by 0.4 mm (0.016 in) and to the specified assembling
clearance.
NOTE: In case of boring, all cylinder bores should have the NHIL13ENG0286AA 2
same oversize 0.4 mm (0.016 in).
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Crankcase - Check
Prior operation:
Crankshaft - Remove (10.103)
Main bearing housings

Check main bearing housings as follows:
1. Install the main bearing caps onto the engine block
without bearings.
2. Torque the main cap bolts in the following three stages.
• Stage 1: 44 - 55 N·m (32 - 41 lb ft).
• Stage 2: 74 - 86 N·m (55 - 63 lb ft).
• Stage 3: Use the angular torquing gauge tool
380001001 and turn the bolts an additional 85 - 95 °.
3. Use a dial bore gauge 380000827 to check main bear-
ing bore diameter. The values for four and six cylinder
engines should be as follows:
• No. 1,5 or 1,7 should be within 87.982 - 88.008 mm
(3.464 - 3.465 in).
• No. 2,3,4 or 2,3,4,5,6 should be within 87.977 -
88.013 mm (3.464 - 3.465 in).
4. Replace if a higher value is found.
Checking head supporting surface on cylinder unit

1. Use a straightedge (2) placed diagonally across the
cylinder head dowel pins (3) and use a feeler gauge
(1) to check across the cylinder block for distortion.
NOTE: The planar surface distortion should not exceed
0.075 mm (0.003 in). If the value is higher than the speci-
fied value, the cylinder block will need to be resurfaced.
2. Check the condition of the freeze plugs (4), replace
them in case of uncertain seal or if rusted.
NHIL13ENG1388AA 1
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Crankcase - Pressure test

1. Remove the crankcase ventilation tube from the air in-
take tube.
2. Cap the port on the air intake tube to prevent dirt
ingress.
3. Construct a fitting to adapt a water manometer to the
crankcase ventilation system. You will need:
• (1) 1/2” NPT female pipe tee
• (2) 3/4” Hb x 1/2” NPT male beaded hose barb fitting
• (3) 1/2” x 1/4” NPT pipe reducer
• (4) 5/16” Hb x 1/4” NPT male hose barb fitting
• (5) 1/2” NPT hollow hex pipe plug
4. Drill a 5.613 mm (0.221 in) orifice into the center of the
1/2” NPT hollow hex pipe plug (3) .
5. Assemble the fittings as shown.
NHIL16ENG0021AA 1
6. Connect the crankcase ventilation tube to the 3/4” Hb

x 1/2” NPT male beaded hose barb fitting (2).
7. Connect the water manometer to the 5/16” Hb x 1/4”
NPT male hose barb fitting (4).
8. Run the engine until the coolant temperature is approx-
imately 84 °C (183 °F)
9. Record the values measured with the water manometer
at each interval listed below. Values should not exceed
20.42 cm H₂₂O (8.04 in H₂₂O).
• Low idle
• 1500 RPM
• High idle (rated speed)
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Engine - Troubleshooting
Problem Possible Cause Correction
Engine will not start An engine no start is defined as an engine 1. Faulty battery, voltage too low
that will crank but will not start. The most 2. Insufficient fuel level
likely causes of this failure are issues re-
lated to the battery, fuel system or low en- 3. Contaminated fuel (water or air)
gine compression. 4. Clogged fuel filter
5. Faulty fuel injectors
6. Faulty glow plugs (if equipped)
7. Faulty fuel lift pump (if equipped)
8. Faulty high pressure pump, (if
equipped)
9. Faulty mechanical pump, (if equipped)
10. Low engine compression
11. Engine timing incorrect
The engine starts then This symptom is usually caused by fuel Visually inspect the fuel system for exter-
stalls leakage or a clogged fuel filter. nal leakage. If leakage is found, repair as
necessary. Check fuel system pressure for
adequate pressure. If fuel pressure is lower
than expected, repair as necessary.
Engine will not crank An engine no-crank condition is defined 1. Check battery voltage. Charge or re-
as an engine that will not crank. Possible place the battery as necessary.
failures include a dead or weak battery, 2. Verify the status of the battery discon-
an open battery disconnect switch (if
nect switch (if equipped). The switch
equipped) or a starting system failure.
must be closed.
3. Check the starting system for possible
failures. Check the starter relay and
battery voltage at the starter. Perform
a voltage drop test between the bat-
tery and the engine starter to check the
starter wiring. Repair as necessary.
The engine is difficult to The cause of an engine hard start condi- 1. Faulty battery, voltage too low.
start tion is similar to those of an engine no start 2. Insufficient fuel level
condition. Failures can include inadequate
fuel pressure, air supply, engine compres- 3. Contaminated fuel (water or air)
sion, faulty glow plugs or incorrect injection 4. Clogged fuel filter
timing during start up.
5. Faulty fuel injectors
6. Faulty glow plugs (if equipped)
7. Faulty fuel lift pump (if equipped)
8. Faulty high pressure pump
9. Restricted air induction system
10. Low engine compression
11. Engine timing incorrect
Engine has a slow A slow engine crank condition can be 1. Load test the battery. Charge or replace
cranking condition caused by a weak battery, worn starter the battery as necessary.
internal engine resistance. Extremely cold
2. Perform a voltage drop test on the start-
operating temperatures can also be a fac-
ing circuit. There should be a drop less
tor in a slow engine crank condition.
than 0.5 V on both the positive and neg-
ative circuits. If the drop is greater than
0.5 V, repair as necessary.
3. Bench test the starter. If the starter op-
erates slower than expected, replace
the starter.
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Problem Possible Cause Correction

The engine is consuming Engine oil consumption can be caused Verify that the engine is using the correct
an excessive amount of by faulty piston rings, valve guide seals, engine oil. Perform testing on the engine
engine oil. main bearings, connecting rod bearings, to help locate the cause of oil consumption.
camshaft bearings, crankshaft journals, Perform an engine leak down test or wet
tapered or out-of-round cylinders etc. cylinder compression test.
The cooling system is Cooling system leaks can be caused by Visually inspect all hoses, thermostat hous-
leaking coolant. faulty seals, gaskets, hoses, radiator or ra- ing, water pump, radiator, and all other
diator cap etc. cooling system components for signs of
leakage. If no visual leakage is found,
pressure test the cooling system and check
for leakage.
The engine is leaking Engine oil leakage can be caused by faulty Visually inspect the engine lubrication sys-
engine oil. seals or gaskets, excessive crankcase tem for any signs of leakage. Inspect the
pressure, faulty lubrication system compo- engine oil filter, oil cooler, oil pump, and all
nents, or the wrong engine oil. seals and gaskets for leaks. Verify that the
engine oil is the recommended oil. Verify
that the engine oil level is not overfull.
The engine is leaking Refrigerant leaks can be caused by faulty Use a refrigerant dye kit to locate the leak.
refrigerant. air condition components such as the com-
pressor, condenser, evaporator, or faulty
seals.
The engine is firing when A runaway engine condition is caused Leaking fuel injectors
not commanded. when diesel fuel continues to be injected Engine oil leakage into cylinders
or leaked into the engine when not com- Faulty ECU software
manded by the operator. Engine oil leak-
age into the cylinder can also cause this
condition.
The engine is misfiring. Engine misfires can be caused by faulty Check injection timing. Test for proper fuel
injection timing, malfunctioning injectors, pressure. Test fuel injectors for proper op-
malfunctioning injection pump or internal eration. Perform an engine compression
engine failures such as a burnt valve or a test.
hole in a piston.
Low oil pressure Engine oil level low Fill to proper level
Wrong grade of oil Replace with correct grade oil
Clogged oil 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. Re-
oil pipe place defective components
Excessive main or connecting rod bearing Replace bearings or shaft if necessary
clearances
Oil pump axial clearance not properly set Check pump clearance and shim as
needed to proper tolerance.
Faulty oil pressure sensor/oil pressure Check for fault codes, and testing proce-
switch or electrical circuit dures to check electrical circuits.
The engine oil pressure is Blockage in the engine oil filter. Replace the engine oil filter and cut it open
high. to inspect the element for the cause of
blockage.
Stuck engine oil pressure regulating valve. Remove and inspect the valve for signs of
siezure or debris.
Stuck engine oil overpressure valve. Remove and inspect the valve for signs of
siezure or debris.
Blockage in the lubrication passages. Inspect the passages for debris.
Incorrect oil grade used for environmental Drain and refill the engine oil with the cor-
operating conditions rect grade of oil per the chart in the Opera-
tor’s Manual
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Engine - Testing - Engine oil in air intake system

Test N°1
Test Point Check
Check the engine oil level in the sump.
Expected Result
Result The engine oil level is within specification.
Action
Go to test 2
Other Result
Result The engine oil level is high.
(Possible Action
Cause) Drain the oil to proper specification.
Run the engine under full load for 1 h to check symptom reoccurrence
Test N°2
Test Point Check
Remove the air intake pipe between the air filter and turbocharger. Visually inspect the inside of the pipe
for the presence of engine oil downstream of the crankcase ventilation fitting.
Expected Result
Result There is little to no traces of engine oil present in the intake piping.
Action
Go to test 3
Other Result
Result There is large amounts of engine oil present in the intake piping.
(Possible Action
Cause) Go to test 6
Test N°3
Test Point Check
Inspect the intake piping from the air filter to the turbocharger for damage or restrictions.
Expected Result
Result No damage or restriction is found.
Action
Go to test 4
Other Result
Result Damage or restrictions are found.
(Possible Action
Cause) Clean or replace the intake piping.
Test N°4
Test Point Check
Inspect the intake air filter for clogging.
Expected Result
Result The air intake filter is clean.
Action
Install the air filter.
Go to test 5
Other Result
Result The air filter is clogged or dirty.
(Possible Action
Cause) Replace the air filter with new.
Test N°5
Test Point Check
Inspect the charge air system from the turbocharger to the intake manifold for loose clamps, damaged
piping or leaks in the hoses.
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Expected Result
Result There are no loose clamps, damage to piping or leaks found.
Action
Go to test 7
Other Result
Result Leaks are found.
(Possible Action
Cause) Repair or replace the damaged parts.
Test N°6
Test Point Check
Perform the Crankcase - Pressure test (10.001).
Expected Result
Result The crankcase pressure is less than 20.40 cm H₂₂O (8.03 in H₂₂O).
Action
Visually inspect the crankcase ventilation system filter and replace if necessary
Go to test 7
Other Result
Result The crankcase pressure is greater than 20.40 cm H₂₂O (8.03 in H₂₂O).
(Possible Action
Cause) Replace the crankcase ventilation filter.
Test N°7
Test Point Check
Remove the oil return line from the turbocharger. Visually inspect the line for damage or restrictions that
could cause increased pressure in the return circuit.
Expected Result
Result No damage or restrictions are found.
Action
Go to test 8
Other Result
Result Damage or restrictions are found.
(Possible Action
Cause) Clean or replace the turbocharger oil return line.
Test N°8
Test Point Check
With the key OFF, manually move the exhaust flap actuator.
Expected Result
Result The actuator moves through it’s full stroke with little resistance.
Action
Go to test 9
Other Result
Result The actuator is stuck partially closed.
(Possible Action
Cause) Clean any carbon build-up from the exhaust flap to free the actuator.
Test N°9
Test Point Check
Manually move the wastegate actuator.
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Expected Result
Result The wastegate actuator moves freely throughout its full stroke.
Action
Go to test 10
Other Result
Result The wastegate actuator is stuck or binds during full stroke.
(Possible Action
Cause) Repair or replace the wastegate actuator as needed.
Test N°10
Test Point Check
Inspect the radial backlash of the turbocharger impeller shaft. See Turbocharger - Inspect - Borg-
Warner (10.250).
Expected Result
Result The impeller does not contact the compressor housing.
Action
Go to test 11
Other Result
Result The impeller contacts the compressor housing..
(Possible Action
Cause) Replace the turbocharger.
Go to test 11
Test N°11
Test Point Check
Connect a mechanical pressure gauge to the engine lubrication system to check for a high oil pressure
condition. See Engine lubrication system - Test (10.304) .
Expected Result
Result The engine oil pressure is within specification.
Action
Collect an oil sample for analysis, clean and reassemble all parts, and return the machine to service.
Other Result
Result The engine oil pressure is above specification.
(Possible Action
Cause) See Engine - High pressure - Engine oil (10.001).
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Index
Engine - 10

Crankcase - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankcase - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine - Testing - Engine oil in air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Engine - 10
Pan and covers - 102

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F4HFE613Z*B002
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Contents
Engine - 10
SERVICE
Engine oil pan

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine block cover
Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Timing gear housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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CONSUMABLES INDEX

Loctite® 5205 Engine block cover Front - Cleaning 10.2 / 13
Loctite® 5205 Engine block cover Front - Install 10.2 / 14
Loctite® 5205 Engine block cover Rear - Cleaning 10.2 / 18
Loctite® 518™ Gasket Engine block cover Rear - Cleaning 10.2 / 23
Eliminator®
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Engine - Pan and covers
Engine oil pan - Remove

F4HFE413H*B001
F4HFE413H*B002
F4HFE413L*B001
F4HFE413M*B001
F4HFE413N*B001
F4HFE413P*B001
F4HFE413V*B001
F4HFE413W*B001
F4HFE413X*B001
F4HFE413Y*B001
F4HFE6133*B001
F4HFE6133*B003
F4HFE6135*B001
F4HFE6136*B003
F4HFE6137*B003
F4HFE613A*B001
F4HFE613A*B002
F4HFE613B*B001
F4HFE613B*B002
F4HFE613B*B003
F4HFE613B*B005
F4HFE613B*B006
F4HFE613C*B001
F4HFE613C*B002
F4HFE613C*B004
F4HFE613C*B006
F4HFE613D*B001
F4HFE613D*B006
F4HFE613D*B007
F4HFE613E*B001
F4HFE613E*B005
F4HFE613F*B001
F4HFE613F*B002
F4HFE613F*B004
F4HFE613G*B001
F4HFE613G*B002
F4HFE613H*B001
F4HFE613H*B003
F4HFE613J*B001
F4HFE613J*B002
F4HFE613J*B004
F4HFE613J*B005
F4HFE613K*B001
F4HFE613K*B002
F4HFE613R*B001
F4HFE613R*B002
F4HFE613R*B005
F4HFE613R*B006
F4HFE613S*B001
F4HFE613S*B002
F4HFE613S*B003
F4HFE613S*B004
F4HFE613T*B001
F4HFE613T*B002
F4HFE613T*B005
F4HFE613T*B006
F4HFE613U*B001
F4HFE613U*B002
F4HFE613W*B001
F4HFE613W*B002
F4HFE613W*B003
F4HFE613W*B005
F4HFE613W*B006
F4HFE613X*B001
F4HFE613Y*B001
F4HFE613Y*B002
F4HFE613Y*B003
F4HFE613Z*B001
F4HFE613Z*B002
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1. Remove the bolts (2) retaining the oil pan (1).

2. Remove the oil pan (1) from the engine block.
NOTE: The shape and dimensions of the oil pan and of
the oil pick up tube may vary according to the application
of the engine. However, the procedures described are still
applicable.
NHIL13ENG0273AA 1
3. Remove the oil pick up tube (2) by removing the bolts

(3) and (1).
4. Remove the bolts (5) retaining the stiffening plate (4)
and then remove the stiffening plate (4).
NHIL13ENG0282AA 2
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10.2 [10.102] / 5
Engine oil pan - Install

F4HFE413H*B001
F4HFE413H*B002
F4HFE413L*B001
F4HFE413M*B001
F4HFE413N*B001
F4HFE413P*B001
F4HFE413V*B001
F4HFE413W*B001
F4HFE413X*B001
F4HFE413Y*B001
F4HFE6133*B001
F4HFE6133*B003
F4HFE6135*B001
F4HFE6136*B003
F4HFE6137*B003
F4HFE613A*B001
F4HFE613A*B002
F4HFE613B*B001
F4HFE613B*B002
F4HFE613B*B003
F4HFE613B*B005
F4HFE613B*B006
F4HFE613C*B001
F4HFE613C*B002
F4HFE613C*B004
F4HFE613C*B006
F4HFE613D*B001
F4HFE613D*B006
F4HFE613D*B007
F4HFE613E*B001
F4HFE613E*B005
F4HFE613F*B001
F4HFE613F*B002
F4HFE613F*B004
F4HFE613G*B001
F4HFE613G*B002
F4HFE613H*B001
F4HFE613H*B003
F4HFE613J*B001
F4HFE613J*B002
F4HFE613J*B004
F4HFE613J*B005
F4HFE613K*B001
F4HFE613K*B002
F4HFE613R*B001
F4HFE613R*B002
F4HFE613R*B005
F4HFE613R*B006
F4HFE613S*B001
F4HFE613S*B002
F4HFE613S*B003
F4HFE613S*B004
F4HFE613T*B001
F4HFE613T*B002
F4HFE613T*B005
F4HFE613T*B006
F4HFE613U*B001
F4HFE613U*B002
F4HFE613W*B001
F4HFE613W*B002
F4HFE613W*B003
F4HFE613W*B005
F4HFE613W*B006
F4HFE613X*B001
F4HFE613Y*B001
F4HFE613Y*B002
F4HFE613Y*B003
F4HFE613Z*B001
F4HFE613Z*B002
Prior operation:
Engine oil pan - Remove (10.102)
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10.2 [10.102] / 6
1. Install the stiffening plate (4) and the oil pick up tube
(2).
2. Torque bolts (1), (3) and (5) to 20 - 28 N·m (15 - 21 lb
ft).
NHIL13ENG0282AA 1
3. Set the gasket (1) onto the oil pan (2) .

NOTE: The pictures of the instructions relating to the oil
pan and to the oil pick up tube may not reflect the actual
shape and dimensions of your engine equipment. How-
ever, the procedures described are still applicable.
NHIL13ENG0315AA 2
4. Install the oil pan (1) and the mounting plate (3) onto
the engine block.
5. Torque the bolts (4) to 15 - 21 N·m (11 - 15 lb ft).
6. Install the oil drain plug (2) into the oil pan.
NOTE: Before any assembly operation always verify that
the hole and bolt threads have no evidence of dirt or wear.
7. Torque the drain plug to 5 - 7 N·m (44 - 62 lb in).
NHIL13ENG0277AA 3
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10.2 [10.102] / 7
Engine oil pan - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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1. Remove the oil pan retaining bolts (2).

2. Remove the oil pan (1) and gasket.
NHIL13ENG0287AA 1
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Engine oil pan - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
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10.2 [10.102] / 10
1. Install the oil pan (1) onto the engine block.

the hole and bolt threads have no evidence of wear or dirt.
3. Install the oil drain plug (3) into the oil pan.
4. Torque the drain plug to 5 - 7 N·m (44 - 62 lb in).
NHIL13ENG0287AA 1
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Engine block cover Front - Remove

Prior operation:
Crankshaft damper - Remove (10.110)
1. Remove the bolts (1) from the front cover (2).

NOTE: Take note of bolt (1) locations as they have different
lengths.
2. Remove the two bolts (3) from underneath the cover.
3. Remove the front cover (2) from the engine block.
NHIL13ENG0317AA 1
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Engine block cover Front - Cleaning

Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the sealing ring (2) from the front cover (1).
NHIL13ENG0318AA 1
2. Clean the sealing surfaces and apply LOCTITE® 5205.
NHIL13ENG0319AA 2
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Engine block cover Front - Install

NOTICE: The front crankshaft seal must be replaced once the cover is removed from the crankcase.
1. Thoroughly clean the sealing surfaces (1) on the cover
and the crankcase.
NHIL13ENG0318AA 1
2. Apply a consistent bead of LOCTITE® 5205 (1) or equiv-

alent to the crankcase as shown.
NHIL13ENG0319AA 2
3. Install the front cover (2) onto the crankcase.

NHIL13ENG0320AA 3
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Engine block cover Front - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
1. See Engine oil pump - Remove (10.304).
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10.2 [10.102] / 15
Engine block cover Front - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
1. See Engine oil pump - Install (10.304).
48076871 15/11/2016
10.2 [10.102] / 16
Engine block cover Rear - Remove

Prior operation:
Engine flywheel - Remove (10.103)
1. Remove the retaining bolts (2) from the rear cover (1).
NOTE: Take note of the retaining bolts (2) location due to
the different lengths. This will aid in ease of installation.
2. Remove the cover (1).
NHIL13ENG0324AA 1
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10.2 [10.102] / 17
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 tim-
ing gear cover.
NOTE: A perfect seal is only obtained by completely clean-
ing the surface to seal. Any imperfection should be cor-
rected 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, a few millimeters
thick, to the sealing surface (1) of the cover.
NOTE: After applying the sealant, the cover should be in-
stalled within 10 to 20 minutes.
NHIL13ENG0325AA 1
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10.2 [10.102] / 18
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. Position the cover (1) onto the timing gear housing and
install the retaining bolts in same location which they
were removed.
2. Follow the torque sequence in the image 2.
• Torque the M10 bolts to 44.0 - 49.0 N·m (32.5 -
36.1 lb ft)
62.7 lb ft)
• Torque the M16 bolt to 170.0 - 174.0 N·m (125.4 -
128.3 lb ft)
NHIL13ENG0326AA 1
NHIL13ENG0326AA 2
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10.2 [10.102] / 19
Engine block cover Rear - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
48076871 15/11/2016
10.2 [10.102] / 20
1. Remove the bolts (2) from the rear cover (1).

NOTE: Record bolt size and location to aid installation.
2. Remove the rear cover.
NHIL13ENG0328AA 1
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10.2 [10.102] / 21
Engine block cover Rear - Cleaning

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
48076871 15/11/2016
10.2 [10.102] / 22
1. Clean the rear cover and it's mating surface on the tim-
ing gear cover.
2. Apply a thin bead of LOCTITE® 518™ GASKET
ELIMINATOR ®, a few millimeters thick, to the sealing
surface (1) of the cover.
NOTE: After applying the sealant, the cover should be as-
sembled within 10 to 20 minutes. NHIL13ENG0327AA 1
48076871 15/11/2016
10.2 [10.102] / 23
Engine block cover Rear - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
Engine block cover Rear - Cleaning (10.102)
NOTICE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.
48076871 15/11/2016
10.2 [10.102] / 24
1. Position the rear cover (1) onto the engine and install
the retaining bolts (2) in the same position from which
they have been removed.
2. Torque the bolts (2) as follows:
• M12 - 85 N·m (63 lb ft)
• M16 - 200 N·m (148 lb ft)
NHIL13ENG0328AA 1
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10.2 [10.102] / 25
Timing gear housing - Remove

1. Remove the retaining bolts (2) from the timing gear
case.
NOTE: Take note of the retaining bolts (2) location due to
the different lengths. This will aid in ease of installation.
2. Remove the timing gear case (1) from the engine block.
NHIL13ENG0332AA 1
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Timing gear housing - Cleaning

Prior operation:
Timing gear housing - Remove (10.102)
1. Clean the timing gear housing (1) and it's mating sur-
face on the engine block.
thick, to the sealing surface (2) of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
NHIL13ENG0333AA 1
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10.2 [10.102] / 27
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. Position the housing (1) onto the engine block install
the retaining bolts in the same position found upon re-
moval.
NHIL13ENG0334AA 1
2. Follow the torque sequence.

• Torque the M8 bolts to 20 - 28 N·m (15 - 21 lb ft)
38.4 lb ft)
65.6 lb ft)
NHIL13ENG0334AA 2
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10.2 [10.102] / 28
Timing gear housing - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
48076871 15/11/2016
10.2 [10.102] / 29
1. Disconnect the high pressure fuel pump stroke sensor

(3).
2. Remove the bolts (2) and remove the timing gear hous-
ing (1) from the engine block.
NHIL13ENG0335AA 1
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10.2 [10.102] / 30
Timing gear housing - Cleaning

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
Timing gear housing - Remove (10.102)
48076871 15/11/2016
10.2 [10.102] / 31
1. Clean the timing gear housing and it's mating surface

on the engine block.
thick, to the sealing surface of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
48076871 15/11/2016
10.2 [10.102] / 32
Timing gear housing - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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.
48076871 15/11/2016
10.2 [10.102] / 33
1. Position the housing (1) onto the engine block install

the retaining bolts (2) in the same position found upon
removal.
2. Torque the retaining bolts to 20 - 28 N·m (15 - 21 lb ft).
3. Connect the high pressure fuel pump stroke sensor (3).
NHIL13ENG0335AA 1
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10.2 [10.102] / 34
Index
Engine - 10

Engine block cover Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine block cover Front - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine block cover Front - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine block cover Rear - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine block cover Rear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine block cover Rear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine oil pan - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pan - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine oil pan - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pan - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Timing gear housing - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Timing gear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Timing gear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Engine - 10
Valve drive and gears - 106

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10.3 [10.106] / 1
F4HFE613Z*B002
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Contents
Engine - 10
FUNCTIONAL DATA
Valve drive and gears

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rocker arm
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rocker shaft
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Camshaft bushings
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshaft gear
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Engine - Valve drive and gears
Valve drive and gears - Overview

Rocker assembly components
NHIL13ENG0338AA 1
(1) Bolts (2) Shafts (3) Rockers (4) Bracket
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Rocker arm - Disassemble

Prior operation:
Valve cover - Remove (10.101)
1. Loosen tappet adjustment jam nuts (1) and loosen the

adjusting bolts.
2. Remove the rocker shaft mounting bolts (2).
3. Remove the rocker assembly, which consists of the
pedestal (5), rockers (3), and shaft (4).
4. Remove the valve bridges (7).
5. Remove the push rods (6).
NHIL13ENG0339AA 1
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Rocker arm - Assemble

Prior operation:
Camshaft - Install (10.106)
1. Check that the tappet adjusters (1) are loose to prevent

their binding on the push rods when installing the rocker
assembly.
2. Install the rocker assembly onto the cylinder head con-
sisting of:
• Bracket (5)
• Rockers (3)
• Shafts (4)
3. Torque the rocker shaft mounting bolts (2) to 36 Nm
(27 lb ft).
NHIL13ENG0339AA 1
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Rocker arm - Adjust

F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
F4HFE6133*B001
F4HFE6133*B003
F4HFE6135*B001
F4HFE6136*B003
F4HFE6137*B003
F4HFE613A*B001
F4HFE613A*B002
F4HFE613B*B001
F4HFE613B*B002
F4HFE613B*B003
F4HFE613B*B005
F4HFE613B*B006
F4HFE613C*B001
F4HFE613C*B002
F4HFE613C*B004
F4HFE613C*B006
F4HFE613D*B001
F4HFE613D*B006
F4HFE613D*B007
F4HFE613E*B001
F4HFE613E*B005
F4HFE613F*B001
F4HFE613F*B002
F4HFE613F*B004
F4HFE613G*B001
F4HFE613G*B002
F4HFE613H*B001
F4HFE613H*B003
F4HFE613J*B001
F4HFE613J*B002
F4HFE613J*B004
F4HFE613J*B005
F4HFE613K*B001
F4HFE613K*B002
F4HFE613R*B001
F4HFE613R*B002
F4HFE613R*B005
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F4HFE613R*B006
F4HFE613S*B001
F4HFE613S*B002
F4HFE613S*B003
F4HFE613S*B004
F4HFE613T*B001
F4HFE613T*B002
F4HFE613T*B005
F4HFE613T*B006
F4HFE613U*B001
F4HFE613U*B002
F4HFE613W*B001
F4HFE613W*B002
F4HFE613W*B003
F4HFE613W*B005
F4HFE613W*B006
F4HFE613X*B001
F4HFE613Y*B001
F4HFE613Y*B002
F4HFE613Y*B003
F4HFE613Z*B001
F4HFE613Z*B002
Prior operation:
Rocker arm - Install (10.106)
1. Set the engine to cylinder number one Top Dead Center

