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SERVICE

MANUAL SERVICE MANUAL


8035.05.716 8035.05.716 / 8035.25C.313T /
8035.25C.313T 8035.25D.313T / 8045.05.260 /
8035.25D.313T
8045.05.260 8045.05.716 / 8045.05R.939T /
8045.05.716 8045.25.260 / 8045.25.261 /
8045.05R.939T
8045.25.260
8045.25.262 / 8045.25L.939T
8045.25.261 S8000
8045.25.262 Engine
8045.25L.939T
S8000
Engine

Part number 47454136 Part number 47454136


1st edition English
November 2013

Copyright © 2013 CNH America LLC. All Rights Reserved.


Contents

INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

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

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

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

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

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


[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

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INTRODUCTION

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Contents

INTRODUCTION

Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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INTRODUCTION

Foreword - Ecology and the environment


Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:

• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be
harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not
be allowed to get into the soil, but should be collected and disposed of properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.
Your CNH dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the
system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.

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

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

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

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

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

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


IN DEATH OR SERIOUS INJURY.

Machine safety
NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color
associated with Notice is BLUE.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.

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

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

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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.

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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 unless instructed otherwise.
• 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.
• While 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 jeopardize 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 "Service Parts Catalogue", used for order processing

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INTRODUCTION

Protecting the electrical/electronic systems during charging or 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 quan-
tities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A

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 machine or on any attachments
on the machine.
• 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 machine
• 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 machine with a battery
charger.
NOTICE: If welding must be performed on the unit, the battery ground cable must be disconnected from the machine
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.

Tools
The tools that CNH suggests and illustrated 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

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
in) in) in) in) in) in)
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)
85 N·m (63 lb 121 N·m (90 lb 58 N·m (43 lb 83 N·m (61 lb
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
in) in) in) in) in) in)
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
in) in) in) in) in) in)
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
in) in) in) in) in) in)
20 N·m (179 lb 27 N·m (240 lb 29 N·m (257 lb 39 N·m (343 lb 18 N·m (163 lb 27 N·m (240 lb
M8
in) in) in) in) in) in)
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)
174 N·m (128 lb 231 N·m (171 lb 248 N·m (183 lb 331 N·m (244 lb 158 N·m (116 lb 226 N·m (167 lb
M16
ft) ft) ft) ft) ft) ft)
350 N·m (259 lb 467 N·m (345 lb 484 N·m (357 lb 645 N·m (476 lb 318 N·m (235 lb 440 N·m (325 lb
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)
261 N·m 348 N·m 369 N·m 491 N·m 271 N·m (200 lb 383 N·m (282 lb
3/4
(193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) ft) ft)
420 N·m 561 N·m 594 N·m 791 N·m 437 N·m (323 lb 617 N·m (455 lb
7/8
(310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) ft) ft)
630 N·m 841 N·m 890 N·m 1187 N·m 654 N·m (483 lb 924 N·m (681 lb
1
(465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft) ft) ft)

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

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INTRODUCTION

INCH FLANGED HARDWARE


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
12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 12 N·m (106 lb
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
19 N·m (168 lb 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb 24 N·m (212 lb
5/16
in) in) in) in) in) in)
33 N·m (25 lb 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb
3/8 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft) ft)
53 N·m (39 lb 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb
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)
287 N·m (212 lb 383 N·m 405 N·m 541 N·m 261 N·m (193 lb 369 N·m (272 lb
3/4
ft) (282 lb ft) (299 lb ft) (399 lb ft) ft) ft)
462 N·m (341 lb 617 N·m 653 N·m 871 N·m 421 N·m (311 lb 594 N·m (438 lb
7/8
ft) (455 lb ft) (482 lb ft) (642 lb ft) ft) ft)
693 N·m (512 lb 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb 890 N·m (656 lb
1
ft) (682 lb ft) (722 lb ft) (963 lb ft) ft) ft)

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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SERVICE MANUAL
Engine

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

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

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

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

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

47454136 25/11/2013
10
Engine - 10

Engine and crankcase - 001

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
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Contents

Engine - 10

Engine and crankcase - 001

TECHNICAL DATA

Engine
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA

Engine
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE

Crankcase
Liner - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Liner - Rebore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Liner - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models

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Engine - Engine and crankcase

Engine - General specification


8035.25C.313T

Specifications
Engine type 4–stroke diesel
Fuel injection Direct
Number of cylinders 3
Orientation of cylinders In-line
Bore 104 mm (4.094 in)
Stroke 115 mm (4.528 in)
Displacement 2931 cm³ (178.9 in³)
Compression ratio 18 : 1
Maximum power at 2300 RPM 48 kW (65 Hp)
Maximum torque at 1400 RPM 261 N·m (192.5 lb ft)
Number of main bearings 4
Oil pan construction Structural, Cast iron

Engine - General specification


8035.25D.313T

Specifications
Engine type 4–stroke diesel
Fuel injection Direct
Number of cylinders 3
Orientation of cylinders In-line
Bore 104 mm (4.094 in)
Stroke 115 mm (4.528 in)
Displacement 2931 cm³ (178.9 in³)
Compression ratio 18 : 1
Maximum power at 2300 RPM 53 kW (72 Hp)
Maximum torque at 1400 RPM 295 N·m (217.6 lb ft)
Number of main bearings 4
Oil pan construction Structural, Cast iron

Engine - Service limits


Specifications
Inside diameter of cylinder liners 104.000 - 104.024 mm (4.094 - 4.095 in)
Outside diameter of cylinder liners 107.020 - 107.050 mm (4.213 - 4.215 in)
Diameter of cylinder bores 106.850 - 106.900 mm (4.207 - 4.209 in)
Interference fit between cylinder liners and bores 0.120 - 0.200 mm (0.005 - 0.008 in)
Liner internal diameter oversizes 0.4 - 0.8 mm (0.016 - 0.031 in)
Liner external diameter oversizes 0.2 mm (0.008 in)
Maximum permissible liner ovality or taper due to wear 0.12 mm (0.005 in)
Diameter of crankshaft bore 84.200 - 84.230 mm (3.315 - 3.316 in)
Diameter of camshaft bore
- Front 54.780 - 54.805 mm (2.157 - 2.158 in)
- Middle 54.280 - 54.305 mm (2.137 - 2.138 in)
- Rear 53.780 - 53.805 mm (2.117 - 2.118 in)
Diameter of tappet bore 15.000 - 15.018 mm (0.591 - 0.591 in)
Spare tappet oversizes 0.1 mm (0.004 in)
0.2 mm (0.008 in)
0.3 mm (0.012 in)

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Engine - Engine and crankcase

Engine - Sectional view

NHIL12ENG0237AA 1

(1) Rocker shaft pedestal bolts (5) Main bearing cap bolts
(2) Cylinder head bolts (6) Fan and alternator pulley bolts
(3) Flywheel bolts (7) Crankshaft hub bolts
(4) Big-end cap bolts

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Engine - Engine and crankcase

NHIL12ENG0238AA 2

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Engine - Engine and crankcase

Crankcase Liner - Measure

NHIL12ENG0321AA 1

1. Use figure 1 to measure the cylinder liners.


2. Measure the upper and lower ends of area (X) parallel
to the crankshaft (a) and perpendicular to the crank-
shaft (b).
3. Compare the measured values to determine liner oval-
ity and taper. The values should not exceed 0.12 mm
(0.005 in).
4. Measure area (Z) parallel to the crankshaft (a) and per-
pendicular to the crankshaft (b).
5. Compare the measured value with the diameter of
the piston. The calculated value should not exceed
0.3 mm (0.012 in).
6. Bore the cylinders or replace the liners if any of the
values above are exceeded.

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Engine - Engine and crankcase

Crankcase Liner - Rebore


1. Determine if boring the cylinder liner is necessary
by following steps in Crankcase Liner - Measure
(10.001).
NOTICE: If one liner requires boring, all of the liners in the
engine must be bored to the same oversize and matched
with a piston of the same size.
2. Bore the liners to 0.4 - 0.8 mm (0.016 - 0.031 in) over-
size.
3. Restore the 30 ° chamfer 0.5 mm (0.020 in) into the
liner as shown in the figure.
4. Follow the steps in Crankcase Liner - Measure
NHIL12ENG0319AA 1
(10.001) to verify that the liners are within specifica-
tions.
5. Replace the liners if they are still outside of the accept-
able ranges.

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Engine - Engine and crankcase

Crankcase Liner - Replace


1. Press the liner from the bottom side of the crankcase.
2. Measure the ovality of the bore in the crankcase and
rebore if necessary to 0.22 mm (0.009 in) oversize.
3. Press the new liner into the top of the crankcase.
4. Bore the new liner according to the specifications out-
lined in Crankcase Liner - Rebore (10.001).

