647412en - Group 10

ENGINE
10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE CIRCUITS FLOW DIAGRAM
- ENGINE COMPONENTS LOCATION
- ENGINE CONTROL AND ADJUSTMENT
- ENGINE REMOVAL
- ENGINE REFIT
- ENGINE TROUBLESHOOTING
- SPECIFIC ENGINE TOOLING
- REMOVAL l647461EN
- REFIT (ENGINE TCD 3.6 L4)
- SPECIFIC TOOLING
10
ENGINE CHARACTERISTICS AND SPECIFICATIONS
pages
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
POLLUTION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(9/6/2013) 10-01-M218EN
ENGINE CHARACTERISTICS AND
2 SPECIFICATIONS
CHARACTERISTICS
 4 cylinders in line
 Firing order from flywheel: 1, 3, 4, 2
10
 Anti-clockwise (viewed from flywheel)

 3,6 ℓ cubic capacity
 Electronic management
 Direct injection
 Turbo with cooler
 Compression ratio: 18:1
 Power rating 74,4 and 90 kW
 Specific consumption: 210 and 220 g/kWh
 Maximum torque: 390 and 480 N.m (at 1600 rpm)
 Dry engine weight: 270 kg
 Idle speed: - Min rpm: 930 rpm
- nominal laden: 2200 rpm
- max. unladen: 2360 rpm
 Pre-heating and post-heating times: 10 and 140 s from -30 to -20°C
10 and 100 s at -10°C
5 and 50 s at 0°C
No pre-heating above 5°C
POLLUTION MANAGEMENT
The Stage 3B pollution standard is complied with by optimizing combustion to produce small amounts
of soot but which, in turn, produces large quantities of NOx.
Among other parameters, the EGR management is designed accordingly and the engine is therefore
equipped with a large exhaust gas recirculation cooler, thus reducing NOx levels.
This version does not have a throttle valve so as to allow more air to be supplied to the engine and thus
improve NOx management.
The remaining NOx is treated to 90 % by the catalytic converter.
There is no lambda probe as all the operating conditions are on the ECU map.
10-01-M218EN (9/6/2013)
10
ENGINE CIRCUITS FLOW DIAGRAM
pages
AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . .2

LUBRICATION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DIESEL FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
(9/6/2013) 10-02-M218EN
2 ENGINE CIRCUITS FLOW DIAGRAM
AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation)
Controls the flow of exhaust gases towards the intake.

A proportional actuator ensures accurate control of the EGR flow rate according to engine load,
10
temperature and other factors. This ensures optimum control of NOx emissions and particles. The one
way valves prevents boost air entering the EGR system.
Key:
1 - From air filter 9 - Cooling liquid supply
2 - Turbo 10 - EGR cooler
3 - Air turbo cooler 11 - Cooling liquid return
4 - Cooled air temperature sensor 12 - Non-return valves
5 - Intake 13 - Gas cools
6 - Exhaust 14 - To exhaust
7 - Exhaust gas by-pass
8 - EGR Valve
1 9
10
12 13
8
7
11
2
5
6
14
10-02-M218EN (9/6/2013)
ENGINE CIRCUITS FLOW DIAGRAM 3
LUBRICATION CIRCUIT
The oil pressure and volume flow rate ensure lubrication of the engine and also, to a large extent, engine
cooling. The pressure relief valve opens at 9 bar and the maximum oil temperature in the sump is 125°C.
10
Key:
1 - Oil sump 9 - Camshaft bearing
2 - Oil pump 10 - Crankshaft bearing
3 - Pressure relief valve 11 - Piston cooling nozzle
4 - Oil cooler 12 - Rocker arm
5 - By-pass valve 13 - Hydraulic tappets
6 - Pressure control valve 14 - Turbocompressor
7 - Oil filter 15 - Air compressor (optional)
8 - Main oil gallery
12
14
15
11
8
13
5
4
9
7
10
6 3 2
7
6
2
3 6
(9/6/2013) 10-02-M218EN
COOLING SYSTEM
The engine temperature is controlled by the ECU control unit (EMR 4) and depends on the required
performance. Exceeding the temperature limits will trigger the warning, power reduction and engine
10
shutdown stages. The maximum temperature difference across the radiator is 8°C. The maximum cooling
system pressure is 1,2 bar.
Key:
1 - Water pump 6 - Cab heating connection
2 - Coolant enters the engine 7 - Temperature sensor
3 - Cylinder tube / head cooling 8 - Thermostat (opening 92°C, max 110°C)
4 - Lubricating oil radiator 9 - Radiator
5 - Exhaust return radiator 10 - Expansion tank
6
10
9
7
8
5 4 3
2
1
10-02-M218EN (9/6/2013)
ENGINE CIRCUITS FLOW DIAGRAM 5
DIESEL FUEL CIRCUIT
Max. fuel supply. Pressure: 8 bar.

Regulated pressure fuel supply: 4 - 4,5 bar. Startup not allowed if P < 3,2 bar.
10
Fuel rail pressure, maximum service pressure: 1600 bar.
PRV (Pressure Relief Valve) on the fuel rail, opening pressure: 1700 bar.
Low Pressure:
Within the high pressure pump, the MPROP (Magnetic Proportional Electrovalve) controls the amount
of fuel delivered to the pump relative to the amount returned to the fuel tank.
High Pressure:
Fuel under high pressure is sent from the high pressure pump (Item 6) to the fuel rail (Item 7) where it
is available to all the injectors (Item 8).
Return:
The fuel return is generated by the opening of each injector (Item 8), of the MPROP (Item 6), and (in the
event of a malfunction) of the safety valve in the fuel rail (Item 7).
Key:
1 - Fuel tank 11 - Return to tank
2 - Water separator / pre-filter 12 - ECU (Electronic Control Unit)
3 - Electrical fuel pump
4 - Fuel filter
5 - Supply pressure sensor
6 - High pressure pump / FCU (Fuel Control Unit)
7 - High pressure fuel rail
8 - Injector
9 - Non-return valve
10 - Return line
9
12 8
10
2
4 5
11
3 6
(9/6/2013) 10-02-M218EN
10
10-02-M218EN (9/6/2013)
10
ENGINE COMPONENTS LOCATION
pages
ENGINE ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
WATER AND AIR COOLING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
HYDRAULIC VENTILATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DIESEL FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FUEL INJECTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
EGR (EXHAUST GAS RECIRCULATION) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
(9/6/2013) 10-03-M218EN
2 ENGINE COMPONENTS LOCATION
ENGINE ELEMENTS
Key:
1 - Cooling water inlet 18 - Intake air sensor
10
2 - Alternator belt 19 - Water temperature sensor