(TDC). Refer to Engine - Service instruction - Find-
ing Top Dead Center (TDC) (10.001) for the proper
procedure.
2. Measure the circumference of the tone wheel (1) and
divide the measurement by 3.
3. Mark the tone wheel at the casting (2) on the front
cover.
4. From the mark, measure the distance obtained in Step
2 and make another mark.
5. Measure the same distance from the mark made in
NHVM13ENG0691AA 1
Step 4 and make another mark.
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6. Adjust the clearance of the intake and exhaust valves

for cylinder number 1 by following Steps 7 through 11.
7. Loosen the jam nut (2).
8. Insert the feeler gauge between the valve bridge (4)
and the rocker arm shoe (3).
NOTE: See the “Valve clearance specifications” table be-
low for the proper feeler gauge thickness.
9. Turn the adjustment screw (1) until there is a slight drag
on the feeler gauge.
10. Torque the jam nut to 20 - 28 N·m (15 - 21 lb ft) while
holding the adjustment screw in position. NHVM13ENG0692AA 2
11. Turn the crankshaft clockwise until the next mark on

the tone wheel aligns with the casting on the front
cover.
12. Repeat Steps 7 through 11 for cylinder number 5 in-
take and exhaust valves.
Valve clearance specifications

Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Firing order 1-5-3-6-2-4
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Rocker arm - Adjust

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4HFE413H*B001
F4HFE413H*B002
F4HFE413L*B001
F4HFE413M*B001
F4HFE413N*B001
F4HFE413P*B001
F4HFE413V*B001
F4HFE413W*B001
F4HFE413X*B001
F4HFE413Y*B001
Prior operation:
1. Set the engine to cylinder number one Top Dead Center

(TDC). Refer to Engine - Service instruction - Find-
ing Top Dead Center (TDC) (10.001) for the proper
procedure.
2. Measure the circumference of the tone wheel (1) and
divide the measurement by 3.
3. Mark the tone wheel at the casting (2) on the front
cover.
4. From the mark, measure the distance obtained in Step
2 and make another mark.
5. Measure the same distance from the mark made in
NHVM13ENG0691AA 1
Step 4 and make another mark.
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10.3 [10.106] / 9
6. Adjust the clearance of the intake and exhaust valves

for cylinder number 1 by following Steps 7 through 11.
7. Loosen the jam nut (2).
8. Insert the feeler gauge between the valve bridge (4)
and the rocker arm shoe (3).
NOTE: See the “Valve clearance specifications” table be-
low for the proper feeler gauge thickness.
9. Turn the adjustment screw (1) until there is a slight drag
on the feeler gauge.
10. Torque the jam nut to 20 - 28 N·m (15 - 21 lb ft) while
holding the adjustment screw in position. NHVM13ENG0692AA 2
11. Turn the crankshaft clockwise until the next mark on

the tone wheel aligns with the casting on the front
cover.
Valve clearance specifications

Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Firing order 1-3-4-2
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Rocker shaft - Clearance

Prior operation:
Rocker arm - Disassemble (10.106)
Check that the shaft/rocker coupling surfaces are not

showing excessive wear or damage.
SHAFTMEASURE 1
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Camshaft - Remove
Prior operation:
Camshaft gear - Remove (10.106)
1. Remove the bolts (1) and remove camshaft (2) retain-

ing plate (3).
NOTE: Take note of the retaining plate (3) assembly posi-
tion.
NHIL13ENG0350AA 1
2. Carefully remove the camshaft (1) from the cylinder

block (2).
NHIL13ENG0351AA 2
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Camshaft - Measure
Prior operation:
Camshaft - Remove (10.106)
1. Set the camshaft on the tailstock and using a 1/100

gauge set on the central support, check the alignment
error.
The alignment error should not exceed 0.04 mm
(0.002 in).
If the error is exceeded, replace the camshaft.
2. Check the camshaft lift. The values should be as fol-
lows:
• Exhaust lobe lift - 6.830 mm (0.269 in)
• Intake lobe lift - 6.045 mm (0.238 in)
NOTE: If the values are not within the specifications, re-
place the camshaft.
3. Check the camshaft (2) pin diameter using a microme-
ter 380000645 (1) on two perpendicular axes.
The diameter should be within 53.995 - 54.045 mm
(2.126 - 2.128 in).
NOTE: If the values are not within the specifications, re-
place the camshaft.
NHIL13ENG0352AA 1
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10.3 [10.106] / 13
BAIL07APH360FSA 2
NOTE: Camshaft pin and cam surfaces should be absolutely smooth; if they show any signs of seizing or scoring
replace the camshaft and the bearings.
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Camshaft - Install
Prior operation:
Camshaft - Measure (10.106)
1. Lubricate the camshaft bearings with clean engine oil

and carefully install the camshaft (1) into the engine
block.
NOTE: Be careful not to damage the camshaft bearings or
housings while sliding the camshaft into the engine block.
CRIL04J056A01 1
2. Set the camshaft (2) retaining plate (1) with the slot fac-
ing the top of the engine block and the marking facing
the operator.
CRIL04J064A01 2
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Camshaft - End play

Prior operation:
1. Use a dial indicator 17270 to check the camshaft (1)

end play.
The end play should be between 0.10 - 0.36 mm (0.004
- 0.014 in).
CRIL04J065A01 1
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Camshaft Push rod - Install

Prior operation:
1. Before installation be sure to check that there is no

signs of wear or distortion. Intake and exhaust push
rods are identical and therefore interchangeable.
PUSHROD 1
2. Install the push rods (2).

3. Install the valve bridges (1) with the marks facing the
exhaust manifold.
NHIL13ENG0358AA 2
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Camshaft Tappets - Remove

Prior operation:
1. Remove the tappets (1) from the engine block.
NHIL13ENG0359AA 1
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Camshaft Tappets - Measure

Prior operation:
Camshaft Tappets - Remove (10.106)
NHIL13ENG0363FA 1
Main data concerning the tappets and the relevant housings on the engine block
(A) 16.000 - 16.030 mm (0.630 - 0.631 in) (E) 44 mm (1.732 in)

(B) 15.924 - 15.954 mm (0.627 - 0.628 in) (F) 15.924 - 15.954 mm (0.627 - 0.628 in)
(C) 8 mm (0.315 in) (G) 15.960 - 15.975 mm (0.628 - 0.629 in)
(D) 26 mm (1.024 in)
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Camshaft Tappets - Install

Prior operation:
Camshaft Tappets - Measure (10.106)
Lubricate the tappets (1) with clean engine oil and install
them into the relevant housings on the engine block.
NHIL13ENG0359AA 1
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Camshaft bushings - Measure

Prior operation:
1. Camshaft bearings (3) are pressed into their housings.

Check the internal surface of the bearings for seizing
or wear.
2. Use a bore dial gauge OEM1032 (2) to measure the
camshaft bearings (3) and intermediate housing (1) di-
ameter. The measurements should be performed on
two perpendicular axis.
3. Camshaft bearing inside diameter should be within
54.083 - 54.147 mm (2.129 - 2.132 in).
CRIL04J060A01 1
NHIL13ENG0365AA 2
*Height to be obtained after installing the bearing.
(A) 59.222 - 59.248 mm (2.332 - (B) 54.089 - 54.139 mm (2.129 - (C) 54.083 - 54.147 mm (2.129 -
2.333 in) 2.131 in) 2.132 in)
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Camshaft bushings - Replace

Use the beater with hand grip (2) 380000145 to replace
the bushing (1).
NOTICE: When installing the bushing , take note of orien-
tation to make sure the lubricating holes on the bushing
coincide with the holes on the block housing.
NHIL13ENG0366AA 1
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Camshaft gear - Remove

Prior operation:
1. Remove the retaining bolts (1).

2. Remove the camshaft gear (2) from the camshaft (3).
NHIL13ENG0368AA 1
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Camshaft gear - Install

Prior operation:
Camshaft gear - Remove (10.106)
1. With a felt tip pen, highlight the timing mark on the

crankshaft gear (1) mounted on the crankshaft (2) upon
the upright surface on which a groove (3) has been cre-
ated for the injection timing.
NOTE: For ease of crankshaft rotation, install two pins in
the end of the crankshaft.
NHIL13ENG0369AA 1
2. Turn the crankshaft (1) and the camshaft (2) so that the
camshaft gear (3) can be mounted on the camshaft (2)
to coincide with the timing mark on the crankshaft gear
(4).
NHIL13ENG0370AA 2
3. Position a dial indicator gauge 380001543 (1) on the

camshaft gear (2).
4. Check that the clearance between gears (2) and (3) is
within 0.076 - 0.280 mm (0.003 - 0.011 in).
NHIL13ENG0371AA 3
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10.3 [10.106] / 24
5. Torque the bolts (1) that secure the gear (2) to camshaft
(3) to 32 - 40 N·m (24 - 30 lb ft).
NHIL13ENG0372AA 4
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Index
Engine - 10

Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rocker arm - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rocker arm - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rocker arm - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker arm - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rocker shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valve drive and gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Cylinder heads - 101

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F4HFE613Z*B002
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Contents
Engine - 10
SERVICE
Valve cover
Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valves
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve guide
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve seat
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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CONSUMABLES INDEX

Molykote® G-N Metal Cylinder head - Install 10.4 / 11
assembly paste
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Engine - Cylinder heads
Valve cover Rocker housing - Remove

Prior operation:
1. Remove the nuts (2) securing the electro-injectors (3)

and disconnect the electrical wires.
2. Remove the bolts (1) securing the rocker arm housing
(4).
3. Remove the rocker arm housing (4) and gasket from
the cylinder head.
NHIL13ENG0382AA 1
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Valve cover Rocker housing - Install

Prior operation:
1. Check the condition of the electrical cables (2) and

their electrical connectors (4). Replace if damage was
caused from removing the retaining bolt (3).
2. Install a new gasket (1) onto the support (5).
NHIL13ENG0383AA 1
NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.
3. Install the housing (2) and torque the bolts (1) to 20 -
28 N·m (15 - 21 lb ft).
NHIL13ENG0384AA 2
4. Connect the electrical cables (1) to the injectors (3).

5. Use a torque wrench (2) to torque the retaining nuts (4)
to 1 - 2 N·m (11 - 15 lb in).
NHIL13ENG0385AA 3
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Valve cover - Remove

1. Remove the nuts (1) securing the valve cover (2) to the
base.
2. Remove the valve cover (2) and the gasket.
NHIL13ENG0386AA 1
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Valve cover - Install

Prior operation:
1. Install a new gasket (1) onto the valve cover (2).

2. Install the valve cover (2) onto the cylinder head.
3. Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0387AA 1
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Cylinder head - Remove

Prior operation:
Fuel injectors - Remove (10.218)
1. Remove the cylinder head bolts (1) from the cylinder

head (2).
NOTE: Take note of bolt positions since they have different
lengths.
NHIL13ENG0393BA 1
2. Hook the provided cylinder head lifting brackets (1) to

suitable lifting chains.
3. Use a suitable hoist to remove the cylinder head (2) and
gasket from the engine block.
NHIL13ENG0394AA 2
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Cylinder head - Check

Prior operation:
Cylinder head - Remove (10.101)
Checking cylinder head wet seal

Use the proper tools when you perform this check.
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 pres-
sure.
2. Replace the core plugs (1) if any leakage is found. Use
the proper punch for their removal and installation.
NOTE: Before refitting, smear the plug surfaces with water
repellent sealant.
3. Replace the cylinder head if leaks are found.
NHIL13ENG0395AA 1
Checking cylinder head supporting surface

1. Distortion found along the whole cylinder head should
not exceed 0.20 mm (0.008 in).
If higher values are found, resurface the cylinder head
according to values and indications shown in the fol-
lowing figure.
2. 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 resurfacing, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NHIL13ENG0396AA 2
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Cylinder head - Install

Prior operation:
Cylinder head - Check (10.101)
1. Check the cleanliness of the cylinder head and engine

block coupling surface.
2. Without damaging the gasket, set the gasket (1) onto
the engine block with the marking "TOP" facing the
cylinder head.
3. The reference arrow (2) shows the point at where the
head gasket thickness is given.
NHIL13ENG0397AA 1
4. There are two head gasket thicknesses, ( 1.25 mm

Type A and 1.15 mm Type B). To determine the cor-
rect head gasket to use, piston protrusion must be mea-
sured.
• For each piston, measure protrusion in two places
(A) and (B) 180 ° apart, at a distance of 45 mm
(1.8 in) from the center of the piston S1 and S2.
Then calculate the average:
NHIL13ENG0398AA 2
• 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.
5. Before you reuse the cylinder head bolts, measure
them twice as indicated in the picture. Check the D1
and D2 diameters for the following specifications:
• if D1 - D2 < 0.1 mm (0.004 in) the bolt can be utilized
again.
• If D1 - D2 > 0.1 mm (0.004 in) the bolt must be re-
placed.
the hole and bolt threads have no evidence of dirt or wear.
NHIL13ENG0399AA 3
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6. Hook the provided cylinder head lifting brackets (1) with

a suitable hoist.
7. Set the cylinder head (2) onto the engine block.
8. Lubricate the cylinder head bolts with MOLYKOTE ® G-N
METAL ASSEMBLY PASTE .
9. Install the bolts into the cylinder head.
NHIL13ENG0400AA 4
10. Follow the tightening sequence in Figure 6 for the 6

cylinder, and Figure 7 for the 4 cylinder, and then
torque the head bolts (1) as follows:
• 12x1.75x130 are torqued to 30 - 40 Nm (22 - 30 lb
ft)
• 12x1.75x150 are torqued to 50 - 60 Nm (37 - 44 lb
ft).
11. Follow the sequence and use tool DM370(3/4) (2) to
turn each bolt clockwise 85 - 95 °.
12. Turn each bolt clockwise an additional 85 - 95 °.
NHIL13ENG0401AA 5
Tightening sequence for the 6 cylinder engine.
NHIL13ENG0402AA 6
Tightening sequence for the 4 cylinder engine.
TORQUEPATTERNG2 7
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Valves - Remove
Prior operation:
Cylinder head - Remove (10.101)
1. Intake (1) and exhaust (2) valves have the same diam-
eter valve head. The central notch of the exhaust valve
(2) head distinguishes it from the intake valve.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to reinstall them in the
same position.
NHIL13ENG0425AA 1
2. Use tool 75291050 (1) for valve removal, 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. Turn over the cylinder head and remove the valves (5).
NHIL13ENG0426AA 2
5. Remove the sealing rings (1) and (2) from the valve
guides.
NOTE: Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
NHIL13ENG0427AA 3
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Valves - Measure
Prior operation:
Valves - Cleaning (10.101)
NHIL13ENG0428AA 1
Intake and exhaust valve main data
1. Use a micrometer (1) and check the valve stem
(2). The valve stem diameter for intake and exhaust
valves should be between 6.970 - 6.990 mm (0.274 -
0.275 in).
NHIL13ENG0429AA 2
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Valves - Cleaning
Prior operation:
Valves - Remove (10.101)
1. Use the proper metal brush to remove carbon deposits

from valves.
2. Check that the valves show no signs of seizing, scoring,
or cracking.
3. If necessary, grind the valve seats, taking away the
least amount of material possible.
NHIL13ENG0430AA 1
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Valves Spring - Check

Prior operation:
Before installing the valve springs, use a valve spring

load checking tool 99305047 to check spring load.
Compare load and elastic deformation data with those
of the new springs in the following table:
NHIL13ENG0431AA 1
Height Weight applied

(H) - 47.75 mm (1.880 in) None
(H1) - 35.33 mm (1.391 in) (P1) - 320.8 - 358.8 N (72.1 - 80.7 lb)
(H2) - 25.2 mm (0.992 in) (P2) - 702.0 - 780.0 N (157.8 - 175.4 lb)
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Valves - Install
Prior operation:
Valves - Cleaning (10.101)
1. Lubricate the valve stems (2) and install them into the
relevant valve guides according to the position marked
at removal.
2. Install the sealing rings (1) and (3) on the valve guides.
NOTE: Sealing rings (1) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
NHIL13ENG0432AA 1
3. Position the springs (4) and the upper cap (3) on the
cylinder head. Use tool 75291050 (1) to compress the
spring (4) and lock the parts to the valve (5) by the
keepers (2).
NHIL13ENG0433AA 2
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Valve guide - Clearance

Prior operation:
1. Use a magnetic base dial bore gauge (1) set as shown

in the figure. The assembling clearance should be be-
tween 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).
NHIL13ENG0442AA 1
3. Use a bore dial gauge to measure the inside bore diam-

eter of the valve guides. The values for both intake (C)
and exhaust (B) valve guides should be within 7.042 -
7.062 mm (0.277 - 0.278 in) (A).
NHIL13ENG0443AA 2
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Valve seat - Regrind

Prior operation:
Should slight scratches or burns be found, go over the

valve seat (2) with a valve seat grinding tool (1) (pur-
chased locally) according to the inclination values indi-
cated as follows:
NHIL13ENG0446AA 1
NHIL13ENG0447FA 2
Valve seat main data (4 cylinder)
(A) 29.5 - 30.5 ° (E) 60 °

(B) 45 ° (F) 29.5 - 30.5 °
(C) 69.5 - 70.5 ° (G) 3.020 - 3.280 mm (0.119 - 0.129 in)
(D) 69.5 - 70.5 ° (H) 3.370 - 3.630 mm (0.133 - 0.143 in)
If valve seats can not be reground within specification,

replace them with new ones. Use a valve seat grinding
tool to remove as much material as possible from the
valve seats without damaging the cylinder head until
they can be extracted from the cylinder head with use
of a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F)
and use the proper punch to install the new, previously
cooled valve seats into the cylinder head.
2. Use a valve seat grinding tool and go over the valve
seats according to the values stated in the previous
Figure 2.
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NHIL13ENG0448FA 3
Main data concerning the seats on the cylinder head
(1) Exhaust (2) Intake

(A) 27.25 - 27.75 mm (1.07 - 1.09 in) (E) 36.78 mm
(B) 1.10 - 1.50 mm (0.04 - 0.06 in) (F) 39.50 - 40.50 mm (1.56 - 1.59 in)
(C) 27.25 - 27.75 mm (1.07 - 1.09 in) (G) 36.78 mm
(D) 34.837 - 34.863 mm (1.372 - 1.373 in) (H) 34.837 - 34.863 mm (1.372 - 1.373 in)
3. After regrinding, use the base 380000364 (2) and the
dial bore gauge 380000228 (1) to check the valve (3)
sinking value.
• Intake valve sink should between 0.59 - 1.11 mm
(0.023 - 0.044 in).
• Exhaust valve sink should be between 0.96 -
1.48 mm (0.038 - 0.058 in).
NHIL13ENG0449AA 4
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Index
Engine - 10

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve cover Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - 10
Connecting rods and pistons - 105

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Contents
Engine - 10
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
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting rod bearing
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston pin bushings
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Connecting rods and pistons
Connecting rod and piston - Overview
NHIL13ENG0454AA 1
(1) Piston (5) Connecting rod

(2) Split rings (6) Bearing
(3) Bolts (7) Snap rings
(4) Half bearings (8) Pin
NOTE: The pistons are supplied spare with the following sizes:
- Standard
- 0.4 mm (0.016 in) oversize.
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Connecting rod and piston - Remove

Prior operation:
1. Remove the connecting rod nuts (2) and remove the

connecting rod caps (1).
2. Remove the piston and connecting rod as one unit from
the top of the engine block.
3. Repeat these steps for the remaining cylinders.
NOTE: Keep the half bearings with their correct housing in
case of reuse.
NHIL13ENG0455AA 1
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Connecting rod and piston Connecting rod - Measure
NHIL13ENG0456GA 1
* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.
(A) 40.987 - 41.013 mm (1.614 - 1.615 in) (D) 38.000 - 38.006 mm (1.496 - 1.496 in)
(B) 40.987 - 41.013 mm (1.614 - 1.615 in) (E) 1.9550 - 1.9680 mm (0.0770 - 0.0775 in)
(C) 38.019 - 38.033 mm (1.497 - 1.497 in) (F) 72.987 - 73.013 mm (2.874 - 2.875 in)
NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recom-
mended not to smooth the knurls.
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NHIL13ENG0457AA 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 replace-
ment, 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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Connecting rod and piston - Assemble

Prior operation:
Piston Pin - Remove (10.105)
1. The piston crown is marked as follows:

• (1) - Part number and design modification number.
• (2) - Arrow showing piston installation direction into
cylinder.
• (3) - Manufacturing date.
• (4) - Stamp indicating the ring carrier US inspection.
NHIL13ENG0458AA 1
2. Connect the piston (1) to the connecting rod (4) with

the piston pin (5) so that the reference arrow (2) for in-
stalling the piston (1) into the cylinder and the numbers
(3) marked on the connecting rod (4) are read as shown
in the figure.
NHIL13ENG0459AA 2
3. Position the piston (1) on the connecting rod (2) accord-

ing to the diagram shown in the figure and install the pin
(3) and stop at the snap rings (4).
NHIL13ENG0460AA 3
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Connecting rod and piston - Install

Prior operation:
Connecting rod and piston Connecting rod - Install (10.105)
1. Well lubricate the pistons, including the split rings and

the cylinder walls with clean engine oil.
2. Use the piston band clamp 380000325 (1) to install pis-
ton and connecting rod assembly (2) into the cylinders
and check for the following:
1. The number of each connecting rod should corre-
spond to the number on the connecting rod cap.
2. Split ring end gaps should be displaced with each
other by 120 °.
3. Piston and connecting rod assemblies should have
the same weight.
4. The arrow (3) marked on the piston crown should
be facing the front side of the engine block or the
slot obtained on the piston skirt should l be corre- NHIL13ENG0461AA 1
sponding to the oil nozzle position.
NOTE: Standard and oversized 0.4 mm (0.016 in) split
rings are supplied as spares.
NHIL13ENG0462AB 2
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10.5 [10.105] / 8
Piston - Measure
Prior operation:
Piston - Remove (10.105)
1. Use a micrometer (2) to measure the diameter of the

piston (1) and determine the assembly clearance. The
value should be between the following specifications:
• 103.714 - 103.732 mm (4.083 - 4.084 in)
• (*) 103.759 - 103.777 mm (4.085 - 4.086 in)
NOTE: (*) Valid for engines: F4HE9684P, F4HE9684A,
F4HE9687P, F4HE9687A.
NHIL13ENG0463AA 1
2. The clearance between the piston and the cylinder bore

can be checked also with a feeler gauge (1) as shown
in the figure.
NHIL13ENG0464AA 2
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10.5 [10.105] / 9
Piston - Remove
Prior operation:
1. Use split ring pliers 380000324 (2) to remove the split

rings (1) from the piston (3).
NHIL13ENG0465AA 1
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10.5 [10.105] / 10
Piston Ring - Measure

Prior operation:
1. Use a micrometer (2) to check piston split ring (1) thick-

ness. The values should be as follows:
• Combustion ring - 2.560 - 2.605 mm (0.101 -
0.103 in)
• Intermediate ring - 2.350 - 2.380 mm (0.093 -
0.094 in)
• Oil control ring - 3.970 - 3.990 mm (0.156 - 0.157 in)
NHIL13ENG0466AA 1
2. Use a feeler gauge (2) and check the clearance be-

tween the piston rings (1) of the 2nd and 3rd slot and
the relevant housings on the piston (3).
NHIL13ENG0467AA 2
3. Since the first piston ring is trapezoidal, the clearance

between the slot and the ring should be measured as
follows:
1. Make the piston (1) protrude from the engine block
(2) so that the ring (4) protrudes half-way from the
cylinder bore (3).
2. In this position, use a feeler gauge to check the
clearance (X) between the ring and the slot.
Values should be as follows:
• Combustion ring: 0.100 - 0.175 mm (0.004 -
0.007 in)
NHIL13ENG0468AA 3
• Intermediate ring: 0.060 - 0.110 mm (0.002 -
0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in)(*)
• Oil control ring: 0.040 - 0.080 mm (0.002 - 0.003 in)
NOTE: (*) Valid for engines: F4HE9684P, F4HE9684A,
F4HE9687P, F4HE9687A
48076871 15/11/2016
10.5 [10.105] / 11
4. Use the feeler gauge (1) to measure the piston split ring
(2) end gap installed into the cylinder bore (3). Values
should be as follows:
• Combustion ring - 0.30 - 0.40 mm (0.012 - 0.016 in)
• Intermediate ring - 0.60 - 0.80 mm (0.024 - 0.031 in)
• Oil Control ring - 0.30 - 0.55 mm (0.012 - 0.022 in)
NHIL13ENG0469AA 4
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Piston - Install
Prior operation:
1. Use pliers 380000221 (2) to install the piston split rings

(1) onto the piston (3).
2. Split ring end gaps should be displaced with each other
by 120 °.
NOTICE: Split rings shall be fitted with the marking "TOP"
(4) facing upwards.
NOTE: Standard and oversized 0.4 mm (0.016 in) split
rings are supplied as spares.
NHIL13ENG0470AA 1
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Piston Pin - Remove

Prior operation:
1. Use a scriber (2) to remove the snap rings (3).