NHIL12ENG0320AA 1

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Index

Engine - 10

Engine and crankcase - 001


Crankcase Liner - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankcase Liner - Rebore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankcase Liner - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models

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Engine - 10

Cylinder heads - 101

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Engine - 10

Cylinder heads - 101

TECHNICAL DATA

Cylinder heads
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Injector cup - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valves
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valve guide
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve seat
Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - Cylinder heads

Cylinder heads - Service limits


Specifications
Original height of cylinder head 92 mm (3.622 in)
Maximum surface regrinding depth 0.5 mm (0.02 in)
Diameter of valve guide bores 13.950 - 13.983 mm (0.549 - 0.551 in)
Outside diameter of valve guides 13.993 - 14.016 mm (0.551 - 0.552 in)
Guide interference fit in bores 0.010 - 0.066 mm (0.0004 - 0.003 in)
Inside diameter of valve guide (installed in head) 8.023 - 8.043 mm (0.316 - 0.317 in)
Valve stem diameter 7.985 - 8.000 mm (0.314 - 0.315 in)
Assembly clearance between valve stem and guide 0.023 - 0.058 mm (0.001 - 0.002 in)
Maximum permissible clearance 0.13 mm (0.005 in)
Maximum run-out of valve measured from the valve head 0.03 mm (0.001 in)
Valve guide oversizes 0.2 mm (0.008 in)
Valve seat angle
- Intake valve 60 °
- Exhaust valve 45 °
Valve face angle
- Intake valve 61 °
- Exhaust valve 46 °
Valve head diameter
- Intake valve 45.300 - 45.500 mm (1.783 - 1.791 in)
- Exhaust valve 37.500 - 37.750 mm (1.476 - 1.486 in)
Valve recess 0.7 - 1.0 mm (0.028 - 0.039 in)
Maximum permissible valve recess 1.3 mm (0.051 in)
Valve spring height
- Free height 46 mm (0.181 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
- Under a load of 502 - 544 N (113 - 122 lb) 23.8 mm (0.051 in)
Injector protrusion 0.3 - 1.1 mm (0.012 - 0.043 in)

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Engine - Cylinder heads

Valve cover - Remove


1. Remove the nuts, washers, and seals.
2. Remove the valve cover (1).

NHIL12ENG0268AA 1

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Engine - Cylinder heads

Valve cover - Install


1. Install the the valve cover (1) onto the cylinder head.
2. Install the washers and seals.
3. Torque the retaining nuts to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0268AA 1

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Engine - Cylinder heads

Cylinder head - Remove


1. Remove the bolts (1).
2. Lift the cylinder head (2) from the crankcase using a
suitable hoist.
3. Remove the cylinder head gasket.

NHIL12ENG0271AA 1

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Engine - Cylinder heads

Cylinder head - Install


1. Clean the surface of the crankcase (1).
2. Install the head gasket with the word TOP (ALTO) fac-
ing up.

NHIL12ENG0313AA 1

3. Install the cylinder head.


4. Install the cylinder head bolts (1).
5. Torque the bolts in the following phases using the
torque order diagram in figure 3.
1. Torque the bolts to 70 N·m (52 lb ft).
2. Check the bolts to ensure an even torque of
70 N·m (52 lb ft).
3. Use the angular torque gauge tool DM370(3/4) to
turn the bolts 90 °.
4. Turn the bolts an additional 90 °.
NHIL12ENG0315AA 2

NHIL12ENG0314AA 3
(A) = front

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Engine - Cylinder heads

Cylinder head Injector cup - Replace


Prior operation:
Fuel injectors - Measure - Protrusion (10.218)

NOTE: Use the injector sleeve replacement tool kit 380000246 for the following steps.
1. Install the ring nut (4) onto the tap (2) so that the bottom
edge of the ring nut is 9 mm (0.354 in) from the end of
the tap.
2. Tighten the set screw (3) to keep the ring nut from mov-
ing.
3. Cut an internal thread into the injector sleeve (1).
NOTICE: Ensure the threads are only being cut into the
injector sleeve.

NHIL12ENG0356AA 1

NOTE: Refer to figure 2 for the following steps.


4. Install the mounting nuts (3) for the injectors onto the
studs in the cylinder head.
5. Install the injector sleeve puller 380000832 (2) onto the
injector mounting studs in the cylinder head.
6. Install the threaded shaft (4) into the threaded injector
cup.
7. Tighten the nut (1) to extract the injector cup from the
cylinder head.
8. Remove any copper residue from the inside of the head
(5).
9. Install the O ring seals (7) on the new injector cup.
10. Install the injector cup into its bore.
NOTICE: Ensure that the cup is tight against the bottom of
its seat in the cylinder head.
11. Dress the injector cups using tool 380000834 (6).
12. Install the guide bushing 380000830 (8) into the injec-
tor cup and tighten the ring nut (10).
13. Install the reamer (9) and ream the lower portion of
the injector cup.
14. Remove the guide bushing.
15. Install the cutter (11).
16. Install the guide bushing.
17. Work with the cutter to remove any imperfections in
the sealing surface.
18. Remove the tools from the injector cup.
19. Install the injector and check that the injector protru-
sion is within 0.3 - 1.1 mm (0.012 - 0.043 in).

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Engine - Cylinder heads

NHIL12ENG0359AA 2

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Engine - Cylinder heads

Valves - Remove
1. Remove the collets (1) from the valve stems.
2. Turn the cylinder head over and remove the valves.

NHIL12ENG0270AA 1

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Engine - Cylinder heads

Valves - Install
1. Insert the valves into the cylinder head.
2. Turn the cylinder head over.
3. Install the collets (1) onto the valve stems to retain the
valves.

NHIL12ENG0270AA 1

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Engine - Cylinder heads

Valves - Measure
1. Measure the valves as shown in figure 1.
2. Check that the step below the valve contact band is no
less than 0.5 mm (0.020 in).
(1) - Exhaust valve
(2) - Intake valve

NHIL12ENG0339AA 1

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Engine - Cylinder heads

Valve guide - Replace


1. Enlarge the bore of the valve guide with a drill.
2. Use valve guide punch 380000219 (1) to remove the
valve guide.

NHIL12ENG0345AA 1

3. Drive the new valve guide into the bore of the cylin-
der head using valve guide punch 380000219 (1) and
bushing 380000242 (2).

NHIL12ENG0346AA 2

4. Ream the new valve guide bore using 380000222 (1).

NHIL12ENG0347AA 3

NOTICE: If the exhaust valve guides have been replaced, the inside bore must be tapered on the end. Follow steps
5 through 15 to properly mill the valve guide.
5. Measure the distance (L) between the cylinder head
face and the base of the valve guide with a caliper
gauge and the plate from tool kit 380000277.
6. Determine the depth of taper by subtracting the mea-
sured value (L) in step 5 from 43.4 mm (1.709 in). The
result is the depth of which the valve guide should be
milled to obtain the correct amount of taper within a tol-
erance of 0.25 mm (0.010 in).

NHIL12ENG0348AA 4

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Engine - Cylinder heads

7. Install the guide bushing (1) from tool kit 380000277 on


the top side of the valve guide to be milled.

NHIL12ENG0349AA 5

8. Slide the cutter (2) and depth stop (1) from tool kit
380000277 into the valve guide until the cutting head
is in contact with the valve guide.

NHIL12ENG0350AA 6

9. Install the plate (3) from tool kit 380000277 around the
cutter shaft (1) flush against the cylinder head face.
10. Slide the depth stop (2) up to the plate.
11. Measure the distance (A) between the depth stop and
the end of the cutter shaft.

NHIL12ENG0351AA 7

12. Determine the position of the depth stop by subtract-


ing the depth of taper obtained in step 6 from the cutter
shaft length obtained in step 11.
13. Lock the depth stop at the distance (D) obtained in
step 12 measured from the end of the cutter shaft (1)
to the top of the depth stop (3).
14. Tighten the set screw (2) to prevent the depth stop
from moving.

NHIL12ENG0352AA 8

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Engine - Cylinder heads

15. Turn the cutter (2) until the depth stop (1) comes in
contact with the plate (3).
NOTICE: Thoroughly clean the cylinder head after all the
valve guides have been milled.

NHIL12ENG0353AA 9

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Engine - Cylinder heads

Valve seat - Resurface


1. Use a universal valve seat grinder (1) to improve the
sealing surface of the valve seats.
NOTICE: Remove as little material as possible.