3 - Tensioning pulley 20 - Thermostat
4 - Crankshaft sensor 21 - Cooling water outlet
5 - Ventilation pump 22 - Fuel return
6 - Camshaft sensor 23 - Oil cooler
7 - Water pump 24 - Main connector
8 - Alternator 25 - Injection pump
9 - EGR Valve 26 - MPROP (magnetic proportional valve)
10 - Air supply to turbo 27 - Fuel intake
11 - EGR cooler 28 - Starter
12 - Non-return valves 29 - Oil filter
13 - Crankcase breather 30 - Control cartridge
14 - Oil filler plug 31 - Drain plug
15 - Air supply to intake 32 - Boost relief valve
16 - Fuel rail 33 - Oil pressure sensor
17 - Fuel rail pressure sensor 34 - Engine ECU
34
Cooling
Air
12
Diesel 10
Electricity 11
Lubrication
EGR
9
13
17
14
15
16
18
8
22
19
23 7
20
28
21
24
26 6
27 5
25
4
3 2
29 30
32 1 33
31
10-03-M218EN (9/6/2013)
ENGINE COMPONENTS LOCATION 3
WATER AND AIR COOLING CIRCUIT
Key:
1 - To water pump 6 - Air filter 12 - Air cooler
10
2 - Boost pressure line 7 - Clogging sensor 13 - Intake
3 - Thermostat outlet 8 - Air filter temperature sensor
4 - Degassing line 9 - Turbo air intake
5 - Bleeder (Behind high 10 - Turbo air outlet
pressure pump) 11 - Turbo air temperature sensor
2 4
11
12
9
13
7 8
10
(9/6/2013) 10-03-M218EN
HYDRAULIC VENTILATION SYSTEM
Key:
1 - Oil supply 7 - Motor outlet
10
2 - Oil return 8 - Cooler

3 - Ventilation pump 9 - Hydraulic oil temperature sensor
4 - Fan motor 10 - Hydraulic oil compartment
5 - Motor supply 11 - Transmission oil compartment
6 - Drain e 20 - Location
9
180°
MT
7 4
10
8
11
6
2 1
2
6
4
180°
4
7
1
5 3
2
6
1 9
10
11
8
MLT
7
2
6
4
10-03-M218EN (9/6/2013)
DIESEL FUEL CIRCUIT
Key:
1 - Fuel supply 6 - Water in diesel sensor
10
2 - Fuel return 7 - Fuel pump
3 - Fuel gage 8 - Filter
4 - Fuel valve 9 - Pressure sensor
5 - Pre-filter 10 - Pressure test port (in place of the sensor)
9
10
5 8
(9/6/2013) 10-03-M218EN
FUEL INJECTION CIRCUIT
Key:
1 - Low pressure fuel supply 7 - Pressure Relief Valve (PRV)
10
2 - High pressure pump 8 - PRV return

3 - MPROP (magnetic proportional valve) 9 - Injector electrical connector
4 - FCU (Fuel Control Unit) return 10 - High pressure fuel supply
5 - High pressure fuel rail 11 - Injector return
6 - High pressure fuel line pressure sensor
Red circuit = 350 - 1800 bar

Green circuit = low pressure return
11
10 9
6
8
5 7
10-03-M218EN (9/6/2013)
EGR (Exhaust Gas Recirculation) CIRCUIT
Key:
1 - Partial exhaust gas flow (not cooled) 8 - Exhaust manifold
10
2 - EGR valve, controller (electrical action) 9 - Turbo attachment
3 - Cooling liquid return 10 - One-way valves
4 - Exhaust gas return radiator (EGR)
5 - EGR radiator coolant supply line
6 - Partial exhaust gas flow (cooled)
7 - Intake
10
8
2 1
9
(9/6/2013) 10-03-M218EN
10
10-03-M218EN (9/6/2013)
10
ENGINE CONTROL AND ADJUSTMENT
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

COMPONENT REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– A – MOVABLE ENGINE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– B – RADIATOR AND FAN MOTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– C – RADIATOR AND FAN MOTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– D – FAN HYDRAULIC MOTOR REMOVAL / REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– E – RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– G – ENGINE OIL DIPSTICK FITTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– H – FIXED ENGINE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– I – EXHAUST REMOVAL / REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– J – AIR-CONDITIONING BELT REMOVAL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– K – AIR-CONDITIONING BELT REFIT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– L – DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– M – AIR-CONDITIONING COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– N – STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– O – ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– P – WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– Q – TURBO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– R – ENGINE SHOCK ABSORBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INJECTION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
BOSCH CP4.1 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
– A – FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– B – PRINCIPLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– D – SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– C – DESCRIPTION OF HYDRAULIC MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . 16
(11/15/2013) 10-04-M218EN
2 ENGINE CONTROL AND ADJUSTMENT
PREPARATION AND SAFETY INSTRUCTIONS
b Operate the battery cut-off no less than 30 seconds after turning off the ignition with the ignition
key.
10
Stabilize the machine on level ground.

Position the boom in the raised position and install the safety wedge.
COMPONENT REMOVAL / REFIT
A – MOVABLE ENGINE COVER REMOVAL
Unclip the strut from the cover (flat screwdriver) and support
the cover using a strap.
1
1
Undo the 4 screws of the 2 hinges (13 mm wrench) (Item 1).
Remove the mobile cover.
B – RADIATOR AND FAN MOTOR REMOVAL
2 3
 Carry out the "MOVABLE ENGINE COVER REMOVAL"
1
operation e A
Drain the water and oil radiators.
Remove the water and air hoses (Fig. A (Item 1) and (Item 2)) .
Remove the expansion tank (2 nuts, 1 connector) and its support

Fig.A bracket (3 screws).
6 Unscrew the bottom 2 silent blocks.

