Service Manual Engine Case

ISM
Tier 4
Engine
See the following page for engine model numbers
SERVICE MANUAL
Printed in U.S.A. Part number 47632293

2nd edition English
Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.
Case is a registered trademark of CNH Industrial America LLC. September 2014
Racine Wisconsin 53404 U.S.A. Replaces part number 47434944
SERVICE MANUAL
N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 ,

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
47632293 16/09/2014
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
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INTRODUCTION
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1
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
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m 225 N·m (166 lb 301 N·m (222 lb 143 N·m (106 lb 205 N·m (151 lb
M16
ft) (155 lb ft) ft) ft) ft) ft)
319 N·m (235 lb 425 N·m 440 N·m (325 lb 587 N·m (433 lb 290 N·m (214 lb 400 N·m (295 lb
M20
ft) (313 lb ft) ft) ft) ft) ft)
551 N·m (410 lb 735 N·m 762 N·m (560 lb 1016 N·m 501 N·m (370 lb 693 N·m (510 lb
M24
ft) (500 lb ft) ft) (750 lb ft) ft) ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
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INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
ft) ft) ft) ft) ft) ft)
M20
ft) ft) ft) ft) ft) ft)
607 N·m (447 lb 809 N·m (597 lb 838 N·m (618 lb 1118 N·m 552 N·m (407 lb
M24
ft) ft) ft) (824 lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
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INTRODUCTION
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class
10 properties, and marks 120 ° apart indicate Class 8.
INCH NON-FLANGED HARDWARE

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

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

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120 ° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60 ° Apart
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INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
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CONSUMABLES INDEX
Consumable Reference PAGE

Loctite® RTV 598™ Basic instructions - Shop and assembly 6
Loctite® Instant Gasket 587™ Basic instructions - Shop and assembly 6
Blue
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SERVICE MANUAL
Engine

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
47632293 16/09/2014
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CONSUMABLES INDEX

Loctite® 5970™ Engine oil pan - Install 10.2 / 5
Molykote® G-N Metal Camshaft Tappets - Install 10.3 / 22
assembly paste
Molykote® Cylinder head - Install 10.4 / 17
Loctite® 5970™ Flywheel housing - Install 10.6 / 11
Loctite® 5970™ Crankshaft oil seal Rear seal - Install 10.6 / 14
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47632293 16/09/2014
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Engine - 10
Engine and crankcase - 001

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
TECHNICAL DATA
Engine
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Engine
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SERVICE
Engine
Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankcase
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSTIC
Engine
Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
(*) See content for specific models
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Engine - Engine and crankcase
Engine - Torque
N4LDI-TA-45SL
N4LDI-TA-50SL
Parts name Tightening torque Remarks

Bearing holder (upper / lower) 49 - 54 N·m (36 - 40 lb ft)
Bearing holder (Cylinder block / 49 - 54 N·m (36 - 40 lb ft) Hexagon bolt
crankshaft)
Bearing holder (Cylinder block / 25 - 29 N·m (18 - 21 lb ft) Hexagon socket head bolt
crankshaft)
Flywheel 73 - 78 N·m (54 - 58 lb ft)
Connecting rod 49 - 54 N·m (36 - 40 lb ft)
Crankshaft pulley 274 - 333 N·m (202 - 246 lb ft)
Rocker arm assembly 27 - 39 N·m (20 - 29 lb ft)
Head cover 12 - 16 N·m (9 - 12 lb ft)
Drain ; oil sump 29 - 39 N·m (21 - 29 lb ft)
Head bolt Snug torque 48 - 52 N·m (35 - 38 lb Angle method
ft) after that 120 - 180 °
Injection pipe complete 20 - 25 N·m (14.8 - 18.4 lb ft) Injector / Rail
Glow plug 15 - 20 N·m (11 - 15 lb ft)
Relief valve assembly 59 - 69 N·m (44 - 51 lb ft)
Oil pressure switch 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)
High Pressure (HP) pump 25 - 35 N·m (18.4 - 25.8 lb ft)
Return pipe 12 - 14 N·m (9 - 10 lb ft)
Rail 12 - 14 N·m (9 - 10 lb ft)
Oil pipe complete 10 - 13 N·m (7.4 - 9.6 lb ft)
Cam gear 68 - 72 N·m (50 - 53 lb ft)
Pump gear 58 - 62 N·m (43 - 46 lb ft)
Rocker arm adjust screw 12 - 16 N·m (9 - 12 lb ft)
Sensor ; Water temperature 20 - 24 N·m (15 - 18 lb ft)
Sensor ; Induction temperature 14.5 - 24.5 N·m (10.7 - 18.1 lb ft)
Sensor ; Exhaust temperature 25 - 35 N·m (18.4 - 25.8 lb ft) Apply an “Anti seize compound” to
the threads of the sensor.
Engine - Torque
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

Bearing holder (upper / lower) 49 - 54 N·m (36 - 40 lb ft)
Bearing holder (Cylinder block / 49 - 54 N·m (36 - 40 lb ft) Hexagon bolt
crankshaft)
Bearing holder (Cylinder block / 25 - 29 N·m (18 - 21 lb ft) Hexagon socket head bolt
crankshaft)
Flywheel 73 - 78 N·m (54 - 58 lb ft)
Connecting rod 49 - 54 N·m (36 - 40 lb ft)
Crankshaft pulley 274 - 333 N·m (202 - 246 lb ft)
Rocker arm assembly 27 - 39 N·m (20 - 29 lb ft)
Head cover 12 - 16 N·m (9 - 12 lb ft)
Drain ; oil sump 29 - 39 N·m (21 - 29 lb ft)
Return nut (Nozzle and holder) 25 - 29 N·m (18 - 21 lb ft) Tighten return pipe
Head bolt Snug torque 48 - 52 N·m (35 - 38 lb Angle method
ft) after that 120 - 180 °
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Nozzle and holder 59 - 69 N·m (44 - 51 lb ft)
Injection pipe complete 23 - 36 N·m (17 - 27 lb ft)
Glow plug (engine and afterburner) 15 - 20 N·m (11 - 15 lb ft)
Relief valve assembly 59 - 69 N·m (44 - 51 lb ft)
Oil pressure switch 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)
Engine stop solenoid 14.7 - 24.5 N·m (10.8 - 18.1 lb ft)
Sensor ; Water and induction 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)
temperature
Sensor ; Speed 5.6 - 8.4 N·m (4.1 - 6.2 lb ft)
Sensor ; Exhaust temperature 25 - 35 N·m (18.4 - 25.8 lb ft) Apply an “Anti seize compound” to
the threads of the sensor.
Engine - General specification

N4LDI-TA-45SL
N4LDI-TA-50SL
Engine model N4LDI – TA – 50SL N4LDI – TA – 45SL

Number of cylinders 4
Combustion system Direct Injection (DI)
Bore x Stroke 84 mm x 100 mm ( 3.31 in x 3.94 in)
Displacement 2216 cm³ ( 135.2 in³
Compression ratio 18:1
Engine speeds (RPM)
High idle 2825 RPM +/- 25 (No load)
Rated 2800 RPM (Full load)
Low idle 1200 RPM +/- 50
Engine horsepower @ 2800 RPM 50 kW (68 Hp) 45 kW (61 Hp)
Peak torque @ 1800 RPM 208 N·m (153 lb ft) 183 N·m (135 lb ft)
Firing order 1-3-4-2
Cylinder arrangement In-Line Vertical
Valve arrangement Overhead
Aspiration Turbocharged with waste gate
Emissions control External Exhaust Gas Recirculation (EGR)
Fuel injection system Common rail system HP-CRS
Lubrication method Pressure feed by gerotor pump
Oil capacity with filter inlcuded 7.1 L (7.5 US qt)
Oil filtration Replaceable full flow spin on cartridge
Water pump style Centrifugal
Water pump flow @ rated RPM 55.5 L/min (14.7 US gpm)
Coolant volume (engine only) 4.2 l (4.4 US qt)
Engine dry weight 206 kg (454.2 lb)
Air cleaner Dry type
Engine - General specification

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Engine model N844L – F – 36SL N844LT – F – 45SL

Number of cylinders 4
Combustion system Swirl chamber
Bore x Stroke 84 mm x 100 mm ( 3.31 in x 3.94 in)
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Engine model N844L – F – 36SL N844LT – F – 45SL

Displacement 2216 cm³ ( 135.2 in³)
Compression ratio 22.5:1
Engine horsepower @ 2800 RPM 36 kW (49 Hp) 44 kW (60 Hp)
Peak torque @ 1800 RPM 143 N·m (105 lb ft) 188 N·m (139 lb ft)
Engine speeds (RPM)
High idle 2825 RPM +/- 25 (No load)
Rated 2800 RPM (Full load)
Low idle 1200 RPM +/- 50
Firing Order 1-3-4-2
Cylinder Arrangement In-line vertical
Valve Arrangement Overhead
Aspiration Indirect naturally aspirated Indirect turbocharged with waste gate
Emissions control N/A External Exhaust Gas Recirculation
(EGR)
Injection pump Bosch, In-line mechanical injection
Injection nozzle Throttle type
Alternator output 12 V — 85 A
Starter output 12 V — 2.0 kW
Lubrication method Pressure feed with gerotor pump
Oil capacity with filter included 7.1 L (7.5 US qt)
Oil filtration Replaceable full flow spin on cartridge
Water pump style Centrifugal
Water pump flow @ rated RPM 55.5 L/min (14.7 US gpm)
Coolant volume (engine only) 2.8 l (3.0 US qt)
Engine dry weight 227 kg (500 lb)
Air cleaner Dry type
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Crankcase - Dimension
Bore
Standard 84 - 84.019 mm (3.3071 - 3.3078 in)
Head surface warp
Standard 0.05 mm (0.002 in)
Maximum 0.12 mm (0.005 in)
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Engine - Component identification

N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0043AA 1
(1) Diesel Oxidation Catalyst (DOC) (6) Timing sensor (11) Fuel filter
Assembly
(2) Throttle valve assembly (7) Crankshaft pulley (12) High Pressure (HP) fuel pump
(3) Exhaust Gas Recirculation (EGR) (8) Oil pressure relief valve (13) Common rail assembly
pipe
(4) Exhaust Gas Recirculation (EGR) (9) Oil filter (14) Blow-by recirculation filter
valve
(5) Oil pressure switch (10) Oil cooler (15) Fuel injectors
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N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0044AA 1
(1) Differential pressure sensor (3) Exhaust Gas Recirculation (EGR) cooler
(2) Engine PIN plate (4) Turbocharger
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NHVM13ENG0187AA 1
(1) Turbocharger (5) Crank pulley (9) Shut-off solenoid

(2) Air pump (6) Injection pump (10) Blow-by recirculation assembly
(3) Oil pressure switch (7) Oil cooler (11) Glow plugs
(4) Speed sensors (8) Oil filter
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NHVM13ENG0186AA 1
(1) Wastegate (4) After burner assembly

(2) Flywheel (5) Reed valve
(3) Temperature sensor
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Engine - Exploded view

N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0018AA 1
(1) Fuel filter assembly (7) Balancer assembly

(2) Tappets (8) Suction pipe and bracket
(3) Push rods (9) Oil pan gasket
(4) Oil level dipstick tube (10) Oil pan
(5) Alternator (11) Oil cooler
(6) Cylinder block (12) Oil filter
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N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0017AA 1
(1) Rocker arm assembly (8) Oil transfer pipe

(2) Valve cover gasket (9) Thermostat housing
(3) Valve cover (10) Cylinder head gasket
(4) Throttle valve (11) Cylinder head assembly
(5) Intake manifold (12) Glow plug connector
(6) Exhaust Gas Recirculation (EGR) cooler (13) Injection pipe / Return pipe
(7) Exhaust Gas Recirculation (EGR) valve (14) Fuel injectors
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N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0016AA 1
(1) Diesel Oxidation Catalyst (DOC) assembly (8) Water pump

(2) Differential pressure sensor (9) Cylinder block
(3) Cylinder head (10) Cylinder head gasket
(4) Cylinder head bolts (11) Temperature sensor
(5) Exhaust manifold (12) Blow-by recirculation filter
(6) Turbocharger (13) Exhaust elbow
(7) Cooling fan / Fan pulley
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N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0019AA 1
(1) Camshaft (6) V-belt

(2) Camshaft gear (7) Crankshaft pulley
(3) Front plate and gasket (8) Idler gear
(4) Timing cover gasket (9) Oil pump
(5) Timing cover (10) High Pressure (HP) fuel pump
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NHIL13ENG0023AA 1
(1) Flywheel assembly (6) Connecting rod

(2) Rear plate (7) Key
(3) Thrust washer (8) Crankshaft
(4) Bearing holders / bearings (9) Gear; Balancer
(5) Piston / Rings / Piston pin (10) Rear oil seal
The cylinder block assembly contains the pistons, connecting rods, crankshaft, timing gears, and engine oil pump.
The crankshaft is supported on five main bearings. The front bearing is positioned in a bore in front of the block. The
other bearings are split liners located in holders bolted to the block. The camshaft is supported on four cam bearings
located in the block.
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Engine - Compression test

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Compression test is performed through the glow plug ports. The test adapter tool (1), is equipped with quick coupler
ends for easy installation of the hose and gauge.
1. Remove the two pin connector from the fuel injection

pump solenoid.
2. Remove the glow plug electrical wire and wire connec-
tor from top of the glow plugs. Refer to Cold start aid
- Remove — Glow plug (55.202).
3. Remove all of the glow plugs.
SECT10C01PG17_1 1
NOTE: Be sure all the glow plugs are removed before starting the compression tests.
4. Install the adapter Tool No. FNH00120, hose and
gauge assembly OEM1074 (2), in each port and crank
the engine until pressure stabilizes. The gauge should
read 2944.1 kPa (427 psi) plus or minus 344.7 kPa
(50 psi).
SECT10C01PG17_2 2
NOTE: It may be necessary to remove some injector fuel lines to install the adapter tool.
NOTE: There should not be more than 344.7 kPa (50 psi) variation between the cylinders.
5. Install the glow plugs and electrical connections. Refer
to Cold start aid - Install — Glow plug (55.202).
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Engine - Compression test

N4LDI-TA-45SL
N4LDI-TA-50SL
Compression test is performed through the glow plug ports. The test adapter tool (1), is equipped with quick coupler
ends for easy installation of the hose and gauge.
1. Remove the two pin connector (1) from the fuel meter-
ing unit located on the high pressure pump.
NHIL13ENG0030AA 1
2. Remove the glow plug electrical wire and wire connec-

tor from top of the glow plugs. Refer to Cold start aid
- Remove — Glow plug (55.202).
3. Remove all of the glow plugs.
SECT10C01PG17_1 2
NOTE: Be sure all the glow plugs are removed before starting the compression tests.
4. Install the adapter Tool No. FNH00120, hose and
gauge assembly OEM1074 (2), in each port and crank
the engine until pressure stabilizes. The gauge should
read 2944.1 kPa (427 psi) plus or minus 344.7 kPa
(50 psi).
SECT10C01PG17_2 3
NOTE: It may be necessary to remove some injector fuel lines to install the adapter tool.
NOTE: There should not be more than 344.7 kPa (50 psi) variation between the cylinders.
5. Install the glow plugs and electrical connections. Refer
to Cold start aid - Install — Glow plug (55.202).
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Crankcase - Inspect
1. Inspect the cylinder block top face for cracks, dam-
age, and warping. Replace the cylinder block if warp
is greater than 0.12 mm (0.005 in).
2. Visually inspect the cylinder bore. There should be no
scoring, rust, or corrosion.
3. Use a telescoping gauge to measure the cylinder bore
at the top, center and bottom of the piston ring contact
area (A) parallel to the crankshaft axis (2).
4. Repeat Step 3 perpendicular to the crankshaft axis (1).
5. If any of the measurements taken exceed 84.2 mm
(3.315 in) replace the engine block.
NHIL13ENG0004AA 1
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Engine - Troubleshooting
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Problem Possible Cause Correction

Engine does not start Defective key switch or loose connection. Check for disconnected connectors, or bro-
ken wiring. Check the key switch contact
points.
Insufficient charging or completely dis- Charge the battery.
charged battery.
No fuel. Check the fuel level. Fill to proper level if
needed.
Air mixed in the fuel system. See Injection pump - Bleed (10.218) to
bleed the fuel system.
Improper fuel supply. Injection system mal- See Fuel injection system - Overview
function. (10.218) for an overview of the injection
system.
Clogged fuel filter. Replace the fuel filter.
Defective glow plug. See Cold start aid - Test (55.202) to test
the glow plug.
Improper viscosity of lubricating oil. Check the oil. Change if needed.
Clogged air cleaner. Clean the air cleaner.
Defective engine stop solenoid. Check the switch. Check the wiring. Repair
or replace as needed.
No engine compression. See Engine - Compression test (10.001)
to perform the engine compression test.
Electrical fault. Check for fault codes using the diagnostic
service tool.
Irregular engine speed Air mixed in the fuel system. See Injection pump - Bleed (10.218) to
Uneven fuel injection. There may be trouble with the injection
pump. See Injection pump - Dynamic
description (10.218) for injection pump
information.
Trouble with the governor. See Governor - Dynamic description
(10.220) for governor information.
service tool.
Engine stops during No fuel. Check the fuel level. Fill to proper level if
operation needed.
Air mixed in the fuel system. See Injection pump - Bleed (10.218) to
service tool.
Engine overheat Insufficient cooling water. Replenish the cooling water. Check and
repair water leaking points.
Loosened or slipping fan belt. Clean oil dust, etc. and retighten.
Failure of fan belt. Replace the belt.
Clogged radiator. Clean the radiator.
Clogged radiator fin. Clean the radiator fins.
Cooling water passage clogged with dust, Clean out and wash parts.
etc.
Improper function of thermostat. Check and replace.
Insufficient lubricating oil. Check and replace oil if needed.
Overloading the engine. Decrease the load.
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Improper color of engine Too much engine oil. Check and adjust the quantity.
exhaust
Too low viscosity of engine oil. Check and change the oil if needed.
service tool.
Defective burner assembly. See After-burner - Inspect (10.501) to in-
spect the burner assembly.
Improper engine exhaust Improper fuel. Check and change fuel if needed.
(black or dark gray)
Clogged air cleaner. Clean the air cleaner.
service tool.
Defective burner assembly. See After-burner - Inspect (10.501) to in-
spect the burner assembly.
Improper charging. Loosened fan belt. Correct the belt tension.
Electrical wiring fault. Check the wiring from the battery to the
alternator.
Defective battery. Check and charge the battery. Replace if
needed.
Defective alternator. See Alternator - Preliminary test — Al-
ternator Output (55.301) for alternator
testing.
Starting motor does not Starter electrical problems. See Engine starter - Troubleshooting
operate. (55.201).
Oil pressure lamp does Insufficient engine oil. Check and fill to specified gauge level.
not go out.
Defective oil pressure switch. See Engine oil pressure sensor and
switch - Inspect – Pressure switch
(10.304) to inspect the pressure switch.
Oil leakage from lubricating system. Check and retighten leaking section.
Clogged oil filter. Replace the oil filter.
Short circuit wiring between oil pressure Check the wiring from the oil pressure
lamp and main contact. switch to the Engine Control Unit (ECU).
Oil pressure lamp does Burnt out lamp. Replace the lamp.
not light up with the key
switch turned ON. (While
engine stops.)
Disconnected wire between battery and oil Check the wiring from the oil pressure
pressure lamp. switch to the Engine Control Unit (ECU).
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Index
Engine - 10

Crankcase - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankcase - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine - Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine - 10
Pan and covers - 102

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Contents
Engine - 10
SERVICE
Engine oil pan

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Timing gear housing
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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CONSUMABLES INDEX

Loctite® 5970™ Engine oil pan - Install 10.2 / 5
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10.2 [10.102] / 3
Engine - Pan and covers
Engine oil pan - Remove

1. Remove the oil pan retainer bolts (1).
2. Remove the oil pan and discard gasket.
NHIL12ENG0209AA 1
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Engine oil pan - Install

1. Apply a thin coat of LOCTITE® 5970™ flange sealant or
equivalent to the oil pan sealing area.
2. Install the pick up tube (1) and a new gasket.
NHIL12ENG0208AA 1
3. Install the oil pan and retaining bolts (1).
NHIL12ENG0209AA 2
4. Torque the retaining bolts in the order shown to 8.3 -

11.3 N·m (6.1 - 8 lb ft).
NHIL13ENG0202AA 3
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Timing gear housing - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Crankshaft pulley - Remove Pulley (10.103)
NOTICE: Keep all parts clean from contaminants. Contaminates may cause rapid wear and shortened component
life.
1. Remove the hydraulic pump or block off plates from the
bottom left of the timing cover (3).
2. Remove the nuts (1) and bolts (2) from the timing cover.
3. Remove any wire fasteners and identify fastener loca-
tions for installation.
4. Remove the cover and gasket.
NOTICE: Take care not to damage the lip of the oil seal.
NOTICE: Never rotate the engine with the timing cover re-
moved.
NHIL13ENG0057AA 1
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Timing gear housing - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
Crankshaft pulley - Remove Pulley (10.103)
NOTICE: Keep all parts clean from contaminants. Contaminates may cause rapid wear and shortened component
life.
1. Remove the hydraulic pump or block off plates from the
bottom left of the timing cover (3).
2. Remove the nuts (1) and bolts (2) from the timing cover.
3. Remove any wire fasteners and identify fastener loca-
tions for installation.
4. Remove the cover and gasket.
NOTICE: Take care not to damage the lip of the oil seal.
NOTICE: Never rotate the engine with the timing cover re-
moved.
NHIL13ENG0182AA 1
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Timing gear housing - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component
life.
1. The timing cover contains the front oil seal (2) and the
oil pump alignment pin (1). Inspect the front oil seal
(2) for tears or signs of wear. Ensure the oil pump
alignment pin (1) is intact in the housing.
NHIL13ENG0066AA 1
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Timing gear housing - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
life.
1. The timing cover contains the front oil seal (2) and the
oil pump alignment pin (1). Inspect the front oil seal
(2) for tears or signs of wear. Ensure the oil pump
alignment pin (1) is intact in the housing.
NHIL13ENG0184AA 1
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Timing gear housing - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTICE: Never rotate the engine with the timing cover removed.
life.
1. Ensure the timing cover and the nose of the crankshaft
(2) are clean and free from damage. Clean the mating
surface (1) of the plate.
NHIL12ENG0192AA 1
2. Align the pin hole (1) on the oil pump cover with the bolt
hole directly above the crankshaft (3), to accept the pin
on the timing cover.
3. Install a new gasket timing cover gasket.
4. Align the front timing cover to the studs (2) in the plate.
NHIL12ENG0192AA 2
5. Ensure the pin (1) in the timing cover aligns with the
pin hole (1), Figure 2 on the oil pump cover. Install the
timing cover to the plate.
NOTICE: Take care not to damage the oil seal (2) during
installation.
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6. Install the retaining bolts (2) and nuts (1) on the studs.
7. Evenly torque the retaining bolts (2) and nuts (1) to
50 N·m (37 lb ft).
NHIL13ENG0073AA 4
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Timing gear housing - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTICE: Never rotate the engine with the timing cover removed.
life.
1. Ensure the timing cover (2) and the nose of the crank-
shaft (3) are clean and free from damage. Clean the
mating surface (1) of the plate.
2. Install a new timing cover gasket.
NHIL13ENG0182AA 1
3. Align the front timing cover to the studs (1) in the block.
4. Guide the linkage for the injection pump into position
so that the link is free to move inside the aperture on
the cylinder block for the injection pump.
NHIL13ENG0182AA 2
5. Ensure the pin (2) in the timing cover aligns with the pin
hole (1) on the oil pump cover. Install the timing cover
to the plate.
NOTICE: Take care not to damage the oil seal during in-
stallation.
NHIL13ENG0185AA 3
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6. Install the retaining bolts (2) and nuts (1) on the studs.
7. Evenly torque the retaining bolts (2) and nuts (1) to
50 N·m (37 lb ft).
NHIL13ENG0182AA 4
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Timing gear housing - Remove - Front plate

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Camshaft - Remove (10.106)
1. Remove the front plate retaining bolts (2).