NHIL12ENG0354AA 1

NHIL12ENG0355AA 2

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Index

Engine - 10

Cylinder heads - 101


Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head Injector cup - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder heads - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valve guide - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve seat - Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10

Pan and covers - 102

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.3 [10.102] / 1
Contents

Engine - 10

Pan and covers - 102

SERVICE

Engine oil pan


Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine block cover
Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timing gear housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Pan and covers

Engine oil pan - Remove


1. Remove the oil pan cover bolts.
2. Remove the oil pan cover (1) and gasket (2).
3. Remove the bolts from the oil pan.
4. Install lifting hooks.
5. Use a suitable hoist and remove the oil pan.

NHIL12ENG0272AA 1

6. Remove the rear seal (1).

NHIL12ENG0275AA 2

7. Remove the front seal (1).

NHIL12ENG0274AA 3

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Engine - Pan and covers

Engine oil pan - Install


1. Install the front seal (1).

NHIL12ENG0274AA 1

2. Install the rear seal (1).


3. Install lifting hooks onto the oil pan.
4. Use a suitable hoist and install the oil pan onto the
engine block.

NHIL12ENG0275AA 2

5. Torque the oil pan bolts to 39 - 49 N·m (29 - 36 lb ft).


6. Install the oil pan cover (1) and gasket (2).
7. Torque the oil pan cover bolts to 20 - 30 N·m (15 - 22 lb
ft).

NHIL12ENG0272AA 3

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Engine - Pan and covers

Engine block cover Front - Remove


1. Remove the timing gear cover (1).

NHIL12ENG0281AA 1

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Engine - Pan and covers

Engine block cover Front - Install


1. Install the timing gear cover (2).
2. Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0281AA 1

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Engine - Pan and covers

Timing gear housing - Remove


1. Remove the bolts (1).
2. Remove the timing gear housing (2).

NHIL12ENG0287AA 1

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Engine - Pan and covers

Timing gear housing - Install


1. Replace the O-ring seal (1) for the lubrication line to the
drive shaft of the fuel lift pump.

NHIL12ENG0288AA 1

2. Install the timing gear housing (2).


3. Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0287AA 2

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Index

Engine - 10

Pan and covers - 102


Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10

Crankshaft and flywheel - 103

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
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Contents

Engine - 10

Crankshaft and flywheel - 103

TECHNICAL DATA

Crankshaft and flywheel


Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankshaft pulley
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flywheel housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft oil seal
Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main bearings
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Engine - Crankshaft and flywheel

Crankshaft and flywheel - Service limits


Specifications
Journal diameter 79.791 - 79.810 mm (3.141 - 3.142 in)
Journal undersizes 0.254 mm (0.01 in)
0.508 mm (0.02 in)
0.762 mm (0.03 in)
1.016 mm (0.04 in)
Main bearing shell thickness 2.168 - 2.178 mm (0.085 - 0.086 in)
Main bearing shell undersizes (insidel diameter) 0.254 mm (0.01 in)
0.508 mm (0.02 in)
0.762 mm (0.03 in)
1.016 mm (0.04 in)
Bearing shell to journal clearance 0.034 - 0.103 mm (0.001 - 0.004 in)
Maximum permitted wear clearance 0.180 mm (0.007 in)
Crankpin diameter 63.725 - 63.744 mm (2.509 - 2.51 in)
Crankpin undersizes 0.254 mm (0.01 in)
0.508 mm (0.02 in)
0.762 mm (0.03 in)
1.016 mm (0.04 in)
Big-end bearing shell thickness 1.805 - 1.815 mm (0.0711 - 0.0715 in)
Big-end bearing shell undersizes (insidediameter) 0.254 mm (0.01 in)
0.508 mm (0.02 in)
0.762 mm (0.03 in)
1.016 mm (0.04 in)
Big-end bearing shell to crankpin clearance 0.033 - 0.087 mm (0.001 - 0.003 in)
Maximum permitted wear clearance 0.180 mm (0.007 in)
Crankshaft thrust washer thickness 3.378 - 3.429 mm (0.133 - 0.135 in)
Thrust washer oversizes (thickness) 0.127 mm (0.005 in)
0.254 mm (0.01 in)
0.381 mm (0.015 in)
0.508 mm (0.02 in)
Width of main bearing including thrust washers 31.766 - 31.918 mm (1.251 - 1.257 in)
Width of corresponding crankshaft journal 32.000 - 32.100 mm (1.26 - 1.264 in)
Crankshaft assembly end play 0.082 - 0.334 mm (0.003 - 0.013 in)
Maximum permitted end play 0.40 mm (0.016 in)
Maximum ovality or taper of journals and crankpin after 0.01 mm (0.0004 in)
regrinding
Maximum ovality or taper of journals and crankpin 0.05 mm (0.002 in)
Maximum tolerance for alignment of crankshaft journals 0.10 mm (0.004 in)
with crankshaft supported on the two outer journals
Maximum tolerance for alignment, in both directions, of 0.25 mm (0.01 in)
crankpins or each pair of crankpins
Maximum tolerance for run-out between the outer 0.10 mm (0.004 in)
surfaces of the crankshaft journals and the crankshaft
centerline
Maximum permitted tolerance on flywheel run-out 0.025 mm (0.001 in)
Maximum permitted tolerance on flywheel co-axial 0.04 mm (0.0016 in)
alignment

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Engine - Crankshaft and flywheel

Engine flywheel - Remove


1. Remove the bolts (1).
2. Remove the flywheel (2) with a suitable hoist.

NHIL12ENG0303AA 1

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Engine - Crankshaft and flywheel

Engine flywheel - Install


1. Use the diagram in figures 1 and 2 to measure the
diameter of the bolts for the flywheel prior to reusing
them. If the measured value in area (a) is less than
13.5 mm (0.531 in), replace the bolts with new.
2. Lubricate the bolts with clean engine oil.

NHIL12ENG0328AA 1

NHIL12ENG0329AA 2

3. Install the flywheel (1).


NOTE: The mounting holes in the flywheel are offset so
that it can only be mounted in one position.
4. Torque the bolts (2) to 40 N·m (30 lb ft).

NHIL12ENG0303AA 3

5. Use the angular torque gauge tool 380001001 to turn


the bolts 60 °.

NHIL12ENG0304AA 4

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Engine - Crankshaft and flywheel

Engine flywheel - Replace - Ring gear


1. Remove the damaged ring gear with a press.
2. Heat the new ring gear in oil to 80 - 90 °C (176 - 194 °F).
3. Position the ring gear with the bevel on the teeth facing
towards the starter motor.

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Engine - Crankshaft and flywheel

Crankshaft pulley - Remove


1. Remove the bolts (2).
2. Remove the pulley (1).

NHIL12ENG0278AA 1

3. Straighten the lock tab on the crankshaft nut.


4. Remove the nut (1).

NHIL12ENG0279AA 2

5. Install puller 380000226 (1) on the crankshaft.


6. Remove the pulley hub from the crankshaft.
NOTE: Retain the woodruff key for installation.

NHIL12ENG0280AA 3

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Engine - Crankshaft and flywheel

Crankshaft pulley - Install


1. Use the woodruff key and install the pulley hub onto the
crankshaft.

NHIL12ENG0280AA 1

2. Install the engine turning blocking tool 380000988 onto


the flywheel housing.
3. Torque the nut (1) to 287 - 301 N·m (212 - 222 lb ft).
4. Install the lock tab on the crankshaft nut.

NHIL12ENG0279AA 2

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


6. Torque the bolts (2) to 105 - 115 N·m (77 - 85 lb ft).

NHIL12ENG0278AA 3

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Engine - Crankshaft and flywheel

Flywheel housing - Remove


1. Remove the bolts.
2. Remove the flywheel housing (1).
NOTE: The flywheel housing is doweled to the crankcase.
Light tapping with a plastic hammer may be necessary to
remove.

NHIL12ENG0293AA 1

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Engine - Crankshaft and flywheel

Flywheel housing - Install


1. Clean the sealing surface of the crankcase and the fly-
wheel housing.
2. Install the new gasket and flywheel housing (1) onto the
crankcase.

NHIL12ENG0293AA 1

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Remove


1. Remove the bolts (1).
2. Remove the crankshaft pulley (2).

NHIL12ENG0361AA 1

3. Straighten the tab on the lock washer.


4. Remove the nut for the pulley hub (1).

NHIL12ENG0362AA 2

5. Use tool 380000226 (1) to remove the pulley hub from


the crankshaft.
NOTE: Be sure to retrieve the woodruff key.

NHIL12ENG0363AA 3

6. Remove the front crankshaft seal (1).

NHIL12ENG0364AA 4

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install


1. Install the front crankshaft seal (1).

NHIL12ENG0364AA 1

2. Install the woodruff key.


3. Install the crankshaft pulley hub.
4. Install the lock washer and nut (1).
5. Torque the nut to 294 N·m (217 lb ft).
6. Bend the tab on the lock washer over the nut.