2. Remove the piston pin (1).
NHIL13ENG0471AA 1
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10.5 [10.105] / 14
Piston Pin - Measure

Prior operation:
1. Use a micrometer (1) to measure the piston pin (2)

diameter. The diameter should be within 37.994 -
38.000 mm (1.496 - 1.496 in).
NHIL13ENG0472AA 1
2. Lubricate the pin (1) and its seat on the piston hubs
with clean engine oil. The pin should be installed into
the piston with slight finger pressure. The piston pin
housing diameter should be within 38.010 - 38.016 mm
(1.496 - 1.497 in).
NHIL13ENG0473AA 2
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Piston - Check
1. Once piston and connecting rod assemblies installation
is completed, use the dial bore gauge 380000228 (1)
equipped with the base 380000364 (3) to check piston
(2) protrusion at Top Dead Center (TDC) with respect
to the top of the engine block.
Protrusion should be between 0.28 - 0.52 mm (0.011 -
0.020 in).
NHIL13ENG0474AA 1
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Connecting rod bearing - Install

Prior operation:
1. Install the half-bearings (1) onto the connecting rods

and connecting rod caps.
NOTICE: Install the bearings that have not been replaced
in the same position found at removal. Do not relocate the
half-bearings.
NHIL13ENG0475AA 1
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Connecting rod bearing - Clearance

Prior operation:
Connecting rod and piston - Install (10.105)
1. Clean and remove all oil from the connecting rod and
bearing parts thoroughly.
2. Set a piece of calibrated wire (1) on the crankshaft pins
(2).
3. Install the connecting rod caps (4) with the correct half
bearings (3).
NOTE: Before the final fitting of the connecting rod cap
retaining bolts, 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 bolt end.
NHIL13ENG0476AA 1
4. Lubricate the bolts (2) with engine oil and use a torque
wrench (1) to torque the bolts to 55 - 65 N·m (41 - 48 lb
ft).
NHIL13ENG0477AA 2
5. Attach an angular torque gauge tool 380001001 (1) to

the torque wrench (2) and turn the bolts (3) 60 °.
NHIL13ENG0478AA 3
48076871 15/11/2016
10.5 [10.105] / 18
6. Remove the connecting rod cap and find the existing

clearance by comparing the calibrated wire width (2)
with the scale on the provided wire envelope (1).
7. If a different clearance value is found, replace the con-
necting rod half bearings and repeat the check.
8. Once the specified clearance has been obtained, lubri-
cate the connecting rod half bearings with engine oil
and install them onto the connecting rod.
9. Torque the bolts to 55 - 65 N·m (41 - 48 lb ft).
10. Attach the angular torque gauge 380001001 to the
torque wrench and turn the bolts 60 °.
NHIL13ENG0479AA 4
11. Check manually that the connecting rods (1) are slid-
ing axially on the crank pins. Use a feeler gauge (2)
to make sure that the connecting rod end float is be-
tween 0.10 - 0.33 mm (0.004 - 0.013 in).
NHIL13ENG0480AA 5
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Piston pin bushings - Check

Prior operation:
1. Check the connecting rod small side bearing (1) for

scoring or seizing and make sure that it is not loose. If
the bearing shows signs to scoring, seizing or is loose,
replace the bearing.
2. Removal and reinstalling the bearing should be per-
formed with the proper beater.
3. When reinstalling, make sure the oil holes in the bear-
ing coincide with the holes in the connecting rod small
end.
4. Use the dial bore gauge OEM1032 to check the con-
necting rod small end bearing diameter. The bearing
diameter should be within 38.019 - 38.033 mm (1.497 NHIL13ENG0457AA 1
- 1.497 in).
48076871 15/11/2016
10.5 [10.105] / 20
Index
Engine - 10

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting rod bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston pin bushings - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - 10
Crankshaft and flywheel - 103

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F4HFE613Z*B002
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10.6 [10.103] / 1
Contents
Engine - 10
SERVICE
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft pulley
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft oil seal
Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crankshaft gears
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Main bearings
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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10.6 [10.103] / 2
Engine - Crankshaft and flywheel
Engine flywheel - Remove

1. Insert flywheel rotation locking tool 380000988 (1) into
flywheel housing (3) to keep the flywheel (2) from rotat-
ing.
NHIL13ENG0481AB 1
2. Remove two bolts opposite each other and place two

guide pins (3) 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. Install two bolts of medium length into the threaded
holes (2) at the top of the flywheel to sling the flywheel
with a hoist.
6. Remove the flywheel (1) from it's housing.
NHIL13ENG0482AA 2
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10.6 [10.103] / 3
Engine flywheel - Check

Prior operation:
1. Check the clutch supporting side of the engine flywheel

(1) for any scoring or scratching. If any scratching is
found, the flywheel should be resurfaced.
2. Check the flywheel ring gear teeth (2) for breakage or
excessive wear. If wear is found, remove the ring gear
from the engine flywheel with a suitable hammer.
3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20
minutes.
4. Install the new ring gear with the chamfering on the
inside diameter facing the flywheel.
NHIL13ENG0483AA 1
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10.6 [10.103] / 4
Engine flywheel - Install

Prior operation:
Engine flywheel - Check (10.103)
1. Install two guide pins (1) having suitable length into the
engine crankshaft holes.
2. Use the proper sling and hoist to install the flywheel (2)
onto the engine crankshaft (3).
NHIL13ENG0484AA 1
3. Install the flywheel rotation locking tool 380000988 (4)

to the flywheel housing to stop rotation of the flywheel
(2).
4. Install the flywheel bolts (1) to secure the flywheel (2)
to the crankshaft (3).
NHIL13ENG0485AB 2
5. Torque the flywheel bolts (1) to the engine crankshaft

(2) in two stages:
1. Torque the bolts to 26 - 34 Nm (19 - 25 lb ft).
2. Use the angular torque gauge tool 380001001 and
turn the flywheel bolts an additional 55 - 65 °.
NHIL13ENG0486AA 3
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10.6 [10.103] / 5
Engine flywheel - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
48076871 15/11/2016
10.6 [10.103] / 6
1. Install the flywheel locking tool 380000988 (4) into the

flywheel housing to keep the flywheel (3) from rotating.
2. Remove two opposing flywheel bolts (1) and install two
guide pins in place of the bolts.
3. Remove the remaining flywheel retaining bolts from the
crankshaft (2) and remove the flywheel locking tool (4).
NHIL13ENG0487AB 1
4. Install two bolts of medium length into flywheel holes

(2) to sling the flywheel with a suitable hoist.
5. Use the two guide pins (1) previously installed into the
flywheel mounting holes (4), to remove the engine fly-
wheel (3) after slinging it with the hoist.
NHIL13ENG0488AA 2
48076871 15/11/2016
10.6 [10.103] / 7
Engine flywheel - Check

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
48076871 15/11/2016
10.6 [10.103] / 8
1. Check the clutch supporting side of the engine flywheel

(1) for any scoring or scratching. If any scratching is
found, the flywheel should be resurfaced.
2. Check ring gear teeth (2) for any breakage or excessive
wear. If any wear is found, remove the ring gear from
the engine flywheel with a suitable hammer.
3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20
minutes.
4. Install the new ring gear with the chamfering on the
inside diameter facing the flywheel.
NHIL13ENG0489AA 1
48076871 15/11/2016
10.6 [10.103] / 9
Engine flywheel - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
Engine flywheel - Check (10.103)
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1. Install two bolts of medium length into the engine fly-

wheel at holes (2).
2. Install two guide pins (1) with suitable length into the
engine crankshaft holes as shown.
3. Use the proper sling and hoist to install the flywheel (3)
onto the engine crankshaft (4).
NHIL13ENG0488AA 1
4. Secure the engine flywheel retaining bolts (1) onto the

engine crankshaft (3).
5. Install the flywheel rotation locking tool 380000988 to
the flywheel housing (2) to stop the rotation of the fly-
wheel.
NHIL13ENG0487AB 2
6. Torque the flywheel bolts (1) to the engine crankshaft

(2) in two stages:
1. Use a torque wrench (3) and torque the bolts to 26
- 34 Nm (19 - 25 lb ft).
2. Use an angular torque gauge tool 380001001 and
turn the flywheel bolts an additional 55 - 65 °.
NHIL13ENG0517AA 3
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Crankshaft pulley - Remove

1. Remove the bolts (1) retaining the crankshaft pulley (2).
2. Remove the pulley (2).
NHIL15ENG0256AA 1
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Crankshaft pulley - Install

Prior operation:
1. Align the small hole (3) in the crankshaft pulley with the
locating dowel (4) in the crankshaft.
2. Install the fixing plate (1) onto the crankshaft.
3. Torque the mounting bolts (2) to 105 - 115 N·m (77 -
85 lb ft).
NHIL15ENG0257AA 1
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Crankshaft oil seal Front seal - Remove

Prior operation:
1. Remove the crankshaft front oil seal from the front

cover (4). Use tool 99340055 (6) to operate on the
front bar hold of the crankshaft.
2. 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).
3. Install the tool to the ring and tighten the six bolts (5)
provided with the equipment. Then proceed removing
the ring (2) by tightening the bolt (3).
NHIL13ENG0526AA 1
4. Use the specific tie rod (3) of the seal extracting tool
380000669 with the ancillary lever (4) to remove the
external holding ring (2) from the front cover (1).
NHIL13ENG0527AA 2
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Crankshaft oil seal Front seal - Install

Prior operation:
Crankshaft oil seal Front seal - Remove (10.103)
1. Apply tool 380000666 (7) to the front crankshaft tang

(5) and secure it with bolts (6).
2. Install the new sealing ring (4).
3. Position part (2) on part (7), tighten nut (3) until com-
pleting installation of the sealing ring (4) into the front
cover (1).
NHIL13ENG0528AA 1
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Crankshaft oil seal Rear seal - Remove

Prior operation:
1. Remove the holding ring of the flywheel cover box, use

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. Install the tool (3) to the ring and tighten the six bolts
(4) provided with the equipment.
4. Then proceed removing the ring (1) by tightening the
bolt (2).
NHIL13ENG0529AA 1
5. Use the specific tie rod (3) of the tool 380000669 and
an ancillary lever (4), remove the external holding ring
(2) from the rear cover (1).
NHIL13ENG0530AA 2
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Crankshaft oil seal Rear seal - Install

Prior operation:
Crankshaft oil seal Rear seal - Remove (10.103)
1. Install the inner part of tool 99346253 (1) onto the

crankshaft with the supplied bolts (2).
2. Install the new seal (3)on the inner part of the tool.
3. Position the outer part of the tool (4) over the inner part
and install the supplied nut (5).
4. Tighten the nut until the seal is flush with the flywheel
housing.
NHIL13ENG0531AA 1
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Crankshaft - Remove
Prior operation:
Main bearings - Remove (10.103)
1. Use tool 380000362 (1) to hoist and remove the crank-

shaft (2) from the engine block.
NHIL13ENG0532AA 1
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Crankshaft - Remove
F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
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1. Use tool 380000362 (1) to hoist and remove the crank-

shaft (2) from the engine block.
NHIL13ENG0533AA 1
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Crankshaft - Measure
Prior operation:
Crankshaft - Remove (10.103)
1. Check the crankshaft journals and pins for seizing,

scoring or excessive ovalization. If any are present,
machining of the crankshaft is necessary.
2. Use a micrometer (1) and measure the journals and
pins (2). Machining may be required if the measure-
ments are not within the following:
• Crankshaft main journals - 82.99 - 83.01 mm (3.267
- 3.268 in).
• Crankshaft pins - 68.987 - 69.013 mm (2.716 -
2.717 in).
NOTE: Before grinding the crankshaft 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. NHIL13ENG0534AA 1
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.
Measuring journals and crank pins
NHIL13ENG0535AA 2
Fill the provided table with crankshaft journal and crank pin measured values
* Rated value
(A) - 82.99 - 83.01 mm (3.27 - 3.27 in) (B) - 68.987 - 69.013 mm (2.716 - 2.717 in)
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NHIL13ENG1405AA 3
* Measured on a radius greater than 45.5 mm (1.791 in)

** 0.500 mm (0.020 in) between adjacent main journals
Tolerances Tolerance characteristic Graphic symbol

Roundness
Shape
Cilindricity
Parallelism
Direction Verticality
Straightness
Position Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Levels of importance for product characteristics Graphic Symbol

Critical
Important
Secondary
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Crankshaft Journal - Clearance

Prior operation:
Crankshaft - Measure (10.103)
1. Use tool 380000362 and install the crankshaft (1) into

the engine block (2).
2. Check the backlash between crankshaft main journals
and the relevant bearings as follows:
NHIL13ENG0537AA 1
3. Thoroughly clean all parts and remove any traces of oil.

4. Position a piece of calibrated wire on the crankshaft
pins (2) so that it is parallel to the longitudinal axis.
5. Install the crankshaft main journal caps (1) and the half
bearings (3) on the relevant supports.
NHIL13ENG0538AA 2
NOTE: Before you use the bearing cap bolts again, mea-
sure them twice as indicated in the picture, checking (D1)
and (D2) diameters:
If (D1)- (D2) < 0.1 mm (0.004 in) the bolt can be used
again.
If (D1)- (D2) > 0.1 mm (0.004 in) the bolt must be replaced.
NHIL13ENG0539AA 3
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6. Torque the pre-lubricated bolts (2) in the following three

successive stages:
1. Stage 1: Use a torque wrench (1) and torque the
bolts (2) to 44 - 56 Nm (33 - 41 lb ft).
2. Stage 2: Use a torque wrench (1) and torque the
bolts (2) to 74 - 86 Nm (55 - 63 lb ft).
NHIL13ENG0540AA 4
7. Stage 3: Use an angular torque gauge tool 380001001

(1) and turn the bolts (2) an additional 85 - 95 °.
NHIL13ENG0541AA 5
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 provided
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 torquing the retaining bolts as previ-
ously described.
NHIL13ENG0542AA 6
Checking crankshaft end play

1. This check is performed by setting a magnetic base dial
bore gauge (2) on the crankshaft (3) as shown in the
figure. The end play value should be within 0.095 -
0.265 mm (0.004 - 0.010 in).
If higher value is found, replace the main thrust half
bearings of the second last rear support (1) and repeat
the clearance check between crankshaft pins and main
half bearings.
NHIL13ENG0543AA 7
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Crankshaft - Install
Prior operation:
Main bearings - Install (10.103)
1. Use tool 380000362 (1) to hoist the crankshaft (2) into

the engine block.
NHIL13ENG0532AA 1
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Crankshaft gears - Replace

1. Check that the teeth on the crankshaft gear (1) are not
damaged or worn. If damage or wear is present, use
the crankshaft gear puller tool 380001717 (3) to remove
the gear from the crankshaft (2).
2. When installing the new gear, heat the gear to 180 °C
(356 °F) for 10 min in an oven and then install it onto
the crankshaft.
NHIL13ENG1406AA 1
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Main bearings - Remove

Prior operation:
1. Remove the retaining bolts (1) and the main bearing

caps (2).
NHIL13ENG0544AA 1
2. The second to last main bearing cap (1) and the it’s
support are fitted with a shouldered half-bearing (2).
NOTE: Take note of the lower and upper half-bearing as-
sembling positions since in case of reuse they should be
fitted in the same position found at removal.
NHIL13ENG0545AA 2
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Main bearings - Install

Prior operation:
1. Reinstall the main bearings that have not been re-

placed, 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.
2. Thoroughly clean the main bearings (1), lubricate them
with clean engine oil and install them into their hous-
ings.
NOTE: Do not lubricate the connecting rod side housing
side of the bearing. Only lubricate the internal side of the
bearing which rides along the crankshaft pins.
NOTE: The second last main half bearing (1) is fitted with
shoulder half rings.
NHIL13ENG0546AA 1
NOTICE: Do not try to adapt the bearings.
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Index
Engine - 10

Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine flywheel - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine flywheel - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine flywheel - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Engine - 10
Balancer and damper - 110

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F4HFE613Z*B002
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Contents
Engine - 10
SERVICE
Balancer
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankshaft damper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Balancer and damper
Balancer - Remove
F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4HFE413H*B001
F4HFE413H*B002
F4HFE413L*B001
F4HFE413M*B001
F4HFE413N*B001
F4HFE413P*B001
F4HFE413V*B001
F4HFE413W*B001
F4HFE413X*B001
F4HFE413Y*B001
Prior operation:
1. Set the engine to cylinder number 1 TDC.

2. • Verify all of the dots (1) on the gears of the balancer
are aligned. There are four gears total, all have tim-
ing marks on them.
• Lock the balancer using an M8 bolt (2) in the
threaded hole towards the center of the housing.
NHIL15ENG0252AA 1
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10.7 [10.110] / 3
3. Remove the retaining bolts (3) and (5), and then re-
move the oil pickup tube.
4. Remove the bolts (2), and then remove the dynamic
balancer (4).
NHIL13ENG0547AA 2
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10.7 [10.110] / 4
Balancer - Install
F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4HFE413H*B001
F4HFE413H*B002
F4HFE413L*B001
F4HFE413M*B001
F4HFE413N*B001
F4HFE413P*B001
F4HFE413V*B001
F4HFE413W*B001
F4HFE413X*B001
F4HFE413Y*B001
1. • Align all of the dots (1) on the gears of the balancer.

There are four gears total, all have timing marks on
them.
• Lock the balancer using an M8 bolt (2) in the
threaded hole towards the center of the housing.
2. Set the engine to cylinder number 1 TDC.
NHIL15ENG0252AA 1
3. Install the balancer onto the engine.

4. Torque the bolts (1) to 48.0 N·m (35.4 lb ft).
5. Remove the lock bolt (2).
NHIL15ENG0253AA 2
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10.7 [10.110] / 5
6. Install the oil pickup tube (1).

7. Torque the mounting bolts (2) to 24.0 N·m (17.7 lb ft).
NHIL13ENG0547AA 3
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Crankshaft damper - Remove

1. Remove the bolts (1) retaining the crankshaft vibration
damper (2).
2. Remove the damper (2).
3. Remove the pulley (3).
NHIL13ENG0551AA 1
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Crankshaft damper - Install

Prior operation:
1. Align the small hole (1) in the crankshaft pulley with the
locating dowel (2) in the crankshaft.
2. Install the vibration damper (3) onto the crankshaft.
3. Torque the mounting bolts (4) to 105 - 115 N·m (77 -
85 lb ft).
NHVM15ENG0004AA 1
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Index
Engine - 10

Balancer - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Balancer - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Pump drives - 114

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Contents
Engine - 10
Pump drives - 114
SERVICE
Pump drives
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Pump drives
Pump drives - Remove

1. Remove the cover bolts (3) and remove the cover (1).
Make sure to save the cover gasket (2).
2. Remove the Power Take-Off (PTO) adapter (5). Make
sure to save the gasket (4).
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Pump drives - Install

1. Install the Power Take-Off (PTO) adapter (5) with the
gasket (4).
2. Install the front cover (1) with the gasket (2).
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Pump drives - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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1. Remove the snap ring (1).

2. Remove the spacer ring (2).
3. Remove the rear timing gear housing. See Timing
gear housing - Remove (10.102).
NHVM15ENG0292AA 1
4. Remove the M8x18 retaining bolt (1).
NHVM15ENG0293AA 2
5. Slide the hydraulic pump adapter (1) towards the rear

of the engine to remove it from the crankcase.
NHVM15ENG0294AA 3
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Pump drives - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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1. Install the power take-off gear (where equipped) into

the specially provided housing and torque the nut (1)
to 98 - 112 N·m (72 - 83 lb ft).
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Index
Engine - 10
Pump drives - 114

Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump drives - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump drives - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Lift pump and lines - 210

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Contents
Engine - 10
FUNCTIONAL DATA
Fuel lift pump

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fuel supply lines

Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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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
NHIL13ENG0557AA 1
(A) Fuel supply from the primary filter (1) Fuel supply relief valve 5 bar (73 psi)
(B) Fuel supply to the secondary filter (2) Supply pump bypass valve (for bleeding)
Overpressure condition
NHIL13ENG0558AA 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).
Jettison condition
NHIL13ENG0559AA 3
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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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Fuel supply lines Low pressure - Connect

1. Connect the fuel line to the pressure limiter (1).
2. Connect all the fuel lines between the fuel filter base
(2) and the high pressure pump.
3. Connect the pipeline from the high pressure pump to
the engine control module cooling plate (3).
4. Connect the pipeline from the high pressure pump (4)
to high pressure common rail.
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Fuel supply lines Low pressure - Disconnect

1. Disconnect the fuel return pressure limiter (1). Refer to
Common rail lines - Disconnect (10.218).
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Index
Engine - 10

Fuel lift pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Fuel filters - 206

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Contents
Engine - 10
Fuel filters - 206
FUNCTIONAL DATA
Fuel heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Fuel filters
Fuel heater - Overview
4442596398GHDC 1
The fuel temperature is monitored by the Engine Control Unit (ECU). The fuel filter heater is activated if the fuel
temperature is less than 0 °C (32 °F). Once the fuel heater is activated, the fuel is heated to 5 °C (41 °F).
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Fuel filters - Remove

Prior operation:
Fuel supply lines Low pressure - Disconnect (10.210)
1. Use the fuel filter wrench 34591-00100 to loosen the

fuel filter (5) and remove it from the support (1).
2. Disconnect the electrical connections (3) from the sup-
port (1) including the connection for the fuel heater.
3. Disconnect the fuel low pressure fuel lines (2) from the
support (1).
4. Disconnect the fuel line (4) from the support (1).
5. Remove the sustaining support bracket (1) from the
engine block.
4442596398GHDC 1
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Fuel filters - Install

Prior operation:
Fuel filters - Remove (10.206)
1. Install the fuel filter (9) bracket and support (1).

2. Torque the bracket bolts to 20 - 28 N·m (15 - 21 lb ft).
3. Proceed connecting in sequence the pipelines (5) (2)
(3) (4) (6) of the support (1) to the high pressure pump
(7).
4. Connect the pipeline (8) 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.
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel injection system - 218

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Contents
Engine - 10
FUNCTIONAL DATA
Fuel injection system

Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High pressure pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure regulating valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Common rail
Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel injectors
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE
Fuel injection system

Test Common rail fuel injection - Fuel supply/Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
High pressure pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pressure regulating valve
Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Common rail
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Relief valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Relief valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Relief valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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Common rail lines
Disconnect - Low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connect - Low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel injectors
Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Injector fuel lines
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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CONSUMABLES INDEX

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Engine - Fuel injection system
Fuel injection system - Dynamic description
NHIL13ENG0500AA 1
(1) Electro-injector (5) Pre-filter mounted on the frame

(2) Common rail (6) High-pressure pump
(3) Pressure limiting device for fuel return (7) Mechanical vane pump
(4) Common rail pressure relief valve (8) 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 Engine Control Unit (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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F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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NHIL13ENG0502AA 1
(1) Electro-injector (5) Mechanical rotor pump

(2) Pressure limiter for fuel return (6) Fuel filter
(3) Common rail pressure relief valve (7) Prefilter mounted on the block
(4) High pressure pump (8) Common rail
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 Engine Control Unit (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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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 (14), 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 (14) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain
piping (15) from piping (17).
The pressure relief valve housed on the cylinder head, assembled on injector return (18), 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 (5) 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 (10) allows filling the supply system through the manual priming pump (7).
NHIL13ENG0501AA 1
(1) Common rail relief valve (7) Priming pump (13) Pressure regulator
(2) Common rail (8) Pre-filter (14) Low pressure relief valve
(3) Common rail pressure sensor (9) Fuel tank (15) High pressure pump cooling passage
(4) Electro-injector (10) By-pass valve (16) High-pressure pump
(5) Charge pressure relief valve (11) Fuel filter (17) Return fuel line
(6) ECU cooling plate (12) Mechanical supply pump (18) Return fuel relief valve
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Low pressure circuit
Fuel is drawn from the tank through an in-line fuel water separator filter located on the chassis of the vehicle. This filter
removes the larger contamination from the fuel before it enters the system. This fuel water separator filter incorporates
a fuel primer pump to be able to remove air from the system when filters are serviced. See the vehicle operator manual
for the service interval and procedure for this filter.
The Engine Control Unit (ECU) is mounted to the engine in most applications. The engine operating temperatures
can have an impact on the ECU. To control the maximum temperature that the ECU will be subject to, fuel from the
diesel tank is typically routed through a heat exchanger element integrated in the ECU. The fuel is used as a cooling
medium as it is the coolest liquid available on an engine system.
The injection pump is mounted to the side of the engine. One component of the injection pump is a low pressure gear
pump. This low pressure gear pump draws fuel from the diesel tank and supplies it to the high pressure pump. This
gear pump is driven by the input shaft of the injection pump. The gear pump incorporates a bypass check valve which
allows fuel to flow through this pump to the system when the primer pump in the fuel water separator filter is being
activated. A high pressure check valve is incorporated in the gear pump to limit the maximum pressure available to
the injection pump if the low pressure regulator were to malfunction.
Outlet flow from the gear pump is ported to the fuel filter mounted to the side of the engine. This fuel filter removes
the fine contamination from the fuel system. Moisture can be carried into the fuel system by the fuel. The fuel water
separator filter has a specialized media which limits the passage of water through it. This causes the water to collect
at the bottom of the filter. A sensor is typically installed in the bottom of the fuel water separator filter to signal the
operator that the filter requires that the water be drained out. See the vehicle operator manual for the drain procedure
and interval. Located in the fuel filter is a fuel temperature sensor which reports data directly to the ECU. When
operating in cold climates, an electrically operated fuel heater is located in the fuel water separator filter head. This
heater is controlled by the ECU based on inputs from sensors on the engine. Typically the fuel filter head is used as
the porting manifold to return the drain connections from different locations on the engine to the tank through only one
connection.
The fuel pressure at the inlet of the high pressure injection pump is controlled by the low pressure control valve located
in the injection pump. This valve controls the pressure to the system at approximately 5 - 7 bar (75 - 100 psi) pressure.
Once this pressure is reached, some of the excess flow from the low pressure gear pump is circulated through the
internal components of the high pressure pump to act as a lubrication medium. Any excess fuel available to the
pressure regulator that is not required to operate the engine or provide lubrication is then returned back to the low
pressure gear pump inlet through internal porting.
The output delivery of the high pressure injection pump is controlled by the high pressure pump control valve. This
Pulse Width Modulated (PWM) operated valve is controlled by the ECU based on sensor inputs from the engine. This
valve requires a signal to reduce the delivery of the high pressure pump. If the control signal is lost or the valve fails,
the delivery of the high pressure pump defaults to full output. This allows the system to have a limp home feature.
High pressure circuit

The high pressure delivery section consists of two piston assemblies which are operated by lobes on the camshaft.
The piston to camshaft interface is lubricated by excess fuel from the gear pump flowing through the area. Each
piston assembly has an inlet and an outlet check valve to control the flow through the valve. The amount of fuel
delivered during each stroke is regulated by the high pressure control valve to control the injection pressure available
to the common rail. When the engine is operating at low idle and no load, the output pressure is the lowest. When the
engine is operating at full speed and load, the output pressure would be greatest. The output pressure to the common
rail can exceed 2100 bar (30450 psi). Use extreme caution when checking for suspected high pressure leakage.
Output from the high pressure piston pump assembly flows directly to the common rail. The common rail is basically a
high pressure fuel storage device which is then connected to each of the injectors. Each injector has full common rail
pressure available. A high pressure sensor is located at one end of the common rail. This sensor monitors the real
time pressure available to the injectors and reports the data to the ECU. The computer based Electronic Service Tool
(EST) is required to check pressure in the common rail. In the event that the high pressure control valve malfunctions,
the delivery from the high pressure pump defaults to full delivery. When full fuel is delivered to the common rail, the
common rail pressure increases excessively. A maximum pressure relief valve is located at one end of the common
rail. This relief valve is a two stage valve. The initial opening pressure of this valve is greater than the normal maximum
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operating pressure of the system. Once the common rail pressure exceeds the opening pressure of the relief, fuel is
allowed to pass through it and flow to the tank. Once the relief has opened, the pressure will drop to approximately
one half of the maximum system pressure. This allows the common rail to maintain adequate pressure to inject fuel
although the system will not be operating at full efficiency. When fuel is flowing through the common rail relief valve,
the system is basically operating in limp home mode. This high pressure relief valve automatically resets when the
engine stops. If the malfunction is still present, the valve will open again.
The fuel delivery and pressure available to the common rail is available to each of the injectors any time that the
engine is running. Typically the injectors are located near the top center of each piston. Each injector is electrically
controlled by the ECU. Each injector can be triggered more that once during each injection cycle. The pre-injection
opening is typically used to reduce the combustion noise from the engine. The main injection opening delivers the
required output power. The injector can also be opened after the main combustion, typically to reduce the generation
of exhaust emissions. As the injectors are triggered, a small drain flow passes from the injector.
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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 EDC17 CV41 control unit through a Pulse Width Modulated (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 until 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 compo-
nents are absolutely clean.
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Rail
NHIL13ENG0507AA 1
(1) Pressure sensor (2) Fuel inlet from (3) Rail (4) Overpressure valve
high-pressure pump
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 (1) 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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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.
For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure
of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at
pressures up to 1450 bar (21025 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.
Air pressure/temperature system

It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures
the maximum inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. The outlet voltage is
proportional to the pressure or temperature obtained by the sensor.
Engine oil temperature and pressure sensor

Same as the air pressure/temperature sensor, it is fitted on the engine oil filter base, in a horizontal position. It mea-
sures engine oil temperature and pressure.
Fuel pressure sensor

Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The
injection pressure value is used to control the pressure and to determine the electric injection control length.
Coolant temperature sensor

It is a variable resistance sensor suitable to measure the coolant temperature to provide the control unit with an index
of the engine thermal state.
Output shaft sensor