2. Remove the front plate (1) and gasket (3).
NHIL13ENG0070AA 1
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Timing gear housing - Install - Front plate

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Clean the mating surface of the block and front plate.

2. Install a new gasket (3).
3. Install the front plate (1) and secure with retaining bolts
(2).
4. Torque bolts (2) to 23 - 28 N·m (17 - 21 lb ft).
NHIL13ENG0070AA 1
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Timing gear housing - Remove - Front plate

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Remove the retaining bolts.

2. Remove the front plate (2) and gasket (1).
NHVM13ENG0198AA 1
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Timing gear housing - Install - Front plate

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Clean the mating surface of the block and front plate.

3. Install the front plate (2) and secure with retaining bolts.
4. Torque retaining bolts to 23.0 - 28.0 N·m (17.0 - 21 lb
ft).
NHVM13ENG0198AA 1
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Index
Engine - 10

Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Timing gear housing - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Timing gear housing - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Timing gear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Timing gear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Timing gear housing - Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timing gear housing - Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Timing gear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timing gear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Timing gear housing - Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Timing gear housing - Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Engine - 10
Valve drive and gears - 106

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Contents
Engine - 10
TECHNICAL DATA
Rocker arm
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camshaft
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Valve drive and gears

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Camshaft
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Rocker arm
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rocker shaft
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rocker support
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Camshaft
Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Camshaft gear
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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CONSUMABLES INDEX

Molykote® G-N Metal Camshaft Tappets - Install 10.3 / 22
assembly paste
47632293 16/09/2014
10.3 [10.106] / 4
Engine - Valve drive and gears
Rocker arm - Dimension

Shaft Diameter
Standard 14.95 - 14.97 mm (0.5886 - 0.58937 in)
Minimum 14.87 mm (0.585 in)
Shaft-to-Rocker Clearance
Standard 0.032 - 0.068 mm (0.00126 - 0.00268 in)
47632293 16/09/2014
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Camshaft - Dimension
N4LDI-TA-45SL
N4LDI-TA-50SL
Cam height-valve
Standard 34.438 - 34.538 mm (1.3558 - 1.3598 in)
Camshaft run out
Standard Less than 0.03 mm (0.001 in)
Maximum More than 0.1 mm (0.004 in)
Cam gear backlash
Standard 0.08 - 43.06 mm (0.0031 - 1.6953 in)
Allowable limit 0.25 mm (0.0098 in)
Camshaft - Dimension
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Cam height - (valve lobes)

Standard 34.438 - 34.538 mm (1.3558 - 1.3598 in)
Cam height - (injection pump lobes)
Standard 42.94 - 43.06 mm (1.6906 - 1.6953 in)
Camshaft run out
Standard Less than 0.03 mm (0.001 in)
Maximum More than 0.1 mm (0.004 in)
Cam gear backlash
Standard 0.08 - 43.06 mm (0.0031 - 1.6953 in)
Allowable limit 0.25 mm (0.0098 in)
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Valve drive and gears - Exploded view

N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0045AA 1
(1) Rocker arm housing (5) Oil pressure switch

(2) Springs (6) Rocker shaft
(3) Washers (7) Gasket
(4) Rocker arm
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Valve drive and gears - Exploded view

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NHIL13ENG0178AA 1
(1) Rocker arm (5) Rocker shaft

(2) Spring (6) Rocker arm housing gasket
(3) Washers (7) Rocker arm housing
(4) Oil pressure switch
47632293 16/09/2014
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Camshaft - Exploded view
NHIL13ENG0005AA 1
(1) Camshaft (4) Camshaft gear

(2) Bearing (5) Spacer
(3) Washers (6) Key
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Rocker arm - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Rocker support - Remove (10.106)
1. Thread an 8mm bolt (4) into the front end of the rocker
shaft (3).
2. Slowly withdraw the rocker shaft (3) while removing the
rocker arms (1) and springs (2).
NHIL12ENG0189AA 1
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Rocker arm - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Thread the banjo bolt from the oil supply line into the
front end of the rocker shaft (4).
2. Slowly withdraw the rocker shaft (4) while removing the
rocker arms (1), springs (2), and washers (3).
NHIL13ENG0178AA 1
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Rocker arm - Inspect

1. Use a micrometer to measure the outside diameter of
the rocker shaft.
NOTE: Rocker arms have no bushings and only one lube
hole.
2. Calculate the clearance (2) between the rocker arm and
rocker arm shaft. If the clearance exceeds 0.2 mm
(0.008 in), replace the rocker arm.
3. Check the valve cap contact surface (1) for uneven
wear and streaks.
NOTE: Minor damage can be fixed using a fine grinding
stone or sand paper.
NHIL13ENG0050AA 1
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Rocker arm - Install

Prior operation:
Rocker arm - Inspect (10.106)
1. Install the rocker shaft (5) into the rocker housing (1)
while installing the rocker arms (4), washers (3) and
springs (2).
NHIL13ENG0045AA 1
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Rocker arm - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
Rocker arm - Inspect (10.106)
1. Install the rocker shaft (4) into the rocker housing (5)
while installing the rocker arms (1), springs (2) and
washers (3).
NHIL13ENG0178AA 1
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Rocker arm - Clearance

NOTICE: Adjust the valve clearance only while the engine is cold.
1. Rotate the crankshaft clockwise and bring each piston
to Top Dead Center (TDC) on the compression stroke
(both valves closed).
NOTE: This will ensure the tappet is in its lowest position
before making the adjustment.
2. Loosen the nut (2) and adjust the clearance of both the
intake and exhaust valves to 0.2 mm (0.008 in) (3) with
the adjusting screw (1).
3. Hold the adjusting screw from turning and torque nut to
12 - 16 N·m (9 - 12 lb ft).
76075742 1
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Rocker shaft - Inspect

Prior operation:
Rocker arm - Remove (10.106)
1. Use a micrometer to measure the wear points (arrows)

on the rocker shaft.
2. The shaft diameter should be between 14.95 -
14.97 mm (0.588 - 0.589 in).
3. Replace the rocker shaft if the measured value at any
point is less than 14.87 mm (0.585 in).
NHIL13ENG0048AA 1
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Rocker support - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Valve cover - Remove (10.101)
1. Remove the banjo fitting (3) on the pulley side of the

engine.
2. Remove bolts (1).
3. Loosen nuts (2) one turn at a time, in an alternating or-
der. This will prevent any distortion of the rocker shaft.
4. Remove nuts (2).
NHIL12ENG0175AA 1
5. Remove the rocker arm shaft and support bracket (4)

as an assembly.
6. Remove push rods from the cylinder head.
NHIL12ENG0189AA 2
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Rocker support - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
Valve cover - Remove (10.101)
1. Remove the banjo fitting (3) on the pulley side of the

engine.
2. Remove bolts (1).
3. Loosen nuts (2) one turn at a time, in an alternating or-
der. This will prevent any distortion of the rocker shaft.
4. Remove nuts (2).
5. Remove the rocker arm shaft and support bracket (4)
as an assembly.
6. Remove push rods from the cylinder head.
NHIL12ENG0189AA 1
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Rocker support - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install the push rods into the cylinder head.

2. Install a new gasket.
3. Install rocker arm shaft and support bracket (4) as an
assembly on top of the cylinder head (5).
NOTICE: Ensure the push rods are properly seated on the
ball of the rocker arm.
4. Evenly tighten the nuts and bolts (2) in an alternating
order to prevent distortion.
5. Torque nuts and bolts (2) to 27 - 39 N·m (20 - 29 lb ft).
6. Install the banjo fitting (3) and torque to 10.0 - 12 N·m
(7.4 - 9 lb ft).
NHIL12ENG0175AA 1
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Rocker support - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the push rods into the cylinder head.

2. Install a new gasket.
3. Install rocker arm shaft and support bracket (4) as an
assembly on top of the cylinder head (5).
NOTICE: Ensure the push rods are properly seated on the
ball of the rocker arm.
4. Evenly tighten the nuts and bolts (2) in an alternating
order to prevent distortion.
5. Torque nuts and bolts (2) to 27 - 39 N·m (20 - 29 lb ft).
6. Install the banjo fitting (3) and torque to 10.0 - 12 N·m
(7.4 - 9 lb ft).
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Camshaft Tappets - Remove

Prior operation:
Cylinder head - Remove (10.101)
1. Remove the valve tappets (1) from the machined bores

in the cylinder block.
NHIL12ENG0216AA 1
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Camshaft Tappets - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Coat tappets with MOLYKOTE ® G-N METAL ASSEMBLY

PASTE .
2. Insert valve tappets (1) into cylinder block bores.
NHIL12ENG0216AA 1
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Camshaft Tappets - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Coat tappets with clean engine oil.

2. Insert valve tappets (1) into cylinder block bores.
NHIL12ENG0216AA 1
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Camshaft - Remove
N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Timing gear housing - Remove (10.102)
1. Refer to Timing gear housing - Remove (10.102).

NOTICE: The idler gear must be removed prior to rotat-
ing the camshaft. Refer to Engine oil pump - Remove
(10.304) for the proper procedure.
2. Rotate the camshaft to access the retaining bolts (1)
that secure the camshaft plate (2) and remove bolts.
3. Remove the plate (2).
4. Remove the camshaft (3) from the front of the block.
NHIL13ENG0032AA 1
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Camshaft - Inspect
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Place the camshaft in a set of V-blocks and check the

runout using a dial indicator (1).
2. Replace or straighten the camshaft if the runout is
greater than 0.1 mm (0.004 in).
3. Use a micrometer to measure the height of the
camshaft lobes.
4. Replace the camshaft if any of the cam lobes are worn
to less than the following dimensions:
• Intake/Exhaust valve lobes: 34.1 mm (1.3425 in)
20093402 1
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Camshaft - Install
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Lubricate the cam lobes with engine oil.

2. Install the camshaft (3) into the engine block while
aligning the timing marks of the High Pressure (HP)
pump gear and camshaft gear (A).
NOTICE: The idler gear must be removed prior to rotat-
ing the camshaft. Refer to Engine oil pump - Remove
(10.304) for the proper procedure.
3. Rotate the camshaft gear to access the bolt holes on
the block.
4. Install the camshaft support plate (2) and secure with
retaining bolts (1).
5. Torque bolts to 9 - 13 N·m (6.6 - 10 lb ft).
NHIL13ENG0032AA 1
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Camshaft - Timing adjust

N4LDI-TA-45SL
N4LDI-TA-50SL
1. The idler gear is integral to the oil pump. See En-

gine oil pump - Install (10.304) for proper timing of
the camshaft and crankshaft gears.
2. For timing of the high pressure fuel pump, see High
pressure pump - Timing adjust (10.218).
NOTICE: It is very important to install the front cover prior
to rotating the engine with the oil pump installed. Damage
to the port shaft of the oil pump can occur.
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Camshaft - Remove
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
1. Remove the bolts (3) securing the plate (1) to the block.
One must be accessed using the access hole (2) in the
cam gear.
NOTICE: Never rotate the cam gear unless the idler gear
is removed.
2. Remove the cam gear and camshaft out of the engine
bore.
SECT10C01PG45_1 1
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Camshaft - Inspect
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Place the camshaft in a set of V-blocks and check the

runout using a dial indicator (1).
20093402 1
2. Use a micrometer to measure the height of the

camshaft lobes.
Height of intake/exhaust cam lobes (1):
• Standard valvue — 34.453 - 34.508 mm (1.356 -
1.359 in)
• Service limit — 34.100 mm (1.343 in)
Height of injection pump cam lobes (2):
• Standard value — 42.940 - 43.060 mm (1.691 -
1.695 in)
NHIL13ENG0167AA 2
3. Replace or straighten the camshaft if the runout is less
then the service limit.
47632293 16/09/2014
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Camshaft - Install
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
Timing gear housing - Install — Front plate (10.102)
1. Install the tachometer shaft (3).

2. Carefully insert the camshaft (1) into its bore so as not
to damage the bearings or bearing surfaces.
3. Align the retaining plate (4) to the block bolt holes and
install the retaining bolts (2).
4. Torque the bolts to 8.8 - 12.9 N·m (6.5 - 9.5 lb ft)
NHIL13ENG0166AA 1
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Camshaft gear - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Remove the slide (4) from the camshaft gear.

2. Use a gear pull to remove the gear assembly (5).
3. Remove the spacer (3), spacer gear (6), spacers (2),
bearing (7) and key (1) from the camshaft (8).
20093401 1
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Camshaft gear - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Check the timing gears for wear and damage on the

contact area. Replace if any defect is found.
2. Measure the backlash of gears with a feeler gauge or
dial indicator. The measured value should be between
0.08 - 0.25 mm (0.0031 - 0.0098 in).
3. Replace the gears if the allowable limit is exceeded.
20093400 1
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Camshaft gear - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install bearing (7), two spacers (2), spacer gear (6), and
spacer (3).
NOTE: The spacer gear (6), serves as a spacer only. There
is no other purpose for this gear.
2. Insert the key (1) into the key slot on shaft (8) and press
the gear assembly (4) over the shaft onto the key.
3. Install the slider (5) back onto the gear assembly (4).
20093401A 1
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Camshaft gear - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Remove the nut (4) and spacer (3) from the camshaft.
2. Use a gear puller to remove the camshaft gear (2).
3. Collect the washers (1) and spacer (5).
NHIL13ENG0005AA 1
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Camshaft gear - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Check the camshaft gear for wear and damage on the

contact area (1). Replace if any defect is found.
NHIL13ENG0005AA 1
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Camshaft gear - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install bearing (6), two washers (1), spacer (5) and one
washer (1).
2. Insert the key (7) into the slot on the shaft and press
the cam gear (2) on the shaft aligning the key.
3. Install the spacer (3) and secure assembly with nut (4).
4. Torque the nut (4) to 68 - 72 N·m (50 - 53 lb ft).
NHIL13ENG0005AA 1
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Index
Engine - 10

Camshaft - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Camshaft - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Camshaft - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Camshaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Camshaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Camshaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Camshaft - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Camshaft Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshaft Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Camshaft gear - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Camshaft gear - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Camshaft gear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Camshaft gear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Camshaft gear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Camshaft gear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Rocker arm - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rocker arm - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker arm - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rocker arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rocker arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rocker arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rocker shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rocker support - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rocker support - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rocker support - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rocker support - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valve drive and gears - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve drive and gears - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - 10
Cylinder heads - 101

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
TECHNICAL DATA
Cylinder heads
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valves
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve guide
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve seat
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUNCTIONAL DATA
Cylinder head
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve guide
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Valve seat
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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CONSUMABLES INDEX

Molykote® Cylinder head - Install 10.4 / 17
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Engine - Cylinder heads
Cylinder heads - Dimension

N4LDI-TA-45SL
N4LDI-TA-50SL
Head warp
Cylinder heads - Dimension

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Head warp
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Valves - Dimension
N4LDI-TA-45SL
N4LDI-TA-50SL
Valve stem thickness

Standard 6.955 - 6.97 mm (0.27382 - 0.27441 in)
Maximum 6.89 mm (0.27126 in)
Valve head thickness
Standard 0.9 - 1.1 mm (0.03543 - 0.04331 in)
Valves - Dimension
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Valve stem thickness

Standard (Intake) 6.955 - 6.97 mm (0.27382 - 0.27441 in)
Maximum (Intake) 6.89 mm (0.27126 in)
Standard (Exhaust) 6.94 - 6.95 mm (0.27323 - 0.27362 in)
Maximum (Exhaust) 6.84 mm (0.26929 in)
Standard 0.8 - 1.1 mm (0.03150 - 0.04331 in)
Valves Spring - Dimension

Out of square
Free length
Standard 35 mm (1.37795 in)
Maximum 33.5 mm (1.31890 in)
Spring force when compressed to 30.4 mm (1.20 in)
Standard 79.4 N (17.8 lb)
Maximum 68.6 N (15.4 lb)
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Valve guide - Dimension

N4LDI-TA-45SL
N4LDI-TA-50SL
Valve stem to valve guide clearance

Standard 0.03 - 0.06 mm (0.00118 - 0.00236 in)
Valve guide - Dimension

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Valve stem to valve guide clearance

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Valve seat - Dimension

N4LDI-TA-45SL
N4LDI-TA-50SL
Valve seat recess

Standard 0.75 - 0.85 mm (0.02953 - 0.03346 in)
Valve seat width
Valve seat - Dimension

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Valve seat recess

Standard 0.85 - 1.15 mm (0.03346 - 0.04528 in)
Valve seat width
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Cylinder head - Exploded view
NHIL13ENG0058AA 1
(1) Valve guide seals (4) Valve cotter

(2) Cap (5) Spring
(3) Retainer (6) Valve
The cylinder head incorporates the valve assemblies, rocker arms, rocker shaft, push rods, and lifters. A swirl cham-
ber located between the injector assembly and the main combustion chamber of the cylinders provides improved
starting and greater fuel efficiency. Initial combustion starts in the precombustion chamber and as the expansion oc-
curs a strong swirl pattern is created in the main combustion chamber for more complete combustion of the air-fuel
mixture. The air intake manifold is separate from the cast aluminum valve cover. The exhaust manifold is bolted on
the left-hand side of the cylinder head.. Cylinder heads have integral valve guides. Standard size valves only are
used.
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Valve cover - Remove

Prior operation:
Throttle Valve Actuator (TVA) - Remove (55.014)
1. Remove the seal washer (2) and cap nuts (1).

2. Lift the valve cover (4) and gasket from the rocker shaft
support (3).
NHIL12ENG0174AA 1
NHIL12ENG0175AA 2
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Valve cover - Install

1. Inspect and clean the gasket contact area (1) of the
rocker shaft support housing.
NHIL12ENG0175AA 1
2. Install the gasket and valve cover (4) onto the shaft
support housing (3).
3. Install the seal washers (2) and cap nuts (1).
4. Evenly torque the cap nuts (1) to 8.3 - 11.3 N·m (6.1 -
8.3 lb ft).
NHIL12ENG0174AA 2
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Cylinder head - Remove

1. Evenly loosen the cylinder head bolts following the pat-
tern shown.
20002380 1
2. Remove the head from the block.
NHIL12ENG0188AA 2
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Cylinder head - Disassemble

Prior operation:
Cylinder head - Remove (10.101)
1. Clean the cylinder head and remove any carbon de-

posits from around the valve heads.
2. Remove the stem cap (1) from the valve stem.
3. Use a valve spring compressor to compress the spring.
4. Remove the valve spring keepers (2), spring cap (3)
and spring (4) from each valve (5).
5. Remove the valves and place the valve components to-
gether in separately marked containers for reassembly
in their original position.
6. Remove the valve guide seals (6).
NOTE: The valve guide seals for the intake and exhaust
are different.
NHIL13ENG0058AC 1
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Cylinder head - Inspect

1. Clean all carbon deposits from the combustion cham-
ber and valve ports using a wire brush and scraper.
2. Clean all dirt and residue from the gasket surface using
care not to scratch or nick the machined surface.
3. Clean the cylinder head in solvent and air dry.
4. Inspect the head for cracks or damage in the following
areas:
• Valve ports
• Valve seats
• Water jackets
5. Inspect the gasket surfaces for scratches or nicks,
which could cause leakage.
6. Examine the core hole plugs for rust or signs of leak-
age. If a plug shows signs of damaging rust or leakage,
replace all plugs in the head.
7. Apply a straight edge to the bottom surface of the cylin-
der head at six locations from (A) to (F) and check for
warp lengthwise, crosswise, and diagonally.
NHIL13ENG0075AA 1
8. Use a feeler gauge at six points from (A) to (F) to mea-

sure distortion.
9. If distortion exceeds 0.12 mm (0.00472 in) at any point,
replace the cylinder head.
NOTE: If any cracks or other damage is found during in-
spection, replace the cylinder head.
20093371F 2
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Cylinder head - Assemble

1. Insert each valve (5) in the guide (6) from which it was
removed and lightly lap the valve to be sure of an even
seat around the valve face. Remove the valve and
remove all traces of lapping compound.
2. Install new intake valve seals on the valve guides using
a suitable driver.
NOTE: Be sure to check the seals, the valve guide seals
for the intake and exhaust are different sizes.
3. Use a spring compressor to assemble the valves (5),
springs (4), spring cap (3), keepers (2).
4. Install the valve stem cap (1).
NHIL13ENG0058AC 1
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Cylinder head - Install

Prior operation:
Cylinder head - Inspect (10.101)
1. Clean all dirt and residue from the gasket surface of

the block and head using care not to scratch or nick
the machined surface.
Head gasket selection

During assembly, the engine compression ratio is estab-
lished by the thickness of the head gasket used. For ser-
vice replacement, head gaskets of different thickness are
available. The correct head gasket must be selected based
on piston protrusion. The correct head gasket usage is de-
termined as follows:
1. Position each of the pistons at top dead center.
2. Use a dial indicator to determine the distance each pis-
ton projects above the face of the block.
NOTE: Measure each of the pistons while holding a slight
down pressure on the piston.
NOTE: The variation in the amount of protrusion among all
pistons must be within 0.1 mm (0.004 in).
3. Use the dimension taken from the cylinder which has
the greatest projection and select a head gasket as
indicated in the following chart.
20002377 1
Selection chart
Measured value Thickness when tightened
0.3 - 0.4 mm (0.01181 - 0.01575 in) 1.1 mm (0.04331 in)
0.4 - 0.5 mm (0.01575 - 0.01969 in) 1.2 mm (0.04724 in)
0.5 - 0.6 mm (0.01969 - 0.02362 in) 1.3 mm (0.0512 in)
Install cylinder head