NHIL12ENG0362AA 2

7. Install the crankshaft pulley.

NHIL12ENG0361AA 3

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Remove


1. Remove the rear seal carrier (1) and gasket.

NHIL12ENG0291AA 1

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install


1. Install the rear seal housing (1).
2. Torque the bolts to 25 N·m (18 lb ft).
3. Use a feeler gauge (2) to make sure the crankshaft hub
(3) is centered in the housing.

NHIL12ENG0301AA 1

4. Install the seal using a suitable driver.

NHIL12ENG0302AA 2

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Engine - Crankshaft and flywheel

Crankshaft - Remove
1. Mark the main bearing caps to ensure proper installa-
tion.
2. Remove the bolts (1).
3. Remove the main bearing caps (2) and main bearings.
4. Remove the thrust washers located on main bearing
number four (3).
5. Lift the crankshaft (4) from the crankcase using a suit-
able hoist and a nylon sling.
6. Remove the bearing shells and thrust washers.

NHIL12ENG0292AA 1

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Engine - Crankshaft and flywheel

Crankshaft - Measure
1. Clean all parts of the crankshaft.
2. Inspect the crankshaft for any cracks, seizure, or scor-
ing. Any visible cracks will require crankshaft replace-
ment. Slight scoring or seizure marks can be removed
with a fine grade emery cloth.
3. If scoring, ovality or taper exceeds 0.05 mm (0.002 in)
the crankshaft will have to be re-ground.
4. Measure the journal (1) diameter to determine the near-
est undersize.
5. Restore the journal and crankpin radii and fillets ac-
cording to figure 2.
NHIL12ENG0322AA 1
6. Perform the following checks:
• The main journal and crankpin ovality does not ex-
ceed 0.008 mm (0.0003 in).
• The main journal and crankpin taper does not ex-
ceed 0.01 mm (0.0004 in).
• The misalignment of the main bearing journals do
not exceed 0.10 mm (0.004 in). Figure 3.
• The center lines of the crankpins lie in the same
plane as the main journal center lines, with a maxi-
mum deviation of 0.25 mm (0.010 in) as measured
perpendicularly to the same plane. Figure 2.
• The distances between the outer surfaces of the
crankpins and the crankshaft center line are equal
with a tolerance of 0.10 mm (0.004 in).
• The run-out measured with the dial gauge contact
point resting on surface (A) figure 2, does not exceed
0.025 mm (0.001 in).

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Engine - Crankshaft and flywheel

NHIL12ENG0323AA 2

NHIL12ENG0324AA 3

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Engine - Crankshaft and flywheel

Crankshaft - Install
1. Use the diagram in figure 1 to measure the diameter
of the bolts for the main bearing caps prior to reusing
them. If the measured value in area (a) is less than
13.5 mm (0.531 in), replace the bolts with new.

NHIL12ENG0326AA 1

2. Install the main bearings (1) into the crankcase.


3. Install the thrust washers (2) to both sides of the num-
ber four main bearing.
NOTE: Use grease to hold the thrush washers in place until
the crankshaft is installed.

NHIL12ENG0295AA 2

4. Lubricate the surface of the main bearings with clean


engine oil.
5. Carefully install the crankshaft (1) into the crankcase.
NOTICE: Be sure the thrust washers were not disturbed
during installation of the crankshaft.

NHIL12ENG0296AA 3

6. Lubricate the crankshaft main journals with clean en-


gine oil.
7. Install the lower half of the main bearings into the main
bearing caps.
8. Lubricate the surface of the main bearings.
9. Install the thrust washers (1) with the number four main
bearing cap.
10. Install the main bearing caps and hand tighten the
bolts.
11. Rotate the crankshaft to allow the parts to settle into
position. NHIL12ENG0297AA 4

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Engine - Crankshaft and flywheel

12. Torque the bolts to 80 N·m (59 lb ft).

NHIL12ENG0298AA 5

13. Use the angular torque gauge tool DM370(3/4) to turn


the bolts 90 °.

NHIL12ENG0299AA 6

Next operation:
Crankshaft - End play (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - End play


1. Install a dial indicator (1) on the end of the crankshaft
(2) as shown in the figure.
2. Use a pry bar (3) to move the crankshaft along its hor-
izontal axis.
3. The measured value should be within 0.082 -
0.334 mm (0.003 - 0.013 in).
4. Replace the thrust washers if the measured value is not
within range.

NHIL12ENG0300AA 1

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Engine - Crankshaft and flywheel

Main bearings - Measure


1. Clean all parts.
2. Install the upper bearing halves in the crankcase.
3. Carefully install the crankshaft (1).
4. Place plastic-gauge (2) across the width of the crank-
shaft journals (6).
5. Install the main bearing caps (3) with the lower bearing
halves (4).
6. Lubricate the bolts for the main bearing caps with clean
engine oil.
7. Torque the bolts to 80 N·m (59 lb ft). NHIL12ENG0325AA 1

8. Turn the bolts an additional 90 °.


9. Remove the main bearing caps.
10. Measure the plastic-gauge at the widest point using
the scale on the package (5).
11. The measured value should not exceed 0.103 mm
(0.004 in).

47454136 25/11/2013
10.4 [10.103] / 21
Index

Engine - 10

Crankshaft and flywheel - 103


Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft and flywheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankshaft pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine flywheel - Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flywheel housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flywheel housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main bearings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

47454136 25/11/2013
10.4 [10.103] / 22
Engine - 10

Connecting rods and pistons - 105

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.5 [10.105] / 1
Contents

Engine - 10

Connecting rods and pistons - 105

TECHNICAL DATA

Connecting rods and pistons


Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Connecting rod and piston


Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

47454136 25/11/2013
10.5 [10.105] / 2
Engine - Connecting rods and pistons

Connecting rods and pistons - Service limits


Specifications
Diameter of small end bushing seat 41.846 - 41.884 mm (1.647 - 1.649 in)
Outside diameter of small end bushing 41.979 - 42.017 mm (1.653 - 1.654 in)
Interference between small end bushing and seat 0.095 - 0.171 mm (0.004 - 0.007 in)
Inside diameter of small end bushing (installed) 38.004 - 38.014 mm (1.496 - 1.497 in)
Diameter of big end shell bearing seats 67.407 - 67.422 mm (2.654 - 2.654 in)
Maximum tolerance for bend between the small end and 0.07 mm (0.003 in)
big end axes measured at 25 mm (0.984 in)
Maximum weight difference between connecting rods 25 g (0.882 oz)
Piston diameter 103.852 - 103.870 mm (4.089 - 4.089 in)
Piston clearance in cylinder liner 0.130 - 0.172 mm (0.005 - 0.007 in)
Maximum permitted clearance 0.30 mm (0.012 in)
Piston oversizes 0.6 mm (0.024 in)
Piston protrusion at Top Dead Center (TDC) from 0.355 - 0.761 mm (0.014 - 0.03 in)
cylinder block face
Piston pin Diameter 37.983 - 37.990 mm (1.495 - 1.5 in)
Diameter of piston pin bore 37.994 - 38.000 mm (1.4958 - 1.4961 in)
Piston pin to pin bore clearance 0.004 - 0.017 mm (0.0002 - 0.0007 in)
Piston pin to small end bearing clearance 0.014 - 0.031 mm (0.0006 - 0.0012 in)
Maximum permitted wear clearance 0.06 mm (0.002 in)
Maximum weight difference between pistons 20 g (0.705 oz)
Piston ring groove clearance
- Combustion ring 0.090 - 0.122 mm (0.0035 - 0.0048 in)
- Intermediate ring 0.060 - 0.092 mm (0.0024 - 0.0036 in)
- Oil control ring 0.040 - 0.075 mm (0.0016 - 0.003 in)
Maximum permissible clearance
- Combustion ring 0.50 mm (0.02 in)
- Intermediate ring 0.20 mm (0.008 in)
- Oil control ring 0.20 mm (0.008 in)
Piston ring end gap (Installed)
- Combustion ring 0.40 - 0.65 mm (0.016 - 0.026 in)
- Intermediate ring 0.30 - 0.55 mm (0.012 - 0.022 in)
- Oil control ring 0.30 - 0.55 mm (0.012 - 0.022 in)
Maximum permissible gap 1.20 mm (0.047 in)

47454136 25/11/2013
10.5 [10.105] / 3
Engine - Connecting rods and pistons

Connecting rod and piston - Remove


1. Mark the position of the connecting rod caps and the
connecting rods to ensure proper installation.
2. Remove the bolts (1).
3. Remove the connecting rod caps (2) and bearings.