It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines
that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is
used by the Engine Control Unit (ECU) as injection phase signal. Though being equal to the flywheel sensor, it is
NOT interchangeable since it has a different outside shape.
System functionality
The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.
Fiat Power Train (FPT) code recognition

The EDC17 CV41 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.
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NHIL13ENG0508AA 1
(1) Coolant temperature sensor (5) Air temperature/pressure sensor (9) EDC17 CV41
(2) Connection to electro-injectors (6) Camshaft sensor (10) Crankshaft sensor
(3) Fuel pressure sensor (7) Fuel heater cable and fuel (11) Oil temperature/pressure sensor
temperature sensor
(4) Electro-injector (8) Pressure gauge cabling
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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.
NHIL13ENG0509AA 1
(1) Outlet to common rail (4) Inlet from primary filter (7) Drive gear
(2) Transfer pump (5) Return to filter (8) Pressure regulator valve
(3) Outlet to secondary filter (6) Supply fuel inlet from filter (9) High pressure pump
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Inside structure
NHIL13ENG0510FA 2
(1) Pumping element (5) Inlet valve

(2) Low pressure fuel inlet (6) Rotary coupling
(3) Fuel supply ducts to pumping elements (7) Eccentric pump shaft
(4) Outlet valve (8) Piston
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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Working principle
NHIL13ENG0511GA 3
(1) Fuel to common rail (5) Eccentric pump shaft

(2) Pulse Width Modulated (PWM) pressure regulator (6) Pumping element
valve
(3) Low pressure fuel supply (7) Outlet valve
(4) PWM metered fuel
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 Pulse Width Modulated (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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NHIL13ENG0512AA 4
(1) Pumping element inlet passage (6) PWM pressure regulator valve
(2) Pumping element inlet passage (7) Main supply passage
(3) Relief valve outlet passage (8) Pumping element inlet passage
(4) Relief valve 5 bar (73 psi) (9) Pump lubrication passage
(5) 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 pres-
sure at a constant 5 bar (73 psi) limit at gauge entry.
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NHIL13ENG0513AA 5
(1) Fuel exhaust galley (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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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 EDC17 CV41 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.
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NHIL14ENG0139HA 1
(A) To tank
(B) From injectors
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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 ap-
proximately 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.
Torque: 100.0 N·m (73.8 lb ft)
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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 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
(1) Electrical connection (6) Control duct (11) Pressure chamber

(2) Ball shutter (7) Pressure rod (12) Spring
(3) Control volume (8) Supply duct (13) Control fuel outlet
(4) Pilot valve (9) Plunger (14) High pressure fuel inlet
(5) Control area (10) Nozzle (15) Coil
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Injection start
93095367 2
When coil (1) is energized, it makes shutter (2) move upwards. The control volume (3) fuel flows towards flow duct
(6) making a pressure drop occur in control volume (3). Simultaneously the fuel pressure into pressure chamber (5)
makes plunger (4) lift, following fuel injection into the cylinder.
Injection end
When coil (1) is de-energized, shutter (2) goes back to its closing position, in order to recreate such a force balance
as to make plunger (4) 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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Electro-injector solenoid valves

Each injector is connected to the Engine Control Unit (ECU on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description EDC pin

Connector (1)
Pin #1 Cylinder 2 injector 11A
Connector (2)
Connector (3)
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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 traditional ones, 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
(1) Electrical connection (6) Control duct (11) Pressure chamber

(2) Ball shutter (7) Pressure rod (12) Spring
(3) Control volume (8) Supply duct (13) Control fuel outlet
(4) Pilot valve (9) Plunger (14) High pressure fuel inlet
(5) Control area (10) Nozzle (15) Coil
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Injection start
93095367 2
When coil (1) is energized, it makes shutter (2) move upwards. The control volume (3) fuel flows towards flow duct
(6) making a pressure drop occur in control volume (3). Simultaneously the fuel pressure into pressure chamber (5)
makes plunger (4) lift, following fuel injection into the cylinder.
Injection end
When coil (1) is de-energized, shutter (2) goes back to its closing position, in order to recreate such a force balance
as to make plunger (4) 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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Electro-injector solenoid valves

Each injector is connected to the Engine Control Unit (ECU) on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description EDC pin

Connector (1)
Connector (2)
Connector (3)
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Fuel injection system - Test Common rail fuel injection - Fuel

supply/Leakage test
NOTE: This diagnostic procedure requires using NEF test kit # 380140055.
1. Install special tool 380100056 pressure gauge (1) at the
inlet of the low pressure pump (after the primary filter).
NOTE: This test line contains a compound gauge – 0 mm
(0.0 in) to 762 mm (30 in) of Hg vacuum and 0 bar / 0 kPa
(0 psi) to 2.07 bar / 207 kPa (159.5 psi) positive pressure.
NHIL12ENG0050AA 1
2. Install special tool 380100057 (1) between the outlet of

the fuel filter and the inlet of the high pressure pump.
NOTE: This test line contains a pressure gauge – 0 bar /
0 kPa (0 psi) to 11 bar / 1100 kPa (159.5 psi).
3. Operate the engine to purge air from the system which
entered during gauge installation.
4. When air is no longer visible in the clear test line, mea-
sure and record operating pressure, while continually
observing for air in the fuel.
NOTE: The clear line could be left in place over night to
check for a slow air ingress leak.
NHIL12ENG0050AA 2
Condition: Fuel pressure specification between filter and high

pressure pump:
Test the fuel pressure at LOW idle; no load to the engine.
Test the fuel pressure at 1500 RPM; no load to the 5 bar / 500 kPa (72.5 psi)
engine.
Test the fuel pressure at HIGH idle; apply load to the
engine using the hydraulics (over relief), hydrostatic stall,
converter stall, or dynamometer. Load the engine to its
rated RPM.
5. If the fuel pressure testing point between the primary

filter outlet to the low pressure pump inlet drops below
5 bar / 500 kPa (72.5 psi) at any time during the test,
check/replace the following as needed:
Component: Action:
Fuel Pre-filter (if equipped) Some applications do not use a fuel pre-filter.
Primary fuel filter Replace
Fuel tank Clean the fuel tank as required.
Fuel lines and connections The line from the fuel supply pump inlet to the fuel tank.
Check for damaged lines (a kink creates a restriction, rub
marks may allow air to enter) and leakage at the Voss
o-ring fittings.
The fuel pick-up tube in the fuel tank. Check for cracks, plugging, or contact with the
bottom/sidewalls of the tank.
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Fuel tank cap Be sure a vacuum is not being formed in the fuel tank. A
vacuum at the tank would reduce the fuel supply pressure
to the injection fuel pump inlet. Vacuum in the fuel tank
might not be observable during short-term running.
Fuel tank outlet valve Check the valve at the fuel tank outlet (if equipped).
Ensure that fuel supplied to and from the valve assembly
is properly connected.
6. Rerun the fuel pressure test. If the pressure is still be-

low 5 bar 500 kPa (72.5 psi) supply fuel from an alter-
nate fuel source (a separate container, 380100058) (1),
located not more than 1 m (3.3 ft) below the engine with
a known good fuel supply line.
7. This bypasses:
• Fuel tank
• Inlet lines
• Connections
• Pre-filter (if equipped)
NHIL12ENG0054AA 3
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High pressure pump - Remove

Prior operation:
Injector fuel lines - Disconnect (10.218)
1. Disconnect all fuel lines (1) from the high pressure

pump.
2. Disconnect the electrical connection (2) from the high
pressure pump.
NHIL13ENG1347AA 1
3. Remove the three mounting nuts (1) from the high pres-
sure pump.
4. Remove the high pressure pump along with the feed
pump as one unit.
NHIL15ENG0136AA 2
5. Remove the nut (1) from the high pressure pump shaft.
6. Use a suitable gear puller to remove the high pressure
pump gear (2).
NOTE: The high pressure pump shaft is tapered.
NHIL15ENG0135AA 3
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High pressure pump - Install

Prior operation:
High pressure pump - Remove (10.218)
1. Install the high pressure pump gear (2) onto the high
pressure pump shaft.
2. Install the shaft nut (1) on the high pressure pump shaft.
3. Torque the shaft nut (1) to 100 - 110 N·m (74 - 81 lb ft).
NHIL15ENG0135AA 1
4. Position the high pressure pump with the feed pump

together, into place on the rear cover.
5. Secure the pump to the rear cover with the three mount-
ing nuts (1).
6. Torque the mounting nuts (1) to 20.0 - 28.0 N·m (14.8
- 20.7 lb ft).
NHIL15ENG0136AA 2
7. Connect all fuel lines (1) to the high pressure pump.

8. Torque the fuel lines to 18 - 22 N·m (13 - 16 lb ft).
9. Connect the electrical connection (2).
NHIL13ENG1347AA 3
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Pressure regulating valve - Configure - Reset ECU data

NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the
fault has been repaired. Afterrun must be completed between each key cycle.
1. Connect the Electronic Service Tool (EST) and turn the
key switch ON without starting the engine.
2. Click the “Configuration” icon (1).
NHPH14ENG0006AA 1
3. Select “Replacement of the Rail Pressure Metering Unit

– Reset ECU Data” (1).
4. Click the “CONFIGURE SELECTED ITEM” button (2).
NHPH14ENG0018AA 2
5. Click the “RESET” button (1).
NHPH14ENG0019AA 3
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Common rail - Remove

Prior operation:
1. Remove the retaining bolts (2) from the common rail.

2. Remove the common rail (1).
NHIL13ENG1349AA 1
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Common rail - Install

Prior operation:
1. Install the common rail (6) onto the cylinder head.

2. Torque the mounting mounts (1) to 20 - 28 N·m (15 -
21 lb ft).
3. Connect new fuel lines (2) to the common rail (6) and
to the manifold for the fuel injectors (5).
4. Torque the fuel line fittings (3) to 20 Nm (15 lb ft).
5. Install the low pressure fuel line (4) to the common rail
(6). Refer to Common rail lines - Connect (10.218)
for the proper procedure.
NHIL13ENG0593AA 1
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Common rail Relief valve - Configure - Reset ECU data

The Engine Control Unit (ECU) monitors for sudden decreases in rail pressure. The ECU counts and stores these
events to monitor Pressure Relief Valve (PRV) degradation. The counter needs to be manually reset when the PRV
is replaced.
NOTE: This procedure is only to be used after the PRV has been replaced.
NHPH14ENG0006AA 1
3. Select “Replacement of the Rail Pressure Relief Valve

(PRV) – Reset ECU Data” (1).
NHPH14ENG0020AA 2
NHPH14ENG0021AA 3
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Common rail Relief valve - Remove

WARNING
Hot liquid under pressure!
Fuel in the high pressure fuel line is still under pressure immediately after you shut down the engine.
Before performing any maintenance or inspection, wait for 2 minutes after engine shutdown to allow
the pressure to drop.
W0249A
1. Clean the area around the pressure relief valve (1) with
de-greaser, than dry with compressed air.
2. Detach the low-pressure connection. See Common
rail lines - Disconnect (10.218).
NOTE: Collect any escaping fuel.
3. Slowly loosen the pressure relief valve (1) to allow the
pressure in the fuel system to drop to ambient pressure.
4. Remove the pressure relief valve.
5. If the pressure relief valve is used with a gasket, re-
move the gasket.
NHIL13ENG1349AA 1
6. Clean the threads and the sealing surface of the com-
mon rail.
7. Cap the common rail orifice after you remove the pres-
sure relief valve.
8. If the pressure relief valve will be reused, carefully re-
move the sealing ring.
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Common rail Relief valve - Inspect

1. Inspect the threads (1) of the pressure relief valve for
signs of damage. Only concentric grooves are allowed.
NOTICE: No cuts in the radial direction are tolerable.
2. Inspect the bite edge (2) of the pressure relief valve for
signs of damage.
NHIL14ENG0520AA 1
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Common rail Relief valve - Install

1. If the pressure relief valve is going to be reused, replace
the sealing ring (1).
2. Lubricate the sealing ring (1) with MOBILUX® EP 023 or
equivalent heavy duty grease.
3. Install the new sealing ring (1) onto the pressure relief
valve.
4. Lubricate the bite edge (2) and the threads with
MOBILUX® EP 023 or equivalent heavy duty grease.
5. Remove the cap from the common rail orifice.
6. Install the pressure relief valve by hand.
NHIL14ENG0521AA 1
7. Torque the pressure relief valve (1) to 100.0 N·m

(73.8 lb ft).
NHIL13ENG1349AA 2
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Common rail lines - Disconnect - Low pressure

1. Press and hold down the clasp (1) and release the
quick fitting joint.
NHIL13ENG0594AA 1
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Common rail lines - Connect - Low pressure

Prior operation:
Common rail lines - Disconnect (10.218)
1. Connect low pressure lines to the common rail by in-

serting the rapid fitting joint into the connection joint and
press until the clip fastens securely (1).
2. Check for proper fuel connection.
NHIL13ENG0595AA 1
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Fuel injectors Cross tube - Remove

1. Thoroughly clean the area around the cross tube to
prevent contamination of internal components.
2. Remove the nuts (1).
3. Pull the cross tube (2) from the cylinder head.
NOTICE: Cross tubes cannot be reused. Replace them
with new before installation.
NHIL13ENG0605AA 1
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Fuel injectors - Remove

Prior operation:
Fuel injectors Cross tube - Remove (10.218)
1. Disconnect the wires from the injector solenoid.

2. Remove the injector hold-down bolts (1).
NHIL13ENG0600AA 1
3. Install tool 380001099 (1) around the injector body.

4. Remove the injector (2) from the cylinder head.
NHIL13ENG0596BA 2
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Fuel injectors - Install

1. Install a new O-ring (2) and sealing washer (3) onto the
fuel injector (1).
2. Lubricate the O-ring (2) with petroleum jelly.
NHIL13ENG0597AA 1
3. Install the fuel injectors (1) into the cylinder head with
the fuel inlet hole (2) facing the cross tube seat (3).
NHIL13ENG0598AA 2
4. Install the injector hold-down bolts (2).

5. Tighten them evenly until the injector is fully seated.
6. Loosen the injector hold-down bolts to allow installation
of the cross tube.
NHIL13ENG0600AA 3
7. Install the cross tube. See Fuel injectors Cross tube

- Install (10.218) for the full procedure.
8. Torque the cross tube nut to 50 N·m (37 lb ft).
9. Torque the injector hold-down bolts (1) in four phases:
1. 3.5 N·m (31 lb in)
2. Then 25 °
3. Then 25 °
4. Then 25 °
NHIL13ENG0601AA 4
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Fuel injectors Cross tube - Install

NOTICE: Cross tubes cannot be reused. Replace them with new before installation.
1. Install the o-ring (4) on the cross tube (5) and lubricate
with petroleum jelly.
2. Install the cross tube into the cylinder head so that the
positioning ball (3) is aligned with the notch in its seat
(2).
3. Loosely install the nut on the cross tube.
NOTE: The injector (1) must be loose enough to adjust its
position in order to properly seat the cross tube.
NHIL13ENG0606AA 1
4. Torque the cross tube nut (2) to 50 Nm (37 lb ft).

5. Torque the injector bolts. See Fuel injectors - Install
(10.218) for the full installation procedure.
NHIL13ENG0607AA 2
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Injector fuel lines - Disconnect

Prior operation:
Common rail lines - Disconnect - Low pressure (10.218)
1. Disconnect the fuel lines (2) from the common rail (1)
and from the fuel injectors (3).
NOTICE: When releasing the fuel line connections from the
common rail, use the proper wrench to avoid rotation of flow
limiters.
NHIL13ENG1407AA 1
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Injector fuel lines - Connect

1. Connect new fuel lines (1) between the high pressure
common rail (3) and the fuel injectors (2).
NHIL13ENG0608AA 1
2. Torque the nuts (1) to 20 Nm (15 lb ft) .

NOTE: Connections should be tightened by holding the
flow limiting valve hexagon with the proper wrench.
NHIL13ENG0609AA 2
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Index
Engine - 10

Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Common rail - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Common rail Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Common rail Relief valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Common rail Relief valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Common rail Relief valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Common rail lines - Connect - Low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Common rail lines - Disconnect - Low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel injection system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel injection system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel injection system - Test Common rail fuel injection - Fuel supply/Leakage test . . . . . . . . . . . . . . 29
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fuel injectors Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel injectors Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
High pressure pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Injector fuel lines - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pressure regulating valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - 10
Turbocharger and lines - 250

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Contents
Engine - 10
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect - BorgWarner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbocharger oil supply line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Turbocharger and lines
Turbocharger - Remove
Prior operation:
Exhaust flap - Remove - Exhaust flap (10.254)
1. Remove the turbo oil supply line (2) from the oil filter
base and from the pipe fitting (1) on the turbine.
2. Remove the nuts (3) securing the turbocharger to the
exhaust manifold.
3. Remove the turbocharger.
NHIL13ENG1408AA 1
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Turbocharger - Install
1. Install the turbocharger (1) with a new gasket on the
exhaust manifold.
2. Secure the turbocharger to the manifold with the
mounting nuts (3).
3. Torque the mounting nuts (3) as follows:
• 4 cylinder - 20.0 - 28.0 N·m (14.8 - 20.7 lb ft)
• 6 cylinder - 37.0 - 49.0 N·m (27.3 - 36.1 lb ft)
4. Refer to Turbocharger oil supply line - Install
(10.250) to install the oil supply line (2).
NHIL13ENG1408AA 1
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Turbocharger - Inspect - BorgWarner

1. Visually inspect the turbo charger for damage to the
turbine wheel and the compressor wheel.
2. Use a dial indicator to measure the following:
• (CS) Radial deflection of the compressor side of the
shaft.
• (TS) Radial deflection of the turbine side of the shaft.
• (AX) Axial movement of the shaft.
NHIL16ENG0027AA 1
Specifications
Compressor side radial deflection 0.560 mm (0.022 in)
Turbine side radial deflection 0.580 mm (0.023 in)
Axial movement 0.050 mm (0.002 in)
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Turbocharger oil supply line - Remove

1. Disconnect the oil return line (2) from the fitting (3) on
the engine block.
2. Remove the retaining bolts from the turbocharger side
(1) of the return line, and then remove the line.
NHIL13ENG1409AA 1
3. Disconnect the oil supply line (2) from the oil filter base
and the fitting on the turbocharger (1), and then remove
the line.
NHIL13ENG1408AA 2
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Turbocharger oil supply line - Install

1. Install the oil supply line (2) at the turbocharger (1) and
the oil filter housing.
2. Torque the oil supply line retaining nut at the tur-
bocharger inlet to 8 - 12 N·m (6 - 9 lb ft).
3. Torque the fitting at the oil filter housing to 20 - 28 N·m
(15 - 21 lb ft).
NHIL13ENG1408AA 1
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Index
Engine - 10

Turbocharger - Inspect - BorgWarner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Intake and exhaust manifolds and muffler - 254

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Contents
Engine - 10
FUNCTIONAL DATA
Intake and exhaust manifolds and muffler

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust flap
Remove - Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Overview
NHIL13ENG0620AA 1
(1) Air filter (4) Turbocharger turbine

(2) Turbocharger compressor (5) Muffler (Turbocharger exhaust gas outlet)
(3) Exhaust gas inlet to the turbocharger (6) Intercooler
During the engine working process, the exhaust flow (3) to the turbocharger will actuate the turbine (4). The turbine
will the start to turn the compressor (2) wheel. The intake system will to draw in air. As the air passes through the air
filter (1) housing, it is then directed into the compressor housing. The compressed air will exit the turbocharger, and
to the intercooler (6). The cooled air is then directed into the intake manifold. The cooler the intake air is, the more
dense the air will be entering the cylinder. More air in the cylinder allows for more fuel to be added. This will generate
increased power during the combustion process.
After the combustion process, the exhaust manifold will collect the fuel gases from the cylinder. A wastegate is in-
stalled before the turbine which diverts exhaust flow from the turbine to the muffler (5). This prevents excessive boost
pressure which could lead to mechanical failure.
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Intake manifold - Remove

Prior operation:
Common rail - Remove (10.218)
1. Remove the intake manifold (2) retaining bolts (1).

2. Remove the intake air heater (3) retaining nuts.
3. Remove the heater.
NHIL13ENG0622FA 1
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Intake manifold - Install

Prior operation:
Intake manifold - Remove (10.254)
1. Apply LOCTITE 5999 to the mounting surface of the air

intake heater (3) and the intake manifold (2).
2. Install the air intake heater (3).
3. Torque the retaining nuts to 6 - 10 N·m (4 - 7 lb ft).
4. Install the intake manifold (2) onto the cylinder head.
5. Torque the retaining bolts (1) to 20 - 28 N·m (15 - 21 lb
ft).
NHIL13ENG0622FA 1
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Exhaust manifold - Remove

Prior operation:
Turbocharger - Remove (10.250)
1. Remove the bolts (1) and remove the exhaust manifold

(2) from the cylinder head.
2. Remove the exhaust manifold (2) and gasket from the
cylinder head.
NHIL13ENG0625AA 1
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Exhaust manifold - Install

Prior operation:
Exhaust manifold - Remove (10.254)
1. Install the exhaust manifold (2) with a new gasket onto

the cylinder head and secure with the retaining bolts
(1).
2. Torque the bolts (1) to the following specifications:
• 4 cylinder engines – 55 N·m (41 lb ft)
• 6 cylinder engines – 55 N·m (41 lb ft)
NHIL13ENG0625AA 1
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Exhaust flap - Remove - Exhaust flap

1. Disconnect the electrical connector (2).
2. Remove the coolant supply line (1).
3. Remove the coolant return line (3).
NHIL13ENG1359AA 1
4. Remove the two upper bolts (3) from the support

bracket.
5. Loosen the clamp (2) between the exhaust flap and
turbocharger.
6. Remove the exhaust flap assembly (1)
NHIL13ENG1360AA 2
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Exhaust flap - Install - Exhaust flap

1. Install the two upper bolts (3) of the support bracket.
2. Torque the bolts (3) to 37 - 49 N·m (27.3 - 36.1 lb ft).
3. Position the exhaust flap assembly (1) against the tur-
bocharger and tighten the clamp (2).
NHIL13ENG1360AA 1
4. Install the coolant return line (3).

5. Install the coolant supply line (1).
6. Torque the banjo bolts for the coolant supply and return
lines to 5.0 - 7.0 N·m (3.7 - 5.2 lb ft).
7. Connect the electrical connector (2) to the exhaust flap
assembly.
NHIL13ENG1359AA 2
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Index
Engine - 10

Exhaust flap - Install - Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust flap - Remove - Exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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
Selective Catalytic Reduction (SCR) exhaust treatment - 500

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F4HFE613Z*B002
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Contents
Engine - 10
TECHNICAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

Technical Data - Nitrogen Oxides (NOx) and Ammonia (NH3) vs Temperature . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA

Overview - Emission Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dynamic description Diesel Oxidation Catalyst (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dynamic description - Reduction of NOx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview - Thermal Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overview - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Coolant control valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diesel Oxidation Catalyst (DOC)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Selective Catalytic Reduction (SCR) muffler and catalyst
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dynamic description - Clean Up Catalyst (CUC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE

Service instruction - SCR fault repair verification test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Configure - Engine restart counter reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service instruction - Hydrocarbon (HC) accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diesel Exhaust Fluid (DEF)/AdBlue® tank
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Diesel Exhaust Fluid (DEF)/AdBlue® lines
Tool usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Selective Catalytic Reduction (SCR) muffler and catalyst
Selective Catalytic Reduction (SCR) exhaust treatment coolant lines
Tool usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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CONSUMABLES INDEX

(DEF)/AdBlue®
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Technical

Data - Nitrogen Oxides (NOx) and Ammonia (NH3) vs Temperature
In this graph the temperature area is the highest
efficiency to conversion of NOx.
• (A) NOx conversion percentage
• (B) Temperature
NHPH14ENG1268AA 1
Temperature
100.0 °C (212.0 °F)
200.0 °C (392.0 °F)
300.0 °C (572.0 °F)
400.0 °C (752.0 °F)
500.0 °C (932.0 °F)
600.0 °C (1112.0 °F)
In this graph you can see stored ammonia (NH3)
dependant on temperature. Maximum ammonia slip
allowed is 10 ppm.
• (A) Maximum amount of ammonia percentage
• (B) Temperature
NHPH14ENG1269AA 2
Temperature
100.0 °C (212.0 °F)
200.0 °C (392.0 °F)
300.0 °C (572.0 °F)
400.0 °C (752.0 °F)
500.0 °C (932.0 °F)
600.0 °C (1112.0 °F)
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Selective Catalytic Reduction (SCR) exhaust treatment - Overview -

Emission Standard
Due to the composition of fossil fuel during the combustion process several toxic substances are produced. These
substances are primarily:
• Carbon Monoxide (CO)
• Hydrocarbons (HC)
• Nitrogen Oxides (NOx)
• Particulate Matter (PM)
The primary focus is on the reduction of NOx and Particulate Matter (PM).
Particulate Matter (PM) - Particulates are harmful to your health, and is harmful to the environment. PM is mainly
composed of small carbon particles, and other toxic substances created during incomplete fuel burning, i.e. low
combustion temperature.
Nitrogen Oxides (NOx) - NOx is a generic term for mono-nitrogen oxides NO & NO2. The (nitric oxide & nitrogen diox-
ide are produced from the reaction of nitrogen & oxygen gases during combustion, especially at high temperatures.
This can cause acid rain.
Ammonia (NH3) - Ammonia is a compound of nitrogen and hydrogen with the formula NH3. It is a colorless gas with
a characteristic of a pungent smell. Exposure to high levels of ammonia in air may be irritating to your skin, eyes,
throat, lungs, and can cause coughing and burns.
Inside the combustion chamber, Particulate Matter (PM), and Nitrogen Oxides (NOx) have conflicting chemical factors.
As PM decreases, NOx will increase. As NOx decreases, PM will increase.
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Selective Catalytic Reduction (SCR) exhaust treatment - Component

identification
NHPH14ENG1262FA 1
(A) Diesel Exhaust Fluid

(B) Coolant line flow (C) Exhaust gas flow
(DEF)/AdBlue® flow
(1) Electronic Control Unit (ECU) (12) Diesel Oxidation Catalyst (DOC) upstream
temperature sensor
(2) Exhaust flap (13) Selective Catalytic Reduction (SCR) upstream
temperature sensor
(3) Intake air humidity and temperature sensor (14) SCR downstream temperature sensor
(4) Air filter (15) NH3 sensor
(5) NOx sensor (16) NOx sensor
(6) DEF/AdBlue® pipes (17) Engine
(7) DEF/AdBlue® level and temperature sensor (18) Supply module
(8) DEF/AdBlue® quality sensor (19) DOC
(9) Tank (20) SCR muffler
(10) Coolant control valve (21) Clean-up Catalyst (CUC), internal to the SCR muffler
(11) DEF/AdBlue® dosing module
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Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic

description
NHIL13ENG1393FA 1
(1) Intake air humidity and temperature sensor (9) Exhaust flap
(2) Air filter (10) Engine Control Unit (ECU)
(3) Supply module (11) SCR upstream temperature sensor
(4) Diesel Exhaust Fluid (DEF)/AdBlue® tank (12) SCR catalyst
(5) DEF/AdBlue® dosing module (13) SCR downstream temperature sensor
(6) DOC and mixer (14) NH3 sensor
(7) DOC upstream temperature sensor (15) NOX sensor
(8) NOx sensor (16) Engine
The supply module contains an electronically controlled pump motor and reverting valve and an electronically moni-
tored pressure and temperature sensor.
Each of these elements is controlled or monitored by the Engine Control Unit (ECU).
DEF/AdBlue® drawn from the DEF/AdBlue® storage tank is pressurized by the Supply module pump. The DEF/
AdBlue® pressure is sensed by the Supply module pressure sensor. Once the pressure is stabilized at approximately
9.0 bar (130.5 psi), the system is ready for normal operation. During cold weather operation the Dosing module
solenoid is energized (actuated) for approximately 1.0 s. If this opening of the dosing valve causes a pressure drop,
then the pipe (tube) is assumed to be free of ice (blockage). Otherwise defrosting is continued for 5.0 min then
re-checked. This process is repeated up to five times. DEF/AdBlue® system pressure needs to be between 5.5 -
11.0 bar (79.8 - 159.5 psi) to assure correct dosing quantities.
As the DEF/AdBlue® system needs to be evacuated when the engine is not running to prevent potential damage due
to frozen DEF/AdBlue®, the system requires filling and pressurizing after each engine start. DEF/AdBlue® system
evacuation is accomplished by the Supply module reverting valve, internal to the supply module, which removes the
DEF/AdBlue® from all of the lines and returns it to the storage tank by reversing the direction of the DEF/AdBlue®
flow. During system evacuation the system pressure is expected to drop to 0.2 bar (3.6 psi) within 40.0 s.
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The DEF/AdBlue® system filling and pressurizing is done in ECU controlled steps. The Supply module pump operates
with the Dosing module solenoid de-energized (closed) until the Supply module pressure sensor senses more than
1.5 bar (21.8 psi) continuously for more than 1.0 s then the pressure build up (pressurization) step begins. Once the
system reaches 6.5 bar (94.2 psi), the system is ready for injection (normal operation). However, during pressure
build up, if the system pressure does not reach 6.5 bar (94.2 psi) within 60.0 s, the system enters a ventilation state
where the Dosing module solenoid is energized (opened) 75.0 % and the Supply module pump is commanded to
operate 100.0 % for a duration of 1.0 s before returning to the pressure build up state.
Start-Up / System Operation