1. Install the head gasket (1) on the block (3).
2. Align the locating dowels (2) and install the cylinder
head.
NHIL12ENG0211AA 2
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3. Apply MOLYKOTE ® to the threads of each bolt and in-

stall.
4. Torque the head bolts in the sequence as shown to 48
- 52 N·m (35.4 - 38 lb ft).
5. Then turn the head bolts an additional 120 - 180 °.
20002380 3
6. Install the push rods (1).
NHIL12ENG0217AA 4
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Valves - Inspect
N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Cylinder head - Disassemble (10.101)
1. Clean all deposits from the valves using a soft wire

brush. Inspect the condition of the valves and discard
any that are badly burned, cracked, or bent.
2. Using a micrometer, measure the valve stem diameter
at points (A), (B), and (C).
3. If the valve stem diameter is less than 6.89 mm
(0.2713 in) it must be replaced.
20093375A 1
Wear of valve stem

Standard assembling value 6.955 - 6.97 mm (0.2738 - 0.2744 in)
Service limit 6.89 mm (0.2713 in)
4. If the valve head is less than 0.5 mm (0.0197 in) it must

be replaced.
20093376 2

5. If inspection indicates that the valve may be reused, the

valve should be ground:
(1) 45 ° Angle Seat
(2) Minimum Valve Margin
Valve seat contact width

Standard assembling value Repair value
Intake 2.16 - 2.38 mm (0.0850 - 0.0937 in) 2.7 mm (0.1063 in)
Exhaust 1.50 - 1.86 mm (0.0591 - 0.0732 in) 2.5 mm (0.0984 in)
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6. After grinding the valve and seat:

1. Check to ensure the seat contacts the center of the
valve face.
2. Use Prussian Blue to lightly coat the valve seat.
3. Place the valve in position and rotate the valve
slightly while holding a light pressure against the
valve.
4. If the blue is transferred to the center of the valve
face, the contact is correct.
NOTE: If Prussian Blue is not available, mark the valve face
or seat (1) with a soft lead pencil. Rotate the valve slightly
20093377 3
in the seat. The penciled lines will be broken at the seat
contact area.
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Valves - Inspect
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Prior operation:
Cylinder head - Disassemble (10.101)
1. Clean all deposits from the valves using a soft wire

brush. Inspect the condition of the valves and discard
any that are badly burned, cracked, or bent.
2. Using a micrometer, measure the valve stem at points
(A), (B), and (C).
3. Replace the valve if the measured values are less than:
• Intake – 6.89 mm (0.27126 in)
• Exhaust – 6.84 mm (0.26929 in)
20093375A 1
4. If the valve margin (2) is less than 0.5 mm (0.01969 in)

it must be replaced.
5. Grind the valve face angle (1) to 45 ° if the valve is to
be reused.
6. Check that the valve seat contacts the center of the
valve face after grinding using valve lapping com-
pound. Rotate the valve against the seat with a slight
pressure.
20093376 2
7. If valve lapping compound is not available, mark the

valve face or seat (1), with a soft lead pencil. Rotate
the valve slightly in the seat. The penciled lines will be
broken at the seat contact area.
20093377 3
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Valves Spring - Inspect

1. Place the valve springs on a flat surface.
2. Measure the free length of the spring and squareness.
If the spring exceeds 2.0 mm (0.079 in) out of square,
replace springs.
3. Place the springs in a suitable spring load tester.
4. Compress the spring to 30.4 mm (1.197 in). If the
spring exerts less than 7 kg (15.43 lb) of force, replace
the springs.
SECT10C01P52_1 1
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Valve guide - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
Thoroughly clean the valve guides before attempting to check internal wear.
1. Using a telescoping gauge and micrometer, measure

the valve guide bore at the top and bottom wear points
(1).
20093378A 1
2. Determine the valve stem to valve guide clearance (1)

by subtracting the valve stem outside diameter from
the valve guide inside diameter. Replace valves if the
clearance (1) is more than 0.2 mm (0.008 in).
3. Replace the cylinder head if excessive clearance is de-
termined and the valves have met all specified mea-
surement requirements.
20093379A 2
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Valve guide - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Thoroughly clean the valve guides before attempting to check internal wear.
1. Use a telescoping gauge and micrometer to measure

the valve guide bore at the top and bottom wear points
(1).
20093378A 1
2. Determine the valve stem to valve guide clearance (1)

by subtracting the valve stem outside diameter from
the valve guide inside diameter. Replace valves if the
clearance (1) exceeds:
• 0.2 mm (0.008 in) for intake valves
• 0.25 mm (0.010 in) for exhaust valves.
3. Replace the cylinder head if excessive clearance is de-
termined and the valves have met all specified mea-
surement requirements.
20093379A 2
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Valve seat - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
Examine the valve seats and surface the seat if damaged. Valve seat grinding requires that the seat be ground to
the correct width and properly positioned. A valve that extends too deep into the combustion area will result in valve
burning. If the valve is recessed too deep into the head it will cause a rapid build-up of carbon deposits.
20093372 1
(1) Correct valve seat width and Intake Exhaust

location
Standard assembling value 2.16 - 2.38 mm (0.0850 - 0.0937 in) 1.50 - 1.86 mm (0.0591 - 0.0732 in)
Service limit 2.7 mm (0.1063 in) 2.5 mm (0.0984 in)
(2) Valve recess
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1. Check the seat for surface defects. Use a 45 ° stone if

necessary to reface. Grind away only enough material
to provide a smooth even seat.
2. Check the seat width. If necessary, use a 15 ° stone
to lower the seat contact point and use a 75 ° stone to
raise the seat contact point.
NOTE: Refacing the seat should always be coordinated
with refacing of the valve to ensure a compression tight fit.
20093373 2
(1) Lower seat location — 15 ° stone

(2) Seat angle — 45 ° stone
(3) Raise seat location — 75 ° stone
(4) Contact width Intake Exhaust
3. Coat the valve seat surface with compound and lap the
contact surface turning the valve.
4. Check that the valve contact surface is within the stan-
dard value and the contact position is even.
5. When the cylinder head is replaced with a new one,
adjust the seat contact width and seat recess to the
specified values with a seat cutter before lapping.
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Valve seat - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Examine the valve seats and surface the seat if damaged. Valve seat grinding requires that the seat be ground to
the correct width and properly positioned. A valve that extends too deep into the combustion area will result in valve
burning. If the valve is recessed too deep into the head it will cause a rapid build-up of carbon deposits.
20093372 1
(1) Correct valve seat width and location

Intake Exhaust
(2) Valve recess
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1. Check the seat for surface defects. Use a 45 ° stone to

reface if needed.
NOTE: Grind away only enough material to provide a
smooth even seat.
2. Check the seat width. If necessary, use a 15 ° stone
to lower the seat contact point and use a 75 ° stone to
raise the seat contact point.
NOTE: Refacing the seat should always be coordinated
with refacing of the valve to ensure a compression tight fit.
20093373 2
(1) Lower seat location - 15 ° stone

(2) Seat angle - 45 ° stone
(3) Raise seat location - 75 ° stone
(4) Contact width Intake Exhaust
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3. Coat the valve seat surface with compound and use a

valve lapper (1) to lap the contact surface turning the
valve.
4. Check that the valve contact surface is within the stan-
dard value and the contact position is even.
5. When the cylinder head is replaced with a new one,
adjust the seat contact width and seat recess to the
specified values with a seat cutter before lapping.
NHIL13ENG0055AA 3
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Index
Engine - 10

Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder head - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder heads - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder heads - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve guide - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve guide - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve guide - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve guide - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Valve seat - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve seat - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve seat - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve seat - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valves - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valves - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valves - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valves - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Valves Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valves Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Engine - 10
Connecting rods and pistons - 105

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
TECHNICAL DATA
Connecting rod and piston

Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston
Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting rod bearing
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston pin bushings
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - Connecting rods and pistons
Connecting rod and piston Connecting rod - Dimension

Rod twist
Rod bend
On crankshaft side play
Standard 0.1 - 0.3 mm (0.004 - 0.012 in)
Crankshaft bearing clearance
Standard 0.035 - 0.083 mm (0.0014 - 0.00327 in)
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Piston - Dimension
Diameter
Standard 83.943 - 83.958 mm (3.30484 - 3.30543 in)
Bore clearance
Standard 0.0425 - 0.0615 mm (0.00167 - 0.00242 in)
Piston pin bore
Standard 27.996 - 28.000 mm (1.102 - 1.1023 in)
Piston pin clearance
Standard 0.001 - 0.011 mm (0.00004 - 0.00043 in)
Piston Pin - Dimension

Diameter
Standard 27.994 - 28.0 mm (1.10213 - 1.10236 in)
Minimum 27.97 mm (1.10118 in)
Pin-to-bushing clearance
Standard 0.010 - 0.027 mm (0.00039 - 0.00106 in)
Piston Ring - Dimension

N4LDI-TA-45SL
N4LDI-TA-50SL
End gap
Combustion ring 0.25 - 0.40 mm (0.00984 - 0.01575 in)
Intermediate ring 0.50 - 0.70 mm (0.01969 - 0.02756 in)
Oil control ring 0.10 - 0.40 mm (0.00394 - 0.01575 in)
Ring-to-groove clearance
Combustion ring —
Piston Ring - Dimension

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
End gap
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Ring-to-groove clearance
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Connecting rod and piston - Remove

1. Remove the two nuts (1), retaining the connecting rod
caps (2).
2. Remove the connecting rod caps and lower half of con-
necting rod bearing.
3. If necessary, remove any ridge from the top of the cylin-
der bores using a suitable ridge reamer.
76075710 1
4. Push the piston and connecting rod assembly out of the

top of the cylinder block.
5. Replace the connecting rod cap to the piston assem-
bly it was removed from. Keep together in cylinder se-
quence.
SECT10C01PG46_3 2
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Connecting rod and piston - Disassemble

1. Remove the piston pin retaining rings and drive the pin
(2) out of the piston using a suitable driver (1).
20093381 1
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Connecting rod and piston Connecting rod - Inspect
NHIL13ENG0060AA 1
(1) Gauge (A) Bent rod

(2) Alignment fixture (B) Twisted rod
(3) Connecting rod
1. Check the connecting rods for damage and alignment.

Place each rod in an alignment fixture to check for bent
or twisted condition.
2. Straighten or replace rods that are bent or twisted more
than the following dimensions:
• Maximum bend (A): 0.15 mm (0.0059 in) per
100 mm (3.94 in).
• Twist (B): 0.2 mm (0.0078 in) per 100 mm (3.94 in).
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Connecting rod and piston - Assemble

1. Align the arrow marking (2) for the front side of the
piston and the match marks (1) of the connecting rod
and cap.
NOTE: Ensure the match marks (1) are aligned correctly.
2. Install the piston pin through the piston and connecting
rod and secure with retaining clips.
NHIL13ENG0047AA 1
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Connecting rod and piston - Install

1. Coat the bearing faces, pistons, and piston rings with
clean engine oil. Slide the piston rings to permit a suf-
ficient amount of oil to be applied in the grooves.
2. Set the piston ring gaps 120 ° apart from each other.
Do not position these gaps toward the piston pin or the
right angle of the pin.
3. Using a piston ring compressor (1) insert the pistons
in the cylinders with the arrow in the piston pointing
toward the front of the engine.
NOTE: Install the pistons from the front to the rear in order.
20093408 1
NHIL13ENG0047AA 2
4. Install the connecting rod caps (1) making sure the rod
and cap matching marks (2), Figure 2 align. Tighten
the connecting rod nuts (2) to 49 - 54 N·m (36 - 40 lb
ft).
NOTE: After installation, ensure the crankshaft moves
freely. Ensure the axial play of 0.1 - 0.3 mm (0.004 -
0.012 in) is provided between the connecting rod and
crank pin.
NOTICE: Replace the connecting rod if axial play of the
connecting rod on the crank pin is more then 0.7 mm
(0.0276 in).
76075710A 3
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Piston Ring - Remove

1. Use piston ring pliers (1) to remove the piston rings.
20002376 1
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Piston - Inspect
1. Wash the pistons and connecting rods in a suitable sol-
vent and air dry.
2. Use a groove cleaner to remove the carbon deposits
from the ring grooves.
NOTICE: Be careful to avoid cutting any metal from either
side or the bottom of the grooves.
20093382 1
3. Inspect the piston ring lands for excessive wear. Use a

new ring (1) and feeler gauge (2) to check the ring side
clearance. Replace pistons having a ring side clear-
ance exceeding the following dimensions:
• Combustion ring = 0.25 mm (0.010 in)
• Intermediate ring = 0.25 mm (0.010 in)
• Oil control ring = 0.25 mm (0.010 in)
20093383 2
4. Use a micrometer to check the piston diameter at 90 °

from the piston pin bore. Replace the pistons if the
measured value is less than 83.7 mm (3.3 in).
20093384 3
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5. Use a telescoping gauge and a micrometer to measure

the piston pin bore and the piston pin diameter. Re-
place piston and/or piston pins that exceed the follow-
ing limits:
• Bore diameter: 28.0 mm (1.102 in)
• Pin diameter: 27.97 mm (1.101 in)
• Clearance: 0.02 mm (0.0008 in)
NOTE: In some instances the piston pin diameter may be
equal to or slightly larger than the piston pin bore. This 20093385 4
interference fit is normal.
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Piston Ring - Inspect

1. Install a piston ring (1) cylinder bore.
2. Use the top of the piston to square the ring in the bore.
3. Measure the clearance of the ring end gap (2) with a
feeler gauge.
4. Replace the piston rings if the end gap exceeds the
following measurements:
• Combustion ring = 1.0 mm (0.03937 in)
• Intermediate ring = 1.0 mm (0.03937 in)
• Oil control ring = 1.2 mm (0.04724 in)
NHIL13ENG0046AA 1
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Piston Ring - Install

1. Use piston ring pliers to install the piston rings. Position
the ring gaps at approximately 120 ° from each other.
Install the third (oil control ring) first as follows:
• Put the expander ring (1) into position in its groove.
• Install the outer oil ring (2) into position in its groove,
while making sure the outer oil ring gap is 90 ° apart
to the joint on the expander ring (1).
10044359 1
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Connecting rod bearing - Inspect

1. Remove oil or foreign matter from the bearing and
crankshaft.
2. Cut a piece of plastic gauge (1) to the same width as
the bearing. Place it on the crankshaft and avoid the
oil hole.
3. Install the rod cap and torque to 49.0 - 54 N·m (36.2 -
39.8 lb ft).
4. Remove the rod cap and measure the width of the flat-
tened plastic gauge (3) using the scale (2) on the pack-
age.
5. The widest portion of the plastic gauge is the minimum
clearance. Select the proper size bearing liners to ob-
tain the correct clearance.
20093392 1
• Standard assemble value — 0.035 - 0.085 mm
(0.001 - 0.003 in)
6. Install the connecting rod on the crankshaft and mea-
sure the play (1) in shaft direction. If the play is more
than 0.7 mm (0.028 in) replace the connecting rod.
20093391 2
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Piston pin bushings - Inspect

1. Use a telescoping gauge (1) and a micrometer (2) to
measure the inside diameter of the connecting rod (3)
piston pin bushing.
2. Measure the clearance between the bushing and piston
pin.
3. Refer to Piston pin bushings - Replace (10.105), if
the measured value exceeds 0.08 mm (0.00315 in).
20093388B 1
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Piston pin bushings - Replace

1. Remove and install the connecting rod (3) piston pin
bushings using a suitable driver (2) and press (1) a new
bushing into the rod bore.
NHIL13ENG0062AA 1
2. Ream and hone the bushing to the following finish size:

• Pin to Bushing Clearance:
• Standard = 0.010 - 0.027 mm (0.00039 -
0.00106 in)
• Max. = 0.08 mm (0.00315 in)
3. Drill a hole in the new bushing using the lube port in the
connecting rod as a guide.
NHIL13ENG0061AA 2
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Index
Engine - 10

Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting rod and piston Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting rod and piston Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting rod bearing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piston Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston pin bushings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piston pin bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - 10
Crankshaft and flywheel - 103

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
TECHNICAL DATA
Crankshaft
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Crankshaft pulley
Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flywheel housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft oil seal
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspect - Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Main bearings
Inspect - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replace - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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CONSUMABLES INDEX

Loctite® 5970™ Flywheel housing - Install 10.6 / 11
Loctite® 5970™ Crankshaft oil seal Rear seal - Install 10.6 / 14
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Engine - Crankshaft and flywheel
Crankshaft - Dimension
Journal diameter
Standard 67.957 - 67.970 mm (2.6754 - 2.676 in)
Crankpin diameter
Standard 51.964 - 51.975 mm (2.0458 - 2.0462 in)
Runout
Endplay
Standard 0.1 - 0.3 mm (0.0039 - 0.01181 in)
Thrust washer thickness
Standard 2.95 - 3.0 mm (0.115 - 0.117 in)
Cylinder block bearing diameter
Standard 68 mm x 72 mm ( 2.677 in x 2.835 in
Journal-to-cylinder block bearing clearance
Standard 0.044 - 0.116 mm (0.0017 - 0.0046 in)
Center bearing to crankshaft clearance
Standard 0.044 - 0.102 mm (0.001732 - 0.004016 in)
Dynamic balancer
Counterweight gear backlash 0.2 - 0.4 mm (0.008 - 0.016 in)
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Crankshaft pulley - Remove Pulley

1. Remove the retaining nut (1) from crankshaft (4).
2. Place tension on the pulley (2) with a suitable puller and
tap the end of the puller with a hammer to release the
hold of the taper.
3. Remove the pulley (2).
4. Remove and retain the key (3).
76075736A 1
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Engine flywheel - Remove

1. Remove the flywheel retaining bolts (1).
2. Use a dead blow hammer to loosen the flywheel (2)
from the shaft.
3. Remove flywheel (2).
NHIL13ENG0102AA 1
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Engine flywheel - Inspect - Ring gear

Prior operation:
Engine flywheel - Remove (10.103)
1. Inspect the ring gear (1) for cracked, broken, chipped,

or worn gear teeth. If damaged is found, refer to En-
gine flywheel - Replace — Ring gear (10.103).
NHVM13ENG0193AA 1
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Engine flywheel - Replace - Ring gear

1. Remove the starter ring gear (1) using a hammer and
chisel to crack the ring gear.
2. Heat the new ring gear to 120 - 150 °C (245 - 300 °F)
from the inside only.
NOTICE: Use a temperature sensitive crayon to avoid
overheating the gear.
3. Install the ring gear with the chamfered teeth side to-
ward the engine.
4. Cool the ring gear quickly to obtain a good shrink fit on
the flywheel.
20093403 1
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Engine flywheel - Install

Prior operation:
Engine flywheel - Inspect - Ring gear (10.103)
1. Fit the flywheel alignment hole to the crankshaft roll pin

(1) and install flywheel (2), Figure 2.
NHIL12ENG0204AA 1
2. Install the flywheel retaining bolts (1) and torque to 73

- 78 N·m (53 - 57 lb ft).
NHVM13ENG0193AA 2
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Flywheel housing - Remove

1. Remove the retaining bolts (1) from the rear plate.
NHIL12ENG0204AA 1
2. Remove rear plate (1).
NHIL13ENG0049AA 2
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Flywheel housing - Install

1. Apply LOCTITE® 5970™ liquid gasket or equivalent to
the threads of the M8 bolts and Install the rear plate (1).
NHIL13ENG0049AA 1
2. Install the retaining bolts (1) to secure the rear plate.