NHIL12ENG0289AA 1

4. Slide the connecting rod and piston assembly (1) out


from the cylinder bore.
NOTE: It may be necessary to remove the carbon build
up from the top edge of the cylinder bore to aid in piston
removal.

NHIL12ENG0290AA 2

47454136 25/11/2013
10.5 [10.105] / 4
Engine - Connecting rods and pistons

Connecting rod and piston - Disassemble


1. Use piston ring pliers 380000221 (2) to properly re-
move the piston rings (1).
2. Remove the snap ring.
3. Remove the piston pin (3) and separate the piston from
the connecting rod.

NHIL12ENG0334AA 1

47454136 25/11/2013
10.5 [10.105] / 5
Engine - Connecting rods and pistons

Connecting rod and piston Connecting rod - Measure


1. Clean all parts.
2. Check that the oil passages (1) and (2) are not ob-
structed by scale or impurities.
3. Check that the bushing in the small end of the connect-
ing rods are firmly seated and flush with the sides of
the rod.
4. Replace the bushings if necessary.
5. Ream the new bushings to 38.004 - 38.014 mm (1.496
- 1.497 in).

NHIL12ENG0330AA 1

6. Check the connecting rod for bend and twist. The


maximum tolerance is 0.07 mm (0.003 in) measured
at 125 mm (4.921 in) from the longitudinal axis of the
connecting rod.
NOTE: Slightly twisted connecting rods can be straight-
ened using a press. Severely deformed connecting rods
should be replaced.
7. Mark new connecting rods with the cylinder number the
rod is being installed.
8. Check that the weight difference of all the connecting
rods in the engine does not exceed. 25 g (0.9 oz).
NHIL12ENG0331AA 2

9. Assemble the connecting rod and piston. Refer to Con-


necting rod and piston - Assemble (10.105).
10. Check that the connecting rod and piston assembly is
perfectly square.

NHIL12ENG0336AA 3

47454136 25/11/2013
10.5 [10.105] / 6
Engine - Connecting rods and pistons

Connecting rod and piston - Assemble


1. Install the piston pin (3).
2. Install the snap ring.
3. Use piston ring pliers 380000221 (2) to install the piston
rings (1).

NHIL12ENG0334AA 1

47454136 25/11/2013
10.5 [10.105] / 7
Engine - Connecting rods and pistons

Connecting rod and piston - Install


1. Measure the diameter of the bolts within area (a). If the
diameter is less than 10.5 mm (0.413 in), replace the
bolts with new.
NOTE: It is recommended to replace the bolts each time
the connecting rod and piston assembly is removed.

NHIL12ENG0337AA 1

2. Set the crankshaft to Bottom Dead Center (BDC) for


the cylinder that is being installed.
3. Lubricate the piston skirts and cylinder bore with clean
engine oil.
4. Compress the piston rings using the piston ring com-
pressor 380000220 (1).
5. Install the connecting rod an piston assembly into the
corresponding cylinder bore.
NOTICE: Ensure that the number stamped on the connect-
ing rod is facing away from the camshaft.
NHIL12ENG0306AA 2

6. Install the connecting rod caps (1) and bearings.


NOTICE: Ensure the number stamped on the connecting
rod corresponds with the number stamped on the cap.
7. Torque the bolts to 40 N·m (30 lb ft).

NHIL12ENG0305AA 3

8. Use the angular torque gauge tool DM370(3/4) to turn


the bolts 60 °.

NHIL12ENG0307AA 4

47454136 25/11/2013
10.5 [10.105] / 8
Engine - Connecting rods and pistons

Connecting rod and piston - Measure - Protrusion


1. Clean the upper face of the crankcase.
2. Set piston number one to Top Dead Center (TDC).
3. Install a dial indicator (1) with a magnetic base (2).
4. Check that the piston protrusion is within 0.355 -
0.761 mm (0.014 - 0.030 in).

NHIL12ENG0308AA 1

47454136 25/11/2013
10.5 [10.105] / 9
Engine - Connecting rods and pistons

Piston - Measure
1. Measure the diameter of the piston 12 mm (0.472 in)
(L) from the base of the skirt.
2. Check the piston ring groove clearance (b) as shown
in figure 1.
3. Measure the piston ring end gap (c) as shown in figure
1.

NHIL12ENG0332AA 1

NHIL12ENG0333AA 2

47454136 25/11/2013
10.5 [10.105] / 10
Index

Engine - 10

Connecting rods and pistons - 105


Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting rod and piston - Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting rods and pistons - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

47454136 25/11/2013
10.5 [10.105] / 11
47454136 25/11/2013
10.5 [10.105] / 12
Engine - 10

Valve drive and gears - 106

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.6 [10.106] / 1
Contents

Engine - 10

Valve drive and gears - 106

TECHNICAL DATA

Valve drive and gears


General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Valve drive and gears


Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker arm
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Idler gear
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker shaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft
Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

47454136 25/11/2013
10.6 [10.106] / 2
Engine - Valve drive and gears

Valve drive and gears - General specification


Specifications
Timing Overhead valves operated by a camshaft located in the
engine crankcase.
Intake
- Open 12 ° Before Top Dead Center (TDC)
- Close 31 ° After Bottom Dead Center (BDC)
Exhaust
- Open 50 ° Before Bottom Dead Center (BDC)
- Close 16 ° After Top Dead Center (TDC)
Valve clearance
- Intake 0.30 mm (0.012 in)
- Exhaust 0.30 mm (0.012 in)

Valve drive and gears - Service limits


Specifications
Timing gear tooth backlash 0.160 mm (0.006 in)
Inside diameter of intermediate gear bushings (installed 37.050 - 37.075 mm (1.459 - 1.460 in)
and reamed)
Diameter of intermediate gear journal 36.975 - 37.000 mm (1.456 - 1.457 in)
Journal to bushing clearance 0.050 - 0.100 mm (0.002 - 0.004 in)
Maximum permissible clearance 0.15 mm (0.0059 in)
Bushing interference fit in seat in intermediate gear 0.063 - 0.140 mm (0.0025 - 0.0055 in)
Outside diameter of camshaft bearings:
- Front 54.875 - 54.930 mm (2.16 - 2.163 in)
- Middle 54.375 - 54.430 mm (2.141 - 2.143 in)
- Rear 53.875 - 53.930 mm (2.121 - 2.123 in)
Interference between bearings and seats in cylinder 0.070 - 0.150 mm (0.003 - 0.006 in)
block
Inside diameter of camshaft bearings (installed and
reamed)
- Front 51.080 - 51.130 mm (2.011 - 2.013 in)
- Middle 50.580 - 50.630 mm (1.991 - 1.993 in)
- Rear 50.080 - 50.130 mm (1.972 - 1.974 in)
Diameter of camshaft journals
- Front 50.970 - 51.000 mm (2.007 - 2.008 in)
- Middle 50.470 - 50.500 mm (1.987 - 1.988 in)
- Rear 49.970 - 50.000 mm (1.967 - 1.969 in)
Clearance between camshaft journals and bearings 0.080 - 0.160 mm (0.003 - 0.006 in)
Maximum permissible clearance 0.20 mm (0.0079 in)
Camshaft end play between thrust plate and seat on 0.070 - 0.220 mm (0.003 - 0.009 in)
camshaft
Tappet bore in crankcase 15.000 - 15.018 mm (0.591 - 0.591 in)
Outside diameter of tappet 14.950 - 14.970 mm (0.589 - 0.589 in)
Tappet running clearance 0.030 - 0.068 mm (0.001 - 0.003 in)
Maximum permissible clearance 0.15 mm (0.006 in)
Spare tappet oversizes 0.1 mm (0.004 in)
0.2 mm (0.008 in)
0.3 mm (0.012 in)
Diameter of shaft bores in rocker arms 18.016 - 18.034 mm (0.709 - 0.71 in)
Rocker arm shaft diameter 17.982 - 18.000 mm (0.708 - 0.709 in)
Rocker shaft to rocker arm bore clearance 0.016 - 0.052 mm (0.001 - 0.002 in)
Maximum permissible clearance 0.15 mm (0.006 in)
Rocker arm spacing springs

47454136 25/11/2013
10.6 [10.106] / 3
Engine - Valve drive and gears

Specifications
- Free spring length 59.5 mm (2.343 in)
- Length under load of 46 - 52 N (10 - 12 lb) 44 mm (1.732 in)
Valve clearance for timing check 0.30 mm (0.012 in)
Cam lift
- Intake lobe 5.97 mm (0.235 in)
- Exhaust lobe 6.25 mm (0.246 in)

47454136 25/11/2013
10.6 [10.106] / 4
Engine - Valve drive and gears

Valve drive and gears - Install


1. Remove the inspection window cover (1) from the fly-
wheel housing.
NOTE: The flywheel is marked in degrees Before Top Dead
Center (BTDC).