At key on, the Supply Module is powers up.
The Electronic Control Unit (ECU) verifies the temperature of the DEF/AdBlue®. The sensors that are monitored
to verify the temperatures are:
• DEF/AdBlue® level and temperature sensor in the tank
• Ambient air using the intake air humidity and temperature sensor
• Supply module internal temperature sensor
If the DEF/AdBlue® is frozen or the ambient temperatures are cold, the coolant control valve is actuated to start the
thawing process.
When the DEF/AdBlue® thaws or the temperatures rise above the freezing point, -11.0 °C (12.2 °F), the diaphragm
pump starts pumping to build pressure in the DEF/AdBlue® system.
• After 15 min, the pump is actuated to see if DEF/AdBlue® will flow.
• The defrosting session will continue checking for DEF/AdBlue® flow every 15 min for up to 8 h (based on tempera-
tures below ‐ -18.0 °C (-0.4 °F) ). The defrosting session will re-initiate a 15 min defrosting cycle until DEF/AdBlue®
flow is achieved.
The reverting valve is cycled to purge the air out of the line.
The supply module continually builds, and maintains Selective Catalytic Reduction (SCR) system pressure of 9.0 bar
(130.5 psi) to the DEF/AdBlue® dosing module.
Normal Operation
The supply module then maintains SCR system pressure until the SCR catalyst has warmed to operating temperature
220.0 - 240.0 °C (428.0 - 464.0 °F), and engine load indicates a need to start dosing DEF/AdBlue®. DEF/AdBlue® is
injected per engine controller request (open loop dosing).
After approximately 10 - 12 min of initial engine startup operation, the NOx and NH3 sensors are heated and dried
enough to sample for the NOx level in the exhaust. The DEF/AdBlue® dosing module is now based upon the NOx
sensors actual reading at the tailpipe (closed loop dosing).
NOTE: The 10 - 12 min delay is called “Dew Point”. The amount of dew point timing is different for both NOx, and
NH3 sensors.
Closed loop dosing is more accurate then open loop dosing due to sensor monitoring.
Upon engine start up, engine coolant is continually circulated through the DEF/AdBlue® dosing module to provide
cooling.
After Run
At key off, the reverting valve shifts to line purge, and the diaphragm pump in the supply module continues to run for
a timed period (approximately ninety seconds).
This evacuates the SCR system and returns the DEF/AdBlue® to the tank.
This is done to prevent damage to the SCR system should it freeze, and also for DEF/AdBlue® not to crystallize in
the system.
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description Diesel Oxidation Catalyst (DOC)
NHVM14ENG1094HA 1
Inside the oxidation catalyst, the exhaust gases flow through a cell structure. The surface has a layer of aluminum
oxide (platinum and palladium). These metals provide for the oxidation of the exhaust gases, and thus achieve the
reduction of Carbon Monoxide (CO) and unburned Hydrocarbons (HC).
The DOC provides the following functions:

• Breaks down hydrocarbons in the exhaust stream and heat is the by-product of this reaction.
• Provides proper Selective Catalytic Reduction (SCR) catalyst temperatures in order to reach high nitrogen oxides
efficiency target.
• Carbon Monoxide (CO) is oxidized and converted to Carbon Dioxide (CO2).
• Increases SCR performance at low temperatures, as it creates Nitrogen Dioxide (NO2) from the Nitrogen Oxide
(NO) in exhaust stream.
• The presence of NO2 increases the NOx conversion efficiency of the SCR Catalyst.
It is required to achieve as close as possible a 50 %: 50 % ratio of nitrogen oxide to nitrogen dioxide before the SCR.
This maximizes SCR performance, especially needed at low temperatures.
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description - Reduction of NOx
NHIL13ENG1393FA 1
The NOx conversion depends on the amount of stored ammonia (NH3).
When exhaust temperatures start to increase, less stored ammonia is necessary to maintain a proper NOx efficiency
level.
The amount of NH3 which can be stored at an ammonia slip limit level of 10 ppm increases, when temperatures start
to decrease. The temperature difference is between 200.0 - 500.0 °C (392.0 - 932.0 °F).
NOTE: Ammonia slip refers to the amount of ammonia passing through the Selective Catalytic Reduction (SCR) (1)
system un-reacted.
When the catalyst is heating up, stored NH3 is either consumed by the SCR reactions, or it desorbs leading to an
increased NH3 slip. Desorb is the process of releasing “something” through pores.
In order to avoid NH3 peaks, the maximum allowed storage of NH3 has to be limited at low temperatures.
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Selective Catalytic Reduction (SCR) exhaust treatment - Overview

- Thermal Management
The Selective Catalytic Reduction (SCR) system that has been developed, is to satisfy the required target of about
99 % conversion efficiency. The SCR system needs to be working at temperatures higher than 270.0 °C (518.0 °F).
The maximum possible SCR efficiency starts to drop off below 270.0 °C (518.0 °F), and falls significantly below
240.0 °C (464.0 °F).
The main purpose of thermal management is to get the SCR system to target temperatures as fast as possible. Ther-
mal management will help avoid any temperature drops in the system, if the natural engine exhaust gas temperatures
are below the target range, due to low load factor or very low ambient conditions.
To obtain proper thermal management, two components
are needed.
• Diesel Oxidation Catalyst (DOC) (1)
• Exhaust flap (2)
NHVM14ENG1097AA 1
Warm Up cycle
Activation conditions:
• After every engine start, the system starts working in warm-up mode.
Description / features:
• In this condition, the SCR is below its optimum operating temperature. Consequently the quantity of ammonia that
needs to be stored in the SCR to meet the necessary NOx conversion efficiency rate increases significantly.
• The exhaust flap is used to reach the optimal SCR temperature of 270.0 - 275.0 °C (518.0 - 527.0 °F) as fast as
possible, by increasing exhaust gas back pressure, and exhaust gas temperatures as required.
• To improve effectiveness, and to reduce emissions during this phase, a simultaneous injection retard strategy is
associated to facilitate the heating effect. This will reduce the engine raw NOx. The SCR required efficiency is
pushed to the maximum value so that the combined effect with the retarded injection strategy to hold tailpipe NOx
values as low as possible.
Exit conditions:
• This phase is over as soon SCR temperature reach 280.0 °C (536.0 °F).
Temperature Hold
Activation conditions:
• The exhaust flap is reactivated when the engine is running at a relatively low load cycle, and/or in cold ambient
conditions.
• When the SCR temperature falls below 240.0 °C (464.0 °F), the exhaust flap will modulate to increase exhaust
temperature.
• The required SCR efficiency is around 95 - 98 % in all of the engine maps, for engine speed lower than 1100 -
1200 RPM. The target efficiency is set at 90 %.
Exit conditions:
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• At 245.0 °C (473.0 °F) efficiency temperature hold mode to normal mode, when the SCR temperature reaches
250.0 °C (482.0 °F), or after 15 min in low-load conditions where power is less than 10 % of rated power
Normal Mode
Activation / exit conditions:
• The exhaust flap is deactivated due to either one of the following conditions:
A. The exhaust temperature has reached its target value. At this time, no flap is necessary for maintaining high
SCR efficiency. This is the normal operating mode for most vehicle missions.
B. When the SCR light off temperatures cannot be reached in a practical manner even with the use of the flap, and
within minimum operating temperatures of the system. At these very low loads there is not enough energy in the
exhaust gas to maintain a good SCR efficiency and hydrolysis of the required Diesel Exhaust Fluid (DEF)/Ad-
Blue® injection. If the engine remains at this low power level for 15 min, then continuous thermal management
is switched off. As soon as engine load increases, the flap will be reactivated. In this temporarily deactivated
state, the flap will still be used intermittently for preventing other issues, such as DEF/AdBlue® deposits forma-
tion or hydrocarbon (HC) accumulation as required.
• Flap is deactivated.
• The required SCR efficiency is around 95 - 98 % in all of the engine maps, for engine speed lower than 1100 -
1200 RPM. The target efficiency is set at 90 %.
Hydrocarbon Accumulation Protection

Background
• If the engine is at very low load or left in idling conditions for long periods, then continuous thermal management is
switched off. When thermal management is switched off, the temperature will fall well below 200.0 °C (392.0 °F).
In this situation the DOC will not oxidize hydrocarbons (HC) produced by the engine, and these will gradually pass
towards the SCR system. Some of the hydrocarbons will be absorbed in the SCR, thus occupying cells that cannot
any longer collect ammonia (NH3) to reduce NOx emissions. In some cases customers will leave engine at low idle
for an entire night and total HC accumulation can be significant.
• If the absorbed hydrocarbons in the SCR is too high, the increase load on the engine can be enough to create
a significant thermal event. This can cause severe damage to the SCR. Cells that are occupied by hydrocarbons
cannot physically collect ammonia any longer. This will cause the SCR efficiency to decrease, and risk the emission
system to not be compliant.
Countermeasures with thermal management

• To eliminate this risk an intermittent use of thermal management is foreseen. After a few hours, but long before
the total HCs accumulated can reach dangerous levels, the exhaust flap is used. Two different strategies are
possible, depending on application requirements (machine configurations, safety conditions, etc..)
○ One strategy is hydrocarbon regeneration control. This strategy can be used to keep HCs under control indef-
initely by intermittently raising the SCR temperatures. The SCR system temperatures will be raised to approx-
imately 300.0 °C (572.0 °F), whenever the HC model reaches a critical level. To reach this target temperature,
the low idle speed must be increased during the intermittent regeneration phases.
○ On some applications the customer needs to be able to leave the normal low idle speed alone. So rather than
intermittently raising temperatures to around 300.0 °C (572.0 °F) to remove HCs, we will use strategy two which
is hydrocarbon oxidation control. This strategy keeps the DOC inlet temperature at around 250.0 °C (482.0 °F) to
avoid further accumulation. The critical level for strategy two is lower than strategy one, and average flap use is
higher, but climatic chamber results demonstrate that this condition can be achieved under all normal operating
conditions without engine speed increase.
The hydrocarbon accumulation rate is dependent on After-Treatment System (ATS) temperature, engine speed,
coolant temperature.
• The lower the ATS temperature, the higher the accumulation rate.
• The faster the engine, the higher the flow of HC reaching the SCR.
• The lower the coolant temperature, the higher HC emission from the engine.
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Once the critical HC level has been reached, a regeneration is needed to clear the SCR muffler from HC.
DEF/AdBlue® deposit protection

Background
• The temperature at the SCR inlet is also critical for
hydrolysis of injected DEF/AdBlue®. At low tempera-
tures the risk of DEF/AdBlue® deposits in the mixer in-
creases significantly. In the intermediate temperature
range 250.0 - 300.0 °C (482.0 - 572.0 °F), this risk is
significantly reduced but DEF/AdBlue® deposits could
very slowly start to build up if temperature never ex-
ceeds this temperature range.
NHPH14ENG1099BA 2
Countermeasures with thermal management:

• A timer is used to monitor the amount of time when the SCR inlet temperature is continuously below 300.0 °C
(572.0 °F), and during which the machine mission is quasi steady-state (when same engine working point is main-
tained continuously, frequency of DEF/AdBlue® deposits creation increases).
• Once the timer has reached a value of 6 - 8 h (dependant on engine/ATS systems), the flap will modulate until the
DOC inlet temperature reaches a value of 450.0 - 530.0 °C (842.0 - 986.0 °F). The flap is used for approximately
25 min to burn off all incipient DEF/AdBlue® deposits.
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Selective Catalytic Reduction (SCR) exhaust treatment - Overview

- Hydraulic
NHPH14ENG1098HA 1
(A) Engine Controller Area (B) Diesel Exhaust Fluid (C) Electrical wiring (D) DEF/AdBlue® heater
Network (CAN) (DEF)/AdBlue® plumbing
(1) Pre-filter (13) Controller Area Network (CAN) terminator

(2) DEF/AdBlue® quality sensor (14) SCR upstream temperature sensor
(3) Reverting valve (internal to the supply module) (15) DEF/AdBlue® dosing module injector
(4) Supply module (16) Nox sensor (upstream)
(5) DEF/AdBlue® temperature sensor (internal to the (17) Diesel Oxidation Catalyst (DOC) upstream
supply module) temperature sensor (inlet)
(6) DEF/AdBlue® level and temperature sensor (18) Exhaust flap
(combination sensor)
(7) DEF/AdBlue® level and temperature sensor (19) DEF/AdBlue® tank
(combination sensor)
(8) Filter (20) Engine Control Unit (ECU)
(9) DEF/AdBlue® pressure sensor (internal to the supply (21) Diesel Oxidation Catalyst (DOC)
module)
(10) NH3 sensor (22) Selective Catalytic Reduction (SCR)
(11) Nox sensor (downstream) (23) Clean Up Catalyst (part of the SCR)
(12) SCR downstream temperature sensor
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Pressure Build Up Cycle

• “Pressure build up” is performed after the engine is
started as the pump creates flow building system pres-
sure.
• The supply pump is driven per the engine controller
instructions, and pressurizes the system to 9.0 bar
(130.5 psi).
• DEF/AdBlue® dosing module (1)

• Pump (internal to the supply module) (2)
• Pre-filter (3)
• DEF/AdBlue® tank (4) NHPH14ENG1102AA 2
• Supply module (5)

Reverting Valve Check
• A reverting valve check is performed per system re-
quirements to close test from the system

• Pre-filter (3)
• DEF/AdBlue® tank (4)
NHPH14ENG1103AA 3
Normal Running
• The pump pressure is up to 9.0 bar (130.5 psi), and
when the temperature in the SCR chamber is 240.0 °C
(464.0 °F) or greater, the system goes into normal op-
eration and starts injection DEF/AdBlue®.
• The dosing valve is pulse width modulated (PWM) by
the Engine Control Unit (ECU), which has full control
over the amount of DEF/AdBlue® injected.

• Pre-filter (3) NHPH14ENG1100AA 4

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After-Run, Emptying the System

• The After-run operation occurs the machine is powered
down – key OFF.
• The injector is set an open position as the reverting
valve is activated in order to evacuate DEF/AdBlue®
out of the lines. The evacuated DEF/AdBlue® is re-
turned to the DEF/AdBlue® tank, approximately eighty
to ninety second run time.

• Pre-filter (3) NHPH14ENG1101AA 5

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Coolant control valve - Overview
NHVM15ENG0001FA 1
(1) Outlet port for system defreeze (4) Directional arrow

(2) Electrical connector (5) Bypass port for dosing module injector
(3) Inlet port
NOTICE: The coolant control valve is directional, if the coolant flow through the valve is reverse (hoses hooked up
incorrectly), the valve will be damaged. Verify the coolant is flowing the correct direction as indicated by the arrow (4)
on the valve.
The coolant control valve is located in a coolant line connected to the engine. When this two position three way valve
is not activated, it sends engine coolant through both the supply module, and the Diesel Exhaust Fluid (DEF)/AdBlue®
supply lines as well as the dosing module injector to thaw the DEF/AdBlue® fluid as the engine is started in freezing
climates. DEF/AdBlue fluid freezes at -11 °C (12 °F). It also degrades at elevated temperatures.
When the DEF/AdBlue® fluid is above freezing, the coolant control valve is activated to only send engine coolant
through the DEF/AdBlue® dosing module injector to then control the maximum temperature of the module as the
engine is operated under load. This temperature regulation minimizes the degradation of the fluid because of the
elevated exhaust temperature. When the engine coolant control valve is activated, coolant is not circulated through
the supply module to prevent heating of the fluid.
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Coolant control valve - Dynamic description
NHPH14ENG1109FA 1
Engine Control Unit (ECU) (1) Diesel Oxidation Catalyst (DOC) (4)
Supply module (2) Selective Catalytic Reduction (SCR) muffler (5)
Diesel Exhaust Fluid (DEF)/AdBlue® tank (3) Coolant control valve (6)
The control software contain a heating strategy.

• This heating strategy provides defrosting of the SCR system components.
• To heat the system after defrosting was completed, this is to avoid that the system freezes again during driving.
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Normal Coolant Flow
NHVM14ENG1263FA 2
The normal coolant flow goes from the:

• Engine (3) to the coolant control valve (4)
• Coolant control valve to the dosing module (2)
• Dosing module line (1) back to the engine
The normal coolant flow helps to cool the dosing module.
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Defrosting / Heating Flow
NHVM14ENG1263FA 3
The defrosting flow goes from the:

• Engine (3) to the coolant control valve (5)
• Coolant control valve to the tank spiral (7) (fluid level and temperature sending unit)
• Tank spiral to the supply module (6)
• Supply module ‘T’ connection (4) to the dosing module (2)
• Dosing module back to the engine (1)
DEF/AdBlue® heating control - Defrosting state

• Supply pump is not running to avoid damage of system components.
• System is heating up until “Defrosting OFF” thresholds for all heating circuits have been reached.
NOTICE: Even if condition “DEFROSTING OFF” was not reached, the system will try to start-up after 68 min defrost-
ing time has elapsed.
Signal Threshold
ON OFF
Fluid tank temperature Less than -10.0 °C (14.0 °F) Greater than -8.0 °C (17.6 °F)
Supply module temperature Less than -4.0 °C (24.8 °F) Greater than -4.0 °C (24.8 °F)
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DEF/AdBlue® heating control - Heating state

• System is starting up and is trying to build-up pressure
• Dosing can be started
• Heating of components is continued until “Heating OFF” thresholds have been crossed
Signal Threshold
ON OFF
Fluid tank temperature Less than 15.0 °C (59.0 °F) Greater than 17.0 °C (62.6 °F)
Supply module temperature Less than -2.0 °C (28.4 °F) Greater than 0.0 °C (32.0 °F)
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Diesel Oxidation Catalyst (DOC) - Overview
NHIL13ENG1391AA 1
The Diesel Oxidation Catalyst (DOC) is a muffler type exhaust after treatment device located first in the exhaust
stream from the engine.
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Diesel Oxidation Catalyst (DOC) - Dynamic description
NHVM14ENG1274FA 1
Inside the Diesel Oxidation Catalyst (DOC), the exhaust gases will flow through a cell structure (1). The cell structure
surface is covered with a layer of platinum and palladium. These metals provide for the oxidation of the exhaust
gases, and thus achieve the reduction of Carbon Monoxide (CO) and unburned Hydrocarbons ( HC).
The DOC provides the SCR system with the following benefits:
• Breaks down hydrocarbons in the exhaust stream, and heat is the by-product of this reaction.
• Provides proper Selective Catalytic Reduction (SCR) catalyst temperatures in order to reach high nitrogen oxides
efficiency target levels.
• Carbon Monoxide (CO) is oxidized and converted to Carbon Dioxide (CO2).
• The DOC also increases SCR performance at low temperatures as it creates Nitrogen Dioxide (NO2) from the
Nitrogen Oxide (NO) in the exhaust stream.
• The presence of NO2 increases the NOx conversion efficiency of the SCR catalyst.
The DOC is required to achieve as close as possible a 50 % : 50 % ratio of nitrogen oxide to nitrogen dioxide before
the SCR. This maximizes the SCR performance, especially needed at low temperatures.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Overview
NHIL13ENG1391AA 1
The Selective Catalytic Reduction (SCR) (1) is a muffler type device located second within the exhaust flow from
the engine. In a SCR system, the catalyst serves as the exhaust muffler as well as the device to remove Nitrogen
Oxides (NOx). All engine exhaust flow passes through the SCR catalyst. Within the catalyst, the urea based Diesel
Exhaust Fluid (DEF) reacts with the higher concentrations of (NOx) caused by the combustion cycle. This chemical
reaction converts the NOx into nitrogen and water vapors that pass out the exhaust. The system requires a minimum
temperature of 230 °C (446 °F) to function.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Dynamic

description - Clean Up Catalyst (CUC)
NHVM14ENG1273FA 1
The Clean Up Catalyst (CUC) (1) is located inside the Selective Catalytic Reduction (SCR) muffler (2).
The CUC is required to eliminate residual ammonia (NH3) for legislation implications.
It is possible to have too much ammonia in the SCR catalyst. In this case we lose ammonia through the exhaust pipe.
The target to lose is less than 10 ppm out of the exhaust pipe.
The excess ammonia reacts with the CUC and oxygen, and then is converted to nitrogen and water vapors out of the
exhaust.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Sectional

view
NHPH14ENG1271AA 1
• (1) Clean Up Catalyst (CUC)

• (2) Selective Catalytic Reduction (SCR)
• (3) Mixing chamber
• (4) Pollutant inlet
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Selective Catalytic Reduction (SCR) exhaust treatment - Service

instruction - SCR fault repair verification test
1. Click the “Controller Tests” icon (1).
NHPH14ENG0022AA 1
2. Select “SCR Fault Repair Verification Test” (1).

3. Click the “START TEST” button (2).
4. Click “START TEST” and follow the on-screen instruc-
tions to complete the test.
NHPH14ENG0023AA 2
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Selective Catalytic Reduction (SCR) exhaust treatment - Configure

- Engine restart counter reset
NHPH14ENG0006AA 1
3. Select “Engine Restart Counter Reset / Unlock Induce-

ment” (1).
4. Click “CONFIGURE SELECTED ITEM” (2).
NHPH14ENG0013AA 2
5. Click the “RESET ENGINE RESTART COUNTER / UN-

LOCK INDUCEMENT” button (1).
NHPH14ENG0012AA 3
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Selective Catalytic Reduction (SCR) exhaust treatment - Service

instruction - Hydrocarbon (HC) accumulation
This procedure is to be used when there is an active fault indicating that the maximum level of Hydrocarbon (HC)
accumulation has been reached. This can occur when operating at lower temperatures and lighter engine loads.
1. Place the machine in park and apply the hand brake (if
equipped).
2. Monitor the SCR upstream temperature sensor using
the Electronic Service Tool (EST).
3. Run the machine until the SCR upstream temperature
sensor reads 300 - 330 °C (572 - 626 °F). Use the
methods below to increase engine load if these tem-
peratures cannot be obtained:
• Dynamometer
• Hydraulic flow meter
4. Maintain temperatures at 300 - 330 °C (572 - 626 °F)
for approximately 30 min.
5. Increase engine load until the SCR upstream temper-
ature sensor reads 400 °C (752 °F) and maintain this
temperature for approximately 30 min.
6. Increase engine load until the SCR upstream temper-
ature sensor reads 500 °C (932 °F) and maintain this
temperature for approximately 30 min.
7. Remove the load from the engine and allow the exhaust
temperatures to cool prior to engine shutdown.
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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Cleaning

After contamination of the DEF/AdBlue® storage tank
the system Dosing Control Unit (DCU), lines, filters,
Dosing Module (DM) and exhaust needs to be cleaned.
Monitoring of the Aftertreatment system after the failure
will need to be performed for the first 50 hours to ensure
catalyst substrate damage has not occurred.
1. Empty storage tank and remove from vehicle.
• Rinse with de-ionized water and steam clean for
15 min.
• Rinse with de-ionized water again.
• Re-install and fill with clean DEF/AdBlue®.
2. Remove Dosing Module (DM) from exhaust.
• Leave lines connected.
• Place in container to catch contaminated DEF/Ad-
Blue®.
3. Remove return line from WEMA at storage tank.
• Place in container to catch contaminated DEF/Ad-
Blue®.
4. With the Electronic Service Tool (EST), run flushing
routine for 5 minutes.
5. Change main filter , inline filter and rinse or replace
nipple filters in inlet and DM inlet and outlet lines (3
total).
6. With EST, run Urea Dosing System Test (UDST) 5
times.
7. With EST, run system empty routine until test termi-
nates.
• Dispose of contaminated DEF/AdBlue®.
8. Reassemble unit and disconnected lines including
re-installing DM.
9. With EASY tool, collect “Stored Engine Data” from En-
gine Control Unit (ECU).
10. Perform active dosing verification (healing) of system
before releasing back to service. Healing can only oc-
cur when a minimum exhaust temperature is reached
of 220 - 240 °C (428 - 464 °F) on both of the upstream
and downstream exhaust temperature sensors.
11. Run unit for 15 h.
12. With EASY tool, collect “Stored Engine Data” from
ECU.
13. Compare stored engine data and provide to CNH for
analysis of system.
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Diesel Exhaust Fluid (DEF)/AdBlue® lines - Tool usage

NOTE: The following procedure shows a Tier 4A (interim)/Stage IIIB DEF/ADBLUE® line repair. Tier 4B (final)/Stage
IV DEF/ADBLUE® line repair follows the same procedure except where noted.
DEF/ADBLUE® repair tools

Item Description Tool Reference
1 Pliers 84480632
2 Jaws for Tier 4A (interim)/Stage IIIB DEF/ADBLUE® 84153500
lines
3 Jaws for Tier 4B (final)/Stage IV DEF/ADBLUE® 84480634
lines
4 Mandrel 84153502
5 Tube expander 84153504
6 Tube cutter 84480637
7 Spare blades 84480640
NOTE: The item numbers in the table correspond to the callouts in this procedure.
1. Cut out the damaged portion of the DEF/ADBLUE® line
with a tube cutter (6).
RAIL15TR00603AA 1
2. Identify the correct replacement DEF/ADBLUE® line fit-

ting.
NOTE: Fitting diameter, type, and clip orientation must
match the damaged fitting.
RAIL15TR01495AA 2
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3. Cut the new DEF/ADBLUE® line with a tube cutter (6)

to match the length of the damaged section of line re-
moved previously.
RAIL15TR01502AA 3
4. Assemble the tool as follows:

1. Place the detent and spring (A) in the location
shown on the pliers (1).
2. Select the appropriate jaws (2) or (3) for the line
being repaired.
3. Place the mandrel (4) into the pliers as shown.
NOTE: Use the jaws (2) for Tier 4A (interim)/Stage IIIB
DEF/ADBLUE® line repair. Use the jaws (3) for Tier 4B (fi-
nal)/Stage IV DEF/ADBLUE® line repair.
RAIL15TR01491AA 4
5. Make a mark on the new DEF/ADBLUE® line section

25 mm (1 in) from the end cut in step 3.
RAIL15TR01496AA 5
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6. Line up the mark made in step 5 with the edge of the

jaws as shown. Clamp the line in the jaws.
RAIL15TR00602AA 6
7. Place the tube expander (5) into the mandrel as shown.
RAIL15TR01501AA 7
8. Press the tube expander into the line until the line
reaches the land on the expander. Remove the tube
expander.
RAIL15TR01493AA 8
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9. Install a clamp over the line.
RAIL15TR01489AA 9
10. Place the union in the mandrel (4).