3. Torque bolts to 23 - 28 N·m (17.0 - 21 lb ft).
NHIL12ENG0204AA 2
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Flywheel housing - Test

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Speed sensor is located on the flywheel housing where

it senses engine speed as engine pulse.
2. Use a multimeter to test the resistance of the sen-
sor. The resistance should be 109.5 - 143.5 Ω at 20 °C
(68.0 °F). Replace sensor if outputs are out of range.
3. Use a dial indicator to check the sensor air gap.
There should be approximately 0.7 - 1.7 mm (0.0276 -
0.0669 in). If the gap is not in range, check the flywheel
and flywheel housing for any damage or obstructions.
4. Ensure to set the O-ring to prevent oil leaking.
5. Torque the sensor to 5.6 - 8.4 N·m (4.1 - 6 lb ft).
NHIL13ENG0053AA 1
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Crankshaft oil seal Rear seal - Remove

1. Remove the rear plate, refer to Flywheel housing -
Remove (10.103).
2. Remove the rear oil seal (1).
NHIL13ENG0037AA 1
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Crankshaft oil seal Rear seal - Install

1. Apply LOCTITE® 5970™ to the rear oil seal.
2. Install the rear oil seal (1) over the rear of the crank-
shaft.
NOTICE: Do not allow the oil seal lip to tear or flip.
NHIL13ENG0037AA 1
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Crankshaft - Remove
1. Remove the crankshaft bearing hex head bolts (1) and
the socket head hex bolts (2).
NHIL12ENG0208AA 1
2. Remove the oil pressure valve (1) from the right-hand

side of the block.
NHIL12ENG0234AA 2
3. Slide the crankshaft and main bearing assembly (1)

through the rear of the block.
NHIL12ENG0206AA 3
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Crankshaft - Inspect
20093394A 1
Taper Readings: (1) vs. (2) Out-of-Round Readings: (A) vs. (B)
1. Inspect the crankshaft gear teeth for wear or damage

and replace if necessary.
2. Mount the crankshaft in a set of V-blocks.
3. Use a dial indicator to measure the crankshaft journals
for runout and taper.
4. The amount of taper in a journal is the difference in the
measurements taken at points (1) and (2) on a journal.
5. The amount of out-of-round in a journal is the difference
in the measurements taken at 90 ° points on the journal.
NOTE: The smallest reading taken at any one of the read-
ings indicates the size of the journal.
6. Straighten or replace crankshafts that exceed runout
specifications. Refer to Crankshaft - Dimension
(10.103).
20093395 2
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Crankshaft - Inspect - Thrust washer

1. Check the thrust washer and replace if signs of wear,
improper contact, seizure, or other damage, or if the
thickness is less than 2.8 mm (0.110 in).
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Crankshaft - Install
1. Install the crankshaft (1) with bearing holders through
the rear of the cylinder block.
2. Align the threaded holes (3) on the bearing holders with
the bolt holes (2) in the cylinder block.
NHIL12ENG0205AA 1
3. Install the socket head hex bolts (2) at the rear of the
block, and install the hex head bolt (1) at each center
bearing. Torque the socket head bolts to 25 - 29 N·m
(18.4 - 21.4 lb ft). Torque the hex head bolts to 49 -
54 N·m (36 - 40 lb ft).
NHIL12ENG0208AA 2
4. Install the oil pressure relief valve (1) in the right-hand

side of the block.
5. Torque the relief valve (1) to 49 - 50 N·m (36 - 37 lb ft).
NHIL12ENG0234AA 3
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Crankshaft - End play

1. Use a dial indicator to measure the crankshaft end play.
If the end play is not within the allowable limit, remove
the crankshaft and check the thrust washers. Refer to
Crankshaft - Inspect — Thrust washer (10.103).
20093405 1
NHIL13ENG0011AA 2
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Main bearings - Inspect - Block bushing

1. Check the bushing for peeling, melting, seizure, or poor
contact.
2. Using a telescoping gauge and micrometer, measure
the oil clearance between the bushing and the crank-
shaft journal.
3. Measure the inside diameters at positions (1) and (2).
At each position, measure in both directions (3) and (4).
The oil clearance can be obtained by subtracting this
value from the maximum crankshaft journal diameter.
4. If the oil clearance exceeds 0.2 mm (0.0078 in) replace
the bushing.
20093396 1
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Main bearings - Replace - Block bushing
NHIL13ENG0078AA 1
Dimensions: Identification:
(A) 12.5 mm (0.492 in) (1) Front side
(B) 15 mm (0.591 in) (2) Align
(3) Lubrication hole
1. Remove the bushing from the front of the cylinder block

housing using a bushing driving tool to prevent dam-
age.
2. Inspect the bushing housing for marks, scratches, or
damage.
NOTE: Fine scratches or marks can be removed with light
sanding.
3. Lubricate the outer surface of the bushing with clean
engine oil.
4. Align the oil hole (3) of the housing and bushing.
5. Use a bushing driving tool to press the bushing into
the cylinder block from the engine front side until the
bushing is flush with the block surface.
NOTICE: Do not press the bushing into the cylinder block
from the opposite side.
NOTE: The leading edge of the bushing is chamfered to
aid with installation.
6. Confirm the housing and bushing are in alignment (2).
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Main bearings - Disassemble
20044366 1
1. Remove the two retaining bolts (1) from the bearing

holders (2).
2. Remove the bearing holders (2), upper main bearings
(5), lower main bearings (4) and thrust washers (3).
NOTE: The upper main bearing (4) has the oil groove.
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Main bearings - Inspect

Prior operation:
Main bearings - Disassemble (10.103)
20044366 1
1. Cut two pieces of plastic gauge to the same width as

the bearing. Place it on the upper main bearing (5) and
the lower main bearing (4) and avoid the oil hole.
2. Install the bearing holder (2) and torque the bolts (1) to
49.0 - 54 N·m (36.2 - 39.8 lb ft).
NOTE: Do not permit the bearing holder to rotate, even the slightest amount.
3. Remove the bearing holders (2) and measure the width
of the flattened plastic gauge using the gauge on the
package.
4. Replace components or grind the crankshaft to the next
undersized bearing as required to obtain the correct
clearance if not within 0.2 mm (0.00787 in).
5. Check the thrust washer (3) for wear, poor contact,
burning, or other defects.
6. Use a micrometer to measure the washer thickness.
If washer thickness is less than 2.8 mm (0.11 in), or
found to be defective, the washers must be replaced.
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Main bearings - Assemble

Prior operation:
Main bearings - Inspect (10.103)
NHIL13ENG0014AA 1
(1) Upper bearing holder (4) Lower main bearing

(2) Upper main bearing (with oil hole) (5) Rear thrust washers
(3) Stepped side (6) Front thrust washer
1. Install the bearing holder with the thrust washers to the

flywheel side, facing the stepped side (3), Figure 1 for-
ward.
NOTE: Be sure to install thrust washers (1) on the rear side
of the lower (2) and upper (3) bearing holders. Position
thrust washers with oil grooves facing outward from bearing
holders.
76075741 2
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2. Install the remaining upper bearing holders (1) and the

lower bearing holders (2) along with their bearings.
NOTE: The upper main bearings have the oil holes.
3. Torque the bearing holder retaining bolts to 49.0 -
54 N·m (36.2 - 39.8 lb ft).
76074367B 3
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Index
Engine - 10

Crankshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft - Inspect - Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft pulley - Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine flywheel - Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine flywheel - Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flywheel housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flywheel housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flywheel housing - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main bearings - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Main bearings - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main bearings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main bearings - Inspect - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main bearings - Replace - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Engine - 10
Balancer and damper - 110

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
SERVICE
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Balancer and damper
Balancer - Remove
1. Remove the banjo bolts (4) and the oil transfer pipe (5).
2. Remove the balancer retaining bolts (3).
3. Remove the balancer assembly (6) from the engine
block (2).
NOTE: Observe the quantity and thickness of the shims (1)
(if used) for assembly.
20002374A 1
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Engine - Balancer and damper
Balancer - Install
NOTE: The balancer assembly on the engines are different due to different connecting rods and length of piston
strokes on each engine.
1. Position the cylinder block with the oil pan mounting
surface facing down.
2. Position the No. (1) and the No. (4) pistons at Top
Dead Center (TDC).
20002376A 1
NOTE: When positioning balancer assembly for installa-

tion to engine, be sure balancer weights are oriented with
weights down towards oil pan (flats on weights should be
facing as shown).
10044365 2
3. With the balancer weights centered straight down

(weights facing away from engine block), position the
balancer assembly (6) and the original quantity of
shims (1) (if used) on the cylinder block (2) using the
dowel pins for alignment.
4. Install the M10 x 70 retaining bolts (3) and torque to 49
- 54 N·m (36 - 40 lb ft).
5. Install the oil transfer pipe (5) and secure with the banjo
bolts (4).
NOTICE: Inspect the backlash between the balancer gear
and the drive gear. Adjust the backlash to 0.2 - 0.4 mm
(0.008 - 0.016 in) using shims.
20002374B 3
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10.7 [10.110] / 4
Index
Engine - 10

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel filters - 206

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
Fuel filters - 206
SERVICE
Fuel filters
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Fuel filters
Fuel filters - Replace

1. Install the new filter and tighten by hand about 3/4 turn
after the gasket contacts the mounting surface.
NOTICE: Do not use a tool when tightening.
NOTICE: Do not clean fuel filter cartridge, replace it.
2. Check for leaks.
NHIL13ENG0024AA 1
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Throttle linkage - 220

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
FUNCTIONAL DATA
Governor
Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Throttle linkage
Governor - Dynamic description

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
These engines have a mechanical governor in order to control engine speed. The governor is installed inside the
timing cover.
The flyweight assembly is installed onto the camshaft gear, its movement is transmitted to the control rack of the injec-
tion pump through the slider control lever link. The spring which controls the movement of the flyweight is connected
to the tension lever.
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Index
Engine - 10

Governor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel injection system - 218

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
TECHNICAL DATA
Fuel injection system

Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Injection pump
Dynamic description - Fuel variation mechanism (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dynamic description - Pumping elements (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dynamic description - Delivery valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
High pressure pump
Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Common rail
Fuel injectors
SERVICE

Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspect – Fuel pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Injection pump
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
High pressure pump
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remove - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Common rail
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel injectors
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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Engine - Fuel injection system
Fuel injection system - General specification

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Injection pump
Pump manufacturer Bosch
Type In-Line
Timing (Before Top Dead Center (BTDC)) 16 - 17.5 °
Timing (piston height at Injection: Start BTDC) 2.532 - 3.022 mm (0.100 - 0.119 in)
Injection nozzle
• Nozzle type Throttle
• Needle valve diameter 0.4 mm (0.0157 in)
• Pintle diameter 1 mm (0.039 in)
Injection pressure 14700 kPa (2132.1 psi)
Spray angle 4°
Service adjustments
• Idle speed 1000 - 1100 RPM
• Max. no-load speed 2815 - 2855 RPM
Fuel injection system - Special tools

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Tool Description Tool No.

Injector Tester FNH01721
Injector Adapter Set FNH01728
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Fuel injection system - Overview

N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0025AA 1
(1) Fuel filter (5) Injector assembly

(2) Pressure sensor (6) ECU
(3) Common rail (7) Fuel tank
(4) Pressure limiter (8) HP pump
Common rail system:
• The High Pressure (HP) pump (8) pressurizes the fuel
and conveys it through the fuel injection pipe.
• The fuel accumulates in the common rail (3).
• The Engine Control Unit (ECU) (6) controls the fuel
quantity, timing and spray frequency electronically ac-
cording to engine speed and load.
• Pressurized fuel in the common rail (3) conveys through
the high pressure pipe into the fuel injectors (5) and
sprays into the combustion chamber.
NOTE: The ECU decides the start and end time in
which the injector operates.
• The sensor (2) will determine and control the engine
speed.
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Injection pump - Dynamic description

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
20097732 1
(1) Five-sided bolt (6) Control rack (11) Delivery valve

(2) Delivery valve holder (7) Plunger spring (12) Delivery valve seat
(3) Pump housing (8) Tappet (13) Delivery valve spring
(4) Eye bolt (9) Control sleeve (14) Sleeve flange
(5) Plunger (10) Plunger barrel
The injection pump is mounted in the cylinder block. It is driven by the engine's camshaft. Plunger (1) movement
is constant, being raised by tappets (2) and returned by the plunger spring (3) as the engine rotates. The plunger
barrel's (4) suction and discharge port opens onto the pump housing's fuel oil chamber, which is always filled with fuel.
When the plunger descends, fuel is sucked into the plunger barrel, and when the plunger reaches it's lowest point,
the suction of fuel stops.
The plunger then ascends, and when the plunger barrel's suction and discharge port is closed by the plunger, the fuel
oil pressure increases. The fuel oil then raises the delivery valve (5) and is delivered through the injection pipe to the
nozzle. When the fuel pressure exceeds the force of the nozzle spring's set force, fuel is injected into the engine's
combustion chamber in the form of a fine spray.
The plunger further ascends, and when the plunger helix meets the plunger barrel's suction and discharge port, fuel
delivery ends (at the same time injection from the nozzle ends). The delivery valve is then closed by the set force of
the delivery valve spring so that fuel is no longer delivered, even though the plunger continues to ascend.
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The effective stroke (2) is from the moment that the

plunger barrel's (6) suction and discharge port is closed
by the end of the plunger (beginning-of-injection) (4) until
the suction and discharge port meets the plunger helix
(1) (end-of-injection) (3). The effective stroke can be
altered by rotating the plunger (5). Accordingly, the rela-
tionship between injection quantity and effective stroke is
proportional.
20097776 2
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Injection pump - Dynamic description - Fuel variation mechanism

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
As well as pressurizing the fuel, the injection pump also functions to vary the fuel injection quantity.
A control sleeve is installed around the plunger barrel, and a flange on the bottom of the plunger is inserted into a
groove in the control sleeve. Teeth on the control sleeve are engaged with teeth on the control rack so that movement
of the control rack results in rotation of the plunger and, consequently, variation of the fuel injection quantity.
20097735 1
(A) Non delivery (B) Partial delivery (C) Maximum delivery
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Injection pump - Dynamic description - Pumping elements

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The pumping elements are operated by cam lobes (1) that

are incorporated on the engine valve train camshaft.
NHIL13ENG0167AA 1
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Injection pump - Dynamic description - Delivery valves

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Located above each pumping element is a delivery valve

assembly. The delivery valve consists of a delivery valve
holder (1), spring (2), piston and stem assembly (3) op-
erating within a cylindrical guide (4) which terminates in a
conical seat. The lower part of the stem has four vertical
flutes which accurately locate within the guide while per-
mitting fuel to pass. Above the flutes is a piston which is
a lapped fit in the bore of the valve guide.
The delivery valve serves as a non-return valve and also

as a means of rapidly reducing the fuel pressure in the in-
jector line when injection ceases. Rapid pressure reduc- 20093466 1
tion is required to be sure injector needle valve "snaps"

shut to prevent fuel "dribble", a condition which can cause
carbon formation on the injector tip.
76075755 2
(1) Spring (A) Valve closed

(2) Piston (B) Valve open
(3) Valve guide (C) Valve closing
(4) Conical seat
The delivery valve operates as follows:
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Position (A):
The pump plunger is at the bottom of the stroke and the inlet ports are uncovered, so the barrel and delivery guides
are filled with fuel. As the fuel is at low pressure, the delivery valve is retained on the seat by spring pressure.
Position (B):
The plunger has risen and closed both inlet ports, pressurized the fuel and the injection process begins. The pres-
surized fuel overcomes the spring tension, lifting the delivery valve off its seat until the piston is clear of the guide,
permitting fuel to pass to the injector.
Position (C):
The helical groove has uncovered the inlet port and released the fuel pressure. The delivery valve spring, aided by
the high pressure still existing in the pipeline, forces the delivery valve to close rapidly.
During closing, the piston portion of the valve returning into the guide increases the volume of the injector line by the
volume of this part of the valve.
This sudden increase in the volume of the injector line causes a rapid collapse of pressure and allows the injector
needle valve to "snap" shut.
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High pressure pump - Dynamic description

N4LDI-TA-45SL
N4LDI-TA-50SL
The High Pressure (HP) pump is driven by the camshaft gear that is secured to the camshaft by a nut and keyway.
Fuel suction quantity is controlled by the solenoid valve. The solenoid valve opening period decides the spray quantity.
The excess fuel returns to the fuel tank. Pulsar for the rotary sensor detects cylinder position where it is placed onto
the camshaft gear.
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Common rail - Dynamic description

N4LDI-TA-45SL
N4LDI-TA-50SL
The common rail accumulates the pressurized fuel, then distributes the fuel to the injectors through the pressure pipe.
A fuel pressure sensor is installed to detect the fuel pressure at the common rail. When the pressure in the common
rail exceeds limitations, the fuel is returned through the pressure adjusting valve.
A fuel temperature sensor is installed to detect the fuel temperature at the fuel return pipe. To reduce pulsations, a
flow damper orifice is installed on the high pressure pipe.
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Fuel injectors - Dynamic description

N4LDI-TA-45SL
N4LDI-TA-50SL
The fuel injectors spray the pressurized fuel from the common rail into the combustion chamber at the proper time
with the correct quantity.
The injector nozzle is composed of a command piston, orifice for flow restriction, a control chamber and solenoid.
Spray timing and quantities are electronically controlled by the Engine Control Unit (ECU). Electric signals switch on
and off the solenoid to determine electricity timing and trigger point.
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Fuel injectors - Dynamic description

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Throttle-type injectors are used in all engine applications.

The injectors have a 1.0 mm (0.04 in) single orifice and
are set at 15700 kPa (2277.1 psi). The pressure adjust-
ment is made by adding or deleting shims from the top
of the injector pressure adjusting spring. The injectors
have an injection angle of 4 °. The injector pipes are of
the same length for each cylinder to help keep the injec-
tion intervals in time.
The engine injection function is to inject fuel into a

pressurized cylinder in a fully atomized condition, which
provides efficient combustion with minimum amount of
smoke. Each injector assembly consists of a nozzle
assembly containing a needle valve, a nozzle holder
assembly, and injector needle valve regulating spring.
20097769 1
(1) Nut
(2) Nipple joint
(3) Body
(4) Shim
(5) Spring
(6) Push rod
(7) Distance piece
(8) Nozzle nut
(9) Nozzle assembly
Fuel from the injection pump enters the injector inlet and
passes down through a drilling in the nozzle holder and
body to the needle valve seat. The fuel pressurized by the
injection pump, lifts the needle valve off the seat against
the action of the spring pressure. The fuel is then forced,
in the atomized state, through the 1.0 mm (0.04 in) orifice
in the nozzle tip. When pressure from the injection pump
drops, the needle valve snaps back onto its seat under
pressure from the spring.
To provide lubrication of the injector, a small amount of

fuel is permitted to leak up between the needle valve and
the nozzle body. The excess fuel rises to the top of the
injector and returns to the fuel tank through the injection
leak-offline. 20097770 2
(A) Nozzle closed

(B) Nozzle initial opening
(C) Nozzle fully opened
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Fuel injection system - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Check the high pressure piping, and common rail com-

ponents.
• Use Service Tool D to run the active test “Fuel Leak
Check Function”.
If the test fails, continue with the rest of the fuel system
checks.
2. Visually inspect all fuel system components for damage
or leaking components.
• Common rail piping
• Injectors
• Fuel hoses
• Fuel filters
3. Check the amount of fuel in the tank and quality.
• Check the color. There should be no color, brownish,
or milky substance.
• Check the odor. There should be no kerosene,
heavy oil, or irritating odor. NHIL13ENG0071AA 1
• Check for separation of materials. There should be

no water, or foreign objects in the tank.
• Check the viscosity. There should not be a waxy or
sticky consistency.
If damage is found, repair or replace as needed.
If fuel is not being delivered, clean or replace fuel piping
system. If the system is clean, check the fuel filter. Replace
if needed, See Fuel filters - Replace (10.206)
NHIL13ENG0024AA 2
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Fuel injection system - Inspect – Fuel pump

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Active test.
• Use the diagnostic service tool.
• Select the “Diagnostic Test” from the “Diagnostics”
drop down menu.
• Select “Override Parameters”.
• Select “Engine Fuel Supply Lift Pump Relay Over-
ride”.
• Select ON from the “Change Parameter Value”
menu.
2. If the fuel pump does not turn ON. Check the following:
• Place the key switch ON.
• Listen and check for the fuel pump pressurizing.
• Check the electrical connection to the fuel pump.
• Check the fuel pump relay.
• Fuel pump fuse.
If the electrical circuit is good, replace the fuel pump.
If the electrical circuit has failed, repair or replace as
needed.
If the fuel pump does turn ON, but there is no fuel flow.
Check the following: NHIL13ENG0170AA 1
• Low fuel level.

• Clogged fuel lines.
• Clogged fuel filter.
• Leaking fuel connection.
Fuel pump electrical wiring/connection specification:
Connector pin Value

Pin 1 12.0 V
Pin 2 Ground
47632293 16/09/2014
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Injection pump - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
WARNING
Pressurized system!
Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and
relieve all pressure from pressurized systems before servicing the machine.
Failure to comply could result in death or serious injury.
W0905A
1. Remove the fuel injection lines (1) by loosening nuts

(2) on the injection pump and the nuts on the injectors.
NOTICE: Cap and plug all openings to prevent contamina-
tion.
76075756 1
2. Disconnect the fuel tank return line by removing bolt

(2).
3. Disconnect fuel inlet line (3) by loosening clamp screw
(1).
20097746 2
4. Disconnect the wire (1) to the fuel shut-off solenoid (3)

and remove the fuel shut-off solenoid.
5. Remove the mounting nuts and bolts (2).
76075757 3
47632293 16/09/2014
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6. Raise the pump and remove the snap pin (1) and sep-
arate the governor link (2) from the pump control rack
(3), Figure 5.
7. Remove the injection pump from the engine.
NOTE: If there are shims between the pump mounting
flange and the engine block, carefully remove the shims
and retain for installation.
20097750 4
20097751 5
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Injection pump - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Attach the pump rack to the governor linkage.

2. Install injection pump assembly with shims into engine
housing.
3. Install the pump mounting nuts and bolts and tighten to
13 - 17 N·m (9.6 - 12.5 lb ft).
4. Install fuel solenoid (5) into rear of injector housing.
5. Torque the fuel solenoid to 14.7 - 24.5 N·m (11 - 18 lb
ft) and connect the electrical connection (1).
6. Connect the fuel inlet line (2) by tightening clamp screw
(3).
7. Install the fuel return line by installing bolt (4). Torque 20097748 1
to 25 - 30 N·m (18 - 22 lb ft).
8. Install injector lines (1) by tightening nuts (2) at the
pump and nuts at the injectors. Torque to 23 - 36 N·m
(17 - 27 lb ft).
20097748 2
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Injection pump - Bleed

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
20097762 1
Fuel flow chart
(A) Fuel tank (E) Injectors (3 or 4 Cylinders)

(B) Fuel filter (F) Cylinders
(C) Lift pump (G) Return to injection pump
(D) Injection pump (H) Return line to fuel tank
With a full tank of fuel, fuel from the tank will push air out of
the fuel filter through the return to tank line. Fuel from the
fuel filter will be delivered to the fuel transfer pump.
The Auto Bleed occurs whenever the engine is started and
the throttle is set at full throttle.
1. Set the hand throttle at full throttle position.
2. Place ignition switch in the start position.
3. With the engine cranking, the fuel transfer pump, which
is activated by the engine camshaft rotating, will deliver
fuel to the injection pump.
4. Air that was in the injection pump will be returned to the
fuel tank via the injector fuel return to tank line.
NOTE: The injector fuel return to tank line is connected to
the fuel filter return to tank line.
5. Rotate the engine until it starts.
NOTE: Due to heat generation in the starter motor, do not
engage the starter for more than 30 seconds continuously.
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High pressure pump - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
1. Disconnect the electrical connection (1).

2. Remove the from tank supply line (4).
3. Remove the common rail return / return to tank banjo
bolt (3) and lines.
4. Remove the common rail supply line (2).
NHIL12ENG0136AA 1
5. Remove the two retaining bolts (2).