NHIL12ENG0309AA 1

2. Rotate the crankshaft to bring cylinder number one to


Top Dead Center (TDC) on the compression stroke.
3. Look through the inspection window and check that the
notch aligns with the correct index mark.

NHIL12ENG0310AA 2

4. Install the timing gears making sure the various refer-


ence marks are aligned as shown in the figure.

NHIL12ENG0311AA 3

47454136 25/11/2013
10.6 [10.106] / 5
Engine - Valve drive and gears

Rocker arm - Adjust


1. Loosen the jam nut on the adjusting screws.
2. Insert a 0.30 mm (0.012 in) feeler gauge between the
rocker arm and the valve stem collet.
3. Tighten the adjusting screw until the feeler gauge can
be removed with a slight drag.
4. Hold the adjusting screw from turning and torque the
jam nut to 22 N·m (16 lb ft).

NHIL12ENG0317AA 1

47454136 25/11/2013
10.6 [10.106] / 6
Engine - Valve drive and gears

Idler gear - Remove


1. Remove the snap ring (1).
2. Remove the thrust washer (2).
3. Remove the idler gear (3).

NHIL12ENG0283AA 1

4. Remove the bolts (1).


5. Remove the idler gear shaft (2).

NHIL12ENG0284AA 2

47454136 25/11/2013
10.6 [10.106] / 7
Engine - Valve drive and gears

Idler gear - Install


1. Install the idler gear shaft (2).
2. Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0284AA 1

3. Install the idler gear (3).


4. Install the thrust washer (2).
5. Install the snap ring (1).

NHIL12ENG0283AA 2

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Engine - Valve drive and gears

Rocker shaft - Remove


1. Remove the rocker shaft retaining bolts (1).
2. Remove the rocker shaft assembly (2).

NHIL12ENG0269AA 1

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10.6 [10.106] / 9
Engine - Valve drive and gears

Rocker shaft - Install


1. Install the rocker shaft assembly (1) onto the cylinder
head.
NOTICE: Ensure the rocker arms are properly seated in all
of the push rods.
2. Evenly tighten the bolts (2) until they are snug.
3. Torque the bolts to 25 N·m (18 lb ft).

NHIL12ENG0269AA 1

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Engine - Valve drive and gears

Camshaft Push rod - Remove


1. Remove the push rods (1).

NHIL12ENG0270AA 1

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Engine - Valve drive and gears

Camshaft Push rod - Install


1. Install the push rods (1).

NHIL12ENG0270AA 1

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10.6 [10.106] / 12
Engine - Valve drive and gears

Camshaft - Remove
1. Remove the bolts (1) from the retainer plate (2) through
the holes in the camshaft gear (3).
2. Remove the camshaft (4) with the gear and retainer
plate.

NHIL12ENG0285AA 1

47454136 25/11/2013
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Engine - Valve drive and gears

Camshaft - Install
1. Install the camshaft (4) with the gear and retainer plate.
2. Torque the bolts (1) for the retainer plate (2) through
the holes in the camshaft gear (3) to 30 - 40 N·m (22 -
30 lb ft).

NHIL12ENG0285AA 1

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Engine - Valve drive and gears

Camshaft - Measure
1. Place the camshaft (2) on “V” blocks (1) as shown.
2. Use a dial indicator (3) to measure journal run out. If the
measured value exceeds 0.02 mm (0.001 in), replace
the camshaft.
3. Use a dial indicator to measure cam lift. The measure
values should be as follows:
• Intake - 5.97 mm (0.235 in)
• Exhaust - 6.25 mm (0.246 in)

NHIL12ENG0340AA 1

4. Measure the camshaft bushings. If they are worn, re-


place them.
NOTICE: New camshaft bushings will need to be reamed
to obtain the inside diameter shown in figure 2.

NHIL12ENG0341AA 2

47454136 25/11/2013
10.6 [10.106] / 15
Engine - Valve drive and gears

Camshaft Tappets - Measure


1. Check that the tappets slide freely in their bores without
excessive play.
2. Bore the seats in the crankcase and install oversize
tappets there is excessive tappet to bore clearance.

NHIL12ENG0338AA 1

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10.6 [10.106] / 16
Index

Engine - 10

Valve drive and gears - 106


Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rocker shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rocker shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve drive and gears - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve drive and gears - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve drive and gears - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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47454136 25/11/2013
10.6 [10.106] / 18
Engine - 10

Pump drives - 114

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.7 [10.114] / 1
Contents

Engine - 10

Pump drives - 114

SERVICE

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

47454136 25/11/2013
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Engine - Pump drives

Pump drives - Remove


1. Remove the power steering pump adapter plate (1),
gasket (2) and drive connector (3).

NHIL12ENG0266AA 1

2. Remove the drive gear carrier (1).

NHIL12ENG0282AA 2

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Engine - Pump drives

Pump drives - Install


1. Install the drive gear carrier (1).

NHIL12ENG0282AA 1

2. Install the power steering pump adapter plate (1), gas-


ket (2) and drive connector (3).
3. Torque the bolts to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0266AA 2

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Index

Engine - 10

Pump drives - 114


Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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47454136 25/11/2013
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Engine - 10

Fuel filters - 206

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.8 [10.206] / 1
Contents

Engine - 10

Fuel filters - 206

SERVICE

Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Fuel filters

Fuel filters - Remove


1. Remove the fuel lines (1) from the sediment filter.

NHIL12ENG0262AA 1

2. Remove the sediment filter assembly (1) from the en-


gine crankcase.

NHIL12ENG0263AA 2

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Engine - Fuel filters

Fuel filters - Install


1. Install the sediment filter assembly (1) to the engine
crankcase.

NHIL12ENG0263AA 1

2. Install the fuel lines (1) to the sediment filter.

NHIL12ENG0262AA 2

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10.8 [10.206] / 4
Index

Engine - 10

Fuel filters - 206


Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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47454136 25/11/2013
10.8 [10.206] / 6
Engine - 10

Lift pump and lines - 210

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
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Contents

Engine - 10

Lift pump and lines - 210

SERVICE

Fuel lift pump


Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Lift pump and lines

Fuel lift pump - Remove


1. Remove the nuts (1) securing the fuel lift pump.
2. Remove the lift pump (2) from the support.

NHIL12ENG0264AA 1

3. Remove the snap ring (1).


4. Remove the thrust washer.
5. Remove the gear and fuel lift pump cam (2).

NHIL12ENG0286AA 2

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Engine - Lift pump and lines

Fuel lift pump - Install


1. Install the gear and fuel lift pump cam (2).
2. Install the thrust washer.
3. Install the snap ring (1).

NHIL12ENG0286AA 1

4. Install the lift pump (2) to the support.


5. Torque the nuts (1) securing the fuel lift pump to 20 -
30 N·m (15 - 22 lb ft).

NHIL12ENG0264AA 2

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Index

Engine - 10

Lift pump and lines - 210


Fuel lift pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel lift pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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47454136 25/11/2013
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Engine - 10

Fuel injection system - 218

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
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Contents

Engine - 10

Fuel injection system - 218

TECHNICAL DATA

Fuel injection system


General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Injection pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel injectors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Injector fuel lines
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models

47454136 25/11/2013
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Engine - Fuel injection system

Fuel injection system - General specification


8035.05.716
8035.25C.313T
8045.05.260
8045.05.716
8045.05R.939T
8045.25.260
8045.25.261
8045.25.262
8045.25L.939T

Specifications
Fuel injection pump type BOSCH — VE 3/12 F 1150 L 1136
Direction of rotation Counter clockwise
Injection order 1–2–3
Fuel injector type BOSCH
Number of holes 6
Pressure setting 260 - 268 bar (3770 - 3886 psi)

Fuel injection system - General specification


8035.05.716
8035.25D.313T
8045.05.260
8045.05.716
8045.05R.939T
8045.25.260
8045.25.261
8045.25.262
8045.25L.939T

Specifications
Fuel injection pump type BOSCH — VE 3/12 F 1150 L 1137
Direction of rotation Counter clockwise
Injection order 1–2–3
Fuel injector type BOSCH
Number of holes 6
Pressure setting 260 - 268 bar (3770 - 3886 psi)

Fuel injection system - Service limits


Specifications
Eccentricity of pump shaft 3 mm (0.118 in)
Diameter of pump shaft journals 31.975 - 32.000 mm (1.259 - 1.260 in)
Inside diameter of installed and reamed bushings 32.050 - 32.075 mm (1.262 - 1.263 in)
Interference between bushings and seats 0.063 - 0.140 mm (0.002 - 0.006 in)
Clearance between shaft and bushings 0.050 - 0.100 mm (0.002 - 0.004 in)
Thickness of internal washer 1.45 - 1.50 mm (0.057 - 0.059 in)
Thickness of external washer 2.93 - 3.00 mm (0.115 - 0.118 in)

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10.10 [10.218] / 3
Engine - Fuel injection system

Injection pump - Remove


1. Remove the low pressure fuel line (1) from the fuel
supply pump and the fuel injection pump.

NHIL12ENG0257AA 1

2. Remove the injection pump drive gear cover (1).

NHIL12ENG0259AA 2

3. Remove the nut securing the drive gear (1) for the in-
jection pump from the shaft.

NHIL12ENG0260AA 3

4. Install tool 380000835 (1).


5. Remove the injection pump gear (2).

NHIL12ENG0261AA 4

47454136 25/11/2013
10.10 [10.218] / 4
Engine - Fuel injection system

6. Remove the nuts (1) securing the fuel injection pump


to the timing gear housing.
7. Remove the fuel injection pump (2).