NOTE: DIESEL EXHAUST FLUID (DEF)/ADBLUE® can be
used to lubricate the union. Do not use any other lubricant.
RAIL15TR01503AA 10
11. Press the union into the line with a smooth and steady
motion.
RAIL15TR01504AA 11
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12. Use an end cutter to crimp the clamp on the line over
the union.
RAIL15TR01499AA 12
13. Repeat steps 5 through 12 for the other side of the

line.
NOTE: When completing the repair, be sure to orient the fitting to the required position for re-installation on the ma-
chine prior to pressing the union into the line in step 11.
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Selective Catalytic Reduction (SCR) muffler and catalyst - Configure

- Reset ECU data
NHPH14ENG0006AA 1
3. Select “Replacement of Catalyst – Reset ECU Data (1).

4. Click “CONFIGURE SELECTED ITEM” (2).
NHPH14ENG0009AA 2
5. Click “RESET” (1).
NHPH14ENG0010AA 3
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Selective Catalytic Reduction (SCR) exhaust treatment coolant

lines - Tool usage
1. Locate the smooth section of the coolant line nearest
to the fitting that needs to be replaced.
NOTE: It may be necessary to pull back some of the bundle
sheathing.
RAIL15TR01498AA 1
2. Cut the coolant line at the beginning of the smooth sec-

tion using the tube cutter 84480637.
NOTE: The cut must be made square.
NOTE: If required, additional blades 84480640 are avail-
able
RAIL15TR01490AA 2
3. Place a clamp (1) over the coolant line. Press the new
line (2) into the smooth section of the existing coolant
line.
NOTE: Engine coolant can be used as a lubricant on the
fitting
RAIL15TR01497AA 3
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4. Orient the fitting and tighten the clamp (1) over the
smooth section of the coolant line.
RAIL15TR01500AA 4
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Index
Engine - 10

Coolant control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Coolant control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diesel Exhaust Fluid (DEF)/AdBlue® lines - Tool usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Diesel Oxidation Catalyst (DOC) - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diesel Oxidation Catalyst (DOC) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Selective Catalytic Reduction (SCR) exhaust treatment - Component identification . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset 29
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description . . . . . . . . . . . . . . . . . 8
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description - Reduction of NOx 11
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description Diesel Oxidation Cat-
alyst (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selective Catalytic Reduction (SCR) exhaust treatment - Overview - Emission Standard . . . . . . . . 6
Selective Catalytic Reduction (SCR) exhaust treatment - Overview - Hydraulic . . . . . . . . . . . . . . . . . 15
Selective Catalytic Reduction (SCR) exhaust treatment - Overview - Thermal Management . . . . . . 12
Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction - Hydrocarbon (HC)
accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair veri-
fication test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Selective Catalytic Reduction (SCR) exhaust treatment - Technical Data - Nitrogen Oxides (NOx)
and Ammonia (NH3) vs Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Selective Catalytic Reduction (SCR) exhaust treatment coolant lines - Tool usage . . . . . . . . . . . . . . 38
Selective Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data . . . . . . . . . 37
Selective Catalytic Reduction (SCR) muffler and catalyst - Dynamic description - Clean Up Catalyst
(CUC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Selective Catalytic Reduction (SCR) muffler and catalyst - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Selective Catalytic Reduction (SCR) muffler and catalyst - Sectional view . . . . . . . . . . . . . . . . . . . . . 27
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Engine - 10
Engine cooling system - 400

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F4HFE613Z*B002
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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

SERVICE
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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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.
NHIL13ENG0629GA 1
6 cylinder version
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Engine cooling system - Dynamic description

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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.
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• Thermostat - regulates the circulation of the cooling liquid.

• If applicable, the circuit may be extended to the compressor.
NHIL13ENG0630GA 1
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Water pump - Remove

Prior operation:
Belt - Remove (10.414)
1. Remove the water pump retaining bolts (1).

2. Remove the water pump (2) and sealing ring.
NHIL13ENG0633AA 1
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Water pump - Install

Prior operation:
Water pump - Remove (10.400)
1. Install a new sealing ring (2) on the water pump (1).
NHIL13ENG0634AA 1
2. Use the two mounting bolts (2) to install the water pump
(1) onto the engine block
NHIL13ENG0635AA 2
3. Torque the water pump mounting bolts (1) to 20 -

28 N·m (15 - 21 lb ft).
NHIL13ENG0636AA 3
Next operation:
If you need to install the belt, see Belt - Install (10.414).
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Water pump Water manifold - Remove

Prior operation:
Alternator - Remove (55.301)

2. Remove the water manifold (2).
NHIL13ENG1350AA 1
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Water pump Water manifold - Install

Prior operation:
Water pump Water manifold - Remove (10.400)
1. Position the water manifold/alternator support (1) with

a new gasket against the engine block (2), and then
install the retaining bolts (3).
ft).
NHIL13ENG1352AA 1
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Coolant thermostat - Remove

1. Remove the three bolts (1) that secure the thermostat
housing (2) to the top of the cylinder head.
NHIL13ENG1351AA 1
2. Remove the thermostat (3) and the seal (2) from the
housing (1).
86082981 2
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Coolant thermostat - Install

Prior operation:
Coolant thermostat - Remove (10.400)
1. Install the seal (2) around the flange of the thermostat

(3).
2. Install the thermostat (3) into the housing (1).
86082981 1
3. Position the thermostat housing (2) in the cylinder

head.
4. Install the three bolts (1) and torque to 37.0 - 49.0 N·m
(27.3 - 36.1 lb ft).
NHIL13ENG1351AA 2
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Index
Engine - 10

Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - 10
Fan and drive - 414

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Contents
Engine - 10
Fan and drive - 414
SERVICE
Fan and drive

Remove - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt tensioner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Idler pulley
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine - Fan and drive
Fan and drive - Remove - Fan support

1. Remove the idler pulley (1).
2. Remove the bolts (3) securing the fan support (2) to the
engine crankcase.
NHVM14ENG0343AA 1
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Fan and drive - Disassemble - Fan support

1. Remove the bolt (1).
NHVM14ENG0342AA 1
2. Remove the retainer plate (4) and hub (1).

3. Remove the snap ring (2).
4. Remove the ball bearing (3).
NHVM14ENG0341AA 2
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Fan and drive - Assemble - Fan support

1. Install the ball bearing (3) into the front of the fan sup-
port.
2. Install the snap ring (2).
3. Install the hub (1) and secure with the retainer plate (4)
and bolt (5).
NHVM14ENG0341AA 1
4. Torque the bolt (1) to 43 N·m (32 lb ft).
NHVM14ENG0342AA 2
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Fan and drive - Install - Fan support

1. Install the fan support (2) onto the engine crankcase.
2. Torque the bolts as follows:
M8 bolts (4) - 24 N·m (18 lb ft)
M10 bolts (3) - 43 N·m (32 lb ft)
3. Install the idler pulley.
4. Torque the bolt (1) to 43 N·m (32 lb ft)
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Belt - Remove
1. Using the proper square drive ratchet in the provided
opening (2), release the tension on the belt (3) by
pulling back on the belt tensioner (1).
2. Remove the belt (3) from all of the pulleys.
NHIL13ENG0671AA 1
Next operation:
Belt - Install (10.414)
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Belt - Install
Prior operation:
Belt - Remove (10.414)
1. Install the Poli-V belt (4) on the drive pulley, water pump
(5), alternator (1), fan pulley (2) and on the idler pulley
(3).
2. Insert a square drive ratchet into the relative hole on
the belt tensioner.
3. Pull on the tensioner (6) and slide the belt (4) into place.
NOTE: In case the old belt is to be reused, examine it
carefully first in order to detect any incision or evidence of
stress.
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Belt tensioner - Remove

1. Remove the bolt (1) from the center of the belt tensioner
(2).
2. Remove the belt tensioner (2).
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Belt tensioner - Install

Prior operation:
Belt tensioner - Remove (10.414)
1. Install the belt tensioner (1) and secure with the mount-
ing bolt (2).
2. Torque the bolt (2) to 37 - 49 N·m (27 - 36 lb ft).
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Idler pulley - Remove

1. Remove the retaining bolt (2) from the center of the idler
pulley (1).
2. Remove the idler pulley (1).
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Idler pulley - Install

Prior operation:
Idler pulley - Remove (10.414)
1. Install the idler pulley (1) secure with the mounting bolt
(2).
2. Torque bolt (2) to 37 - 49 N·m (27 - 36 lb ft).
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Index
Engine - 10
Fan and drive - 414

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan and drive - Assemble - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan and drive - Disassemble - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan and drive - Install - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan and drive - Remove - Fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
FUNCTIONAL DATA
Engine lubrication system

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase ventilation system
SERVICE
Engine lubrication system

Remove - Oil fill tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Oil fill tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil filter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pump
Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankcase ventilation system
Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filter - Remove - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filter - Install - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil pressure valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Piston cooling
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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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.
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Engine lubrication system - Exploded view

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Lubrication by forced circulation is achieved through oil pump, placed in the front part of the engine block. From the
pan, the lubrication oil flows to the crankshaft, to the camshaft and to the valve train. Lubrication involves the heat
exchanger as well, the turbocharger and the eventual compressor for any eventual compressed air system. All these
components may often vary according to the specific duty and will therefore be examined in the specific section.
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Crankcase ventilation system - Dynamic description
NHIL13ENG1410AA 1
The valve cover houses the blow-by recirculation system which 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 lubrication system - Remove - Oil fill tube

1. Remove the M12 x 25 bolts that secure the oil fill tube
(1) to the engine block.
2. Remove the fill tube.
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Engine lubrication system - 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 with the
three M12 x 25 bolts.
3. Torque the M12 x 25 bolts to 30 - 40 N·m (22.1 - 29.5 lb
ft).
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Engine lubrication system - Test

1. Locate connection port on the left hand side of the en-
gine.
2. Remove the plug (1).
3. Use an M10x1.0 O-ring boss fitting to connect a me-
chanical gauge to the lubrication circuit..
NOTE: The gauge should have a working range of at least
0 - 8 bar (0 - 120 psi).
4. Start the engine and allow it to reach normal operating
temperature.
5. Record the pressure values at low idle and at rated
engine speed. NHVM16ENG0026FA 1
Specifications
Engine idle 2 bar (29 psi)
Rated speed 4 bar (58 psi)
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Engine oil filter - Remove

1. Use the oil filter wrench tool 380000670 to remove the
oil filter (1).
NOTE: The oil filter is equipped with an internal check valve
to minimize the amount oil loss when removing the filter.
NOTE: Be sure that the oil filter gasket is removed with the
filter.
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Engine oil filter - Install

Prior operation:
Engine oil filter - Remove (10.304)
1. Lubricate the oil filter O-ring (5) with clean engine oil.
NOTE: Be sure that the O-ring seal from the old engine
oil filter is not still stuck on the oil filter housing and was
removed with the old oil filter.
2. Install the filter (4) onto the oil filter base (1) until contact
is made with the sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn by hand.
4. Apply a new sealing ring on the oil temperature/pres-
sure sensor (2).
5. Install the sensor (2) onto the filter base (1) and secure
with the bolts (3). NHIL13ENG0679AA 1
6. Torque the bolts to 5 - 7 N·m (3.7 - 5.2 lb ft).
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Engine oil pump Gear driven - Remove

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

2. Remove the oil pump (2) from the engine block.
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Engine oil pump Gear driven - Install

Prior operation:
Engine oil pump Gear driven - Remove (10.304)
1. Install the oil pump (2) onto the engine block.

2. Torque the bolts (1) in two stages:
• Stage 1: 7 - 9 N·m (62 - 80 lb in)
• Stage 2: 20 - 28 N·m (15 - 21 lb ft)
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Engine oil pump - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
Prior operation:
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1. Remove the bolts (3) from the cover (2).

NOTE: Take note of the bolt locations as they are different
lengths.
2. Remove the four bolts (1) from underneath the cover
(2).
3. Remove the oil pump assembly (2) from the crankcase.
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Engine oil pump - Install

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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1. Install a new oil pump gasket (1) onto the dowels in the
crankcase.
NHIL13ENG0683AA 1
2. Install the oil pump assembly onto the crankcase.

NOTICE: Ensure that the housing is fully seated on the
locating dowels before tightening the bolts.
NHIL13ENG0684AA 2
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Crankcase ventilation 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.
93110964 1
5. 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.
93110965 2
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Crankcase ventilation 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).
93110965 1
3. Install the retaining nut (4) on the top side of the valve
cover.
93110964 2
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Crankcase ventilation system Filter - Remove - External

1. Remove the bolts (1).
2. Remove the tube (2).
3. Remove the blow-by recirculation system filter (3).
NHVM14ENG0180AA 1
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Crankcase ventilation system Filter - Install - External

1. Install the blow-by recirculation filter (3).
2. Install the tube (2).
3. Torque the bolts to their prescribed torque.
NHVM14ENG0180AA 1
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Oil pressure valve - Remove

1. Remove the plug (1) from the top of the oil filter housing.
2. Remove the spring (2) and plunger (3).
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Oil pressure valve - Install

1. Lubricate the plunger (3) with clean engine oil.
2. Install the plunger and spring (2) into the oil filter hous-
ing.
3. Lubricated the plug threads and O-ring with clean en-
gine oil and Install the plug (1).
4. Torque the plug to 80 N·m (59 lb ft).
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Piston cooling Spray nozzle - Remove

1. Remove the main half bearings (1) to avoid damaging
them.
2. Remove the bolts (2) and remove the oil nozzles (3).
NHIL13ENG0685AA 1
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Piston cooling Spray nozzle - Install

Prior operation:
Piston cooling Spray nozzle - Remove (10.304)
1. Install the nozzles (1) and torque the bolts (2) to 8 -

12 N·m (71 - 106 lb in).
CRIL04J066A01 1
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Index
Engine - 10

Crankcase ventilation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankcase ventilation system - Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankcase ventilation system - Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankcase ventilation system Filter - Install - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crankcase ventilation system Filter - Remove - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine lubrication system - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine lubrication system - Install - Oil fill tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine lubrication system - Remove - Oil fill tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine lubrication system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine oil pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine oil pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil pressure valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Oil pressure valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Engine - 10
Oil cooler and lines - 408

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Contents
Engine - 10
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. Remove the mounting bolts (3).

2. Remove the oil filter base (1), oil cooler (2), and all of
the gaskets.
NHIL13ENG0686AA 1
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Engine - Oil cooler and lines
Engine oil cooler - Install

Prior operation:
Engine oil cooler - Remove (10.408)
NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.
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).
ft).
NHIL13ENG0687AA 1
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Index
Engine - 10

Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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CNH Industrial America New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States
17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2016 CNH Industrial America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
48076871 15/11/2016
EN
SERVICE MANUAL
Electrical systems

F4HFE613Z*B002
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55
Contents
Electrical systems - 55
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
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CONSUMABLES INDEX

(DEF)/AdBlue®
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Engine control system - 015

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Contents
FUNCTIONAL DATA
Engine Control Unit (ECU)

Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine speed/RPM sensor
Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine timing sensors
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
View - Snapshot Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
View - Recording engine parameters while operating machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine wiring harness
Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine speed/RPM sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine timing sensors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine crankcase pressure sensor
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Electrical systems - Engine control system
Engine Control Unit (ECU) - Component identification
NHVM14ENG2264AA 1
(1) Fuel inlet (3) Engine connector

(2) Vehicle connector (4) Fuel outlet
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The ECU is integrated with a cooling circuit.
There are two connectors located on the ECU. Both connections have ninety six pin connectors.
The ECU is programmed using the Electronic Service Tool (EST) software, and not the EASY Engine program.
The software that programs the controller uses an anti-tampering procedure. This will automatically be preformed
after programming by the EST without technician involvement.
This will make sure that only released engine software is installed in appropriate vehicle models to prevent engine
software tampering.
The engine controller contains a software algorithm that will calculate a security check value which is read by the
vehicle controller, and validated a few minutes after engine start up.
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Engine speed/RPM sensor Camshaft - Overview
NHIL13ENG0640AA 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 not interchangeable because of the different exter-
nal shape.
The sensor impedance is ~900 Ω.
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Engine timing sensors Crankshaft sensor - Overview
NHIL13ENG0641AA 1
The crankshaft sensor is an inductive type sensor that is located on the front of the engine.
The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone
wheel installed on the crankshaft. The same signal is utilized to control the eventual electronic engine speed indicator
placed on the vehicle instrument board.
The resistance value of the sensor is about 900 Ω.
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Engine Control Unit (ECU) - Remove

Prior operation:
Fuel supply lines Low pressure - Disconnect (10.210)
1. Disconnect the main wiring harness (1) from the Elec-

tronic Control Unit (ECU).
2. Disconnect the low pressure fuel lines that are attached
to the ECU cooling plate.
3. Remove the three mounting bolts (2) that secure the
ECU and the cooling plate to the engine block.
4. Remove the ECU and cooling plate as one unit.
NHIL13ENG1411AA 1
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Engine Control Unit (ECU) - Install

Prior operation:
Engine Control Unit (ECU) - Remove (55.015)
1. Install the Engine Control Unit (ECU) and cooling plate

on the side of the engine block.
2. Install the retaining bolts (2) and rubber isolators.
NOTE: If the rubber isolators are cracked or excessively
deformed, replace them before installation.
3. Torque the bolts to 8 - 12 N·m (71 - 106 lb in).
4. Connect the main wiring harness (1) to the ECU.
NHIL13ENG1411AA 1
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Engine Control Unit (ECU) - View - Snapshot Data Collection

1. Connect the Electronic Service Tool (EST) to a diag-
nostic port on your machine.
2. Click the “Additional tools” button (1).
NHPH14ENG0006AA 1
3. Start the Easy Engine software.
NHIL15ENG0222AA 2
4. Under “Diagnosis” (1), click “Parameters Reading” (2).
NHIL15ENG0223AA 3
5. Then click on the double arrow icon .
NOTE: The selection may be on page 2.
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6. Ignition Key “on” then click the check mark (1).
NHIL15GEN0016AA 4
7. When the engine is running, click the folder icon
to capture all of the monitored data at that

moment in time.
8. Click the printer icon to generate the report.

9. Select “Microsoft XPS Document Writer”.
10. Click “Print” to generate the .xps file.
11. Name the file. Select the desired location, and click
“Save”.
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Engine Control Unit (ECU) - View - Recording engine parameters

while operating machine
1. Connect the Electronic Service Tool (EST) to a diag-
nostic port on your machine.
2. Click the “Additional tools” button (1).
NHPH14ENG0006AA 1
3. Start the Easy Engine software.
NHIL15ENG0222AA 2
4. Under “Diagnosis” (1), click “Parameters Reading” (2).
NHIL15ENG0223AA 3
5. Then click on the double arrow icon .
NOTE: The selection may be on page 2.
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6. Ignition Key “on” then click the check mark (1).
NHIL15GEN0016AA 4
7. Click on “Groups”.
NHIL15GEN0017AA 5
8. Click on “Create” to build a custom list of engine oper-

ating parameters to view.
NHIL15GEN0018AA 6
9. Enter a name (1) for the custom list, then click check
mark (2).
NHIL15GEN0019AA 7
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10. Select each desired parameter (1).

• Use arrow (2) to add the parameter to your new list.
• Use arrow (3) to delete the parameter from your
new list.
• Use arrows (4) to move a parameter up or down in
the list.
11. Click “Save” (5), then click X (6) to close this screen.
NHIL15GEN0020AA 8
12. Locate, and highlight your custom group (1) in the list.
NOTE: The created group may be on another page. Use
the “<” and “>” arrows (2) to change pages.
13. Click “Select” (3). Your selected parameters will ap-
pear.
NHIL15GEN0021AA 9
14. Click “Parameter Acquisition” (1).
NHIL15GEN0022AA 10
15. Create a name (1) for the report, then click the check
mark (2).
NHIL15GEN0023AA 11
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16. The “Settings” window will appear. Use the “+” (2) and
“-” (1) buttons to set the desired duration and sampling
rate.
• Duration (4) – The total amount of time you want to
record your selected parameters.
• Sampling (5) – The amount of time between each
log of the parameters during the set duration.
17. Click (3) to start sampling.
NHIL15GEN0024AA 12
NOTE: A blue status bar (2) under the icons in the Settings
window will indicate that the parameters are being logged.
Recording can be stopped at any time during the selected
duration by clicking the stop button (1).
NHIL15GEN0025AA 13
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18. Once the status bar reaches the end, and the record-
ing is stopped, the flag (1) re-appears.
• Click the icon (2) to view the results of your record-
ing as a graph.
NHIL15GEN0026AA 14
19. Click the icon (1) to generate the report of the data in
the graph.
NHIL15GEN0027AA 15
20. Click the icon (1) and select the desired file format.
NOTE: PDF format is preferred.
NHIL15GEN0028AA 16
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21. Name the file (1), select the desired location, and click
“Save” (2).
22. Click X (3) to close the graph and continue recording
data as needed.
NHIL15GEN0029AA 17
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Engine wiring harness - Disconnect

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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NHIL13ENG0508AA 1
(1) Connections for electro-injectors (5) Fuel temperature sensor (9) Oil pressure/temperature sensor
(2) Electro-injector (6) Pressure regulating gauge (10) Fuel pressure sensor
(3) Air pressure/temperature sensor (7) EDC17 CV41 (11) Coolant temperature sensor
(4) Timing system sensor (8) Driving shaft sensor
1. Disconnect the engine cable from the following connec-

tors:
• Electro-injector connector (1)
• Air pressure/temperature sensor (3)
• Fuel pressure sensor (10)
• Engine control module (7)
• High pressure pump sensor (6)
• Timing system sensor (4)
• Coolant temperature sensor (11)
• Driving shaft sensor (8)
2. Remove the engine wire harness from the engine block
by removing the holding clamps.
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Engine wiring harness - Disconnect
HARNESS 1
(1) Coolant temperature sensor (5) Timing sensor (9) Crankshaft speed sensor
(2) Fuel pressure Sensor (6) Fuel pressure regulator (10) Engine oil temperature sensor
(3) Electro-injector (7) Fuel temperature sensor (11) Connectors for electro-injectors
(4) Air pressure/temperature sensor (8) EDC17 CV41
1. Disconnect the engines cable from the following con-

nectors:
• Electro-injectors connector (11)
• Air pressure/Temperature sensor (4)
• Fuel Pressure Sensor (2)
• Engine Control Unit (ECU) (8)
• Timing sensor (5)
• Crankshaft speed sensor (9)
2. Remove the engine wire harness from the engine block
by removing the holding clamps.
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Engine wiring harness - Connect

Prior operation:
Engine wiring harness - Disconnect (55.015)
NHIL13ENG0508AA 1
(1) Connections for electro-injectors (5) Fuel temperature sensor (9) Oil pressure/temperature sensor
(2) Electro-injector (6) Pressure regulating gauge (10) Fuel pressure sensor
(3) Air pressure/temperature sensor (7) EDC17 CV41 (11) Coolant temperature sensor
(4) Timing system sensor (8) Driving shaft sensor
1. Reconnect the engine wiring harness to all the sensors,

the engine control module and the common rail.
2. Connect the engines cable from the connectors (1) to
the following points:
• Electro-injectors (2)
• Air pressure/Temperature sensor (3)
• Fuel pressure sensor (10)
• Engine Control Unit (ECU) (7)
• High pressure pump sensor (6)
• Timing system sensor (4)
• Driving shaft sensor (8)
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Engine speed/RPM sensor - Remove

1. Remove the speed sensor retaining bolt (2).
2. Remove the speed sensor (3) from the front cover (1).
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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. Torque the bolt (2) to 6 - 10 N·m (53 - 89 lb in).
NHIL13ENG0644AA 1
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Engine timing sensors - Remove

1. Remove the mounting nut (1) and slide the timing sen-
sor (2) out of the housing.
NHIL13ENG1358AA 1
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Engine timing sensors - Install

Prior operation:
Engine timing sensors - Remove (55.015)
1. Install a new O-ring on the timing sensor (2).

2. Slide the sensor over the mounting stud and install the
nut (1).
3. Torque the nut (1) to 5.0 - 7.0 N·m (3.7 - 5.2 lb ft).
NHIL13ENG1358AA 1
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Engine crankcase pressure sensor - Configure - Reset ECU data

NHPH14ENG0006AA 1
3. Select “Replacement of the Crank Case Pressure Sen-

sor – Reset ECU Data” (1).
NHPH15ENG0285AA 2
NHPH15ENG0287AA 3
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Index

Engine Control Unit (ECU) - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine Control Unit (ECU) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Control Unit (ECU) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Control Unit (ECU) - View - Recording engine parameters while operating machine . . . . . . 11
Engine Control Unit (ECU) - View - Snapshot Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine crankcase pressure sensor - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine speed/RPM sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine timing sensors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine timing sensors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine wiring harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine wiring harness - Disconnect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine starting system - 201

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F4HFE613Z*B002
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Contents
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).
3. Remove the starter (2).
NHIL13ENG0645AA 1
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Electrical systems - Engine starting system
Engine starter - Install

Prior operation:
Engine starter - Remove (55.201)
NOTE: Before any assembly operation verify that the hole and bolt threads have no evidence of wear or dirt.
1. Install the starter (2) on the flywheel housing (1) and
secure with the three mounting bolts (3).
NHIL13ENG0645AA 1
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Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Alternator - 301

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F4HFE613Z*B002
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Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Alternator
Alternator - Remove
1. Remove the cables from the back of the alternator.
2. Remove the retaining bolts (2) that secure the alterna-
tor (1) to the support.
3. Remove the alternator (1).
NHIL13ENG0647AA 1
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Electrical systems - Alternator
Alternator - Install
Prior operation:
Alternator - Remove (55.301)
1. Install the alternator (1) and secure the bolts (2).