Unscrew the tie and the bracket (Fig. A (Item 3)).
1
7
Unscrew the oil hoses (Fig. B (Item 1) to (Item 4)).
Remove the turbo air supply pipe (Fig. B (Item 5)).
2
3
Disconnect the 3 sensors (Fig. B (Item 6) and (Item 7)).
Fig.B 5
10-04-M218EN (11/15/2013)
ENGINE CONTROL AND ADJUSTMENT 3
1 3
Remove the fuse box support bracket.
4 11
Disconnect the cable harnesses (Fig. 1, (Item 1)) and the computer.
7
Remove the anti-recycling plate (Item 2).
10
b
Remove the cap (Item 3) and lift the radiator.
10
Beware of the cable harness beneath the radiator.
C – RADIATOR AND FAN MOTOR REFIT

2
8
9
Fig.1 9
operation e A
When carrying out a replacement, retain:

- the upper right hand silent block (Fig. 1, (Item 4)) and the
b
3 two lower silent blocks (Fig. 1, (Item 9)).
- the 2 (75°C) hydraulic temperature senors (Item 5)
and the (90°C) gear box temperature sensor (Item 6),
(25 N.m ± 15%).
- the turbo air temperature sensor (21 N.m ± 15%).
6 5
- the drain plug (Item 8), the anti-recycling plate (Item 2),
the cap (Item 3), the grommet (Item 11) and the cage nut
(Item 10) on the top of the radiator.
Fig.2 Attach the 3 silent blocs (Fig. 1, (Item 4) and (Item 9)), the tie
(Fig. 1, (Item 7)) and the drain plug (Fig. 1, (Item 8)) to the radiator.
1
Attach the hydraulic hose to the radiator inlet (Fig. 3, (Item 1)).
Pass a sling through the hole at the cap (grommet) location
b
(Fig. 1, (Item 3)), refit the cap after installation.
Lower the radiator, being careful to avoid the turbo and
the computer,
2 Place the radiator and screw the silent blocks (Fig. 1, (Item 4)
and (Item 7)).
Connect the hoses (Fig. 4, (Item 1) and (Item 2)) and the connectors
Fig.3 (Fig. 4, (Item 3) and (Item 4)) to the fan motor.
T Attach the motor fuse box, pass the 2 sensor cables underneath.
Gear
Refit the cable harness grommet to the anti-recycling plate
2
box (Fig. 1, (Item 1)).
Connect the sensors to the harness.
Refit the hydraulic hoses.

3
Refit the tie and the bracket.
1
4
T
Fig.4
(11/15/2013) 10-04-M218EN
Attach the engine water boost pressure line (Item 1) to the

3 holder under the expansion tank.
1
Connect hoses (Item 1 and Item 2).
4
Connect the water level sensor (Item 3).
10
Attach the expansion tank mounting flange (Item 4).

2
Fill the cooling water circuit with approx. 20 liters of water. Top
up the gear box oil and hydraulic oil levels.
Start-up and check the levels.
D – FAN HYDRAULIC MOTOR REMOVAL / REFIT

1 operation e A
 Carry out the "RADIATOR AND FAN MOTOR REMOVAL"
operation e B
Lay the radiator flat, remove the grill, 4 screws.
Undo the nut securing the fan to the motor shaft.
Detach the tapered fan motor shaft by hitting with a hammer

and a bronze drift punch (Item 1), taking care not to damage
the shaft. Recover the cotter and make sure to put it back in the
reinsert it in the fan slot,
Tightening of 45 N.m and 25 N.m couplings (10 mm hose).
2 When refitting: put back the washer and nut, tighten with torque
wrench to 40 N.m ±10%.
Be careful to place the grill in the correct direction so as to
2
use the appropriate hydraulic motor fastening holes (Item 2),
tightening torque 45 N.m ±10%.
After refitting the fan motor on the grill, refit the fan grill, centering
the blades in the shroud.
10-04-M218EN (11/15/2013)
E – RADIATOR REMOVAL
10
operation e A
 Carry out the "RADIATOR AND FAN MOTOR REMOVAL"
operation e B
 Carry out the "FAN HYDRAULIC MOTOR REMOVAL /
REFIT" operated e D
Remove the shroud (Item 1) then detach the radiator by removing

the top and bottom plates (Item 2).
Change the faulty compartment.
2 2
(11/15/2013) 10-04-M218EN
F – VENTILATION PUMP REMOVAL / REFIT
1 2
 Carry out the "ALTERNATOR REMOVAL" operation e L
10
Fastening screw (Item 1): 45 N.m ±20% with normal thread lock.
Wynns SG311 lubricant on pinion.
Hose couplings: 45 N.m (Item 2), 40 N.m (Item 3) ±10%.

3
G – ENGINE OIL DIPSTICK FITTING INSTRUCTIONS
1 - CUTTING THE DIPSTICK
 Undo the 2 screws (Fig. 1, (Item 1)) and remove the

dipstick handle.
1
1  Cut the dipstick guide (Fig. 1, (Item 2)) by 300mm, as well
50
-5
as the dipstick (Fig. 1, (Item 3)).

18
3
2 - FITTING INSTRUCTIONS
Fig.1
 Mount the dipstick guide (Fig. 2, (Item 1)) in contact with
the engine casing. Tighten the clamp (Fig. 2, (Item 2)) to
2 N.m.
1
 Fit the 2 guide retaining clamps (Fig. 3, (Item 1) and
2 (Item 2)). Insert a washer in the small clamp (Fig. 3, (Item 2))
to avoid crushing the guide tube. Ensure that the guide
projects 40 mm as shown (Fig. 3, (Item 3)).
 Ensure that, when installed, the guide tube does not

interfere with the machine components.
Fig.2  Insert the dipstick as far as it will go. Check that the
dipstick extends into the engine casing.
40
3
 Measure the excess length of dipstick and cut if required
2
to obtain the dimension of 18 mm (Fig. 1).
 Fit the handle on the dipstick, set the margin to 5 mm

(Fig. 1) and tighten the 2 screws (Fig. 1, (Item 1)) to 2,5 N.m.
Fig.3
10-04-M218EN (11/15/2013)
H – FIXED ENGINE COVER REMOVAL
2
10
1 operation e A
1
On the black protector, next to the boom, remove the 2 screws
2
(Item 1) (13 mm wrench) and the 2 screws (Item 2).
Remove the 4 screws at the rear (Item 1).