NHIL12ENG0258AA 5

47454136 25/11/2013
10.10 [10.218] / 5
Engine - Fuel injection system

Injection pump - Install


1. Install the fuel injection pump (1).
2. Align the marks (2) on the pump flange and housing.

NHIL12ENG0312AA 1

3. Check to make sure the gears (3) and (4) are timed
properly.

NHIL12ENG0311AA 2

47454136 25/11/2013
10.10 [10.218] / 6
Engine - Fuel injection system

Fuel injectors - Remove


1. Disconnect the fuel return lines (1).
2. Remove the bolts (2).
3. Remove the injector (3).

NHIL12ENG0257AA 1

47454136 25/11/2013
10.10 [10.218] / 7
Engine - Fuel injection system

Fuel injectors - Install


1. Install the injectors into the cylinder head.
2. Position the injector support bracket over the stud.
3. Install the conical washers with the flat surface facing
up.
4. Torque the nuts to 10 N·m (7 lb ft).
5. Torque the nuts to 25 N·m (18 lb ft).
6. Tighten the return fittings.
7. Tighten the high pressure fuel lines.

NHIL12ENG0318AA 1

47454136 25/11/2013
10.10 [10.218] / 8
Engine - Fuel injection system

Fuel injectors - Measure - Protrusion


1. Install the fuel injectors into the cylinder head.
2. Measure the injector nozzle protrusion (a) from the
cylinder head surface.
3. If the measured value exceeds 1.1 mm (0.043 in), re-
place the injector cups. Refer to Cylinder head Injec-
tor cup - Replace (10.101) for the proper procedure.

NHIL12ENG0357AA 1

47454136 25/11/2013
10.10 [10.218] / 9
Engine - Fuel injection system

Injector fuel lines - Remove


1. Remove the high pressure lines (1) from the fuel injec-
tors (2) and the fuel injection pump (3).

NHIL12ENG0255AA 1

47454136 25/11/2013
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Engine - Fuel injection system

Injector fuel lines - Install


1. Install the fuel injection pump (3).
2. Install the high pressure lines (1) to the fuel injectors
(2).

NHIL12ENG0255AA 1

47454136 25/11/2013
10.10 [10.218] / 11
Index

Engine - 10

Fuel injection system - 218


Fuel injection system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injection system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injection system - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel injectors - Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Injector fuel lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Injector fuel lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models

47454136 25/11/2013
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Engine - 10

Intake and exhaust manifolds and muffler - 254

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
10.11 [10.254] / 1
Contents

Engine - 10

Intake and exhaust manifolds and muffler - 254

SERVICE

Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove


1. Remove the bolts (2) and remove the intake manifold
(1) from the cylinder head.

NHIL12ENG0256AA 1

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install


1. Install the intake manifold (1) onto the cylinder head.
2. Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0256AA 1

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove


1. Remove the bolts (1).
2. Remove the exhaust manifold (2) and a gaskets from
the cylinder head.

NHIL12ENG0252AA 1

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install


1. Install the exhaust manifold (2) and gaskets onto the
cylinder head.
2. Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0252AA 1

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Index

Engine - 10

Intake and exhaust manifolds and muffler - 254


Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10

Engine lubrication system - 304

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Engine - 10

Engine lubrication system - 304

TECHNICAL DATA

Engine lubrication system


General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA

Engine lubrication system


Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE

Engine oil filter


Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil pump lines
Remove - Pick up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Pick up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - Engine lubrication system

Engine lubrication system - General specification


Specifications
Lubrication type Forced by gear pump
Oil pump drive Camshaft
Engine speed to oil pump speed ratio 2:1
Oil filter type
- Pick up tube Mesh screen
- Delivery line Cartridge filter
Oil pressure @ 75 - 85 °C (167 - 185 °F)
- @ 2475 - 2575 RPM 2.4 - 3.8 bar (34.8 - 55.1 psi)
- @ 600 - 700 RPM 1.5 - 2.7 bar (21.8 - 39.2 psi)
Pressure relief valve Built into the oil pump housing
- Opening pressure 3.5 bar (50.8 psi)

Engine lubrication system - Service limits


Specifications
Clearance between oil pump drive shaft and bushing 0.016 - 0.055 mm (0.0006 - 0.0022 in)
Clearance between shaft and driven gear 0.033 - 0.066 mm (0.0013 - 0.0026 in)
Tooth backlash between drive and driven gears 0.100 mm (0.004 in)
Radial clearance between drive and driven gears and 0.060 - 0.170 mm (0.0024 - 0.0067 in)
housing
Thickness of drive and driven gears 40.961 - 41.000 mm (1.613 - 1.614 in)
Height of gear seat in pump 41.025 - 41.087 mm (1.615 - 1.618 in)
End play between gears and gear housing in pump 0.025 - 0.126 mm (0.001 - 0.005 in)
Pressure relief valve spring
- Free length 45 mm (1.772 in)
- Length under load of 37.5 mm (1.476 in)
- Length under load of 30.5 mm (1.201 in)

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Engine - Engine lubrication system

Engine lubrication system - Sectional view

NHIL12ENG0239AA 1

(1) Oil filler cap (5) Dipstick


(2) Filter safety valve (6) Oil pump
(3) Filter (7) Oil pressure limiting valve
(4) Switch for low engine oil pressure warning (8) Screen filter on pick-up tube

The oil filter is a full-flow, integral paper cartridge type. It is installed in-line with the oil pump delivery passage. A
built-in safety valve will open to allow the oil to by-pass the filter if it becomes clogged.

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Engine - Engine lubrication system

Engine oil pump - Overview

NHIL12ENG0360AA 1

(1) Pressure relief valve (3) Pump housing


(2) Spring (4) Internal gears

NOTE: The oil pump drive gear is supplied pre-assembled.

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Engine - Engine lubrication system

Engine oil filter - Install


1. Lubricate the oil filter seal with clean engine oil.
2. Screw on the new cartridge until the seal is up against
the mounting surface.
3. Tighten the cartridge, by hand, an additional ¾ turn.

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Engine - Engine lubrication system

Engine oil filter - Remove


1. Unscrew the engine oil filter using tool 34591-00100.
NOTE: Be sure that the oil filter gasket has been removed
along with the filter.

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Engine - Engine lubrication system

Oil pump lines - Remove - Pick up tube


1. Remove the bolts (1).
2. Remove the oil pick up tube (2), screen filter (3), and
seal.

NHIL12ENG0273AA 1

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Engine - Engine lubrication system

Oil pump lines - Install - Pick up tube


1. Install the oil pick up tube (2), screen filter (3), and seal.
2. Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0273AA 1

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Engine - Engine lubrication system

Engine oil pump - Remove


1. Remove the bolts from the oil pump (1).
2. Remove the oil pump assembly.

NHIL12ENG0277AA 1

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Engine - Engine lubrication system

Engine oil pump - Install


1. Install the oil pump (1) assembly.
2. Torque the bolts to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0277AA 1

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Index

Engine - 10

Engine lubrication system - 304


Engine lubrication system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine lubrication system - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine lubrication system - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pump lines - Install - Pick up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil pump lines - Remove - Pick up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - 10

Engine cooling system - 400

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Engine - 10

Engine cooling system - 400

TECHNICAL DATA

Engine cooling system


General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA

Engine cooling system


Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE

Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Engine cooling system

Engine cooling system - General specification


Specifications
Coolant pump type Centrifugal vane
Engine speed to coolant pump speed ratio 1:1.45
Temperature control Thermostat

Engine cooling system - Service limits


Specifications
Interference fit between pump impeller and shaft 0.017 - 0.059 mm (0.0007 - 0.0023 in)
Interference fit between fan hub and shaft 0.024 - 0.058 mm (0.0009 - 0.0023 in)
Interference fit between front seal bushing and impeller 0.012 - 0.058 mm (0.0005 - 0.0023 in)