6. Remove the High Pressure (HP) pump (1) and O-ring
(3).
NHIL13ENG0072AA 2
NOTICE: Never handle the HP pump by the pipe (1), leak-

age can occur.
NHIL13ENG0030AA 3
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High pressure pump - Remove - Pump gear

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
High pressure pump - Remove (10.218)
1. Remove the nut (6) from the High Pressure (HP) pump
(8) shaft.
2. Remove the pulser (5) and HP pump gear (4).
3. Remove the flange retaining bolts (1).
4. Remove the flange (2) and O-ring (3).
5. Remove O-ring (7).
NHIL13ENG0029AA 1
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High pressure pump - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Replace the High Pressure (HP) pump when indicated

by the Engine Control Unit (ECU).
2. Inspect the HP pump for signs of leakage and O-ring
(2) condition.
NOTICE: Never handle the HP pump by the pipe (1), leak-
age can occur
3. If the HP pump is out of specifications or damaged,
install a new HP pump.
NHIL13ENG0029AA 1
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High pressure pump - Install - Pump gear

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
High pressure pump - Inspect (10.218)
1. Install the O-ring (7) onto the High Pressure (HP) pump
(8) shaft.
2. Install the flange (2) onto the HP pump (8) and secure
with the retaining bolts (1).
3. Install O-ring (3) into the flange (2).
4. Install the pump gear (4) onto the HP pump shaft.
5. Align the key position of the pump gear (4) and the
pulser (5) and install the pulser.
6. Secure the gear and pulser with nut (6) and torque to
58 - 62 N·m (43 - 46 lb ft).
NHIL13ENG0029AA 1
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High pressure pump - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTICE: Never handle the High Pressure (HP) pump by

the pipe (1), leakage can occur.
NHIL13ENG0030AA 1
1. Install the O-ring (3) and HP pump (1).
NHIL13ENG0072AA 2
2. Align the timing mark of the HP pump with the camshaft

timing mark, as shown.
3. Install the HP pump retaining bolts (2), Figure 2 and
torque to 58 - 62 N·m (43 - 46 lb ft).
NHIL13ENG0032AA 3
4. Install the common rail supply line (2) and torque to

22.5 - 28.5 N·m (17 - 21 lb ft).
5. Install the common rail return / return to tank lines. Se-
cure with washers and banjo bolt (3) and torque to 12.0
- 14.0 N·m (8.9 - 10.3 lb ft).
6. Install the from tank supply line (4) and torque to 20 -
25 N·m (15 - 18 lb ft).
7. Connect the electrical connection (1).
NOTE: If a new HP pump is installed, driving of the unit is
necessary for proper calibration. Refer to the service tool
for the calibration procedure of the HP pump.
NHIL12ENG0136AA 4
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High pressure pump - Timing adjust

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Make sure the cover indicator, and the pulley notch are
aligned.
NHIL13ENG0105AA 1
2. Remove the inspection cover.
NHIL13ENG0106AA 2
3. Check that the high pressure pump timing mark, and

the camshaft gear timing mark are matched.
NOTE: If the timing marks are not aligned, remove the high
pressure pump, align the timing marks and re-install the
pump. See High pressure pump - Install (10.218) for the
proper procedure.
NHIL13ENG0107AA 3
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Common rail - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Remove the hose clamp (2) from the return to pump

hose (1) and remove hose.
NHIL12ENG0136AA 1
2. Remove the injector supply pipes (2) and the common

rail supply pipe (1) from the common rail.
NHIL12ENG0229AA 2
3. Remove the retaining bolts (1).
NHIL12ENG0227AA 3
4. Remove the common rail from the block.
NHIL12ENG0169AA 4
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Common rail - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Replace the rail when indicated by the Engine Control

Unit (ECU). Actively check the common rail assembly
with the Service Tool D.
2. Check the common rail assembly for leaky conditions.
If the High Pressure (HP) pump is out of specifications,
install a new one. Never dismantle the common rail
assembly. Contact your authorized CNH dealer when
service is necessary.
NOTICE: The common rail assembly is a delicate part,
please handle with care. Avoid contamination of dust and
foreign objects.
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Common rail - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install the common rail onto the block and secure with
the retaining bolts (1).
2. Torque retaining bolts (1) to 23 - 28 N·m (17 - 21 lb ft).
NHIL12ENG0227AA 1
3. Install the common rail supply pipe (1) and the injector
supply pipes (2).
4. Torque supply pipes (2) to 20 - 25 N·m (15 - 18 lb ft).
NHIL12ENG0229AA 2
5. Install the common rail return hose (1) and secure with
hose clamp (2).
NHIL12ENG0136AA 3
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Fuel injectors - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Remove the injector supply pipes (1).
NHIL12ENG0228AA 1
2. Remove the banjo bolts (1) from the return line (2).
NOTE: Each banjo fitting will have two washers.
NHIL13ENG0071AA 2
3. Remove the fuel return line.
NHIL12ENG0170AA 3
4. Remove the retaining bolt (1) from the injector clamp

(2).
NHIL12ENG0218AA 4
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5. Remove the injectors.
NHIL12ENG0171AA 5
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Fuel injectors - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Do not drop, shock or damage the injector. Dust and

foreign objects may cause the injector to clog.
2. Check the injector assembly for fuel leakage. Use the
Service Tool D for detailed inspection. If the injector
assembly is out of specification, install a new one.
3. Solenoid resistance: 0.46 - 0.48 Ω at 20 °C (68.0 °F).
4. Do not dismantle the injector assembly, contact your
authorized CNH when service is necessary.
5. Replace the O-ring every time an injector is removed
to avoid leakage.
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Fuel injectors - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install a new O-ring (1) on the injector.

2. Install the seal ring (3) onto the tip of the injector (2).
NHIL12ENG0171BA 1
3. Install the fuel injector in the head until the O-ring seats.
4. Install the injector clamp (2) and secure with retaining
bolt (1).
5. Torque retaining bolts (1) to 22.6 - 28.4 N·m (16.7 -
21 lb ft).
NHIL12ENG0218AA 2
6. Install the fuel return line (2) and secure with the banjo
bolts (1) and washers.
7. Torque banjo bolts (1) to 15 - 20 N·m (11.1 - 15 lb ft).
NHIL13ENG0071AA 3
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8. Install the injector supply pipes (1).
NHIL12ENG0228AA 4
NOTICE: If any injector was replaced with a new one, a revision level change in the Engine Control Unit (ECU) is
necessary. Use Service Tool D, input the numerical value of the head of the new injector.
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Fuel injectors - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Clean all dirt, oil, and grease from the injectors (1) and
surrounding areas.
2. Disconnect the fuel leak-off lines (2) and injector lines
(3) from the injectors.
NHVM13ENG0194AA 1
3. Remove the injectors (1) and sealing washers (2) from

the cylinder head.
20097771 2
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Fuel injectors - Disassemble

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Loosen and remove the nozzle nut (1) from the injector
body (2) being careful not to drop or damage the noz-
zle.
2. Remove the nozzle assembly (3), spacer (4), spring (5)
and shim (6).
3. Clean the nozzle body and the needle valve. Check the
nozzle for any burn or score marks. Check the needle
seat for evidence of fuel leakage or carbon deposits.
4. Correct fuel leakage at the seat using a polishing stick
and polish the seat area.
5. Inspect the upper and lower contact surfaces of the
nozzle holder for a clean contact surface area.
6. Check the contact area between the push rod and
spring seat.
20097772 1
(1) Nozzle nut

(2) Injector body
(3) Nozzle assembly
(4) Spacer
(5) Spring
(6) Shims
(7) Rod
(8) Nut
(9) Leak-off line
(10) Washer
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Fuel injectors - Assemble

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTE: Clean all parts in clean fuel oil and assemble while still wet.
1. Install the shim(s) (9), spring (4), spacer (5), and nozzle
assembly (7) in the injector body (3).
2. Install the nozzle nut (6) and tighten to 39 - 44 N·m
(28.8 - 32.5 lb ft).
3. Check and adjust the injector pressure setting using an
injector tester and an adapter fitting. Adjust the pres-
sure setting to 15700 kPa (2277.1 psi).
20096956 1
(1) Nut
(2) Leak-off line
(3) Injector body
(4) Spring
(5) Spacer
(6) Nozzle nut
(7) Nozzle assembly
(8) Rod
(9) Shims
(10) Washer
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Fuel injectors - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the fuel injectors (1) and torque to 60 - 69 N·m

(43.4 - 50 lb ft).
2. Install the fuel return line (2) on the injectors (1) and
injection pump.
3. Install the injection piping (3) and torque to 15 - 24 N·m
(11 - 18 lb ft).
NHVM13ENG0194AA 1
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Index
Engine - 10

Common rail - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Common rail - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Common rail - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Common rail - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel injection system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injection system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel injection system - Inspect – Fuel pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel injection system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel injection system - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injectors - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel injectors - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel injectors - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel injectors - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel injectors - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fuel injectors - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel injectors - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fuel injectors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel injectors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High pressure pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High pressure pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
High pressure pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High pressure pump - Install - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
High pressure pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
High pressure pump - Remove - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High pressure pump - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Injection pump - Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Injection pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injection pump - Dynamic description - Delivery valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Injection pump - Dynamic description - Fuel variation mechanism (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Injection pump - Dynamic description - Pumping elements (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Injection pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Injection pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - 10
Turbocharger and lines - 250

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
10.11 [10.250] / 1
Contents
Engine - 10
FUNCTIONAL DATA
Turbocharger
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Turbocharger
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Turbocharger and lines
Turbocharger - Dynamic description

The turbocharger is a forced induction device used to allow more power to be produced for an engine of a given size.
The turbo charger is powered by exhaust gas to drive the turbine wheel and the other coaxial end.
There is a compressor wheel to force air into the engine and increase the power output. The turbo does not need any
service or adjustments.
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Turbocharger - Remove
N4LDI-TA-45SL
N4LDI-TA-50SL
N843LT-F-27
N843T-F-24
N844LT-F-45SL
1. Remove the retaining bolts (1) from the oil supply line,
block side.
NHIL12ENG0230AA 1
2. Remove the oil supply line banjo fitting (1) from the
turbocharge and remove supply line.
NHIL12ENG0232AA 2
3. Remove the retaining bolts (1) oil return line (2) from
turbocharger and engine block.
NHIL12ENG0181AA 3
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4. Remove the three turbocharger flange nuts (1) from

exhaust manifold.
5. Remove turbocharger.
NHIL12ENG0179AA 4
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Turbocharger - Inspect
N4LDI-TA-45SL
N4LDI-TA-50SL
N843LT-F-27
N843T-F-24
N844LT-F-45SL
1. Check turbine (exhaust side) and compressor (intake

side) housings for cracks.
2. Check oil line (return and supply) connections for dam-
age to mating surfaces, stripped threads, or clogged
ports.
3. Check turbine shaft for end play. Replace the tur-
bocharger if the turbine shaft end play exceeds
0.09 mm (0.00354 in).
4. Check the inside of the turbine and compressor hous-
ings for any signs of oil leakage or damage resulting
from a loose shaft.
5. Check turbine and compressor for any signs of missing
pieces.
6. Check mating surfaces for damage that may not allow
gaskets to seal.
7. If any damage is found on inspection, the turbocharger
must be replaced with a new unit.
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Turbocharger - Install
N4LDI-TA-45SL
N4LDI-TA-50SL
N843LT-F-27
N843T-F-24
N844LT-F-45SL
1. Install turbocharger (1) with a new gasket on exhaust

manifold studs (2) and torque nuts to 23 - 28 N·m (17.0
- 21 lb ft).
NHIL12ENG0232AA 1
2. Install oil return line (1) with a new gasket, between

turbocharger and engine block.
NHIL12ENG0181AA 2
3. Install oil supply line (1) with a new gasket, to the engine
block.
NHIL12ENG0230AA 3
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4. Install the oil supply line banjo fitting (1) with washers
and torque to 8 - 11 N·m (6 - 8 lb ft).
5. Check oil level before starting the engine to avoid dam-
age to the turbocharger and engine.
NHIL12ENG0232AA 4
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Index
Engine - 10

Turbocharger - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Intake and exhaust manifolds and muffler - 254

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
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

Prior operation:
Rocker support - Remove (10.106)
1. Remove the manifold retaining bolts (1).

2. Remove the intake manifold (2) and gasket (3).
3. Remove the spacer (4) and gasket (5) from the cylinder
head.
NHIL13ENG0074AA 1
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Intake manifold - Install

1. Install a new spacer gasket (5) and position the spacer
(4) on the cylinder head.
2. Install a new intake manifold gasket (3) and position the
intake manifold (2) over the spacer.
3. Install the manifold retaining bolts (1) and torque to 8.3
- 11.3 N·m (6.1 - 8 lb ft).
NHIL13ENG0074AA 1
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Exhaust manifold - Remove

1. Remove the six bolts (2) and two nuts (1) from the ex-
haust manifold.
2. Remove manifold.
NHIL12ENG0219AA 1
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Exhaust manifold - Install

1. Install the exhaust manifold, with new gasket, to the two
studs (1) of the engine block.
NHIL12ENG0184AA 1
2. Install the two nuts (1) on the studs, and the six retain-
ing bolts (2).
3. Torque the nuts (1) and bolts (2) to 25 N·m (18.4 lb ft)
evenly to prevent distortion.
NHIL12ENG0219AA 2
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Index
Engine - 10

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
Engine - 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic

description
NHIL14ENG0025FA 1
(1) Engine Control Unit (ECU) (A) Boost

(2) Tractor or skid steer (B) Water temperature
(3) Differential pressure sensor (C) Rack position
(4) Diesel Particulate Filter (DPF) (D) Engine speed
(5) Diesel Oxidation Catalyst (DOC) (E) Exhaust out
(6) After burner (F) Air in
(7) Reed valve (G) Flow from air pump
The Exhaust Gas Recirculation (EGR) valve recirculates a portion of exhaust gas into the induction port. This process
effectively burns the recirculated gas and fuel mixture in the combustion chamber, which reduces the temperature and
NOx.
The reed valve (7) act like one way valve and prevent exhaust gas blow back to air pump.
Exhaust gas travels through the afterburner (6) into the Diesel Oxidation Catalyst (DOC) (5) and then into the Diesel
Particulate Filter (DPF) (4).
The DPF’s function is to collect the soot which contains the exhaust gases, and remove the Particulate Matter (PM).
A differential pressure sensor (3) is installed on the DOC / DPF and will determine when soot collecting is beyond the
allowable limit. Automatic regeneration will be processed and remove the soot from the filter.
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Index
Engine - 10

Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF)

exhaust treatment - 501

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
FUNCTIONAL DATA
Exhaust Gas Recirculation (EGR) valve

Diesel Oxidation Catalyst (DOC)
After-burner
Air pump
Dynamic description - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Exhaust Gas Recirculation (EGR) valve

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust Gas Recirculation (EGR) cooler
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diesel Oxidation Catalyst (DOC)
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diesel Particulate Filters (DPF)
Inspect – Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air pump
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspect - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
After-burner
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
Exhaust Gas Recirculation (EGR) valve - Dynamic description

The Exhaust Gas Recirculation (EGR) valve recirculates a portion of exhaust gas into the induction port. This process
effectively burns the recirculated gas and fuel mixture in the combustion chamber, which reduces the temperature and
NOx.
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Diesel Oxidation Catalyst (DOC) - Dynamic description

N4LDI-TA-45SL
N4LDI-TA-50SL
NHIL13ENG0012AA 1
The Diesel Oxidation Catalyst (DOC) oxidizes emissions gas and reduces the Hydrocarbons (HC) and the Carbon
Monoxide (CO2) of emission gas contents. A pressure sensor is installed on the DOC to determine when soot collec-
tion reaches the border line.
The emissions control system is equipped with a Exhaust Gas Recirculation (EGR) device, which regulates the amount
of spent exhaust gas that is mixed into the intake stream. Its purpose is to cool combustion chamber temperatures to
the threshold that reduces the formation of Nitrogen Oxides (NOx ).
On the Direct Inject (DI) common rail system, smoke emit controlling is available at any situation, at start up, moderate
speed or sudden load changes.
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After-burner - Dynamic description

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The after-burner is an electronically controlled device used to raise exhaust temperatures and enhance the chemical
reaction in the Diesel Oxidation Catalyst (DOC).
Stage one (preheat)
1. The glow plug (1) connected to the top of the burner
heats up.
2. Injector number one (2) sprays fuel toward the glow
plug.
3. The air pump feeds the fresh air (5) needed.
4. The three components ignite causing a fire, raising the
temperature of the DOC
Stage two
1. Injector number one (2) continues to inject fuel while
injector number two (3) starts to spray fuel down
stream of the exhaust pipe toward the DOC surface
(4). This process will raise and enhance the exhaust
temperature and activate the Diesel Particulate Filter NHIL13ENG0190AA 1
(DPF).
2. The DPF will start the chemical reaction to burn off the
soot, resolving the filter clogging.
NOTICE: Depending on the load factor, if the pressure
difference is beyond the limit, the “Active regeneration”
will start.
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Air pump - Dynamic description

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NHIL13ENG1419AA 1
The air pump (1) is driven by the engines V-belt. The air pump supplies compressed air to the afterburner promoting
combustion to reduce NOx and particulate matter.
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Air pump - Dynamic description - Reed valve

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NHIL13ENG1419AA 1
The reed valve (1) is installed in-line between the air pump and the afterburner. The reed valve is a type of check
valve which restrict the flow of fluids to a single direction, opening and closing under changing pressure on each face.
This prevents exhaust gas blow back from the afterburner to enter in the air pump.
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Exhaust Gas Recirculation (EGR) valve - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Disconnect the electrical connector (2).

2. Remove the coolant lines (1) from the valve body.
NHIL12ENG0151AA 1
3. Remove the two bolts (5) from the Exhaust Gas Recir-
culation (EGR) cooler.
4. Remove the four bolts (1) from the EGR valve body (3).
5. Remove the EGR pipe (6) and gasket (2).
6. Remove EGR valve (3) and gasket (4).
NHIL13ENG0068AB 2
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Exhaust Gas Recirculation (EGR) valve - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Replace the Exhaust Gas Recirculation (EGR) valve

when indicated by the Engine Control Unit (ECU).
2. Actively check the EGR with the Service Tool D. If the
EGR is out of specifications, replace with a new one.
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Exhaust Gas Recirculation (EGR) valve - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install the Exhaust Gas Recirculation (EGR) valve (3),

new gasket (4), EGR pipe (8), new gasket (2) to the
intake manifold.
2. Use the four retaining bolts (1) to secure the valve and
pipe to the intake manifold.
3. Install the EGR pipe (8) and new gasket (5) to the to
the EGR cooler (6).
4. Torque bolts (1) and (7) to 23 - 28 N·m (17 - 21 lb ft).
NHIL13ENG0015AA 1
5. Install the two coolant lines (1) to the EGR valve.

6. Connect the electrical connector (2) to the valve.
NHIL12ENG0151AA 2
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Exhaust Gas Recirculation (EGR) valve - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Disconnect the electrical connector (1).

2. Remove the three bolts (3) connecting the pipe to the
EGR valve body.
3. Remove the three retaining bolts (2) from the intake
manifold and remove the EGR valve.
NHIL13ENG0214AA 1
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Exhaust Gas Recirculation (EGR) valve - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Replace the Exhaust Gas Recirculation (EGR) valve

when indicated by the Engine Control Unit (ECU).
2. Actively check the EGR with the Service Tool I. If the
EGR is out of specifications, replace with a new one.
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Exhaust Gas Recirculation (EGR) valve - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the three retaining bolts (2) to secure the Exhaust

Gas Recirculation (EGR) valve to the intake manifold.
2. Install the EGR pipe and secure with three bolts (3).
3. Torque all bolts to 23 - 28 N·m (17 - 21 lb ft).
4. Connect the electrical connection (1).
NHIL13ENG0214AA 1
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Exhaust Gas Recirculation (EGR) cooler - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Loosen the hose clamp and remove the coolant hose

(4) to drain fluid.
2. Loosen the hose clamp and remove hose (5).
3. Remove the two bolts (2) securing the pipe to the
cooler.
4. Remove the bolt (3) securing the lower bracket.
5. Remove the two bolts (1) securing the EGR cooler to
the exhaust manifold and remove the EGR cooler.
NHVM13ENG0215AA 1
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Exhaust Gas Recirculation (EGR) cooler - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the two bolts (1) to secure the Exhaust Gas Re-
circulation (EGR) cooler to the exhaust manifold.
2. Install the bolt (3) to secure the lower bracket to the
block.
3. Install the pipe to the cooler secure with the bolts (2).
4. Torque all bolts to 23 - 28 N·m (17 - 21 lb ft).
5. Install the hoses (4) and (5) and tighten hose clamps.
NHVM13ENG0215AA 1
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Diesel Oxidation Catalyst (DOC) - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: The Diesel Oxidation Catalyst (DOC) mounting position depends on the application.
1. Remove the four retaining bolts (2) from the intake side
of the DOC.
2. Remove the two DOC retaining strap bolts (1).
NHIL12ENG0127AA 1
3. Disconnect the exhaust temperature sensors (3).

4. Disconnect the differential pressure sensor (2).
5. Remove the DOC assembly (1).
NHIL13ENG0012AA 2
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Diesel Oxidation Catalyst (DOC) - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install the Diesel Oxidation Catalyst (DOC) assembly

in the retaining straps (1) and secure with bolts (3).
2. Install a new gasket and secure the DOC assembly
with the four mounting bolts (2) on the intake side of
the DOC.
3. Torque bolts (2) to 25.5 - 33.3 N·m (18.8 - 25 lb ft).
NHIL12ENG0127AA 1
4. Connect the exhaust temperature sensors (2).

5. Connect the differential pressure sensor (1).
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Diesel Oxidation Catalyst (DOC) - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTE: The Diesel Oxidation Catalyst (DOC) mounting position depends on the application.
1. Remove the retaining bolts (2) from the intake and ex-
haust sides of the DOC assembly.
NOTE: Intake retaining bolts shown.
2. Remove the two DOC retaining strap bolts (1).
NHVM13ENG0198AA 1
3. Disconnect the DOC inlet temperature sensor (3) wire

connector.
NOTICE: Label connectors and pay attention to the con-
nector wire routing, to avoid burning wires.
4. Disconnect the DPF inlet temperature sensor (4) wire
connector.
5. Disconnect the DPF outlet temperature sensor (5) wire
connector.
6. Disconnect the differential pressure sensor (2).
7. Remove the DOC assembly (1).
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Diesel Oxidation Catalyst (DOC) - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the Diesel Oxidation Catalyst (DOC) assembly

in the retaining straps (1) and secure with bolts (2).
2. Install new gaskets and secure the DOC assembly with
the mounting bolts (2) on the intake and exhaust sides
of the DOC.
NOTE: Intake side retaining bolts shown.
3. Torque bolts (2) to 25.5 - 33.3 N·m (18.8 - 25 lb ft).
NHVM13ENG0198AA 1
4. Connect the DOC inlet temperature sensor (2) wire

connector.
5. Connect the Diesel Particulate Filter (DPF) inlet tem-
perature sensor (3) wire connector.
6. Connect the Diesel Particulate Filter (DPF) outlet tem-
perature sensor (4) wire connector.
7. Connect the differential pressure sensor (1).
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Diesel Particulate Filters (DPF) - Inspect – Differential pressure

sensor
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Inspect the differential pressure sensor (1).

• Check the differential pressure sensor piping (2).
• Check the differential pressure sensor electrical con-
nections.
If there is any damage, repair or replace as needed.
2. Replace the differential pressure sensor when indi-
cated by the Engine Control Unit (ECU).
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Air pump - Remove

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Loosen the V-belt (4) tension.