2
Remove screw (Item 2) inside the housing (on the air filter holder).
1
I – EXHAUST REMOVAL / REFIT

operation e A
 Carry out the "FIXED ENGINE COVER REMOVAL" operation
eH
2
b Carefully mark the position of the exhaust relative to
the clamps and the compensator.
Undo the clamp on the pipe (Item 1), be sure to retain the seal.
b
2 Unscrew the 2 screws (Item 2) on the exhaust pipe clamp.
Whe, refitting, be careful not to place stress on
1 compensator, align the joints of the different items.
Tighten, the clamps to a torque of 12 N.m ±10%.
J – AIR-CONDITIONING BELT REMOVAL

(option)
1
Remove the belt cover, 3 nuts (Item 1).

1
(11/15/2013) 10-04-M218EN
Attach the special belt tool (Item 1) (e 10 - Specific engine

2
tooling) on the ribbed pulley (Item 2) and secure the tool with
the nut (Item 3).
4
10
1 Turn the pulley shaft (Item 4) to move the tool and lift the belt.
Pull the belt by hand to release it, continue turning and remove
the belt and the tool.
K – AIR-CONDITIONING BELT REFIT

(option)
Attach the tool (Item 1) (e 10 - Specific engine tooling) on the

ribbed pulley (Item 2) and secure it with the nut (Item 3).
Place the belt on the pulley (Item 4) on the outside of the machine
and pass it just behind the nut (Item 3). Position it in the center
3
1
of the pulley (Item 2).
4 2
Turn the pulley (Item 5),install the belt and remove the tool.
5
Once the tool is removed, turn the pulleys a number of times
by hand to check that the new belt is properly positioned in
the grooves.
L – DRIVE BELT REMOVAL

2
 Carry out the "AIR-CONDITIONING BELT REMOVAL

(option)" operation e j
1
Move the tensioning roller upwards with the square drive of a
wrench (Item 1) and remove the belt (Item 2).
When changing the belt tensioner, put it back in the upper

right-hand position.
10-04-M218EN (11/15/2013)
M – AIR-CONDITIONING COMPRESSOR REMOVAL
 Carry out the "AIR-CONDITIONING BELT REMOVAL
10
2
(option)" operation e j
1
2
Take off the rear grill, remove the 2 large screws on the right
(Item 1) and the two small screws on the left (Item 2).
Discharge the air-conditioning system (i air-conditioning

1 training course).
Disconnect connector X207 (Item 1).

2
2
Unscrew the 2 hoses (Item 2).
Remove the 3 screws (Item 3) (17 mm wrench).

3
3
3
N – STARTER MOTOR REMOVAL
2
(Item 1) and the two small screws on the left (Item 2).
1
Disconnect the X164 air inlet temperature sensor (Item 1).

Remove the hose from the air filter to the turbo (Item 2), unscrew
the 2 clamps, plug the engine ports.
(11/15/2013) 10-04-M218EN
Unclip the pre-heating cable harness (Item 1) to gain access to

1
the starter.
7
Disconnect the connector on the starter motor (Item 2).
10
7
Unscrew the cable harnesses at the starter motor (Item 3) (15 mm
and 17 mm wrench): harness to battery (Item 4), harness to
7
2 alternator (Item 5), harness to starter motor (Item 6).
6 Remove the 3 screws (Item 7), remove the starter motor via
3 the top.
5 4
O – ALTERNATOR REMOVAL
 Carry out the "DRIVE BELT REMOVAL" operation e L
1
Undo the two screws (Item 1).
Remove the alternator.
1
1 P – WATER PUMP REMOVAL

3
 Carry out the "DRIVE BELT REMOVAL" operation e L
Disconnect the heating circuit outlet hose (Item 1)

(7 mm wrench) and the return hose (Item 2).
Disconnect the engine water filling hose (Item 3).
2
10-04-M218EN (11/15/2013)
Q – TURBO REMOVAL
2
Loosen the turbo side air inlet hose clamp (Item 1), plug the
turbo inlet port.
10
3
Unscrew the 2 expansion tank mounting flange screws (Item 2).

Unscrew the boost hose clamp screw (Item 3).
Tilt the expansion tank forward

1
Remove the exhaust pipe elbow, unscrew the 2 clamps (Item 1

3 2 and Item 2), remove the seal (Item 3).
Tightening torque: Item 1: 10 N.m ± 1 N.m

Item 2: 12 N.m ±1 N.m
Loosen the turbo air output clamp (Item 1).
l 647461 (TCD 3.6 L4 ENGINE) - Turbocompressor

Removal - Refit
R – ENGINE SHOCK ABSORBER REPLACEMENT

Remove the transmission universal joint.
1 Unscrew the screws (Item 1, Item 2 and Item 3) in that order to
change the shock absorber components:
A - Damper B - Seal C - Bush

3
2
Tightening torque: B
Screw no. 1: 35 N.m, 5/16-25 C
Screw no. 2 : 35 N.m with medium thread lock

Screw no. 3: 35 N.m with medium thread lock
(11/15/2013) 10-04-M218EN
INJECTION CYCLE
1 - Fuel pre-injection
2 - Main fuel injection
10
3 - Fuel post-injection
Effects of fuel pre-injection
Pre-conditioning of the combustion chamber prior to main fuel injection

1. Reduces temperature of combustion
2. Reduces the main injection combustion delay
3. Reduces noise emissions (reduced peak combustion pressure)
Effects of fuel post-injection
Injection of an accurately measured amount of fuel during the exhaust stroke,

1. Reduces NOx emissions
2. Slightly higher fuel consumption
The amount of fuel injected during post-injection

is not related to a specific cylinder. The fuel flow
rate is calculated to give the smallest optimized
amount of fuel and is provided for the cylinder
that is ready for the next injection.
The safety valve protects the fuel rail against excessive pressure by opening at approx. 1700 bar.
It remains pen and heats up until the engine and the fuel flow are stopped.
Over time, this heat may affect the hardening of the spring inside the valve.
For this reason, the engine is only allowed to run for period of 4 minutes, once the valve is open, and
the valve must be replaced after 50 openings.
Replace the valve before exceeding the number of openings or there is a risk of premature opening or
leaks.
10-04-M218EN (11/15/2013)
BOSCH CP4.1 HIGH PRESSURE PUMP
Synchronized with idle gear / crankshaft.