2. Torque the bolts (2) to 37.0 - 49.0 N·m (27.3 - 36.1 lb
ft).
3. Connect the positive and negative cables onto the back
of the alternator.
NHIL13ENG0647AA 1
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cold start aid - 202

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Contents
TECHNICAL DATA
Grid heater
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grid heater module
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Grid heater
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Cold start aid
Grid heater - Technical Data

WARNING
Explosion hazard!
DO NOT use ether starting fluid. Serious engine damage, explosion, death, or serious personal injury
could occur.
W0148A
NHIL13ENG0652AA 1
Specifications
Voltage 12 V
Ground Isolated
Resistance 0.5 Ω
Grid heater activation depends on the lowest reported temperature from the following sensors:
• Fuel temperature sensor
• Oil temperature sensor
• Coolant temperature sensor
The Engine Control Unit (ECU) determines how long to activate the grid heater according to the table below.
Working conditions
Temperature -30.04 °C -25.04 °C -20.04 °C -15.04 °C -7.04 °C -3.14 °C -3.04 °C
(-22.07 °F) (-13.07 °F) (-4.07 °F) (4.93 °F) (19.33 °F) (26.35 °F) (26.53 °F)
Pre-heating 30 s 30 s 20 s 16 s 12 s 8s 0s
Post-heating 120 s 120 s 120 s 90 s 60 s 30 s 0s
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Grid heater module - Technical Data

The grid heater module, or relay, controls activation/deactivation of the grid heater.
Specifications
Manufacturer TYCO
Voltage 12 V
Continuous current @ 85 °C (185 °F) 150 A
Maximum switching voltage 60 V
Working temperature range -40 - 125 °C (-40 - 257 °F)
Power consumption 3.3 W
Coil resistance 15 Ω
See Grid heater - Technical Data (55.202) for additional details about grid heater operation.
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Grid heater - Remove

1. Remove the six retaining bolts (1) from the grid heater
(2).
2. Remove the grid heater and gasket from the intake
manifold (3).
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Grid heater - Install

1. Install a new gasket (2) on the grid heater (3).
2. Install the grid heater (3) into the intake manifold (1)
and secure with the retaining bolts (4).
3. Torque the retaining bolts to 6 - 10 N·m (4.4 - 7.4 lb ft).
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Index

Grid heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grid heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grid heater - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grid heater module - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Contents
TECHNICAL DATA
Fuel temperature sensor

FUNCTIONAL DATA
Fuel temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Injection control
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Injection control solenoids
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Water-In-Fuel sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Electrical systems - Fuel injection system
Fuel temperature sensor - General specification

Temperature Resistance (minimum) Resistance (maximum)
-40 °C (-40 °F) 40490 Ω 50136 Ω
-30 °C (-22 °F) 23580 Ω 28647 Ω
-20 °C (-4 °F) 14096 Ω 16827 Ω
-10 °C (14 °F) 8642 Ω 10152 Ω
0 °C (32 °F) 5466 Ω 6326 Ω
10 °C (50 °F) 3542 Ω 4043 Ω
20 °C (68 °F) 2351 Ω 2649 Ω
25 °C (77 °F) 1941 Ω 2173 Ω
30 °C (86 °F) 1615 Ω 1798 Ω
40 °C (104 °F) 1118 Ω 1231 Ω
50 °C (122 °F) 798 Ω 870 Ω
60 °C (140 °F) 573 Ω 618 Ω
70 °C (158 °F) 421 Ω 451 Ω
80 °C (176 °F) 313 Ω 332 Ω
90 °C (194 °F) 237 Ω 250 Ω
100 °C (212 °F) 182 Ω 191 Ω
110 °C (230 °F) 140 Ω 148 Ω
120 °C (248 °F) 109 Ω 116 Ω
130 °C (266 °F) 86 Ω 93 Ω
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Fuel temperature sensor - Overview
NHIL13ENG0654FA 1
(1) Fuel temperature sensor (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.
Settings:
• 80 °C (176 °F) - 304 - 342 Ω
• 20 °C (68 °F) - 2262 - 2760 Ω
• -10 °C (14 °F) - 8244 - 10661 Ω
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Fuel temperature sensor - Overview

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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NHIL13ENG0655FA 1
(1) Fuel temperature sensor
This sensor has a variable resistor able to detect the fuel temperature to provide the engine control module an index
of the fuel thermal status.
The resistor to 20 °C (68 °F) = 2.5 k Ω.
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Injection control - Dynamic description
NHIL13ENG1010FA 1
(1) High pressure pump (5) ECU

(2) Fuel filter (6) Fuel injector
(3) Fuel tank (7) Fuel rail
(4) Fuel pre-filter (8) Rail pressure sensor
Fuel metering unit

The fuel metering unit is an electronic Pulse Width Modulated (PWM) controlled solenoid located at the inlet of the
high pressure pump. It regulates the amount of fuel supplied to the high pressure system based on control signals
received from the Engine Control Unit (ECU) (by modulating the pulses sent to the internal solenoid). This is used to
control the pressure within the fuel rail. The fuel metering is normally open. If no signal is sent by the ECU, fuel flow
will be at maximum delivery. The resistance value for the fuel metering unit is between 2.8 - 3.2 Ω.
High pressure pump

The high pressure pump has 3 radial pistons controlled by the timing gear, without needing any setting. On the rear
side of the high pressure pump is a mechanical supply pump controlled by the high pressure pump shaft. The drive
gear and the pressure regulator are the only serviceable parts on the high pressure pump. The high pressure pump
delivers high pressure fuel to the fuel rail.
Common rail
The common rail provides high pressure fuel to the fuel injectors. The common rail has an internal volume sized to
quickly pressurize the fuel at start up, while having a sufficient volume to support full load fuelling rates. The volume in
the common rail is sufficient to allow the injectors to supply fuel to the cylinders under full load, while still maintaining a
stabile rail pressure, from fuel supplied by the high pressure pump. The PRV and fuel pressure sensor are integrated
within the common rail.
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Fuel injectors
Engine load and rpm are controlled by the fuel injectors. The load requested by the operator is controlled by throttle
position and converted into a fuel quantity by the ECU. The ECU controls the amount and timing of the fuel injection
(using current fuel rail pressure as a factor). If the engine is difficult to start (excessive cranking time and no fault
codes present), you may have fuel injector mechanical problems.
Pressure Relief Valve (PRV)

The Pressure Relief Valve (PRV) is located at rear end of the fuel rail. This PRV protects the fuel system components
from excessive pressure. The PRV is a mechanical value that will open in the event of excessive fuel rail pressure.
For example, if the fuel metering unit allows excessive pressure build in the system, the PRV will open. The ECU can
command this valve open by performing a pressure shock (a sudden increase in fuel pressure), if necessary.

A fuel pressure sensor is integrated into the common rail. It provides feedback to the ECU where the sensor values are
monitored. Rail pressure is changed as needed based on sensor feedback and other engine operating parameters.
Fuel filter / Pre- filter

The fuel filter filters fuel before the fuel is pressurized by the high pressure fuel pump. The pre-filter filters fuel between
the fuel tank and the ECU. Both of these filters are serviceable and should be serviced as necessary.

The ECU is cooled by fuel flow through the ECU. The ECU controls the fuel metering unit and monitors fuel pressure
using the rail pressure sensor.
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Fuel pressure sensor - Overview
NHIL13ENG0656AA 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 V.
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Fuel pressure sensor - Remove

1. Disconnect the electrical connection (1).
2. Remove the fuel pressure sensor from the common rail.
NHIL13ENG0593AA 1
Next operation:
Fuel pressure sensor - Install (55.010)
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Fuel pressure sensor - Install

Prior operation:
Fuel pressure sensor - Remove (55.010)
1. Install the fuel pressure sensor (1) into the end of the
common rail.
2. Torque the sensor to 30 - 35 N·m (22 - 26 lb ft).
3. Connect the electrical connection.
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Injection control solenoids - Remove

1. Disconnect the electrical connection (1) from the high
pressure pump metering unit.
2. Remove the three mounting bolts from the high pres-
sure pump metering unit (2).
NHIL13ENG1347AA 1
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Injection control solenoids - Install

Prior operation:
Injection control solenoids - Remove (55.010)
1. Install the high pressure pump metering unit (2).

2. Torque the mounting bolts to 8.0 N·m (5.9 lb ft) .
3. Connect the electrical connection (1).
NHIL13ENG1347AA 1
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Water-In-Fuel sensor - Remove

1. Disconnect the wiring harness from the sensor (1).
2. Loosen the sensor from the filter.
NHIL13ENG0499AA 1
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Water-In-Fuel sensor - Install

1. Thread the sensor (1) into the filter.
2. Tighten to 1.6 N·m (1.2 lb ft).
3. Connect the wiring harness to the sensor.
NHIL13ENG0499AA 1
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Index

Fuel pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel temperature sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel temperature sensor - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Injection control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Injection control solenoids - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Injection control solenoids - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water-In-Fuel sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Water-In-Fuel sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Engine intake and exhaust system - 014

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F4HFE613Z*B002
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Contents
TECHNICAL DATA
Intake air pressure and temperature sensor

Exhaust flap actuator
FUNCTIONAL DATA

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust flap actuator
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Electrical systems - Engine intake and exhaust system
Intake air pressure and temperature sensor - General specification

Pin Description
1 Ground
2 Temperature signal
3 5 V Supply
4 Pressure signal
Pressure Volts
6.9 bar (100 psi) 0.400 V
79.3 bar (1150 psi) 4.650 V
Temperature Ohms
-40 °C (-40 °F) 45303 Ω
-30 °C (-22 °F) 26108 Ω
-20 °C (-4 °F) 15458 Ω
-10 °C (14 °F) 9395 Ω
-5 °C (23 °F) 7413 Ω
0 °C (32 °F) 5895 Ω
5 °C (41 °F) 4711 Ω
10 °C (50 °F) 3791 Ω
15 °C (59 °F) 3068 Ω
20 °C (68 °F) 2499 Ω
25 °C (77 °F) 2056 Ω
30 °C (86 °F) 1706 Ω
35 °C (95 °F) 1411 Ω
40 °C (104 °F) 1174 Ω
50 °C (122 °F) 833.8 Ω
60 °C (140 °F) 595.4 Ω
70 °C (158 °F) 435.6 Ω
80 °C (176 °F) 322.5 Ω
90 °C (194 °F) 243.1 Ω
100 °C (212 °F) 186.6 Ω
110 °C (230 °F) 144.2 Ω
120 °C (248 °F) 112.7 Ω
130 °C (266 °F) 89.28 Ω
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Exhaust flap actuator - General specification

Pin Description
1 + Battery
2 Ground
3 Open
4 CAN Low
5 CAN High
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Intake air pressure and temperature sensor - Overview
NHIL13ENG0658AA 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 power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.
Reference Description
1 Ground
2 NTC signal (temperature)
3 +5 V power input
4 Signal (pressure)
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Exhaust flap actuator - Overview
NHIL13ENG1364AA 1
The exhaust flap is an electrically controlled throttling valve located in the exhaust plumbing at the outlet of the tur-
bocharger. This valve is opened or closed by the Engine Control Unit (ECU) based upon the temperature in the
exhaust stream at the Diesel Oxidation Catalyst (DOC) and the Selective Catalytic Reduction (SCR). Data between
the exhaust flap and the ECU is transmitted via the engine Controller Area Network (CAN) data bus.
• The exhaust flap helps the SCR to reach optimal temperature as quickly as possible by increasing the exhaust gas
back pressure, and consequently exhaust gas temperature.
• The exhaust flap restricts the exhaust flow, and places a load on the engine. The load causes the engine to inject
more fuel to maintain desired rpm. The result will elevate exhaust temperatures, and will maintain proper exhaust
temperature for NOx reduction.
• Engine coolant helps to cool the exhaust flap.
• If a fault occurs, it will broadcast it on the CAN bus to the ECU. Internal faults cannot be repaired.
• The flap can be tested mechanically by moving the flap by hand, and listening for a metallic sound when deadhead-
ing in closed position.
• Upon start up, the flap will cycle to a fully closed position, back to a fully open position and then to a 5.0 % closed
position.
For general specification see Exhaust flap actuator - General specification (55.014).
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Intake air pressure and temperature sensor - Remove

2. Remove the retaining bolt (2).
3. Remove the sensor (1) and the O-ring seal.
NHIL13ENG0658AA 1
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Intake air pressure and temperature sensor - Inspect

1. Inspect the O-ring for signs of wear or damage. Re-
place the O-ring if damage is present.
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Intake air pressure and temperature sensor - Install

1. Install the sensor (1) into the intake manifold.
2. Install the retaining bolt (2) and torque to 5.0 - 7.0 N·m
(3.7 - 5.2 lb ft).
NHIL13ENG0658AA 1
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Index

Exhaust flap actuator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust flap actuator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake air pressure and temperature sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake air pressure and temperature sensor - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Intake air pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Selective Catalytic Reduction (SCR) electrical system - 988

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F4HFE613Z*B002
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Contents
TECHNICAL DATA
Selective Catalytic Reduction (SCR) humidity sensor

Selective Catalytic Reduction (SCR) temperature sensors
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor
Ammonia (NH3) sensor
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) humidity sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selective Catalytic Reduction (SCR) temperature sensors
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diesel Exhaust Fluid (DEF)/AdBlue® supply module
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nitrogen Oxide (NOx) sensor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ammonia (NH3) sensor
SERVICE
Diesel Exhaust Fluid (DEF)/AdBlue® supply module

Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Filter - Install - Supply module filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Nitrogen Oxide (NOx) sensor
Configure - Reset ECU data (Upstream sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Configure - Reset ECU data (Downstream sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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CONSUMABLES INDEX

(DEF)/AdBlue®
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Electrical systems - Selective Catalytic Reduction (SCR) electrical system
Selective Catalytic Reduction (SCR) humidity sensor - General

specification
NHIL13ENG1362AA 1
(1) +5 V (2) x % Relative Humidity (RH) (3) Ground (4) Temperature
Characteristics of the humidity sensor

Voltage supply 4.75 - 5.25 V
Current consumption Max 10 mA
Humidity operating range 0 - 100 % RH
Temperature operating range -40.0 - 105 °C (-40.0 - 221 °F)
Output voltage range (humidity) See voltage output table below
Output impedance 70 Ω
Insulation resistance 1 MΩ @ 500 V
Time constant ( 33 - 76 % RH) Typically 10 s
Characteristics of the temperature sensor

Temperature operating range -40.0 - 105 °C (-40.0 - 221 °F)
Resistance @ 25 °C (77 °F) 2.186 kΩ +/- 66 Ω
Maximum power @ 25 °C (77 °F) 0.1 W
Storage temperature range -40 - 125 °C (-40 - 257 °F)
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Voltage output
Relative humidity Minimum Nominal Maximum
10 % 1145 mV 1205 mV 1265 mV
15 % 1294 mV 1355 mV 1416 mV
20 % 1440 mV 1500 mV 1560 mV
25 % 1583 mV 1640 mV 1697 mV
30 % 1717 mV 1770 mV 1823 mV
35 % 1848 mV 1905 mV 1962 mV
40 % 1969 mV 2030 mV 2091 mV
45 % 2090 mV 2155 mV 2220 mV
50 % 2207 mV 2275 mV 2343 mV
55 % 2328 mV 2400 mV 2472 mV
60 % 2444 mV 2520 mV 2596 mV
65 % 2561 mV 2640 mV 2719 mV
70 % 2687 mV 2770 mV 2853 mV
75 % 2808 mV 2895 mV 2982 mV
80 % 2914 mV 3020 mV 3126 mV
85 % 3024 mV 3150 mV 3276 mV
90 % 3137 mV 3285 mV 3433 mV
95 % 3240 mV 3410 mV 3581 mV
Temperature dependent resistor (Ohms)

Temperature Minimum Nominal Maximum
-40.0 °C (-40.0 °F) 39714 Ω 42172 Ω 44742 Ω
-30 °C (-22 °F) 23441 Ω 24760 Ω 26129 Ω
-20 °C (-4 °F) 14268 Ω 14995 Ω 15745 Ω
-10 °C (14 °F) 8937 Ω 9348 Ω 9770 Ω
0 °C (32 °F) 5750 Ω 5988 Ω 6230 Ω
10 °C (50 °F) 3792 Ω 3933 Ω 4074 Ω
20 °C (68 °F) 2560 Ω 2644 Ω 2729 Ω
25 °C (77 °F) 2116 Ω 2186 Ω 2256 Ω
30 °C (86 °F) 1759 Ω 1817 Ω 1875 Ω
40 °C (104 °F) 1229 Ω 1274 Ω 1319 Ω
50 °C (122 °F) 875 Ω 910 Ω 946 Ω
60 °C (140 °F) 634 Ω 662 Ω 690 Ω
70 °C (158 °F) 467 Ω 489 Ω 511 Ω
80 °C (176 °F) 349 Ω 367 Ω 385 Ω
90 °C (194 °F) 265 Ω 279 Ω 293 Ω
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Selective Catalytic Reduction (SCR) temperature sensors - General

specification
Grey wire 5 V supply
White wire Ground
Operational current 2.9 - 4.2 mA
Pull-up voltage 5V
Temperature Straight sensor resistance 90 ° sensor resistance

-40 °C (-40 °F) 169.7 Ω 170.2 Ω
0 °C (32 °F) 200.5 Ω 201 Ω
25 °C (77 °F) 219.6 Ω 220.1 Ω
50 °C (122 °F) 238.5 Ω 239 Ω
100 °C (212 °F) 275.9 Ω 276.4 Ω
150 °C (302 °F) 312.7 Ω 313.2 Ω
200 °C (392 °F) 349 Ω 349.5 Ω
250 °C (482 °F) 384.6 Ω 385.1 Ω
300 °C (572 °F) 419.7 Ω 420.2 Ω
350 °C (662 °F) 454.2 Ω 454.7 Ω
400 °C (752 °F) 488.1 Ω 488.6 Ω
450 °C (842 °F) 521.4 Ω 521.9 Ω
500 °C (932 °F) 554.1 Ω 554.6 Ω
550 °C (1022 °F) 586.2 Ω 586.7 Ω
600 °C (1112 °F) 617.8 Ω 618.3 Ω
650 °C (1202 °F) 648.8 Ω 649.3 Ω
700 °C (1292 °F) 679.2 Ω 679.7 Ω
750 °C (1382 °F) 709 Ω 709.5 Ω
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - General

specification
Electric power requirements
12 V system 3700 mA @ 14 V battery voltage
24 V system 2750 mA @ 28 V battery voltage
Hydraulic capability
Normal circulation and no injection Average 8 kg/hr (18 lb/hr)
Maximum with the small urea injector Average 15 kg/hr (33 lb/hr) ( 8 kg/hr (18 lb/hr) + 7 kg/hr
(15 lb/hr))
Maximum with the large urea injector Average 20 kg/hr (44 lb/hr) ( 8 kg/hr (18 lb/hr) +
12 kg/hr (26 lb/hr))
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - General specification
Working temperatures -40 - 85 °C (-40 - 185 °F)
Maximum ratings
Voltage 48 V
Current 300 mA
Power 1.25 W
Negative Temperature Coefficient (NTC) 500 Ω
Temperature Resistance
-40 °C (-40 °F) 23342 Ω
-30 °C (-22 °F) 13018 Ω
-20 °C (-4 °F) 7569 Ω
-10 °C (14 °F) 4569 Ω
0 °C (32 °F) 2854 Ω
10 °C (50 °F) 1838 Ω
20 °C (68 °F) 1217 Ω
25 °C (77 °F) 1000 Ω
30 °C (86 °F) 826.70 Ω
40 °C (104 °F) 574.60 Ω
50 °C (122 °F) 407.40 Ω
60 °C (140 °F) 293.70 Ω
70 °C (158 °F) 214.90 Ω
80 °C (176 °F) 159.30 Ω
90 °C (194 °F) 119.40 Ω
100 °C (212 °F) 90.46 Ω
110 °C (230 °F) 69.16 Ω
120 °C (248 °F) 53.32 Ω
130 °C (266 °F) 41.44 Ω
140 °C (284 °F) 32.43 Ω
150 °C (302 °F) 25.56 Ω
NOTE: The level sensor specifications vary depending on the size of the DEF/AdBlue® tank.
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Ammonia (NH3) sensor - General specification
NHIL13ENG1361AA 1
Heater resistance at 21 °C (70 °F) 2.8 - 4.0 Ω

Heater control frequencies 100 - 600 Hz
Isolation between sensor circuit and housing at 21 °C 30 MΩ
(70 °F)
Isolation between heating element and sensor housing 30 MΩ
at 21 °C (70 °F)
Internal leak at 344.7 kPa (50.0 psi) measured at 21 °C 2.0 mL
(70 °F)
NH3 sensor side wire colors

Purple Heater (+)
White Heater (-)
Black EMF_2
Tan Trim resistor ground
Gray EMF_1
Yellow Trim resistor
Green Temperature cell (+)
Brown Signal ground
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Selective Catalytic Reduction (SCR) humidity sensor - Overview
NHIL13ENG1362AA 1
The intake air humidity sensor is located in the inlet air plumbing between the air filter and the turbocharger. The
sensor monitors the humidity, and temperature of incoming air. The incoming air humidity value is used to correct the
estimation of raw engine NOx production, in order to properly adjust Diesel Exhaust Fluid (DEF)/AdBlue® injection.
This sensor reports information to the ECU.
For general specification see Selective Catalytic Reduction (SCR) humidity sensor - General specification
(55.988).
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Selective Catalytic Reduction (SCR) temperature sensors -

Overview
NHIL13ENG1379AA 1
Diesel Oxidation Catalyst (DOC) inlet temperature sensor

The Diesel Oxidation Catalyst (DOC) inlet temperature sensor is located in the exhaust stream at the inlet to the DOC.
The temperature of the exhaust stream is critical to the function of the emission control system components. This
sensor reports the DOC inlet temperature to the Engine Control Unit (ECU).
Position the sensor in the exhaust pipe, as close as possible to the DOC inlet to meet the threshold; 5 °C (41 °F)
temperature drop under all operating conditions. Make sure there is no external injection of air/gas upstream or close
to the sensor.
Selective Catalyst Reduction (SCR) inlet sensor

The Selective Catalyst Reduction (SCR) inlet temperature sensor is located in the exhaust stream at the inlet to the
SCR. The temperature of the exhaust stream is critical to the function of the emission control system components.
This sensor reports the SCR inlet temperature to the ECU.
Selective Catalyst Reduction (SCR) outlet sensor

The SCR outlet temperature sensor is located in the exhaust stream at the outlet to the SCR. The temperature of the
exhaust stream is critical to the function of the emission control system components. This sensor reports the SCR
outlet temperature to the ECU.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Overview
NHIL14ENG0137HA 1
(1) Supply module main filter (5) DEF backflow to tank

(2) Electrical connection (6) Coolant connector
(3) DEF inlet to tank (7) DEF outlet to dosing module
(4) Coolant connector
The supply module integrates a pump, valves, sensors and a filter within an environmentally secure box. It’s
main function is to control the pressure and the amount of Diesel Exhaust Fluid (DEF)/AdBlue® that is injected
into the exhaust gases.
• A DEF fluid pump delivers fluid from the supply tank to the dosing injection module.
• A reversing valve returns flow from the system back to the DEF supply tank as the system is shutdown. The pump
may run up to 90 s after shutdown.
• The DEF fluid temperature sensor monitors the temperature at the supply module.
• The DEF fluid pressure sensor monitors the fluid pressure to the dosing module.
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• A main DEF filter removes finer contamination. Refer to the machine operators manual for the service interval and
procedure for this filter.
• A DEF fluid supply connector is connected to the supply line from the DEF tank. This connector is fitted with a filter
that is never expected to require service.
• A DEF fluid return connector is connected to the return line to the DEF tank. This connector is fitted with a filter that
is never expected to require service.
• A DEF fluid pressure supply connector is connected to the outlet line to the dosing module.
• An engine coolant supply connector supplies warmed engine coolant to thaw frozen DEF fluid in the supply module
when operating in freezing climates. Engine coolant only flows through this connector at freezing temperature to
prevent overheating of the DEF fluid. This coolant flow is controlled by the engine coolant control valve.
• An engine coolant return connector returns engine coolant required to thaw frozen DEF fluid in the supply module
when operating in freezing climates.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Sectional view
NHVM14ENG1266BA 1
(1) Revering valve (4) Pump

(2) Diesel Exhaust Fluid (DEF)/AdBlue® temperature (5) Electrical connector
sensor
(3) DEF/AdBlue® temperature sensor
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Nitrogen Oxide (NOx) sensor - Dynamic description
NHIL13ENG1382AA 1
The NOx sensor consists of two components, the sensor (2) in the exhaust stream, and also the controller (1) which
reports the data to the Engine Control Unit (ECU) via the engine Controller Area Network (CAN) data bus.
Once the Selective Catalytic Reduction (SCR) chamber is up to operating temperature 240.0 °C (464.0 °F), Diesel
Exhaust Fluid (DEF)/AdBlue® can be injected into the system per engine calculations (open loop).
After approximately 6 - 15 min (if catalyst and engine temperature is reached and maintained), the NOx sensors will
come online, and DEF/AdBlue® will be injected based on the sensors readings (closed loop).
The time delay (Dew point) is needed to ensure no moisture is on the sensing tips of the sensors which could
damage them upon initial startup.
• The Upstream NOx sensor will appear online before the Downstream due to its position.
• The NH3 sensor will appear online immediately after the Downstream NOx sensor appears.
• If viewing the “Dew Point” parameter of the sensors, it will read “not ready” until the moisture is wicked off the tip
of the sensor. Then it will read “Ready”.
• When turning the key switch ON then OFF then ON, the dew point (warm up cycle) begins again. The NOx sensors
may return to a “Ready” status quicker than previously depending upon engine shut down time, engine coolant,
and catalyst temperature.
Upstream NOx sensor

The upstream NOx sensor is located before the Diesel Oxidation Catalyst (DOC). This measures the level of pollutants
coming directly from the engine. It also senses any raw, unburned fuel coming from the combustion chambers.
Downstream NOx sensor

The downstream NOx sensor is located directly after the Selective Catalytic Reduction (SCR). This sensor measures
the pollutants making it through the Diesel Oxidation Catalyst (DOC) and SCR and out of the tailpipe. The data from
this sensor is compared to that of the upstream sensor. If the data between the two sensors becomes more similar,
the vehicle's computer may trigger a catalyst inefficiency code, which turns on a warning light.
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Overview
NHIL13ENG1381AA 1
(1) DEF/AdBlue® connection (4) Cooling adapter

(2) Coolant connections (5) Electrical connector
(3) Heat shield
The dosing module injector is mounted in the exhaust stream near the outlet of the Diesel Oxidation Catalyst
(DOC). The dosing module injector injects a metered amount of Diesel Exhaust Fluid (DEF)/AdBlue® to reduce
NOx levels. It consists of the following components:
• The dosing valve regulates the delivery of DEF/AdBlue® fluid to the exhaust stream. The Engine Control Unit (ECU)
controls this electric solenoid type valve.
• The dosing injection module is cooled by engine coolant circulating through the valve. Hot DEF/AdBlue® fluid can
cause deposits to build up causing blockages in the system.
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Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature

sensor - Overview
NHIL13ENG1380EA 1
(1) Level and temperature sensor connection (4) Level sensor

(2) Coolant heater coil connections (5) Temperature sensor
(3) Diesel Exhaust Fluid (DEF)/AdBlue® suction and (6) Coolant heater coil
return connections
The temperature of the DEF/AdBlue® fluid is important to the Selective Catalytic Reduction (SCR) control system.
The fluid freezes at -11 °C (12 °F). It also degrades at elevated temperatures.
If the fluid is not injected or if it has been contaminated reduced engine power results. A level sensor is installed in the
tank, and the instrument cluster screen displays that fluid level. These sensors report the tank level and temperature
signals to the Engine Control Unit (ECU).
As the float raises and lowers, it will OPEN/Close the switch for each resistor, changing the resistance from the supply
to the return connections. If the fluid level is low, a message will be displayed to the operator, and or reduce engine
power.
The temperature sensor helps determine when the defrosting cycle becomes activated for heating the frozen fluid. If
the fluid temperature is low, the coolant control valve is activated to thaw the fluid.
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Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor - Overview
NHIL13ENG1383AA 1
The quality of the Diesel Exhaust Fluid (DEF)/AdBlue® fluid is important to the proper function of the Selective Cat-
alytic Reduction (SCR) system. The quality sensor monitors the quality of the fluid and reports this information to the
Engine Control Unit (ECU) via the engine CAN data bus. The quality sensor is mounted to the bottom of the tank.
The sensor has two small sensing holes. The fluid enters one hole, and exits the other hole.
• By using two measuring modes, liquids that have similar heat conductivity can be distinguished.
• Measurements are taken approximately every twenty seconds.
If diesel is accidently put into the DEF/AdBlue® tank, the sensor will detect bad concentration, once the diesel that is
floating in the tank gets to the level of the quality sensor. If diesel enters the quality sensor, then the sensor must be
replaced.
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Ammonia (NH3) sensor - Dynamic description
NHVM14ENG1265AA 1
(1) Sensor (3) NH3 sensor controller