2. Disconnect the electrical connection.
3. Remove the intake hose (1) and exhaust hose (2).
4. Remove the air pump retaining bolts (3) and remove air
pump.
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Air pump - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Active test.
drop down menu.
• Select “ARD Air System Relay Override”.
menu.
2. Check the air pump belt.
• If the belt is damaged or dirty, repair or replace as
needed.
• See Air pump - Install (10.501) for belt tension.
3. Check the air pump piping.
• Make sure the induction pipe and discharge pipe are
mounted in the correct position.
• The intake pipe (1) connects to the air intake port.
• The discharge pipe (2) connects to the reed valve.
• Repair or replace as needed.
NHVM13ENG0188AA 1
4. Use a multi-meter to measure the resistance of the air

pump:
• 4.23 - 4.67 Ω at 20 °C (68 °F).
5. If the pump is out of specification, install a new air
pump.
NHIL13ENG0164AA 2
Air pump electrical wiring/connection specification:
Connector pin Value

Pin 1 Ground
Pin 2 12.0 V
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Air pump - Install

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Use the air pump retaining bolts (3) to secure the air
pump to the engine block.
2. Install the intake hose (1) and the exhaust hose (2).
NOTICE: Ensure the hose fittings for each port are secure
to avoid damage to the air pump.
3. Connect the electrical connection.
4. Install the V-belt (4) and apply tension as follows:
• New belt — 265 - 355 N (60 - 80 lb)
• Used belt — 175 - 265 N (40 - 60 lb)
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Air pump - Remove - Reed valve

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Loosen the hose clamps (1) and (2), and remove the
reed valve (3).
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Air pump - Inspect - Reed valve

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Blow air in the valve from the regular direction indicated

by the arrow on the valve, confirm air flow.
2. Blow air in the valve opposite the arrow on the valve. If
any air leakage is confirmed, replace the valve.
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Air pump - Install - Reed valve

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Connect hoses (1) and (2) to the reed valve (3) and
tighten the hose clamps.
NOTICE: The arrow on the reed valve case needs to point
toward the afterburner. Incorrect installation will result in
air pump damage.
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After-burner - Remove
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Disconnect the electrical connectors (1) from the injec-

tors.
2. Disconnect the fuel supply lines (2) from the injectors.
3. Remove the air pump feed tube (5).
4. Remove the after-burner intake pipe (4).
5. Remove the after-burner exhaust pipe (3), connected
to the Diesel Oxidation Catalyst (DOC).
6. Remove the after-burner retaining bolts and remove
after-burner.
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After-burner - Inspect
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTICE: Do not disassemble the after-burner body. Only the glow plug (1) is replaceable. The burner injectors are
considered a subassembly (2).
1. The Engine Control Unit (ECU) will throw an error code
if the after-burner is malfunctioning.
2. Inspect the after-burner body for signs of cracks or leak-
age.
NHIL13ENG0201AA 1
NOTE: Do not test resistance using the glow plug sheath.

3. Check the glow plug resistance.
• Use a multimeter to measure the resistance. There
should be approximately 0.8 Ω.
• If the resistance is out of range, replace the glow
plug.
4. Check the burner injector(s).
• Use a multimeter to check for continuity from pin 1
to pin 2. There should be continuity.
• If there is infinite resistance or 0 Ω, replace the in-
jector.
5. If results do not change, replace the after-burner.
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After-burner - Install
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Secure the after-burner to the block with the retaining

bolts.
2. Install the fuel supple line (2).
3. Install the after-burner intake pipe (4).
4. Install the after-burner exhaust pipe (3).
5. Install the air pump feed tube (5).
6. Install the injector electrical connection (1).
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Index
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
After-burner - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
After-burner - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
After-burner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
After-burner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air pump - Dynamic description - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air pump - Inspect - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air pump - Install - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air pump - Remove - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diesel Oxidation Catalyst (DOC) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diesel Oxidation Catalyst (DOC) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diesel Oxidation Catalyst (DOC) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diesel Oxidation Catalyst (DOC) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diesel Oxidation Catalyst (DOC) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diesel Particulate Filters (DPF) - Inspect – Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exhaust Gas Recirculation (EGR) cooler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust Gas Recirculation (EGR) cooler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust Gas Recirculation (EGR) valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust Gas Recirculation (EGR) valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust Gas Recirculation (EGR) valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust Gas Recirculation (EGR) valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust Gas Recirculation (EGR) valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust Gas Recirculation (EGR) valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust Gas Recirculation (EGR) valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine - 10
Engine cooling system - 400

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Engine - 10
TECHNICAL DATA
Engine cooling system

FUNCTIONAL DATA
Engine cooling system

Water pump
Coolant thermostat
SERVICE
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine - Engine cooling system
Engine cooling system - General specification

N4LDI-TA-45SL
N4LDI-TA-50SL
Engine model N４LTDI-TA-45SL N4LDI-TA-50SL

Type of system Pressurized liquid with recirculating by-pass
Water pump Centrifugal
Drive belt deflection (Tension) 10 - 15 mm (0.39 - 0.59 in) when 89 - 111 N (20 - 25 lb) force is applied
midway between pulleys.
Thermostat
Starts to open 71 °C (160 °F) 80 - 84 °C (176 - 183 °F)
Fully open 82 °C (180 °F) 95 °C (203 °F)
Radiator cap pressure rating 90 kPa (13 psi)
Coolant Ethylene glycol and water in a 50/50% mixture.
Engine cooling system - General specification

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Engine model N844L-F-36SL N844LT-F-45SL

Type of system Pressurized liquid with recirculating by-pass
Water pump Centrifugal
Drive belt deflection (Tension) 10 - 15 mm (0.39 - 0.59 in) when 89 - 111 N (20 - 25 lb) force is applied
midway between pulleys.
Thermostat
Starts to open 69 - 73 °C (156 - 163 °F) 80 - 84 °C (176 - 183 °F)
Fully open 82 °C (180 °F) 95 °C (203 °F)
Radiator cap pressure rating 48 kPa (7 psi)
Coolant Ethylene glycol and water in a 50/50% mixture.
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Engine cooling system - Dynamic description

The cooling system is the recirculating bypass type with a full length water jacket for each cylinder cast into the block.
The coolant is drawn from the bottom of the radiator by the water pump and passes around the cylinders and into the
cylinder head.
The thermostat is located in the front of the cylinder head and thermostatically controls the flow of coolant from the
engine to the radiator. When the thermostat is closed only a small amount of coolant is permitted to flow through the
thermostat bypass to the radiator to effect a faster warm-up. When the thermostat is open, the coolant flows from the
water outlet connection to the top tank of the radiator for maximum cooling.
Cooling occurs as the coolant passes down through the radiator cores which are exposed to the air flow created by
the fan as air is drawn through the radiator.
SECT10C01PG88 1
(1) Radiator (4) Air flow

(2) Radiator cap (5) Water pump
(3) Thermostat (6) Fan
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Water pump - Dynamic description

The water pump (1) is an impeller attached to a shaft
which is belt driven by the engine crankshaft. The impeller
circulates water by centrifugal force. Coolant entering the
pump housing from the radiator through the lower hose is
thrown outward against the housing with sufficient force
to cause a circulating action.
20093421 1
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Coolant thermostat - Dynamic description

The thermostat (1) is located between the coolant outlet
on the engine and the radiator. In this position the thermo-
stat is able to sense the coolant temperature in the engine
and regulate the flow of coolant to the radiator. When the
engine is cold, only a small amount of coolant flows to
the radiator through the thermostat bypass. As the en-
gine warms up, the thermostat opens to allow sufficient
coolant flow to the radiator to maintain a constant engine
temperature.
NHIL13ENG0181AA 1
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Water pump - Remove

1. Remove the oil cooler hose (1), bypass hose (2) and
lower radiator hose (4) from the water pump (3).
2. Remove the water pump retaining bolts (5) and remove
the water pump (3) and gasket from the engine.
NHVM13ENG0196AA 1
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Water pump - Inspect

1. Coolant leakage can be seen from the weep hole (1)
on top of the pump.
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Water pump - Install

1. Install the water pump (3) and new gasket and tighten
the retaining bolts (5).
2. Install the oil cooler hose (1), bypass hose (2) and lower
radiator hose (4) on the water pump (3) and tighten the
hose clamps.
NHVM13ENG0196AA 1
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Coolant thermostat - Remove

1. Remove the two retaining bolts (1) from the thermostat
cover.
NHIL12ENG0184AA 1
2. Remove the thermostat cover (1), gasket (2) and ther-

mostat (3).
NHIL12ENG0187AA 2
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Coolant thermostat - Test

1. Place the thermostat (1) in a container filled with a
50/50% mixture of antifreeze and water. Isolate the
thermostat from the bottom of the container.
2. Place a high temperature thermometer (2) in the
coolant mixture and heat the container.
3. Use a 0.08 mm (0.003 in) feeler gauge (3) to determine
when the thermostat begins to open.
4. Note the coolant temperature at which the thermostat
starts to open and when it is fully opened.
5. Replace the thermostat if it fails to open at the specified
temperature. Thermostat opening temperature:
• Start to open: 69 - 73 °C (156 - 163 °F)
• Fully open: 82 °C (180 °F)
1
• Valve lift: 8.0 mm (0.314 in) 20093423A
6. Thoroughly clean the gasket mating surfaces before

installing thermostat.
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Coolant thermostat - Install

1. Thoroughly clean the mating surface (1) of the thermo-
stat housing and thermostat cover.
2. Install the thermostat into the housing ensuring the air
purge (3) is positioned between the castings (2) on the
housing.
NHIL12ENG0225AA 1
NOTICE: If the air purge (3) is not in the correct position

the thermostat will not function properly.
NHIL12ENG0226AA 2
3. Install a new gasket and the thermostat cover (1).

4. Install the wire clamp (2) and thermostat cover M8 re-
taining bolts (3) and torque between 13 - 17 N·m (9.6 -
13 lb ft).
NHIL12ENG0186AA 3
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Index
Engine - 10

Coolant thermostat - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coolant thermostat - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
FUNCTIONAL DATA
Engine lubrication system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil pressure valve
Dynamic description - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pump
Crankcase ventilation system
SERVICE
Engine lubrication system

Check - Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine oil filter
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankcase ventilation system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Engine - Engine lubrication system
Engine lubrication system - Overview
NHIL13ENG0042AA 1
(1) Turbocharger (5) Oil filter

(2) Oil pressure switch (6) Oil cooler
(3) Oil pump (7) Oil pressure relief valve
(4) Suction filter
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NHIL13ENG0040AA 2
(1) Blow-by gas flow (3) Only oil returns to block

(2) Blow-by recirculation separator (4) Oil inlet pipe
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Engine oil filter - Overview
SECT10C01PG83_1 1
These engines utilize a cartridge type filter. Pressurized oil flows from the pump and enters the full flow filter through
(1) and is discharge through (2). When the full flow filter is clogged, the safety valve (3) opens to bypass the oil,
preventing engine lubrication failure or other troubles.
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Oil pressure valve - Dynamic description - Relief valve
NHIL12ENG0234AA 1
The pressure is relieved by allowing the pressurized fluid to flow from an auxiliary passage out of the main oil circuit.
When the set pressure of 402 kPa (58.3 psi) is exceeded, the relief valve is forced open and a portion of the fluid is
diverted through the auxiliary route.
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Engine oil pump - Dynamic description

A gerotor is a positive displacement pump. The name gerotor is derived from "Generated Rotor". A gerotor unit
consists of an inner and outer rotor. The inner rotor has 4 teeth, and the outer rotor has 5 teeth. The inner rotor
is located off-center and both rotors rotate. The geometry of the two rotors, partitions the volume between them
into different dynamically-changing volumes. During the assembly's rotation cycle, each of these volumes changes
continuously. An increase in volume creates a vacuum. This vacuum creates suction, and hence, this part of the
cycle is where the oil intake is located. As a volume decreases compression occurs. During this compression period,
oil can be pumped.
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Crankcase ventilation system - Dynamic description

A crankcase ventilation system is a way for gases to escape in a controlled manner from the crankcase of an internal
combustion engine. This is necessary because internal combustion inevitably involves a small but continual amount
of blow-by, which occurs when some of the gases from the combustion leak past the piston rings to end up inside the
crankcase.
The blow-by recirculation system contains a Positive Crankcase Ventilation (PCV) valve where it separates the oil
and gases to reduce valve deposits and Particulate Matter (PM).
The PCV valve is an emissions control device that routes unburned crankcase blow-by gases back into the intake
manifold where they can be reburned.
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Engine lubrication system - Check - Oil Consumption

Log oil consumption as follows:
1. Change the engine oil and filter. Use the oil specified
in the operator's manual.
2. Run the engine for 2 minutes.
3. Check the dipstick and add oil, if required, so the level
is at the full mark.
4. Fill the fuel tank with fuel.
5. Record fuel consumption in liters (US gallons), oil
added in liters (US gallons), and hour reading. Record
fuel and oil use for 100 hours of operation, which is the
recommended oil change interval. Check the dipstick
before running the engine each day.
NOTE: The maximum allowable oil consumption is 0.8 %. The following table gives examples:
Fuel Consumption Oil Consumption Percentage

189.27 l (50 US gal) 1.5 l (1.6 US qt) 0.79 %
378.54 l (100 US gal) 3.03 l (3.2 US qt) 0.80 %
757.08 l (200 US gal) 6.06 l (6.4 US qt) 0.80 %
6. If the oil consumption is greater than 0.8 % of the fuel

consumption, oil usage is excessive. A sample calcu-
lation for oil consumption follows:
% consumption = (Quantity of Oil in Liters (US gallons)
⁄ Quantity of Fuel in Liters (US gallons)) x 100
Assume 0.25 l (0.07 US gal) oil is added for 50 l
(13.2 US gal) fuel.
% consumption = ( 0.25 l ⁄ 50 l) x 100 or ( 0.07 US gal
⁄ 13.2 US gal) x 100
% consumption = 0.5 %.
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Engine lubrication system - Pressure test - Engine oil

1. Disconnect the sending lead (2) and remove the oil
pressure sending unit (1).
20093417 1
2. Install the oil pressure test fitting NH00011 (1), and test
gauge (2). Start the engine and observe gauge indica-
tor. Gauge should indicate between 98.04 - 147.07 kPa
(14.22 - 21.33 psi) at low idle and 244.76 - 343.36 kPa
(35.5 - 49.8 psi) at high idle.
NOTE: Pressure test should be with engine at normal op-
erating temperature.
3. If the gauge did not indicate the oil pressure within
specified tolerances at low and high idle, troubleshoot
the lube oil system.
20093418 2
NOTE: Main galley access port (3), located next to the relief
valve (2), and external oil tube (1).
20002360A 3
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Engine oil filter - Replace

1. Remove the old oil filter.
2. Coat the new filter mounting surface with clean engine
oil.
3. Install the new filter and tighten by hand.
4. Never reuse a filter if it was removed once.
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Engine oil pump - Remove

Prior operation:
1. Remove the C-clip (1).

2. Remove the collar (2), spring (3), and shims (4).
3. Remove the oil pump cover (5) and idle gear assembly
(8) together.
4. Remove the rotor (6) and the thrust washer (7).
5. Remove the oil pump cover (5) from the idle gear (8).
76075745 1
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Engine oil pump - Inspect

Prior operation:
Engine oil pump - Remove (10.304)
1. Check for excessive wear on the pump cover (1), inner

rotor (3) and outer rotor (2), replace if parts are worn
out or damaged.
2. Measure the inner to outer rotor clearance (A). Replace
the components as required, if clearance is not within
0.25 mm (0.010 in).
76075745A 1
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Engine oil pump - Install

1. Install the thrust washer (7) and pin (8).
76075745 1
2. Align the timing marks (A) on the idler gear , crankshaft

gear and camshaft gear while you install the idler gear
on the port shaft.
NOTICE: Once the oil pump is installed, do not rotate the
engine until the front cover is installed.
3. Install the spring (10) and rotor (6).
4. Install the oil pump cover (5), shim (4), spring (3) and
collar (2). Secure the assembly to the shaft with the
snap ring (1).
NHIL12ENG0192AA 2
5. Use a dial indicator (2) to measure the axial movement

of the collar (1).
• Standard clearance: 0.01 - 0.15 mm (0.00039 -
0.0059 in)
• Service limit: 0.2 mm (0.0079 in)
6. Install or remove shims (3) as needed to obtain the
standard clearance value.
7. Replace the engine oil filter and fill the sump with oil.
NHIL13ENG0036AA 3
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Engine oil pump - Remove - Pick-up tube

1. Remove the two bolts (2) securing the strainer bracket.
2. Remove the pick-up tube (1) out of the bore.
NOTE: The pick-up tube is held in place by an O-ring seal.
NHIL12ENG0208AA 1
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Engine oil pump - Inspect - Pick-up tube

1. Clean the filter mesh to remove any debris or foreign
objects.
2. Inspect the O-ring on the pick-up tube for wear or dam-
age. Replace the O-ring if it becomes stiff or damaged.
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Engine oil pump - Install - Pick-up tube

1. Install the pick-up tube (1) into the bore (3) of the engine
block.
2. Install the two securing bolts (2) for the strainer bracket
and torque to 9.0 - 13.0 N·m (6.6 - 9.6 lb ft).
NHIL12ENG0208AA 1
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Crankcase ventilation system - Remove

1. Loosen the hose clamps (1) and remove the hoses.
2. Remove the drain hose (2) from the block.
NHIL12ENG0159AA 1
3. Remove the Blow-by recirculation filter assembly (1).
NHIL12ENG0162AA 2
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Crankcase ventilation system - Disassemble

1. Use a 27mm wrench to remove the bottom case (4)
from the body (1).
2. Remove the filter (2) and the O-ring (3).
NHIL12ENG0163AB 1
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Crankcase ventilation system - Inspect

1. Wipe and clean all liquid moisture and debris from the
bottom case (4), filter (2) and body (1).
NOTICE: Do not use any chemical agents when cleaning.
Chemical agents could damage the internal rubber compo-
nents.
2. Remove the O-ring (3) and inspect for damage or wear
on the O-ring and the threads of the bottom case (4).
NOTICE: Do not remove the caps (1) at the top and side
of the body.
NHIL12ENG0163AB 1
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Crankcase ventilation system - Assemble

1. Install the O-ring (3) in place on the bottom case (4).
2. Install the filter (2) into the body (1) of the Blow–by
recirculation filter assembly.
3. Thread the bottom case (4) into the body (1) and torque
to 10 N·m (7.4 lb ft).
NHIL12ENG0163AB 1
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Crankcase ventilation system - Install

1. Install the drain hose (2) to the block.
2. Install the upper hoses and secure with the hose
clamps (1).
NHIL12ENG0159AA 1
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Index
Engine - 10

Crankcase ventilation system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crankcase ventilation system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankcase ventilation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankcase ventilation system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankcase ventilation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankcase ventilation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine lubrication system - Check - Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine lubrication system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine lubrication system - Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil pump - Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine oil pump - Install - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine oil pump - Remove - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pressure valve - Dynamic description - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Oil cooler and lines - 408

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Contents
Engine - 10
FUNCTIONAL DATA
Engine oil cooler

SERVICE
Engine oil cooler

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Oil cooler and lines
Engine oil cooler - Dynamic description

Typical engine oil cooling units run with engine coolant. An oil cooler is functionally similar to thermal conversion, the
engine oil and coolant are circulated at each circuit.
Circulated coolant passes the internal oil cooler and exchanges the excessive heat from the engine oil. The coolant
displaces the heat and emits to the atmosphere through the radiator.
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Engine oil cooler - Remove

1. Remove the oil filter from the oil cooler (3).
2. Loosen the hose clamps and remove the inlet hose (1)
and outlet hose (2).
3. Remove the nut (4) from the center of the oil cooler.
4. Remove oil cooler (3).
NHIL12ENG0201AA 1
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Engine oil cooler - Inspect

1. Confirm there is no leakage or clogging of the oil cooler.
Replace if an abnormal situation is confirmed.
NHIL12ENG0202AA 1
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Engine oil cooler - Install

1. Install the oil cooler (2) to the engine block and secure
with nut (3).
2. Install the coolant hoses (1) and tighten the hose
clamps.
3. Thread the oil filter onto the oil cooler (2).
NHIL12ENG0201AA 1
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Index
Engine - 10

Engine oil cooler - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil cooler - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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CNH Industrial America New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States
17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 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.
47632293 16/09/2014
EN
SERVICE MANUAL
Electrical systems

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
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CONSUMABLES INDEX

Loctite® ODC-Free Cleaner Throttle Valve Actuator 55.7 / 8
and Degreaser
Loctite® ODC-Free Cleaner Exhaust Gas Recirculation 55.8 / 7
and Degreaser
LOCTITE® 8150™ Exhaust Gas Recirculation 55.8 / 11
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Electrical system - 000

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
SERVICE
Electrical system
Computer support tools - Install - Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Computer support tools - Install - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Computer support tools - Configure - User authentication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Computer support tools - Configure - USB port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Computer support tools - Start up - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Computer support tools - View - Start diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Computer support tools - View - Project screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Computer support tools - View - DTC screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Computer support tools - View - Data monitoring screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Computer support tools - View - Trigger detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Computer support tools - View - Active test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Computer support tools - View - Utility (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Computer support tools - View - Finish diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Computer support tools - View - Open diagnosis history (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Computer support tools - Program - Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Computer support tools - View - Start training (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Computer support tools - Configure - System settings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Computer support tools - View - Version information (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Computer support tools - View - Exit application (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Computer support tools - Remove - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Computer support tools - Remove - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Computer support tools - Configure - License activation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Start up - Service Tool I (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Computer support tools - Configure - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Computer support tools - Program - Existing Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . 65
Computer support tools - Program - New Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Computer support tools - Configure - Fuel pump actuator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Computer support tools - View - Engine status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Computer support tools - View - Diagnostic codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Computer support tools - View - Event codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Computer support tools - View - Product status report (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Computer support tools - View - Data logging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Computer support tools - View - Real time graphing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Computer support tools - View - Parameter override mode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Computer support tools - Configure - Diesel Particulate Filter (DPF) soot load reset (*) . . . . . . . . . . . . . 79
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Electrical systems - Electrical system
Electrical system Computer support tools - Install - Software

NOTE: Do not connect communication interface to PC before installing communication interface driver. This may
install driver improperly.
NOTE: When installing the diagnostic tool, be sure to login to the PC with administrator user account.
NOTE: Close all other applications including virus detection software.
1. Insert the Electronic Service Tool (EST) install disk.
2. From the EST Installation menu, click the “Install ISM
Engine Diagnostic Software”.
NHPH13ENG0211AA 1
3. If this prompt appears, click the “Yes” button.
NHPH13ENG0203AA 2
4. Select your language and click the “OK” button.
NHPH13ENG0204AA 3
5. This splash screen will be displayed.
NHPH13ENG0205AA 4
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6. Click on the “Next” button.
NHPH13ENG0206AA 5
7. Select the “I accept the terms in the license agreement”

and then click the “Next” button.
NHPH13ENG0207AA 6
8. Click on the “Install” button.
NHPH13ENG0208AA 7
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9. This screen will display while the program is being in-

stalled.
NHPH13ENG0209AA 8
10. The following window is displayed when Service Tool

I is installed successfully.
11. Click the “Finish” button
NOTE: The first time Service Tool I is opened, you will need
to configure the communication adapter. Refer to Electri-
cal system Computer support tools - Configure - Com-
munication adapter (55.000) for the proper procedure.
NHPH13ENG0210AA 9
12. If this prompt appears, click the “Yes” button.
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13. Select the desired language.