Approximately two strokes per crankshaft rotation.
10
Max. working pressure 1600 bar.
The high pressure pump is lubricated by the fuel. Its reliability can therefore be affected by fuel quality.
Excessive wear of the cam follower and of the bore with possible damage to the cam lobe is frequently
due to a poor quality of fuel.
4
Key:
1 - 2 lobe camshaft 3
2 - Piston type pump
5
3 - High pressure outlet
4 - MPROP (magnetic proportional valve)
5 - Low pressure inlet
6 - Discharge valve
2
6
High pressure pump maintenance
Before the pump is removed for maintenance,

the engine must be turned over until the
synchronization mark of the pump is aligned
with that of the guide wheel. Removing the 1
plug of the timing gear housing, as shown

above will enable you to view the pump and
the idle gears. Once the timing marks have
been aligned, the pump fastening screw can
be removed and the pump removed from the
rear of the timing gear housing.
The pressure of the spring inside the pump
means that a stop pin is not needed to prevent
rotation during installation.
It is not necessary to remove the timing gear

housing for performing maintenance on the
high pressure pump.
If the MPROP is de-energized, a spring pushes

the fuel metering section upwards. The passage
from the fuel delivery pump to the high
pressure pump is completely open and a large volume of fuel is delivered to the high pressure pump.
(11/15/2013) 10-04-M218EN
FAN DRIVE
A – FUNCTION
10
The Fan Drive serves to adjust the speed of the engine cooling fan according to the various temperature parameters.
The Fan Drive can temporarily reverse the direction of flow to unclog the engine cover air intake grills
(MLT versions only).
B – PRINCIPLE OF OPERATION
The Fan Drive is hydraulically driven by a motor and a fixed displacement pump, connected to the
engine's power take-off. The hydraulic flow therefore varies according to the engine speed, and thus the
maximum fan speed also. Control and reversal (MLT only) are incorporated within the hydraulic motor,
as well as a relief valve and an anti-cavitation "freewheel" valve to ensure that the oil is re-aspirated
during engine shut-down, ensuring that the propeller rotation slows very gradually.
The control electrovalve serves to reduce the speed of trotation of the fan from its maximum speed.
The reversing electrovalve serves to change the fan's direction of rotation when it is powered by the
activation of the reversing switch and SPU control, performing an unblocking cycle.
In the event of a control system failure (sensors, continuity, electrovalves), the hydraulic drive is at
maximum power (coils not powered), this is the system's degraded mode.
REVERSAL (MLT only)
When it is activated in automatic mode, a reversal cycle will be

implemented every three minutes. It can also be activated at
any time for a single cycle, but an interval of three minutes is still
necessary between two cycles. Reversing can be deactivated;
the fan will then always turn in the same direction.
Engine water temperature for reversal to be enabled:

min.: 40 °C / maxi.: 104 °C
Max reverse speed ≈ 2000 rpm
Total time of reversal cycle ≈ 9 s

Reversal time at maximum speed ≈ 3 s
D - SCHEMATIC DIAGRAM
Key:
1 - Air filter temperature sensor 9 - Gear change electrovalve
2 - Engine coolant temperature sensor 10 - Changeover valve
3 - Crankshaft speed sensor 11 - Cooler
4 - Engine computer 12 - Hydraulic oil temperature sensor
5 - Machine computer - SPU 13 - Transmission oil temperature sensor
6 - Dashboard module 14 - Boost air temperature sensor
7 - Fan Drive reversing switch (MLT)
8 - Fan motor
10-04-M218EN (11/15/2013)
7
1 11 12
X164 X186 75°C X247
4
5 X56
MT/MLT X246
10
X57 90°C
13
X252
9
CAN 8
X175
10
X174
2 X254
6 MLT
X912
14
3 10
15
X68 X245
RP
5 M
x
10
0
20
X915 0
00
00
00
25
0 30
X121
The analog signal from the boost air temperature sensor (Item 14) arrives at the dashboard (Item 6) on
the printed circuit to correct the signal and send it to the display module, that returns it via the CAN
messaging system to the SPU.
C – DESCRIPTION OF HYDRAULIC MOTORS
Key:
15 - Hydraulic control motor (BRV) 19 - From pump (P)
16 - Reversible hydraulic motor (BRVI) 20 - Return to tank (T)
17 - Fan direction reversal electrovalve 21 - Motor drain (D)
(Y42) (On-Off ) 22 - Valve drain (D1)
18 - Fan speed control electrovalve (Y43) 23 - Anti-shock and anti-cavitation ("freewheel") valve
(PROP = Proportional) and integral relief valve 24 - Anti-cavitation ("freewheel") valve
MT MLT
18
15
20
16
18 21 20
19 21
22 17
19
P
BRV
19.1 cm3/tr BRVI
16.85cm3/tr P
Y43
Y43
D 24
23
D Y42 T
T D1
(11/15/2013) 10-04-M218EN
E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS
(°C) 80
10
Air suralimenté
Control electrovalve supply current management:
75
1 - Analog sensors: boost water and air;
rece
air
tun
2 - On-Off sensors (ventilation at maximum): hydraulic and
reare
Boost
piéff
transmission oils 60
ed
m
uter
0
draet
50
rte
The maximum temperature of the boost air depends o the ambient
cap
TeE 0
m
1
temperature determined by the air filter temperature sensor (see 40
30
diagram opposite).
20 Ambient
The closer we approach to the maximum allowable limit, the more Air
air
ambiant
50
we increase the ventilation. 0
25 35 50 (°C)
CONTROL
Control is achieved by limiting the pressure of the hydraulic circuit, thus limiting the maximum fan speed.
While the pressure in the circuit has not reached that of the control electrovalve, the relationship between
the engine speed and the fan speed remains constant (see graph on next page, Slope A).
The maximum fan speed is limited at high engine speed by the control electrovalve which also serves
as a relief valve.
Graph of the fan speed against engine speed and control current
Oil temperatures below threshold limits (Hydraulic oil temperature = 70 °C).
Fan speed (rpm)
Engine speed (rpm)