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Engine - Engine cooling system

Engine cooling system - Sectional view

NHIL12ENG0240AA 1

(1) Thermostat (4) Temperature sender


(2) Coolant pump (5) Fan
(3) Engine coolant temperature gauge (6) Radiator

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Engine - Engine cooling system

Water pump - Remove


1. Remove the fitting (1).

NHIL12ENG0246AA 1

2. Remove the bolts.


3. Remove the water pump (2).

NHIL12ENG0247AA 2

4. Remove the water pump support (3).

NHIL12ENG0248AA 3

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Engine - Engine cooling system

Water pump - Install


1. Install the water pump support (3) and torque the bolts
to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0248AA 1

2. Install the water pump (2).


3. Torque the bolts to 50 - 60 N·m (37 - 44 lb ft).

NHIL12ENG0247AA 2

4. Install the fitting (1).

NHIL12ENG0246AA 3

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Engine - Engine cooling system

Coolant thermostat - Remove


1. Detach the throttle control lever (1) from the fuel injec-
tion pump.

NHIL12ENG0253AA 1

2. Remove the bolts (2).


3. Remove the thermostat housing (3).

NHIL12ENG0254AA 2

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Engine - Engine cooling system

Coolant thermostat - Install


1. Install the thermostat housing (3).
2. Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

NHIL12ENG0254AA 1

3. Reattach the throttle control lever (1) to the fuel injec-


tion pump.

NHIL12ENG0253AA 2

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Index

Engine - 10

Engine cooling system - 400


Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine cooling system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine cooling system - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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10.13 [10.400] / 10
Engine - 10

Fan and drive - 414

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
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Contents

Engine - 10

Fan and drive - 414

SERVICE

Fan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fan and drive

Fan - Remove
1. Remove the bolts.
2. Remove the fan (1) and pulley from the coolant pump.

NHIL12ENG0243AA 1

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Engine - Fan and drive

Fan - Install
1. Install the fan (1) and pulley onto the coolant pump.
2. Torque the bolts to 50 - 60 N·m (37 - 44 lb ft).

NHIL12ENG0243AA 1

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Engine - Fan and drive

Belt - Remove
1. Loosen the alternator pivot bolt.
2. Loosen the belt tension adjustment bolt (1).
3. Release the belt tension adjustment arm by unscrewing
the retaining nut.
4. Remove the alternator and coolant pump drive belt.

NHIL12ENG0242AA 1

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Engine - Fan and drive

Belt - Install
1. Install the alternator and coolant pump drive belt.
2. Tighten the belt tension adjustment arm by tightening
the retaining nut.
3. Tighten the belt tension adjustment bolt (1).
4. Tighten the alternator pivot bolt.

NHIL12ENG0242AA 1

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10.14 [10.414] / 6
Index

Engine - 10

Fan and drive - 414


Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan - 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.

© 2014 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.

47454136 25/11/2013
EN
SERVICE MANUAL
Electrical systems

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

47454136 25/11/2013
55
Contents

Electrical systems - 55

[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

47454136 25/11/2013
55
Electrical systems - 55

Engine oil system - 013

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Electrical systems - 55

Engine oil system - 013

FUNCTIONAL DATA

Engine oil pressure sensor and switch


Engine oil pressure switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine oil system

Engine oil pressure sensor and switch Engine oil pressure switch
- Overview
The low oil pressure indication consists of a control switch and a red warning lamp in the instrument panel.

The lamp will illuminate in the following conditions:


• Low oil pressure
NOTICE: The warning lamp may illuminate under normal conditions, with no faults present, when the engine is hot
and at low idle.
• Control switch malfunction.

If the red lamp fails to illuminate when the engine is not running and the ignition switch is in the ON position,
the possible causes are:
• Blown fuse.
• Failed bulb in the instrument panel.
• Broken wire in the circuit for the control switch.

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Index

Electrical systems - 55

Engine oil system - 013


Engine oil pressure sensor and switch Engine oil pressure switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55

Engine starting system - 201

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Electrical systems - 55

Engine starting system - 201

SERVICE

Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine starting system

Engine starter - Remove


1. Remove the retaining bolts (1) and remove the starter
(2).

NHIL12ENG0267AA 1

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Electrical systems - Engine starting system

Engine starter - Install


1. Install the starter (2).
2. Torque the bolts (1) to 25 - 35 N·m (18 - 26 lb ft).

NHIL12ENG0267AA 1

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Index

Electrical systems - 55

Engine starting system - 201


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

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Electrical systems - 55

Alternator - 301

8035.05.716 , 8035.25C.313T , 8035.25D.313T , 8045.05.260 , 8045.05.716 ,


8045.05R.939T , 8045.25.260 , 8045.25.261 , 8045.25.262 , 8045.25L.939T

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Contents

Electrical systems - 55

Alternator - 301

SERVICE

Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Alternator

Alternator - Remove
1. Remove the alternator pivot bolt (1).
2. Remove the alternator (2).
3. Remove the alternator support (3).

NHIL12ENG0251AA 1

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Electrical systems - Alternator

Alternator - Install
1. Install the alternator support (3).
2. Install the alternator (2).
3. Torque the alternator pivot bolt (1) to 50 - 60 N·m (37 -
44 lb ft).

NHIL12ENG0251AA 1

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Index

Electrical systems - 55

Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - 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.

© 2014 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.

47454136 25/11/2013
EN
SPECIAL TOOL INDEX

Genuine Reference PAGE


DM370(3/4) [Torque Cylinder head - Install 10.2 / 7
Tightening Angle Gauges
(1/2 Inch And 3/4 Inch)]
380000246 [Cylinder head Cylinder head Injector cup - Replace 10.2 / 8
injector sleeve replacement
kit]
380000832 [Injection Holder Cylinder head Injector cup - Replace 10.2 / 8
Cap Puller]
380000834 [Injection Holder Cylinder head Injector cup - Replace 10.2 / 8
Cap Rolling Beater]
380000830 [Guide Socket ] Cylinder head Injector cup - Replace 10.2 / 8
380000219 [Valve Guide Valve guide - Replace 10.2 / 13
Remover/installer]
380000219 [Valve Guide Valve guide - Replace 10.2 / 13
Remover/installer]
380000242 [Cylinder Head Valve guide - Replace 10.2 / 13
Valve Guide Installer - used
with 4.5L & 6.7L NEF Engines]
380000222 [Valve Guide Valve guide - Replace 10.2 / 13
Reamer]
380000277 [Exhaust Gas Valve guide - Replace 10.2 / 13
Cylinder Head Valve Guide
Reamer ]
380000277 [Exhaust Gas Valve guide - Replace 10.2 / 14
Cylinder Head Valve Guide
Reamer ]
380000277 [Exhaust Gas Valve guide - Replace 10.2 / 14
Cylinder Head Valve Guide
Reamer ]
380000277 [Exhaust Gas Valve guide - Replace 10.2 / 14
Cylinder Head Valve Guide
Reamer ]
380001001 [Set Of 2 Gauges Engine flywheel - Install 10.4 / 5
For Angular Tightening With
1/2” And 3/4” Square Mount]
380000226 [Engine Hub Crankshaft pulley - Remove 10.4 / 7
Puller used on 4.5L & 6.7L
NEF Engines ]
380000988 [Starter opening Crankshaft pulley - Install 10.4 / 8
plate and Flywheel Rotation
Blocker]
380000226 [Engine Hub Crankshaft oil seal Front seal - Remove 10.4 / 11
Puller used on 4.5L & 6.7L
NEF Engines ]
DM370(3/4) [Torque Crankshaft - Install 10.4 / 19
Tightening Angle Gauges
(1/2 Inch And 3/4 Inch)]
380000221 [Pliers For Connecting rod and piston - Disassemble 10.5 / 5
Piston Rings Removal And
Installation (65 -110 mm)]
380000221 [Pliers For Connecting rod and piston - Assemble 10.5 / 7
Piston Rings Removal And
Installation (65 -110 mm)]
380000220 [Band For Piston Connecting rod and piston - Install 10.5 / 8
Insertion Into Cylinder Sleeves
(60 -125 mm)]

47454136 25/11/2013
Genuine Reference PAGE
DM370(3/4) [Torque Connecting rod and piston - Install 10.5 / 8
Tightening Angle Gauges
(1/2 Inch And 3/4 Inch)]
380000835 [Injection Pump Injection pump - Remove 10.10 / 4
Gear Puller]
34591-00100 [Oil Filter Engine oil filter - Remove 10.12 / 7
Wrench]

47454136 25/11/2013
47454136 25/11/2013
CNH Industrial America New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States
17557

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A.

© 2014 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.

47454136 25/11/2013
EN