14. Click the “Next” button.
NHPH13ENG0224AA 11
RAPH13SPT0009BA 12
16. Select the drive location for the system to place the
files.
NOTE: “C” is default.
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18. Click the “Install” button.
RAPH13SPT0012BA 14
19. Installation progress is shown.
RAPH13SPT0011BA 15
20. Click the “Finish” button to complete the installation.

NOTE: To use the Service Tool D, you must first install the
communication adapter drivers. Refer to Electrical sys-
tem Computer support tools - Install - Communication
adapter (55.000) for the proper procedure.
RAPH13SPT0013BA 16
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Electrical system Computer support tools - Install - Communication

adapter
N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: Do not connect the communication interface to your PC before installing communication interface driver. This
may install the driver improperly.
NOTE: When installing the diagnostic tool, be sure to login to the PC with an administrator user account.
NOTE: Close all other applications including virus detection software.
Driver installation
1. Navigate to “C:\PCST\ISM_Engine\ISM_DI_Adapter_
Support” on your PC.
2. Double click “Setup_DST_iV140” to run the install.
NHPH13ENG0233AA 1
NHPH13ENG0234AA 2
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5. Click the “Install” button.
NHPH13ENG0235AA 3
6. The install status screen will be displayed.
NHPH13ENG0237AA 4
7. Click the “Finish” button.
NHPH13ENG0238AA 5
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Software update
8. Navigate to “C:\PCST\ISM_Engine\ISM_DI_Adapter_
Support” on your PC.
9. Double click “DSTi_Interface_V230” to run the update.
NHPH13ENG0225AA 6
11. Follow the on-screen instructions.

NOTE: The ISM communication adapter is not equipped
with a mode switch.
NOTE: If your PC is running Windows XP, refer to Electri-
cal system Computer support tools - Configure - USB
port (55.000) for additional instructions.
NHPH13ENG0232AA 7
NHPH13ENG0226AA 8
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NHPH13ENG0228AA 9
15. The install status screen will be displayed.
NHPH13ENG0229AA 10
16. Click the “Finish” button.
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Electrical system Computer support tools - Configure - User

authentication
N4LDI-TA-45SL
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The Service Tool D software requires a license request using the Electronic Service Tool (EST) Order Form located
on the Dealer Portal.
Order Form
NOTE: User authentication is required to use the diagnostic tool after the software installation process.
NOTE: Do not change your computer configuration. User authentication may fail or user authentication is required
again.
1. Log into the Dealer Portal under “Service” > “Service
Tools” > “EST Order Form”.
Installation ID
1. On the Service Tool D click on “Start” > “All Programs”
> ”Diagnostic Software“ > ”ServiceToolID” > “UserReg-
Tool”.
2. When this screen appears you will see an alphanu-
meric code in the “Installation ID” window.
3. The “Installation ID” code must be submitted through
the EST Order Form at the time of the license request,
to obtain your “Confirmation ID”.
NOTE: Copy and Paste method is recommended for trans-
ferring the “Installation ID” code. If that is not available,
transfer code electronically via USB memory stick.
4. Submit your EST Order Form and allow up to four days
to receive your “Confirmation ID”, which will be returned
via E-mail.
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Confirmation ID
1. When you receive your “Confirmation ID” vie E-mail,
run the “UserRegTool” again on your “Service Tool D”.
2. Enter your “Confirmation ID” into the “Confirmation ID”
window and click the button to continue.

NOTE: Copy / Paste method is recommended for trans-
ferring the “Confirmation ID” code. If that is not available,
transfer code electronically via USB memory stick.
NHPH13ENG0162AA 2
3. This window will be displayed if the authentication is

complete. Click the ”OK’ button and exit this tool.
NOTE: The Service Tool D software activation is for one
year. Each renewal request will be handled in exactly the
same way as the initial license request, using the EST Or-
der Form.
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Electrical system Computer support tools - Configure - USB port

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: Configure the USB port on the PC when connecting to the vehicle for the first time after the diagnostic tool is
installed.
1. The Operating System (OS) will detect connection au-
tomatically when connecting DST-i to the PC.
2. When using Windows XP, select “No, not at this time”
and then click the “Next” button when the following
screen is displayed.
RAPH13SPT0018BA 1
3. Click the “Next” button when the following screen is

displayed.
RAPH13SPT0019BA 2
4. The following screen is displayed if the software is in-

stalled properly. Click on the “Finish” button to com-
plete the installation.
NOTE: This process may take several minutes depending
on your PC specification. If the installation is not the first
time and connected to the same USB port, this process
may not run.
RAPH13SPT0020BA 3
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Electrical system Computer support tools - Start up - Service Tool D

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Open the Electronic Service Tool (EST).

2. To launch the Service Tool D diagnostic tool, select the
“Additional Tools” button (1).
3. Click the “Start the ISM Indirect Inject (Service Tool D)
Engine Controller Diagnostic Tool” button (2).
NHPH13ENG0212AA 1
4. If this prompt appears, click the check box and refer

to Electrical system Computer support tools - Con-
figure - User authentication (55.000) to complete the
authentication process.
RAPH13SPT0030AA 2
5. After the authentication process is completed, this win-

dow will be displayed at start up of the service tool.
6. Click “Menu” for the following options:
RAPH13SPT0031BA 3
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Start Diagnosis
Connect cable to vehicle and start trouble diagno-
sis.
Finish Diagnosis
Finish diagnosis when diagnosis is in progress.
Open Diagnosis History
Display working history.
Close Diagnosis History
Close the history screen.
Start Training
Operate in training mode when not connected to a
vehicle.
Finish Training
Stop training mode and return to normal mode.
ECU Reprogram RAPH13SPT0032BA 4
Reprogram control software in the Engine Control

Unit (ECU).
ECU Serial Number Write
Write the ECU serial number in the engine ECU.
System Setting
Select the language to be displayed or set commu-
nication interface.
Version Info
Display version information of the service tool.
Exit Application
Exit the service tool program.
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Electrical system Computer support tools - View - Start diagnosis

N4LDI-TA-45SL
N4LDI-TA-50SL
New diagnosis
1. When connecting to a vehicle for the first time. Select
“Start Diagnosis” > “New Diagnosis” from the menu.
RAPH13SPT0033BA 1
2. Click on the check box to continue. The Service Tool

D acquires the necessary information by communica-
tions with the Engine Control Unit (ECU). The “Vehicle
Selection” screen will appear when the information has
been acquired properly.
RAPH13SPT0034BA 2
Restart diagnosis
1. When reconnecting to a vehicle to continue a previous
diagnosis history. Select “Start Diagnosis” > “Restart
Diagnosis” from the menu.
NOTE: To restart diagnosis from the continuation of a pre-
vious diagnosis history, the vehicle that is restarted must
be the same vehicle used for the previous diagnosis. If
restarted with a different vehicle, the service tool may not
display the proper information.
RAPH13SPT0035BA 3
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2. Diagnosis history will be displayed. Select the diag-

nosis history whose continuous diagnosis is to be pre-
formed. Click on the button to continue.
Vehicle conditions (DTC, Freeze Frame Data, etc.) will
automatically be obtained and “Project” screen will ap-
pear when restarting the diagnosis.
RAPH13SPT0036AA 4
Vehicle selection
3. Communication with the ECU will start and the “Vehicle
Selection” screen will appear.
RAPH13SPT0037AA 5
4. With the “Vehicle Selection” screen displayed, select

the “Option” information to narrow the vehicle selec-
tions. When complete, click on the check box.
RAPH13SPT0038BA 6
5. The initial status of the vehicle will be displayed and the

“Project” screen will automatically be displayed.
NOTE: Manual selection operation of the “Option” informa-
tion on the “Vehicle Selection” screen may be required de-
pending on the vehicle type.
NOTE: Do not use the system for a vehicle which has not
responded. Be sure to select the correct vehicle informa-
tion, otherwise correct diagnosis may not be possible.
RAPH13SPT0039BA 7
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Electrical system Computer support tools - View - Project screen

N4LDI-TA-45SL
N4LDI-TA-50SL
1. The “Project” screen is displayed after the initial com-

munication with the ECU.
2. Enter the project information or the vehicle information
and click on the button.
NOTE: Diagnosis can be preformed without entering the
project information or vehicle information. This is informa-
tional only.
NOTE: Project information and vehicle information can be
changed at any time.
3. Contents of project information and vehicle information
which you have entered can only saved by clicking the
button.
RAPH13SPT0042BA 1
Project info list

4. The “Project Info List” is displayed on the right side of
the “Project” screen.
5. The date can be deleted from the “Project” view by right
clicking on the data.
NOTE: Data titled ****-TOP and data marked with “*” can-
not be deleted. This is the initial data when the diagnosis
was started.
6. The memo can be added or changed from the “Project”
view by right clicking on the data.
7. Saved data can be displayed in the “File” view. Icon
meanings are in the table below.
RAPH13SPT0043BA 2
NOTE: Data saved in Utility will vary depending on the ve-
hicle being diagnosed.
Display DTC and Freeze Frame data.
Display data monitor measuring data.
Display data monitor setting data.
Display measuring data in the “Active Test” mode.
Display execution results of utility and saved data.
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Electrical system Computer support tools - View - DTC screen

N4LDI-TA-45SL
N4LDI-TA-50SL
Use this function to view Diagnostic Trouble Codes (DTC).
1. The DTC screen is displayed by clicking on the button.
RAPH13SPT0051BA 1
Operations in the DTC screen

Read DTC screen
Read DTC successively
Display Freeze Frame data
Save DTC
Clear DTC
Print DTC list
Diagnosis manual
Save data in CSV format
Replay history in DTC
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Display freeze frame data

1. Freeze Frame data is displayed by clicking on the
button.
2. Freeze Frame data can be printed by clicking on the
button.
RAPH13SPT0053BA 3
Save DTC
1. DTC and Freeze Frame data is displayed by clicking
on the button.
NOTE: A confirmation screen is displayed before you save.
2. Click on the to save the data.
3. Click on the to cancel.

NOTE: Data saved in Project can be viewed by “Replay
History of DTC”.
RAPH13SPT0054BA 4
Clear DTC
1. When clearing the DTC data, stop the engine and turn
the ignition switch to the ON position. A communication
error may occur if the clear function is performed while
the engine is running.
2. DTC saved in the ECU in the “past” can be cleared by
clicking on the button.
3. To clear the information, click on the button.
4. To cancel, click on the

NOTE: Just before the DTC is cleared, freeze frame data is
saved into the project info. The data that is saved in Project
can be viewed by “Replay History of DTC”.
NOTE: A memo can be saved with the DTC just before it RAPH13SPT0055BA 5
is cleared.
NOTE: DTC can be deleted if it is in the “past” and the same
DTC does not exist in the “present”.
NOTE: DTC in the “present” cannot be cleared.
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Diagnosis manual
1. Diagnosis manual related to the DTC is displayed by
clicking on the .
NOTE: Some vehicles have not been adapted to the func-
tion in Diagnosis manual. If vehicle is not adapted, this
button will not be displayed.
RAPH13SPT0056AA 6
Replay history of DTC

1. DTC data and Freeze Frame data can be replayed from
the “Replay” list.
2. Select the title from the list.
3. The content of selected title is displayed at the upper
part of the screen.
4. Select <Current Data> to cancel replaying.
5. In the replay mode, “Read DTC”, “Clear DTC”, “Save
DTC”, and Read DTC successively” functions cannot
be used. To return to the original status, select <Cur-
rent Data>. RAPH13SPT0057BA 7
6. “DTC-TOP” is the DTC data acquired by initial commu-

nication when diagnosis was started.
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Electrical system Computer support tools - View - Data monitoring

screen
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1. Data monitor screen is displayed when the
button is clicked.
2. Data monitor screen consists of:
• List area
• Graph area
• Working area
3. Click on the button to start the data moni-

toring setup.
RAPH13SPT0058BA 1
Data monitoring setup

1. The setting screen is displayed by clicking the
button.
2. Click the button after all of the settings have

been entered.
RAPH13SPT0061BA 2
Tab options
Signal Setting Select signals to be measured and settings for the graph.
Trigger Setting Set the trigger conditions. Trigger settings can only be
set after setting the signal settings.
Save Settings Save setting information in project or external view. The
content saved in project by “Save Setting” is registered
in the list of “Select Signal Group” at the lower part of the
data monitor screen.
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Signal setting
1. The list of parameters that can be measured is dis-
played in the left hand signal list.
2. Select target signal to be measured is displayed in the
right hand signal list.
RAPH13SPT0062BA 3
Button description
Select all available signals in the left hand signal list.
Selected signals move to the right hand list.
Maximum of 32 signals can be displayed. Total signals
may be lower depending on the available parameters.
Select one signal in the left hand signal list and move it
to the right hand list.
Select one signal in the right hand signal list and move
it to the left hand list. Removes the signal from the
monitoring list.
Moves all signal from the rights hand list into the left
hand list. Removes all signals from the monitoring list.
Change the order of the signal list. Move the parameter
up or down in the list.
Set the line color and the range of the Y-axis for each
signal.
Set the display settings back to the default value.
Set the background color of the graph. Common for all

signals.
Set the grid color of the graph. Common for all signals.
Set the cursor color of the graph. Common for all signals.
Set the trigger color of the graph. Common for all signals.
Set the flag color of the graph. Common for all signals.
Set the zero point color of the graph. Common for all
signals.
Set the graph color settings back to the default colors.
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Trigger setting
1. Refer to Electrical system Computer support tools -
View - Trigger detection (55.000) for more details on
trigger settings.
RAPH13SPT0063BA 4
Trigger settings and conditions
RAPH13SPT0075AA 5
Don’t use trigger Measures data without using a trigger.
Detect trigger all the time Measure by using only detecting condition for trigger.
Detects change Measure by using starting condition and following
detecting condition for trigger.
Use permitting condition Measure by using permitting condition and following
detecting condition for trigger.
Detects change Detect change of signals as the trigger for establishing
condition.
Setting for Starting / Permitting condition. These settings are required when “Use starting condition” or “Use
permitting condition” is selected in “Setting for Trigger Using Condition”.
Select signal to set starting or permitting conditions for
monitoring.
RAPH13SPT0076AA 6
Set reference value by using slide bar or up down
buttons.
RAPH13SPT0077AA 7
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Trigger settings and conditions

Select condition for reference value to detect starting or
permitting conditions.
RAPH13SPT0078AA 8
Setting for Trigger Detecting Condition. This setting is required when “Detect trigger all the time”, “Use permitting
condition” or “Detects changes” is selected in “Setting for Trigger Using Conditions”.
Select signal to set starting or permitting conditions for
monitoring.
RAPH13SPT0076AA 9
Set reference value by using slide bar or up down
buttons.
RAPH13SPT0077AA 10
Select condition for reference value to detect starting or
permitting conditions.
RAPH13SPT0078AA 11
Setting for Trigger point
Setting for trigger point. Amount of data saved before the
trigger set point in saved data.
RAPH13SPT0079AA 12
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Save settings
1. Select a project where the setting is to be saved.
2. Enter a title.
NOTE: Enter notes (optional)
3. Click the save button and specify a destination folder.
RAPH13SPT0064BA 13
Display setting screen

1. Set the scale of the y-axis.
2. Set the color of the graph.
3. Set the style of the graph.
4. Set the starting point of the graph on the x-axis.
NOTE: The x-axis can only be set while the data is replay-
ing.
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The maximum and the minimum values for each signal

set in software are used for the “Default Settings”.
Set each value by spin button for “Manual setting”.
RAPH13SPT0084AA 15
Click on the button and select the color from the color
setting dialog box.
RAPH13SPT0085AA 16
Draws a curve line to next data point.
Connects each data point by a straight line.
RAPH13SPT0086AA 17
Select line thickness.
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Replay measured data

1. Data can be replayed by selecting Data Monitor from
the “Replay” list.
2. Select saved title from the list.
3. Selected data is replayed in the data monitor screen.
4. Select “<Current Data>” to cancel replaying.
RAPH13SPT0057BA 19
5. The following dialog is displayed by clicking
or and a memo can be added to the flag.
RAPH13SPT0089AA 20
Available options while data is being replayed

Add flag or delete flag in data. Clicking on the add flag
will open a Flag Memo screen. Enter the data and click
the save button.
Switch graph display modes.
Move cursor to the first or past data point.
Move cursor to the next flag.
Move the cursor to the right or to the left.
Move graph area to be displayed to the right or to the left.
RAPH13SPT0068AA 21
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Enlarge or reduce the graph area to be displayed.
RAPH13SPT0069AA 22
RAPH13SPT0070AA 23
Change the color of the graph or the scale of the Y-axis.
Save the measured data in CSV format.
Print data screen.
Set the time scale. Available only when the data is being
replayed.
RAPH13SPT0071AA 24
Set the number of graphs to be displayed on the screen.
RAPH13SPT0072AA 25
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Select data monitor setting registered in project in
advance. External file can be selected by selecting “File”.
RAPH13SPT0073AA 26
Replay different data saved in project or cancel replaying.
RAPH13SPT0074AA 27
Monitoring data
1. Click on the to start monitoring.
2. Click on the to stop monitoring.

3. Increase the number of sampling signals for longer
sampling time between measurements. To shorten the
sampling time, reduce the number of monitored sig-
nals.
NOTE: Measured data is saved in 10 minute intervals. The
progress of the measurement is displayed in the status bar
in the bottom right hand corner. Old data is overwritten by
new data when the 10 minute interval is reached.
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Save the data screen
1. The Save Data screen will open after the

has been clicked.
2. Enter the title and memo information. Click on the save
button to save the information with the data.
RAPH13SPT0060BA 29
Add flag during data monitoring.
Switch graph viewing modes.
Set the number of data graphs to be displayed in one

screen.
RAPH13SPT0072AA 30
Change the color of the graph and change the scale the
Y-axis.
Move the cursor to the first or last data point.
Move the cursor to the next flag.
Move the cursor to the right or to the left.
Move the graph area to be displayed.
RAPH13SPT0068AA 31
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Enlarge or reduce the graph area to be displayed.
RAPH13SPT0069AA 32
RAPH13SPT0070AA 33
Save the data in CSV format.
Print the data screen.
Scale the time base. Available only when viewing the

data and not while in monitoring mode.
RAPH13SPT0071AA 34
Set the number of graphs to be displayed on the screen.
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Select data monitor setting registered in project in

advance. External file can be selected by selecting “File”.
RAPH13SPT0073AA 36
Replay measured data saved in project.
RAPH13SPT0074AA 37
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Electrical system Computer support tools - View - Trigger detection

N4LDI-TA-45SL
N4LDI-TA-50SL
Trigger detection is explained by giving an example for each trigger using condition.
Example 1 - Detect trigger all the time

The trigger is caused when the engine speed is greater
than the reference value of 4000 RPM.
RAPH13SPT0125BA 1
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Example 2 - Use starting condition

The trigger is caused when the coolant temperature is less
than the reference valve of 80 °C and engine speed is
greater than 2000 RPM.
RAPH13SPT0127BA 3
RAPH13SPT0128BA 4
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Example 3 - Use permitting condition

The trigger is caused when the coolant temperature is
greater than the reference value of 90 °C and engine
speed is less than 1000 RPM.
RAPH13SPT0129BA 5
RAPH13SPT0130BA 6
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Electrical system Computer support tools - View - Active test

N4LDI-TA-45SL
N4LDI-TA-50SL
Active test can be used to test the circuits between the Engine Control Unit (ECU) and certain components such as
injectors, Exhaust Gas Recirculation (EGR) valve or the glow plug relay.
1. The “Active Test” screen is displayed when the
button is clicked.
2. Select the active test in the list and click the

button.
NOTICE: Do not run active tests for longer than 30 s. Ma-
chine damage can occur.
RAPH13SPT0090BA 1
Execution screen
1. The “Active Test Execution” screen is displayed when a
test item is selected in the “Active Test Item Selection”
screen.
2. Set signal to be monitored to execute data monitor at
the same time. Select when

the setting is finished.
3. Active test is available when is clicked.

Data monitor is started if synchronous monitor is se-
lected.
4. Determine the driving specified value by using “Speed”
button or the slide bar.
RAPH13SPT0091BA 2
5. “Active Test” is executed when is clicked.
Driving instructions will be sent to the ECU. Check the
operation of the vehicle and the operating sound of the
actuator being driven.
6. During the “Active Test”, a flag can be added by clicking
on the button.
7. “Active Test” is finished when the button is

clicked. Title and memo information can be saved with
the measured data when data monitor is executed at
the same time.
8. Click the button to return to the “Item Select”

screen.
9. Work with graph screen of the findings of “Active Test”
in the same way as the data monitor screen.
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Replay
1. Select “Active Test” from the “Replay” list in “Item Se-
lect” screen to replay data.
2. Select saved title from the list. After the item is selected
the ”Execution” screen is displayed and the data is re-
played.
3. Click on the to cancel replaying.
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Electrical system Computer support tools - View - Utility

N4LDI-TA-45SL
N4LDI-TA-50SL
The utility menu provides various functions including injector compensation, fuel pump learning, and EGR mainte-
nance time reset.
Item select screen

1. “Utility Item Select” screen is displayed when
button is clicked.
2. Select utility item in the list then click button.

3. When utility item to be preformed is selected, “Expla-
nation”, “Executing Condition” and “Caution” will be dis-
played. Carefully read them and make sure you under-
stand them before performing.
4. Once item to be preformed is decided, click on the Se-
lect button.
5. The utility screen will appear, operate according to the
instructions shown on the screen.
RAPH13SPT0093BA 1
Injector compensation
NOTE: When compensation data is to be registered to the ECU, verify that engine is OFF. Registration cannot be
accomplished while the engine is running.
1. This function is used to set the compensation code for
the new injector assembly or the injectors to the Engine
Control Unit (ECU).
2. When this item is selected on the utility list screen, the
“Injector Compensation” screen will appear.
3. The injector compensation value saved currently in the
ECU is displayed as initial display.
4. Enter the cylinder data to be registered.
5. Click the button for corresponding cylinder

to register, and execute registration.
RAPH13SPT0095BA 2
6. When the screen for rewriting appears, click the
button.
RAPH13SPT0104AA 3
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7. This screen will be displayed when the rewriting is cor-

rectly completed.
RAPH13SPT0105AA 4
Read compensation data for all cylinders from Engine

Control Unit (ECU).
Register compensation data for all cylinders in ECU.
Read compensation data from external file and change

display. (No registering)
Write displayed compensation data in external file.
Scan Compensation Data by using Quick Response (QR) code

1. Compensation data can be scanned directly from QR
code printed on injector by connecting QR code scan-
ner with PC Com port.
2. Select COM port and check QR Code Scanner.
RAPH13SPT0106AA 5
3. Click data area of corresponding cylinder to register.