The digital values represented on the graph above are of an indicative nature and may vary and/or be modified.
10-04-M218EN (11/15/2013)
n (Tr/min)
n+150
n Variation of fan speed with oil temperature
10
n-150
20 70 100
T huile (°C)
b The computer will chose the most unfavourable temperature value between the engine coolant,
transmission oil, hydraulic oil and engine boost air temperature.
VALUE OF FAN SPEED CONTROL PARAMETERS
Difference in
temperature
Engine coolant between the max. Hydraulic oil Transmission oil Engine inlet Control
Fan speed
temperature authorized value temperature temperature pressure current
(rpm)
(°C) and the boost air (°C) (°C) (Bar) (mA)
temperature
(°C)
T ≥ 75 (contact T ≥ 90 (contact
108 0 220 2280 0 MAX
maintained up to T < 60) maintained up to T < 75)
105 500
100 700
FAN SPEED
90 5 108 1570 800
80 900
10 1100
15 1200
30 1300
70 50 14 400 1400 MIN
Sensor and electrovalve electrical data sheets: e 80 - ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
(11/15/2013) 10-04-M218EN
10
10-04-M218EN (11/15/2013)
10
ENGINE REMOVAL
pages

ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– A – GRILL AND DRAINING HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– B – AIR AND WATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– C – HEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– D – LOWER HOSES AND FILTER SUPPORT BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– E – ELECTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– F – VENTILATION PUMP AND EXHAUST HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– G – SILENT BLOCS AND UNIVERSAL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– H – LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– I – STANDARD ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(7/11/2013) 10-06-M218EN
2 ENGINE REMOVAL
Stabilize the machine on level ground.

Perform several maneuvers in forward gear and reverse gear (wheels straight) in order to free the steering
10
and tires of any stresses.

Position the boom in the raised position and install the safety wedge.
b Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
Operate the fuel valve.

Place a tray under the engine.
The following operations must be performed:
e 10 - ENGINE CONTROL AND ADJUSTMENT:

 Movable engine cover removal
 Fixed engine cover removal
 Exhaust removal
 Air-conditioning belt and belt casing (option) removal
ENGINE REMOVAL
A – GRILL AND DRAINING HATCH
(Item 1) and the two small screws on the left (Item 2) (10 mm
wrench).
2
1 Remove the engine water draining hatch (center panel under
2
the housing), 2 screws (13 mm wrench).
Remove the plug and attach the drain hose.
1
B – AIR AND WATER HOSES
2
Disconnect the X164 air inlet temperature sensor (Item 1).
Remove the hose between the air filter and the turbo (Item 2),
1 undo the 2 clamps (7 mm wrench), plug the engine ports.
4
3
Remove the engine water outlet hose (Item 3), undo the 2
clamps (7 mm wrench) and the support clamp (13 mm wrench)
(Item 4), plug the engine ports.
5
Unclip the degassing line, remove the cooled air hose from the
engine radiator (Item 5), undo the clamps (7 mm wrench), plug
the engine ports.
Unscrew the upper 2 radiator silent blocks and keep it shifted
towards the front.
10-06-M218EN (7/11/2013)
ENGINE REMOVAL 3
2 C – HEATING CIRCUIT
Disconnect the upper hose (27 mm wrench) (Item 1).

Disconnect the lower hose (7 mm wrench) (Item 2).
10
3 Disconnect the engine water filling hosed (7 mm) (Item 3).
1
Near to the boom, remove the strut 2 screws (13 mm wrench).
4
D – LOWER HOSES AND FILTER SUPPORT
2 BRACKETS
Disconnect the engine water return hose, loosen the clamp

(7 mm wrench) and support clamp (13 mm wrench).
Remove the engine air outlet hose, loosen the clamp, 7 mm wrench.
1 On the diesel filter support bracket, disconnect the engine

3 supply hose, plug the opening on the filter, remove the 2
screws (15 mm wrench) and tilt the diesel filter support bracket
backwards (Item 1).
On the air filter support bracket, loosen the engine oil gage
dipstick clamp (Item 2).
Disconnect the water presence connector X178 (Item 3) and
clogging connector X166A and X166B (Item 4).
Remove the 3 screws (15 mm wrench) (Item 1), hold the bracket
in the backward position with a sling.
1
Disconnect the engine connector X277.
1
1 Disconnect the diesel return.
1
E – ELECTRICITY
Disconnect the pre-heating cable harness (8 mm wrench)

(Item 1) X167.
(7/11/2013) 10-06-M218EN
4 ENGINE REMOVAL
Next to the starter, disconnect the starter relay connector X281

and the starter battery positive connector (15 mm wrench)
(Item 1).
10
Place the exhaust support half clamps towards the left to leave
a clear passage to the flywheel.
1
Remove the harness support plate (Item 3), 3 screws (15 mm

wrench) : ground (Item 1), harness attachment (Item 2).
On the alternator, disconnect the excitation X59 (8 mm wrench)

and the starter power supply (13 mm wrench).
3
2 2
F – VENTILATION PUMP AND EXHAUST HOSES

1
On the ventilation pump, disconnect the pump supply hose
(41 mm wrench) and ventilation motor supply hose (30 mm
wrench).
Remove the turbo outlet exhaust bend (10 mm wrench)
G – SILENT BLOCS AND UNIVERSAL JOINT
Unscrew the 4 screws of the silent blocks (24 mm wrench) (Item 1).
Unscrew the 4 screws of the universal joint (10 mm wrench) by

blocking motor rotation.
1
H – LIFTING
Install the M12 lifting ring close to,the flywheel (Item 1).
10-06-M218EN (7/11/2013)
ENGINE REMOVAL 5
The suspension device must be adjustable to suit the engine

center of gravity.
10
Sling the engine.
Take out the engine.
I – STANDARD ENGINE REPLACEMENT
When replacing the engine :

1 - Remove the engine control unit in front of the cooler;
2 - The screws of the removed support brackets;
3 - Retain the following items from the removed engine, together
with their screws (e "Engine control and adjustment" for
tightening torques):
70 N.m ± 10%
+ Loctite 243
35 N.m ± 10%
H, 5/16-25
70 N.m ± 10%
+ Loctite 243
180 N.m ± 10%

+ Loctite 243
(7/11/2013) 10-06-M218EN
6 ENGINE REMOVAL
10
10-06-M218EN (7/11/2013)
10
ENGINE REFIT
pages

ENGINE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
POST REFIT ENGINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(9/6/2013) 10-07-M218EN
2 ENGINE REFIT
b Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.
10
Specific tooling: Jib crane (minimum 400 kg)
ENGINE REFIT
Position the engine.