(2) Vehicle connection (4) Sensor connection
The Selective Catalytic Reduction (SCR) outlet NH3 sensor is located in the exhaust stream at the outlet of the SCR.
The NH3 sensor measures the amount of ammonia (NH3) within the exhaust flow after the SCR catalytic reaction.
This NH3 sensor consists of two components, the sensor in the exhaust stream and also the processor which reports
the data to the Engine Control Unit (ECU) via the engine Controller Area Network (CAN) data bus.
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove

1. Remove the filter cover with a 27 mm 12-point socket
wrench.
RAIL13GEN0034AA 1
2. Remove and discard the equalizing element.
RAIL13GEN0027AA 2
3. Remove the filter tool from the new filter element pack-
age. Based on the color of your filter element, insert
the correct end of the filter tool into the filter element.
RAIL13GEN0028AA 3
4. Insert the tool completely until a click is felt indicating

the tool is fully inserted.
RAIL13GEN0029AA 4
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5. Pull the tool with filter element out of the supply module.
RAIL13GEN0030AA 5
6. Clean the supply module filter housing and threads with

distilled water.
RAIL13GEN0031AA 6
Next operation:
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install - Supply module filter (55.988)
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Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install -

Supply module filter
Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove (55.988)
1. Oil the O-rings on the new filter element. Insert the filter
element fully into the supply module.
RAIL13GEN0032AA 1
2. Install the new equalizing element.
RAIL13GEN0027AA 2
3. Install the filter cover and torque to 20 - 25 N·m (15 -

18 lb ft).
RAIL13GEN0026AA 3
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Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data

(Upstream sensor)
NHPH14ENG0006AA 1
3. Select “Replacement of the Nox Upstream Sensor –

Reset ECU Data” (1).
NHPH14ENG0016AA 2
NHPH14ENG0017AA 3
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Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data

(Downstream sensor)
NHPH14ENG0006AA 1
3. Select “Replacement of the Nox Downstream Sensor –

Reset ECU Data” (1).
NHPH14ENG0014AA 2
NHPH14ENG0015AA 3
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Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Configure -

Reset ECU data
NHPH14ENG0006AA 1
3. Select “Replacement of the SCR Dosing Module – Re-

set ECU Data” (1).
NHPH15ENG0286AA 2
NHPH15ENG0288AA 3
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Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor - Cleaning

1. Unclip the locking tabs (1) on both sides of the DIESEL
EXHAUST FLUID (DEF)/ADBLUE® quality sensor cover.
NHIL15ENG0138AA 1
2. Soak the DEF/ADBLUE® quality sensor in warm water

to remove any deposits.
NHIL15ENG0140AA 2
3. Install the DEF/ADBLUE® quality sensor cover (1).
NHIL15ENG0138AA 3
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Index

Ammonia (NH3) sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ammonia (NH3) sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Configure - Reset ECU data . . . . . . . . . . . . . 26
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - General specification . . . . . . . . . . . . . . . . . . . 8
Diesel Exhaust Fluid (DEF)/AdBlue® dosing module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diesel Exhaust Fluid (DEF)/AdBlue® quality sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diesel Exhaust Fluid (DEF)/AdBlue® supply module - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Install - Supply module filter . . . . . . . . 23
Diesel Exhaust Fluid (DEF)/AdBlue® supply module Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - General specification . . 9
Diesel Exhaust Fluid (DEF)/AdBlue® tank level and temperature sensor - Overview . . . . . . . . . . . . 18
Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) . . . . . . . . . . . . . . 25
Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor) . . . . . . . . . . . . . . . . 24
Nitrogen Oxide (NOx) sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selective Catalytic Reduction (SCR) humidity sensor - General specification . . . . . . . . . . . . . . . . . . . 5
Selective Catalytic Reduction (SCR) humidity sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selective Catalytic Reduction (SCR) temperature sensors - General specification . . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) temperature sensors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Contents
TECHNICAL DATA
Engine coolant temperature sensor

FUNCTIONAL DATA

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Engine cooling system
Engine coolant temperature sensor - General specification

Temperature Resistance (minimum) Resistance (maximum)
-40 °C (-40 °F) 40490 Ω 50136 Ω
-30 °C (-22 °F) 23580 Ω 28647 Ω
-20 °C (-4 °F) 14096 Ω 16827 Ω
-10 °C (14 °F) 8642 Ω 10152 Ω
0 °C (32 °F) 5466 Ω 6326 Ω
10 °C (50 °F) 3542 Ω 4043 Ω
20 °C (68 °F) 2351 Ω 2649 Ω
25 °C (77 °F) 1941 Ω 2173 Ω
30 °C (86 °F) 1615 Ω 1798 Ω
40 °C (104 °F) 1118 Ω 1231 Ω
50 °C (122 °F) 798 Ω 870 Ω
60 °C (140 °F) 573 Ω 618 Ω
70 °C (158 °F) 421 Ω 451 Ω
80 °C (176 °F) 313 Ω 332 Ω
90 °C (194 °F) 237 Ω 250 Ω
100 °C (212 °F) 182 Ω 191 Ω
110 °C (230 °F) 140 Ω 148 Ω
120 °C (248 °F) 109 Ω 116 Ω
130 °C (266 °F) 86 Ω 93 Ω
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Engine coolant temperature sensor - Overview
NHIL13ENG0659AA 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.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.
1 Ground
2 Temperature signal
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Engine coolant temperature sensor - Remove

1. Disconnect the electrical connector (1) from the coolant
temperature sensor.
NHIL13ENG1408AA 1
2. Remove the coolant temperature sensor from the cylin-

der head.
Next operation:
Engine coolant temperature sensor - Install (55.012)
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Engine coolant temperature sensor - Install

Prior operation:
Engine coolant temperature sensor - Remove (55.012)
1. Install the coolant temperature sensor into the cylinder

head.
2. Torque the coolant temperature sensor to 24 N·m
(18 lb ft).
3. Connect the electrical connector (1) to the coolant tem-
perature sensor.
NHIL13ENG1408AA 1
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Index

Engine coolant temperature sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine coolant temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine coolant temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine oil system - 013

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Contents
FUNCTIONAL DATA
Engine oil pressure and temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine oil pressure and temperature sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Electrical systems - Engine oil system
Engine oil pressure and temperature sensor - Overview
NHIL13ENG0662AA 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.
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.
1 Ground
2 NTC signal (temperature)
3 +5 V power input
4 Signal (pressure)
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Engine oil pressure and temperature sensor - Remove

2. Remove the mounting bolts (2), the sensor (1), and the
O-ring seal from the oil filter base.
NHIL13ENG0663AA 1
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Engine oil pressure and temperature sensor - Install

1. Install a new O-ring on the oil temperature/pressure
sensor (1).
2. Install the sensor (1) on the oil filter base (3) and secure
with the mounting bolts (2).
3. Torque the mounting bolts (2) to 5.0 - 7.0 N·m (3.7 -
5.2 lb ft).
4. Connect the electrical connection.
NHIL13ENG0663AA 1
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Engine oil pressure and temperature sensor - Remove

F4DFE4131*B001
F4DFE4131*B002
F4DFE4131*B007
F4DFE4131*B008
F4DFE4132*B001
F4DFE4132*B002
F4DFE4132*B005
F4DFE4132*B006
F4DFE4133*B001
F4DFE4133*B002
F4DFE4133*B007
F4DFE4133*B008
F4DFE4134*B001
F4DFE4134*B002
F4DFE4134*B005
F4DFE4134*B006
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE414B*B001
F4DFE414C*B001
F4DFE414D*B001
F4DFE414E*B001
F4DFE6132*B001
F4DFE6132*B007
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
F4DFE617L*B002
F4DFE617M*B001
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1. Disconnect the electrical connector (1) from the oil tem-

perature pressure sensor (3).
2. Remove the mounting bolts (2) securing the sensor to
the oil filter base (4) and remove it from its seat.
NHIL13ENG0664AA 1
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Engine oil pressure and temperature sensor - Install

1. Install a new O-ring on the oil temperature/pressure
sensor (4).
2. Install the sensor on the oil filter base (1) and torque
the mounting bolts (3) to 5 - 7 N·m (44 - 62 lb in).
3. Connect the electrical connection (2) for the sensor.
NHIL13ENG0664AA 1
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Index

Engine oil pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pressure and temperature sensor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electronic modules - 640

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Contents
DIAGNOSTIC
Fuse and controller power relay

Testing Auxiliary relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Electronic modules
Fuse and controller power relay - Testing Auxiliary relay

NOTE: Use these electrical schematic frames, as needed, to perform testing:
Wiring harnesses - Electrical schematic sheet 01 - Power and starting (engine schematics) (55.100)
Wiring harnesses - Electrical schematic sheet 02 - Engine control unit (ECU) power and vehicle inputs/outputs
(engine schematics) (55.100)
Wiring harnesses - Electrical schematic sheet 04 - Engine - Controller Area Network (CAN) (engine schemat-
ics) (55.100)
Test N°1
Test Point Condition
Check for Selective Catalytic Reduction (SCR) sensor control modules supply voltage.
Check
Use a multimeter to check for voltage from the circuit side of the SCR Fuse F-9109 connector X-9149
pin 1 to chassis ground.
Expected Result
Result 12.0 V
Action
There is an open circuit condition in the SCR sensors harness between the SCR Fuse F-9109 connector
X-9149 pin 1 and the harness splice (SP-9137), wire VE-193B. Locate and repair the open conductor.
Other Result
Result No voltage
(Possible Action
Cause) Go to test 2
Test N°2
Verify condition of the SCR sensor control modules supply voltage fuse F-9109.
Check
Use a multimeter to check for voltage from the circuit side of the SCR Fuse F-9109 connector X-9173
Expected Result
Result 12.0 V
Action
Go to test 8
Other Result
Result No voltage
(Possible Action
Cause) Go to test 3
Test N°3
Check for SCR sensor control modules supply voltage.
Check
Use a multimeter to check for voltage from the harness side of the Auxiliary relay K-9107 connector
X-9124 pin 4 to chassis ground.
Expected Result
Result 12.0 V
Action
There is an open circuit condition in the SCR sensors harness between the Auxiliary relay K-9107 con-
nector X-9124 pin 4 and the SCR Fuse F-9109 connector X-9173 pin 1, wire VE-219A. Locate and repair
the open conductor.
Other Result
Result No voltage
(Possible Action
Cause) Go to test 4
48076871 15/11/2016
55.11 [55.640] / 3
Test N°4
Check for Auxiliary relay K-9107 supply voltage.
Check
Expected Result
Result 12.0 V
Action
Go to test 13
Other Result
Result No voltage
(Possible Action
Cause) Go to test 5
Test N°5
Check
Use a multimeter to check for voltage from the circuit side of the Auxiliary relay fuse F-9106 connector
Expected Result
Result 12.0 V
Action
There is an open circuit condition in the application harness between the Auxiliary relay K-9107 connector
X-9124 pin 3 and the Auxiliary relay fuse F-9106 connector X-9174 pin 1, wire VE-217. Locate and repair
the open conductor.
Other Result
Result No voltage
(Possible Action
Cause) Go to test 6
Test N°6
Verify condition of the Auxiliary relay fuse F-9106.
Check
Use a multimeter to check for voltage from the circuit side of the Auxiliary relay fuse F-9106 connector
Expected Result
Result 12.0 V
Action
Go to test 17
Other Result
Result No voltage
(Possible Action
Cause) Go to test 7
Test N°7
Check
Use a multimeter to check for voltage from the circuit side of the Battery disconnect switch S-9100 from
connector X-9157 pin 1 to chassis ground.
48076871 15/11/2016
55.11 [55.640] / 4
Expected Result
Result 12.0 V
Action
There is an open circuit condition in the application supply harness between the Battery disconnect switch
S-9100 and the Auxiliary relay fuse F-9106, wire VE-215C or there may be an ancillary component, such
as an eStop device, included in the supply circuit. Refer to the appropriate application schematics to
locate and restore the Auxiliary relay K-9107 supply voltage.
Other Result
Result No voltage
(Possible Action
Cause) Refer to the appropriate application schematics to locate and restore the Auxiliary relay K-9107 supply
voltage.
Test N°8
The SCR Fuse F-9109 is blown. Check for short to ground circuit condition, before replacing.
Check
Use a multimeter to check for continuity from the circuit side of the SCR Fuse F-9109 connector X-9149
Expected Result
Result No continuity
Action
Replace the SCR Fuse F-9109.
Other Result
Result Continuity
(Possible Action
Cause) There is a short to ground condition in the SCR Fuse F-9109 supply circuit.
Go to test 9
Test N°9
Verify the condition of the SCR downstream NOx sensor A-9102. Disconnect the SCR sensors supply
harness from the SCR downstream NOx sensor A-9102 at connector X-9134.
Check
Use a multimeter to re-check for continuity from the circuit side of the SCR Fuse F-9109 connector X-9149
Expected Result
Action
The SCR downstream NOx sensor A-9102 has failed internally. Replace the sensor.
Other Result
Result Continuity
(Possible Action
Cause) Go to test 10
Test N°10
Verify the condition of the DOC upstream NOx sensor A-9103. Disconnect the SCR sensors supply
harness from the DOC upstream NOx sensor A-9103 at connector X-9133.
Check
Expected Result
Action
The DOC upstream NOx sensor A-9103 has failed internally. Replace the sensor.
Other Result
Result Continuity
(Possible Action
48076871 15/11/2016
55.11 [55.640] / 5
Test N°11
Verify the condition of the Urea quality sensor A-9104. Disconnect the SCR sensors supply harness from
the Urea quality sensor A-9104 at connector X-9131.
Check
Expected Result
Action
The Urea quality sensor A-9104 has failed internally. Replace the sensor.
Other Result
Result Continuity
(Possible Action
Test N°12
Verify the condition of the NH3 Controller A-9101. Disconnect the SCR sensors supply harness from the
NH3 Controller A-9101 at connector X-9132.
Check
Expected Result
Action
The NH3 Controller A-9101 has failed internally. Replace the controller.
Other Result
Result Continuity
(Possible Action
Cause) There is a short to ground condition in the SCR sensors supply harness between the SCR Fuse F-9109
and the SCR sensors on one of the following conductors:
- VE-193B, between the SCR Fuse F-9109 connector X-9149 pin 1 and the SCR sensors supply harness
splice (SP-9137),
- VE-193A, between the SCR sensors supply harness splice (SP-9137) and the SCR downstream NOx
sensor A-9102 connector X-9134 pin 1,
- VE-193, between the SCR sensors supply harness splice (SP-9137) and the DOC upstream NOx sen-
sor A-9103 connector X-9133 pin 1,
- VE-912, between the SCR sensors supply harness splice (SP-9137) and the Urea quality sensor A-9104
connector X-9131 pin 3,
- VE-192A, between the SCR sensors supply harness splice (SP-9137) and the NH3 Controller A-9101
connector X-9132 pin 1.
Locate and repair the grounded conductor.
Test N°13
Verify the status of the Auxiliary relay K-9107, high side, control signal.
Check
Expected Result
Result 12.0 V
Action
The Auxiliary relay K-9107 has failed internally. Replace the relay.
Other Result
Result No voltage
(Possible Action
48076871 15/11/2016
55.11 [55.640] / 6
Test N°14
Verify the status of the Engine Control Unit (ECU) A-9000, high side driver, control signal circuit. Carefully
disconnect the vehicle harness from the ECU A-9000 at connector X-9001. Place a jumper wire between
the harness side of connector X-9001 pin 20 and chassis ground.
Check
Use a multimeter to check for continuity from the harness side of the Auxiliary relay K-9107 connector
Expected Result
Result Continuity
Action
Go to test 15
Other Result
(Possible Action
Cause) There is an open circuit condition in the vehicle and application harnessing between the Auxiliary relay
K-9107 connector X-9124 pin 1 and the ECU A-9000 connector X-9001 pin 20, wire VE-179. Locate
and repair the open conductor.
Test N°15
Verify the status of the Auxiliary relay K-9107, low side, control signal.
Check
X-9124 pin 1 to the harness side of the Auxiliary relay K-9107 connector X-9124 pin 2.
Expected Result
Result 12.0 V
Action
Other Result
Result No voltage
(Possible Action
Test N°16
Verify the status of the ECU A-9000, low side driver, control signal circuit. Carefully disconnect the vehicle
harness from the ECU A-9000 at connector X-9001. Place a jumper wire between the harness side of
connector X-9001 pin 45 and chassis ground.
Check
Use a multimeter to check for continuity from the harness side of the Auxiliary relay K-9107 connector
Expected Result
Result Continuity
Action
The ECU A-9000 has failed internally. Re-flash the module with the appropriate software. If the re-flash
does not resolve the problem, replace the module.
Other Result
(Possible Action
Cause) There is an open circuit condition in the vehicle and application harnessing between the Auxiliary relay
K-9107 connector X-9124 pin 2 and the ECU A-9000 connector X-9001 pin 45, wire VE-180. Locate
and repair the open conductor.
Test N°17
The Auxiliary relay fuse F-9106 is blown. Check for short to ground circuit condition, before replacing.
Check
Use a multimeter to check for continuity from X-9174 pin 1 to chassis ground.
48076871 15/11/2016
55.11 [55.640] / 7
Expected Result
Result Continuity
Action
Go to test 18
Other Result
(Possible Action
Test N°18
Check
Use a multimeter to check for continuity from the Auxiliary relay K-9107 connector X-9124 pin 3 to Aux-
iliary relay K-9107 connector X-9124 pin 2.
Expected Result
Result Continuity
Action
Other Result
(Possible Action
Cause) There is a short to ground condition in the application harness to the Auxiliary relay K-9107 between the
Auxiliary relay fuse F-9106 connector X-9174 pin 1 and the auxiliary relay K-9107 connector X-9124 pin
3, wire VE-217. Locate and repair the grounded conductor.
Test N°19
Check
Use a multimeter to check for continuity from the Auxiliary relay K-9107 connector X-9124 pin 4 to chassis
ground.
Expected Result
Result Continuity
Action
There is a short to ground condition in the Auxiliary relay supply harness between the Auxiliary relay
K-9107 connector X-9124 pin 4 and the Engine sourcing fuses on one of the following conductors:
- VE-219, between the Auxiliary relay K-9107 connector X-9124 pin 4 and the Auxiliary relay supply
harness splice (SP-9115),
- the wire between the Auxiliary relay supply harness splice (SP-9115) and the Electric water pump con-
troller fuse F-9108,
- VE-219A, between the Auxiliary relay supply harness splice (SP-9115) and the SCR sensors fuse
F-9109,
- the wire between the Auxiliary relay supply harness splice (SP-9115) and the Engine plug C F-9107
fuse.
Locate and repair the grounded conductor.
Other Result
(Possible Action
Cause) Replace the Auxiliary relay fuse F-9106.
48076871 15/11/2016
55.11 [55.640] / 8
Index

Fuse and controller power relay - Testing Auxiliary relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48076871 15/11/2016
55.11 [55.640] / 9
17557
PRINTED IN U.S.A.
48076871 15/11/2016
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

DATAR [DATAR Diagnostics] Engine - Compression test 10.1 / 12
DATAR [DATAR Diagnostics] Engine - Compression test 10.1 / 12
380003372 [ENGINE Engine - Service instruction - Finding Top Dead Center 10.1 / 13
TURNING TOOL ADAPTER
PLATE]
380003373 [ENGINE Engine - Service instruction - Finding Top Dead Center 10.1 / 13
TURNING TOOL DRIVE
GEAR]
380001001 [Set Of 2 Gauges Crankcase - Check 10.1 / 15
For Angular Tightening With
1/2” And 3/4” Square Mount]
380000827 [Bore Gauge] Crankcase - Check 10.1 / 15
380000645 [Micrometer Set] Camshaft - Measure 10.3 / 13
17270 [Magnetic Base (For Camshaft - End play 10.3 / 16
Dial Indicators) ]
380000145 [Camshaft Camshaft bushings - Replace 10.3 / 22
Bushing Remover And
Installer]
380001543 [Dial Indicator Camshaft gear - Install 10.3 / 24
With Magnetic Base]
DM370(3/4) [Torque Cylinder head - Install 10.4 / 11
Tightening Angle Gauges
(1/2 Inch And 3/4 Inch)]
75291050 [Cylinder Head Valves - Remove 10.4 / 12
Valve Spring Compressor]
99305047 [Valve Spring Load Valves Spring - Check 10.4 / 15
Checking Tool]
75291050 [Cylinder Head Valves - Install 10.4 / 16
Valve Spring Compressor]
380000364 [Comparator Valve seat - Regrind 10.4 / 19
Holder Base For Different
Surveys]
380000228 [Dial Gauge (0 - 5 Valve seat - Regrind 10.4 / 19
mm)]
380000325 [90 - 175mm Connecting rod and piston - Install 10.5 / 8
Diameter Piston Assembly
Band Clamp]
380000324 [Pliers Piston - Remove 10.5 / 10
For Assembling And
Disassembling Piston Split
Rings (110-150 mm)]
380000221 [Handle] Piston - Install 10.5 / 13
380000228 [Dial Gauge (0 - 5 Piston - Check 10.5 / 16
mm)]
380000364 [Comparator Piston - Check 10.5 / 16
Holder Base For Different
Surveys]
380001001 [Set Of 2 Gauges Connecting rod bearing - Clearance 10.5 / 18
380001001 [Set Of 2 Gauges Connecting rod bearing - Clearance 10.5 / 19
380000988 [Starter opening Engine flywheel - Remove 10.6 / 3
plate and Flywheel Rotation
Blocker]
48076871 15/11/2016
380000988 [Starter opening Engine flywheel - Install 10.6 / 5
Blocker]
380001001 [Set Of 2 Gauges Engine flywheel - Install 10.6 / 5
380000988 [Starter opening Engine flywheel - Remove 10.6 / 7
Blocker]
380000988 [Starter opening Engine flywheel - Install 10.6 / 11
Blocker]
380001001 [Set Of 2 Gauges Engine flywheel - Install 10.6 / 11
99340055 [Front Seal Crankshaft oil seal Front seal - Remove 10.6 / 14
Remover]
380000669 [Seal Extraction Crankshaft oil seal Front seal - Remove 10.6 / 14
Tool]
380000666 [Crankshaft Front Crankshaft oil seal Front seal - Install 10.6 / 15
Seal Installer]
380000669 [Seal Extraction Crankshaft oil seal Rear seal - Remove 10.6 / 16
Tool]
99346253 [Rear Seal Installer] Crankshaft oil seal Rear seal - Install 10.6 / 17
380000362 [Crankshaft Lifting Crankshaft - Remove 10.6 / 18
Hook]
380000362 [Crankshaft Lifting Crankshaft - Remove 10.6 / 20
Hook]
380000362 [Crankshaft Lifting Crankshaft Journal - Clearance 10.6 / 23
Hook]
380001001 [Set Of 2 Gauges Crankshaft Journal - Clearance 10.6 / 24
380000362 [Crankshaft Lifting Crankshaft - Install 10.6 / 25
Hook]
380001717 [Crankshaft Gear Crankshaft gears - Replace 10.6 / 26
Puller]
34591-00100 [Oil Filter Fuel filters - Remove 10.10 / 4
Wrench]
380140055 [Fuel Supply / Fuel injection system - Test Common rail fuel injection - Fuel 10.11 / 29
Leakage Test Kit] supply/Leakage test
380100056 [Gauge and Hose Fuel injection system - Test Common rail fuel injection - Fuel 10.11 / 29
Assembly] supply/Leakage test
380100057 [Pressure Gauge Fuel injection system - Test Common rail fuel injection - Fuel 10.11 / 29
and Hose Assembly] supply/Leakage test
380001099 [Fuel Injector Fuel injectors - Remove 10.11 / 43
Extractor]
84480632 [Hand Tool (DEF Diesel Exhaust Fluid 10.14 / 32
Line Repair)]
84153500 [CLAMPING JAWS Diesel Exhaust Fluid 10.14 / 32
FOR TUBE 8.8X1.4]
84480634 [CLAMPING JAWS Diesel Exhaust Fluid 10.14 / 32
FOR TUBE OD 8mm AND
NW10 CORRUGATE]
84153502 [TOOLING Diesel Exhaust Fluid 10.14 / 32
COLLET FOR NW6
(AD-BLUE)]
84153504 [WIDENING SPIKE Diesel Exhaust Fluid 10.14 / 32
FUR TUBE 8.8X1.4]
84480637 [TUBE SCISSORS] Diesel Exhaust Fluid 10.14 / 32
48076871 15/11/2016
84480640 [SPARE TUBE Diesel Exhaust Fluid 10.14 / 32
BLADE]
84480637 [TUBE SCISSORS] Selective Catalytic Reduction 10.14 / 38
84480640 [SPARE TUBE Selective Catalytic Reduction 10.14 / 38
BLADE]
380000670 [Oil Filter Wrench] Engine oil filter - Remove 10.17 / 10
OEM Reference PAGE
OEM1032 [Dial Bore Gauge ] Crankcase Bore - Check 10.1 / 14
OEM1032 [Dial Bore Gauge ] Camshaft bushings - Measure 10.3 / 21
OEM1032 [Dial Bore Gauge ] Piston pin bushings - Check 10.5 / 20
48076871 15/11/2016
17557
PRINTED IN U.S.A.
48076871 15/11/2016
EN

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SERVICE MANUAL

Part number 48076871

F4DFE4131*B001, F4DFE4131*B002, F4DFE4131*B007, F4DFE4131*B008,

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

Electrical systems ....................................................................... 55

[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Foreword - Important notice regarding equipment servicing

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

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Safety rules - Ecology and the environment

Mandatory battery recycling

Points of sale are obliged to:

Component Size Specification

Component Size Specification

Basic instructions - Important notice regarding equipment servicing

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

Torque - Minimum tightening torques for normal assembly

METRIC FLANGED HARDWARE

Metric Hex head and carriage bolts, classes 5.6 and up

Metric Hex nuts and locknuts, classes 05 and up

INCH NON-FLANGED HARDWARE

INCH FLANGED HARDWARE

Inch Bolts and free-spinning nuts

SAE Grade Identification

Inch Lock Nuts, All Metal (Three optional methods)

Basic instructions - Shop and Assembly

Rotating shaft seals

Protecting the electronic/electrical system during charging or welding

By using these tools, repair personnel will benefit from:

Basic instructions - Shop and assembly

Rotating shaft seals

When ordering spare parts, always provide the following information:

F4DFE4131B001, F4DFE4131B002, F4DFE4131B007, F4DFE4131B008,

F4DFE4131B001, F4DFE4131B002, F4DFE4131B007, F4DFE4131B008,

F4DFE4131B001, F4DFE4131B002, F4DFE4131B007, F4DFE4131B008,

F4DFE4131B001, F4DFE4131B002, F4DFE4131B007, F4DFE4131B008,