Carry out the steps for removing the engine in the reverse order and observe the following instructions:
– Set the height of the cylinder block screws as shown opposite, with a tightening torque of 110 N.m
±10%;
– Refit the universal joint with new self-locking screws and a tightening torque of 60 N.m ±10%
POST REFIT ENGINE INSPECTION
– Fill the hydraulic oil, gear box and coolant liquid tanks.
– Operate the battery cut-off.
– Put the key in the ignition and warm up the vehicle, top up the levels.
– Test the engine for correct operation.
70 N.m ±10%
110 N.m ± 11 N.m
10-07-M218EN (9/6/2013)
10
ENGINE TROUBLESHOOTING
pages
FAULT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– ERROR INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION SWITCHING TEST:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
START-UP CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
LACK OF POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INJECTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FAN DRIVE CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
(10/11/2013) 10-08-M218EN
2 ENGINE TROUBLESHOOTING
FAULT TABLE
Fault Cause Measures

The engine Fuel tank empty Fill the fuel tank
10
starts with
Faulty electric fuel supply pump Check
difficulty or
not at all Clogged fuel intake line Check
Temperature below startup temperature limit Check
Cold start installation Check/Replace
Incorrect engine oil SAE viscosity Change lubrication oil
The fuel quality does not comply with the operating instructions Change fuel
Battery is faulty or not charged Check the battery
Wiring to starter loose or oxidized Check the cables
Faulty starter motor or pinion will not mesh Check the starter motor
Clogged air filter/ Faulty exhaust gas turbo-compressor Check/Replace
Air in the fuel supply system "Bleed fuel supply system"
Low compression pressure Check compression pressure
Engine exhaust gas back-pressure too high Check
Leaking injection line Check the injection line
The engine will The engine's electronic system prevents startup Check the fault according to the error code,
not start and eliminate the fault, if applicable
the diagnostic
lamp is
flashing
The engine Engine exhaust gas back-pressure too high Check
starts but runs
Low compression pressure Check compression pressure
erratically or
stops Cold start installation Check/Replace
Air in the fuel supply system Bleed
Fuel pre-filter clogged Clean
Defective injector Replace
Gear changes The engine electronic management system has detected a system error and Check the fault according to the error code,
are possible activated a replacement gear eliminate the fault, if applicable
and the
diagnostic
indicator light
comes on
The engine is Coolant bled pipe to expansion tank blocked Clean

too hot. The
temperature
warning
system is Faulty engine radiator Check/Replace
tripped Engine oil filter clogged on air or oil side Replace
Engine oil level too high Check oil level, empty if necessary
Oil level too low Fill lubricating oil
Heat exchanger coolant dirty Clean
Faulty coolant pump (V-belt broken or slack) Check whether the belt is broken or has come off
Cooling liquid fault Fill

Resistance in the cooling system is too high/Flow rate too low Check the cooling system
Charging air line not air-tight Check the air line
Charge air radiator clogged Check/Clean
10-08-M218EN (10/11/2013)
ENGINE TROUBLESHOOTING 3
Fault Cause Measures

The engine is Faulty air filter switch/Indicator lamp Check/Replace
too hot. The
Faulty fan / torn or slack v-belt Check the fan/the v-belt/replace if required
temperature
warning
Engine exhaust gas back-pressure too high Check
10
system is
tripped
The engine Engine oil level too high Check oil level, empty if necessary
lacks power
Fuel suction temperature too high Check the system
Faulty air filter switch/Indicator lamp Check/Replace
Faulty fan / torn or slack v-belt Check the fan/the v-belt/replace if required

Charge air radiator clogged Clean
Resistance in the cooling system is too high/Flow rate too low Check the cooling system
"Not all engine Leaking injection line Check the injection line
cylinders are
working"
Engine oil level too high Check oil level, empty if necessary
No or too low Oil level too low Fill lubricating oil
engine oil
Engine angle too steep Check engine position/Reduce inclination
pressure

Excessive Engine oil level too high Check oil level, empty if necessary
engine oil
consumption
Drain crankshaft sump Check/Replace

Oil i the Engine used with insufficient load (< 20-30%) for a long period Check the load factor
exhaust system
Engine Engine oil level too high Check oil level, empty if necessary
emitting blue
smoke
Engine Temperature below startup temperature limit Check

emitting white
Cold start installation Check/Replace
smoke
Engine exhaust Clogged air filter/ Faulty exhaust gas turbo-compressor Check/Replace
is black
Faulty air filter switch/Indicator lamp Check/Replace
Comment: Once all the faults have been repaired, the fault indicator will go off. For certain faults, it is
necessary to switch off the ignition and wait 30 s before switching it on again. In the event of a sensor
failure, the corresponding monitoring functions will be deactivated. Only the sensor failure is recorded
in the fault memory.
According to the configuration of the monitoring functions, the engine's electronic control system can
protect the engine in certain well-defined critical circumstances by ensuring that certain important limits
are not exceeded during operation and the correct operation of the system components. Depending
on the severity of a detected fault, the engine may continue running with restrictions, while the fault
indicator lamp remains on or flashes to indicate a severe system fault. In this event, the engine should
(10/11/2013) 10-08-M218EN
be switched off as soon as the interruption no longer presents any danger.
Error indicator lamp

10
The error indicator lamp is installed at the driver's position. The fault light can issue the following signals:
Operating control
– Ignition working, fault indicator lamp comes on for approx. 2 seconds then goes off.
– No reaction when ignition switched on, check the fault indicator lamp.
The indicator lamp does not come on
– After testing the indicator lamps, an indicator lamp that is not lit indicates no faults and no anomalies
within the limits of the test.
Indicator lamp permanently lit
System error.
– Limited operation.
– When the indicator lamp is permanently lit, a monitored reading (e.g. coolant temperature, lubricating
oil pressure) is no longer within the acceptable range.
According to the type of error, the engine power may be reduced by the electronic controller to protect
the engine.
IGNITION SWITCHING TEST:
Preheating lamp, engine fault lamp and the special "engine stop" lamp come on.
START-UP CONDITIONS
If the engine fails to start, this could be due to:

– The FNR switch being in the neutral position;
– The ECU power supply.
– The fuel pump. If the pressure is below 3,2 b, the engine will be prevented from starting. Disconnect
the sensor to make the system detect high default pressure. If the engine starts, check the fuel pump
and the fuel supply system;
– Missing or incorrect engine speed sensor response. The engine injection system starts as soon as
sensor synchronization is confirmed, otherwise it has difficulty starting with only one sensor;
– Insufficient fuel rail pressure at start-up;
– The fuel supply pressure with the engine running is less than 4 b.
LACK OF POWER
If the engine lacks power, check:

– The error codes;
– That the fuel pump flow rate is OK. If pressure is low (P<=3,4 b) the engine indicator lamp will light;
– That the fuel supply system is not obstructed or leaking;
– That the circuits are not overheating.
10-08-M218EN (10/11/2013)
ENGINE TROUBLESHOOTING 5
INJECTION CODE
b Warning: the injector number in the error codes is equal to the firing order but different than
10
the cylinder number
FAN DRIVE CHECK POINTS
There are two main cases:

1 - The fan runs continuously at maximum speed: this may be due to an electrical system control fault
(degraded mode) or a sticking electrovalve;
2 - The fan does not reach the desired speed: this may be caused by a lack of hydraulic power (motor
or pump) or a sticking electrovalve.
The following tests will help direct the repairs:
Test conditions Check to be performed Correct value Probable cause of failure

Test 0: Preliminary
Engine cold Take engine water, air filter (+17°C) and Ambient temperature Change the sensors, otherwise check
boost air temperature sensor readings harness continuity.
with a diagnostic tool.
Test 1: Validation of non degraded mode function.
Start-up cold engine, water, Place a tachometer in from of the fan. Fan speed Degraded mode: Check continuity of
air, oil temperature sensor < 1000 rpm at all engine speeds. harness, sensors, electrovalves.
readings < 40°C Perform test 2.
Test 2: Validation of hydraulic and transmission oil control + validation of hydraulic circuit power.
Cold engine at max. rpm Place a tachometer in from of the fan. Fan speed Check harness continuity between oil
1- Shunt connector X246 then X247. > 2000 rpm for each of the 3 temperature sensors and SPU terminal
connectors. X57-20.
2- Disconnect X252 For X252 : o Hydraulic control
Test 3: Validation of engine water control.

Hot engine (T>80 °C Place a tachometer in from of the fan. Fan speed Check continuity of harness and sensors.
opening of thermostat), Accelerate to max. rpm > 1200 rpm
allow the engine to warm Parameter readings:
up at min rpm. 1) 75 °C < water temperature < 85 °C
2) X252 driving current
Pressures in the system:

 Fan at max. speed, engine at max. rpm, oil cold:
200 b and 2300 rpm fan;
 Reversal cycle:
10 b minimum and approx. 110 b maximum during the blowing phase.
(10/11/2013) 10-08-M218EN
10
10-08-M218EN (10/11/2013)
10
SPECIFIC ENGINE TOOLING
pages
FAN BELT FITTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ELECTRONIC TENSION METER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ADDITIONAL ENGINE TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(11/21/2013) 10-09-M218EN
2 SPECIFIC ENGINE TOOLING
FAN BELT FITTING TOOL

Tool for facilitating elastic belt installation (Ref. 894113).
10
ELECTRONIC TENSION METER

Electronic tension meter (Ref 895692) for controlling belt tension.
ADDITIONAL ENGINE TOOLS
l 647461EN (TCD 3.6 L4 ENGINE) - SPECIFIC TOOLING
10-09-M218EN (11/21/2013)

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ENGINE

- ENGINE CIRCUITS FLOW DIAGRAM

- ENGINE COMPONENTS LOCATION

- ENGINE CONTROL AND ADJUSTMENT

- SPECIFIC ENGINE TOOLING

- REFIT (ENGINE TCD 3.6 L4)

 Anti-clockwise (viewed from flywheel)

AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . .2

AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation)

Controls the flow of exhaust gases towards the intake.

DIESEL FUEL CIRCUIT

Max. fuel supply. Pressure: 8 bar.

2 - Alternator belt 19 - Water temperature sensor

WATER AND AIR COOLING CIRCUIT

HYDRAULIC VENTILATION SYSTEM

2 - Oil return 8 - Cooler

DIESEL FUEL CIRCUIT

FUEL INJECTION CIRCUIT

2 - High pressure pump 8 - PRV return

Red circuit = 350 - 1800 bar

EGR (Exhaust Gas Recirculation) CIRCUIT

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.

COMPONENT REMOVAL / REFIT

A – MOVABLE ENGINE COVER REMOVAL

Remove the mobile cover.

B – RADIATOR AND FAN MOTOR REMOVAL

Drain the water and oil radiators.

Remove the expansion tank (2 nuts, 1 connector) and its support

6 Unscrew the bottom 2 silent blocks.

C – RADIATOR AND FAN MOTOR REFIT

When carrying out a replacement, retain:

Pass a sling through the hole at the cap (grommet) location

Refit the hydraulic hoses.

Attach the engine water boost pressure line (Item 1) to the

Attach the expansion tank mounting flange (Item 4).

Start-up and check the levels.

D – FAN HYDRAULIC MOTOR REMOVAL / REFIT

 Carry out the "MOVABLE ENGINE COVER REMOVAL"

Lay the radiator flat, remove the grill, 4 screws.

Undo the nut securing the fan to the motor shaft.

Detach the tapered fan motor shaft by hitting with a hammer

 Carry out the "MOVABLE ENGINE COVER REMOVAL"

Remove the shroud (Item 1) then detach the radiator by removing

Change the faulty compartment.

F – VENTILATION PUMP REMOVAL / REFIT

Wynns SG311 lubricant on pinion.

Hose couplings: 45 N.m (Item 2), 40 N.m (Item 3) ±10%.

G – ENGINE OIL DIPSTICK FITTING INSTRUCTIONS

1 - CUTTING THE DIPSTICK

 Undo the 2 screws (Fig. 1, (Item 1)) and remove the

as the dipstick (Fig. 1, (Item 3)).

 Ensure that, when installed, the guide tube does not

 Fit the handle on the dipstick, set the margin to 5 mm

H – FIXED ENGINE COVER REMOVAL

Remove the 4 screws at the rear (Item 1).

 Carry out the "MOVABLE ENGINE COVER REMOVAL"