Following example is clicking data area of cylinder
number 1.
4. Scan data by using QR code scanner.
5. Register compensation data by clicking but-

ton.
RAPH13SPT0095BA 6
Communication requirement for QR code scanner

Procedure [Normal Mode]
Character length [8 bit]
Parity check [No]
Transmission rate [38400 bps]
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Communication requirement for QR code scanner

Stop bit length [1 bit]
Header STX
Terminator CR LF
Transmission of code ID mark [ Disabled ]
Transmission of no. of digits [ Disabled ]
BCC [ Disabled ]
Reading MicroQR Enabled
Reading black-and-white inverted QR codes White code on black background
Edit/Non-edit mode for split QR Codes [Edit Mode]
Reading PDF417 [ Disabled ]
Reading MaxiCode [ Disabled ]
Reading Data Matrix [ Disabled ]
NOTE: Values in [Brackets] are default values and do not need to be changed.
Replay registered compensation data

1. The history is saved automatically when compensation
data is registered. The history of registered compen-
sation data can be replayed from the “Replay” list.
3. Selected history is replaced in the list at the upper part.
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Fuel pump learning

1. The ECU constantly keeps learning to correct disper-
sion caused by differences in the types of fuel pumps
used. After exchanging the ECU or the fuel pump, it is
necessary to carry out the fuel pump learning utility.
2. When this item is selected on the utility item selection
screen, the following screen is displayed.
3. Follow the instructions according to the steps of “De-
scription” displayed on the screen.
RAPH13SPT0096BA 8 RAPH13SPT0097BA 9
RAPH13SPT0098BA 10 RAPH13SPT0099BA 11
Data check/rewrite
1. The Data Check/Rewrite function allows the parame-
ters in the ECU to be viewed (read) or updated (write).
2. When the Data Check/Rewrite function is selected on
the utility screen, the following screen will be displayed.
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3. The value presently in the ECU will be displayed as the

initial display.
4. Select the parameter to be rewritten.
5. Click on the button to write the parameter

into the ECU.
6. Click on the after checking the contents

when cautions are displayed.
RAPH13SPT0108AA 13
7. As the check screen for rewriting will appear, click on
button if rewriting is OK.
RAPH13SPT0104AA 14
8. The following screen will be displayed when rewriting

is complete.
9. When rewriting is complete, the signal of rewriting exe-
cution along with the completion message will change
to blue color.
RAPH13SPT0105AA 15
Replay rewritten data

1. The history is saved automatically in project when data
is rewritten, so history of rewritten data can be replayed
from “Replay” list.
3. Selected history is replayed in the list at the upper part.
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Exhaust Gas Recirculation (EGR) maintenance time 1 reset

1. Use this function to reset EGR maintenance time 1.
2. When this item is selected on the utility item selection
screen, the following screen will appear.
3. Follow the instructions according to steps of “Descrip-
tion” displayed on the screen.
RAPH13SPT0101BA 17
RAPH13SPT0102BA 18
RAPH13SPT0103BA 19
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Electrical system Computer support tools - View - Finish diagnosis

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Select “Finish Diagnosis” from “Menu” button during di-

agnosis to finish diagnosis in progress.
2. The confirmation screen is displayed when “Finish Di-
agnosis” is selected. Click on OK button to finish or the
Cancel button to continue.
NOTE: Diagnosis with connecting vehicle is finished only,
the application is not finished and it goes back to the Initial
Screen.
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Electrical system Computer support tools - View - Open diagnosis

history
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Diagnostic history can be displayed by selecting “Open

Diagnosis History” from “Menu” button. “Open Diagno-
sis History” function is not available during diagnosis.
Finish diagnosis to select this function.
RAPH13SPT0113AA 1
2. Diagnosis history select screen is displayed when the

function is selected.
3. History of diagnosis performed in the past can be con-
formed by opening “Diagnosis History”. This is useful
for analyzing.
4. When replaying diagnosis history, diagnosis can be
restarted for the history by selecting “Start Diagnosis”
> “Restart Diagnosis” from the menu.
RAPH13SPT0114AA 2
Replay diagnosis history in the same screen as the one

during trouble diagnosis.
Delete diagnosis history.
Import file exported by Service Tool D of other PC.
Save diagnosis history in external file.
Print diagnosis history list.
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Electrical system Computer support tools - Program - Engine

Control Unit (ECU)
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Click the “Menu” button and select “ECU Reprogram”

(1).
NHPH13ENG0861AA 1
2. Click the “Browse” button (1).
NHPH13ENG0862AA 2
3. Browse window opens.
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4. Navigate to the folder (1) where the ECU software is

located (C:\PCST\ISM_Engine_Software\...).
NHPH13ENG0864AA 4
5. The “Validate” button (1) should be active now. Click

the “Validate” button.
NHPH13ENG0860AA 5
6. The Reprogram section should be active now. Click the

“Write” button (1).
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Screenshot after the “Second Boot Loader” is complete.
NHPH13ENG0866AA 7
Screenshot during the “Main Program” download.
NHPH13ENG0867AA 8
7. Once the “Main Program” download is complete, follow

the instructions in the pop-up window (1).
8. Click the “Close” button to exit the programming.
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Electrical system Computer support tools - View - Start training

N4LDI-TA-45SL
N4LDI-TA-50SL
Each function of the Service Tool D can be simulated without connecting to a vehicle.
1. Start training mode by selecting “Start Training” from

the menu.
RAPH13SPT0115AA 1
2. When training mode is established, “DEMO” will be dis-

played in the status bar.
3. When operating in Training Mode, diagnosis function
can be simulated without connecting to a vehicle.
4. To finish Training Mode, click on “Menu” then select
“Finish Training”.
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Electrical system Computer support tools - Configure - System

settings
N4LDI-TA-45SL
N4LDI-TA-50SL
In the System Setting, the following settings are provided. ”Language Select” for setting the language displayed on
the Service Tool D. ”Communication Setting” for setting up the communication interface.
Language setting
1. Click “Language Select”.
RAPH13SPT0117AA 1
2. Check the radio button of the language to be selected
and click on the button. The Service Tool

D must be restarted in order to operate in the new se-
lected language.
3. It is recommended to use the same language as the
language specified in the Windows operating system.
If a language other than the language specified in the
Windows operating system is used, button, window or
character strings may not be displayed properly.
RAPH13SPT0118AA 2
Communication setting
1. Communication interface can be set by selecting “Sys-
tem Setting” > “Communication Setting”.
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2. Select the communication interface by using the “Se-

lect Interface” pull down.
3. If you click on “Interface Setting” button, configuration
application of communication interface to be used will
start and “Communications Port”, “Baud Rate”, etc. can
be set.
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Electrical system Computer support tools - View - Version

information
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Click the “Version Info” button.
RAPH13SPT0121AA 1
2. The version number of the tool is displayed.
RAPH13SPT0122AA 2
3. Click “Details” to view the version number of each com-

ponent.
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Electrical system Computer support tools - View - Exit application

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Select “Exit Application” from “Menu” button during di-

agnosis to exit Service Tool D.
2. Click on the button to finish diagnosis and

exit the application or click on the “Cancel” button to
continue diagnosis.
NOTE: Application is exited instantly if diagnosis is not in
progress.
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Electrical system Computer support tools - Remove - Service Tool D

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Open the “Control Panel” by clicking on “Start” > “Con-

trol Panel” or “Start” > “Settings” > “Control Panel”.
2. In the “Control Panel” select “Programs and Features”.
3. From the list of installed applications, select “ Service-
ToolID” then click on “Uninstall”.
RAPH13SPT0021BA 1
4. A message dialog box to confirm the removal of the

diagnostic tool is displayed. Click on “Yes” to uninstall
the program.
RAPH13SPT0022AA 2
5. When the uninstall process is complete, the following

screen will be displayed.
NOTE: In some cases you may need to reboot your PC
after finishing the uninstall process. If a dialog box ap-
pears to requiring your PC to reboot, proceed with the re-
boot process.
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Electrical system Computer support tools - Remove -

Communication adapter
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Open the “Control Panel” by clicking on “Start” > “Con-

trol Panel” or “Start” > “Settings” > “Control Panel”.
2. In the “Control Panel” select “Programs and Features”.
3. From the list of installed applications, select “ DST-i”
then click on “Uninstall”.
RAPH13SPT0024BA 1
4. A message dialog box to confirm the removal of DST-i

is displayed. Click on “Yes” to uninstall the program.
RAPH13SPT0025AA 2
5. Click on “Yes” to continue.

NOTE: In some cases you may need to reboot your PC
after finishing the uninstall process. If a dialog box ap-
pears to requiring your PC to reboot, proceed with the re-
boot process.
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Electrical system Computer support tools - Configure - License

activation
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
License request
1. Log onto the Dealer Portal.
2. Under the “Service” menu, go to “Service Tools” and
click “EST Marketplace”.
3. The “EST Marketplace” will then open. Under “EST
Products”, select “3rd Party Tools and Passwords”.
4. Select “ISM Indirect Injection (IDI) Software License”.
5. Add this item to your cart and checkout.
6. After your request is processed, you will receive and
e-mail containing your “Activation ID”.
NOTE: Processing may take up to 4 days.
Activating the service tool

1. Launch Service Tool I from the “Additional Tools” menu
in EST.
NOTE: The first time the program is opened, you will need
to configure the communication adapter. Refer to Electri-
cal system Computer support tools - Configure - Com-
munication adapter (55.000) for the proper procedure.
NHPH13ENG0213AA 1
2. If this prompt appears, click “OK”.

NOTE: Check the box (1) if you do not want to see this
window again.
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3. Click “Yes” (1) to begin activation.

NOTE: Your computer must have an internet connection to
activate the service tool.
NHPH13ENG0109AA 3
4. Select “Online” (1) and click “Next” (2).

NOTE: The “Manual” license activation process is not sup-
ported.
NHPH13ENG0110AA 4
5. Select “Activate” (1) and click “Next” (2).
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6. Enter your “Activation ID” (1) received in the above

mentioned e-mail.
NOTE: Copy and Paste method is highly recommended to
avoid typographical errors.
7. Click “Activate” (2).
NOTE: The button will become active when all required
fields are populated.
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Electrical system - Start up - Service Tool I

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Open the Electronic Service Tool (EST).

2. To launch the Service Tool I diagnostic tool, select the
“Additional Tools” button (1).
3. Click “Start the ISM Indirect Inject (Service Tool I) En-
gine Controller Diagnostic Tool” button (2).
NHPH13ENG0213AA 1
4. Verify the Engine Control Unit (ECU) information and

icons are visible on the screen.
5. If you cannot connect to the ECU, verify that the com-
munication adaptor is properly set. Refer to Electri-
cal system Computer support tools - Configure -
Communication adapter (55.000) for the proper pro-
cedure.
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Electrical system Computer support tools - Configure -

Communication adapter
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTE: A communication adapter must be selected before you can connect to the Engine Control Unit (ECU).
1. Click the “Utilities” menu and select “Preferences” (1).
NHPH13ENG0115AA 1
2. Select the “Communications” tab.

3. Select “RP1210 Compliant Device” (1) from the drop
down menu.
4. Click “Advanced”.
NHPH13ENG0116AA 2
5. Verify “DG DPA 4/4+/5 USB (150) - DG Dearborn

Group” is selected.
6. Click “OK”.
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7. Click “OK”.
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Electrical system Computer support tools - Program - Existing

Engine Control Unit (ECU)
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this procedure when programming an ECU that already has software installed.
1. Click the “WinFlash” icon (1).
NHPH13ENG0114AA 1
2. The service tool will begin to reconnect.

3. Click the “Folder” icon (1) and select the desired soft-
ware to be installed in the ECU.
4. Confirm the software values:
(A) Current software information.
(B) Desired software to be installed.
5. Click “Begin Flash” (2) to start programming the ECU.
NHPH13ENG0118AA 2
6. Monitor the status bar (1) at the bottom of the screen.

7. When it reaches 100 %, programming is complete.
8. Key OFF, then key ON. the service tool will reconnect
automatically.
NHPH13ENG0119AA 3
9. Click the “Configuration Tool” icon (1).

10. Double click “Engine Serial Number” (2).
11. Enter the engine serial number.
NOTE: The engine serial number is located on the engine
identification plate mounted above the fuel injection pump.
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Electrical system Computer support tools - Program - New Engine

Control Unit (ECU)
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this procedure when programming a blank ECU.
1. Click “Flash” (1).

NOTE: This window will appear automatically when the
service tool is connected to a blank ECU.
NHPH13ENG0121AA 1
2. Select the “Service” menu, “Copy Configuration”, then

click “ECM Replacement” (1).
NHPH13ENG0122AA 2
3. Click “No” (1) if this message appears:

“No data is available. Load from the ECM now?”
NHPH13ENG0123AA 3
4. Click “OK” (1) if this message appears:

“No ECM Replacement data is available to display.”
NHPH13ENG0124AA 4
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5. Click “Load from File” (1).
NHPH13ENG0125AA 5
6. Select the configuration data file (1).

7. Click “Open” (2).
NHPH13ENG0126AA 6
8. Confirm all of the selections are checked (1).

9. Click “Program ECM” (2).
NHPH13ENG0127AA 7
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Electrical system Computer support tools - Configure - Fuel pump

actuator
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this procedure if the fuel pump actuator has been replaced.
1. Click the “Configuration Tool” icon (1).

2. Double click “Fuel Pump Actuator Calibration Code”
(2).
NHPH13ENG1130AA 1
3. Enter the calibration code found on the solenoid.

NOTE: The correct code is the bottom alpha-numeric (1)
as shown.
NHPH13ENG0130AA 2
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Electrical system Computer support tools - View - Engine status

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Click the “Status Tool” icon (1) to view various engine

parameters.
2. Click the “Groups” button (2) to view available preset
groups of parameters.
NHPH13ENG0134AA 1
3. Click “New” to create a custom group.
NHPH13ENG0135AA 2
4. Enter a name for the custom group.

NOTE: The name must be 26 characters or less.
5. Click “OK”.
NHPH13ENG0217AA 3
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6. Scroll through the list of available parameters.

7. To add a parameter to your custom group, highlight the
desired parameter and click the “Right arrow” icon (1)
or double click the parameter.
8. To remove a parameter from your custom group, high-
light the desired parameter and click the “Left arrow”
icon (2) or double click the parameter.
9. Use the “Up arrow” and “Down arrow” icons (3) to move
the parameter higher or lower within the list.
10. Click “OK” (4) to create the group.
NHPH13ENG0218AA 4
11. Select your group (1).

12. Click “OK” (2).
NHPH13ENG0219AA 5
13. Observe your custom group of parameters on the sta-

tus screen.
NHPH13ENG0220AA 6
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Electrical system Computer support tools - View - Diagnostic codes

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
These codes are electrically based faults.
Active diagnostic trouble codes

1. Click the “Active Diagnostic Codes” icon (1).
NHPH13ENG0136AA 1
2. In this window, you can view the active codes in the

Engine Control Unit (ECU) sorted by:
• Code number (1).
• Description (2).
• Number of occurrences (3).
NHPH13ENG0136AA 2
Logged diagnostic trouble codes

1. Click the “Logged Diagnostic Codes” icon (1).
2. This window displays diagnostic codes that are no
longer active but have been stored in the ECU memory.
3. Click the “Clear” button (2) to clear the highlighted code.
4. Click the “Clear All” button (3) to clear the entire list of
logged codes.
NHPH13ENG0137AA 3
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Electrical system Computer support tools - View - Event codes

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
These codes are mechanically based faults.
Active event codes

1. Click the “Active Event Codes” icon (1).
NHPH13ENG0138AA 1
2. In this window, you can view the active codes in the

Engine Control Unit (ECU) sorted by:
• Code number (1).
• Description (2).
• Number of occurrences (3).
NHPH13ENG0138AA 2
Logged event codes

1. Click the “Logged Event Codes” icon (1).
2. This window displays event codes that are no longer
active but have been stored in the ECU memory.
3. Click the “Clear” button (2) to clear the highlighted code.
4. Click the “Clear All” button (3) to clear the entire list of
logged codes.
NHPH13ENG0139AA 3
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Electrical system Computer support tools - View - Product status

report
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Click the “Product Status Report” icon (1).

2. Enter the “Report Name” in the field (2).
3. Check the desired items to appear on your report for
the “Download List” (3) .
4. Click the “Create Report” button (4)
NHPH13ENG0140AA 1
5. The production report will appear as shown.

6. Click the “Save As” button (1) to save a copy of the
report to your computer.
NHPH13ENG0141AA 2
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Electrical system Computer support tools - View - Data logging

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this feature to record and save engine parameters over a set period of time.
1. Select the “Information” menu, then “Data Log”,

“Recorder” (1).
NHPH13ENG0142AA 1
2. Configure the following items:

• Log File - Where you want to save the file.
• Sample Rate - How many times you want to record
the data per hour or minute.
• Duration - How long you would like it to record data.
• Pre-Trigger - Time that the data is captured prior to
starting the recording. Must be between 0 - 30 s.
3. Select the desired engine parameters to be logged by
clicking “Add” (1).
NHPH13ENG0143AA 2
NOTE: Custom parameter groups can be selected or cre-
ated from this window.
4. Click “OK” (2).
5. Click the “Start” button (1) to begin logging data.
NHPH13ENG0144AA 3
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6. View the time remaining (1) in recording session.

NOTE: You can stop recording data at any time by clicking
the “Stop Recorder” button (2).
NHPH13ENG0145AA 4
7. Click the “Graph” button (1).
NHPH13ENG0144AA 5
8. Highlight the parameters (1) you would like to see in

graph form and click the “Right arrow” icon (2).
9. Click the “OK” button (3) to create the graph.
NHPH13ENG0146AA 6
10. View the logged data in the graph.
NHPH13ENG0148AA 7
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Electrical system Computer support tools - View - Real time

graphing
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this feature to view live engine parameters in graph form.
1. Select the “Information” menu, then click “Real Time

Graphing” (1).
NHPH13ENG0149AA 1
2. Click “New”.
NHPH13ENG0150AA 2
3. Highlight the desired engine parameters (1) to view on

the graph and click the “Right arrow” icon (2) to add
them to the set.
4. Click the “Save As” button (3) to save the graph set for
future use.
NOTE: You will need to assign a name to the graph set with
this selection.
5. Click the “OK” button (4) if you do not want to save the
graph set.
NOTE: The selected parameters will be stored in the
“<TEMPORARY SET>” graph set.
NHPH13ENG0151AA 3
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6. Click the “OK” button (1).
NHPH13ENG0150AA 4
7. Monitor the graph.
NHPH13ENG0152AA 5
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Electrical system Computer support tools - View - Parameter

override mode
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this feature to override select parameters.
1. Select the “Diagnostics” menu, then click “Diagnostic

Tests” (1).
NHPH13ENG0153AA 1
2. Highlight a parameter (1).

3. Click the “Change” button (2) .
4. Select the required items.
NOTE: Values vary based on the selected parameter.
5. Click the “OK” button (3).
NOTE: Override mode will stop automatically after 10 s.
NHPH13ENG0155AA 2
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Electrical system Computer support tools - Configure - Diesel

Particulate Filter (DPF) soot load reset
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
Use this feature when the Diesel Particulate Filter (DPF) is cleaned or replaced.
1. Select the “Service” menu, then click “DPF Soot Load

Reset” (1).
2. Click the “Reset” button (2).
NHPH13ENG0156AA 1
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Index

Electrical system - Start up - Service Tool I (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Electrical system Computer support tools - Configure - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . 63
Electrical system Computer support tools - Configure - Diesel Particulate Filter (DPF) soot load reset (*) . . . . . . 79
Electrical system Computer support tools - Configure - Fuel pump actuator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical system Computer support tools - Configure - License activation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Electrical system Computer support tools - Configure - System settings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electrical system Computer support tools - Configure - USB port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical system Computer support tools - Configure - User authentication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical system Computer support tools - Install - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical system Computer support tools - Install - Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical system Computer support tools - Program - Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical system Computer support tools - Program - Existing Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . 65
Electrical system Computer support tools - Program - New Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . 66
Electrical system Computer support tools - Remove - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical system Computer support tools - Remove - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical system Computer support tools - Start up - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical system Computer support tools - View - Active test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical system Computer support tools - View - DTC screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical system Computer support tools - View - Data logging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical system Computer support tools - View - Data monitoring screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical system Computer support tools - View - Diagnostic codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical system Computer support tools - View - Engine status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electrical system Computer support tools - View - Event codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical system Computer support tools - View - Exit application (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical system Computer support tools - View - Finish diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electrical system Computer support tools - View - Open diagnosis history (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical system Computer support tools - View - Parameter override mode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical system Computer support tools - View - Product status report (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Electrical system Computer support tools - View - Project screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical system Computer support tools - View - Real time graphing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical system Computer support tools - View - Start diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical system Computer support tools - View - Start training (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical system Computer support tools - View - Trigger detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Electrical system Computer support tools - View - Utility (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electrical system Computer support tools - View - Version information (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Engine control system - 015

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
SERVICE
Engine timing sensors

Test - Speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect - Crankshaft and camshaft revolution sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine control system
Engine timing sensors - Test - Speed sensor

N4LDI-TA-45SL
N4LDI-TA-50SL
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
Speed sensor is located on the timing cover where it

senses engine speed as engine pulse.
1. Use the Service Tool D and see data monitoring.
2. Use a dial indicator to check the sensor air gap.
There should be approximately 0.5 - 1.2 mm (0.0197 -
0.0472 in). If the gap is not in range, check the timing
cover for damage or obstructions.
3. Ensure to set the O-ring to prevent oil leaking.
4. Torque the sensor to 6 - 8 N·m (4 - 6 lb ft).
NHIL13ENG0051AA 1
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Electrical systems - Engine control system
Engine timing sensors - Inspect - Crankshaft and camshaft

revolution sensors
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
NOTE: Crankshaft sensor is also referred to as revolution sensor (main).

NOTE: Camshaft sensor is also referred to as revolution sensor (backup).
1. Check the sensors are installed correctly.
• Make sure the o-rings are seated properly on the
sensor.
2. Check the wiring harness to the sensors.
• Check the wiring harness to the crankshaft sensor.
• Check the wiring harness to the camshaft sensor.
• If the wiring harness is damaged, repair or replace
as needed.
NHIL13ENG0179AA 1
Crankshaft sensor electrical wiring/connection specifica-

tion:
Connector pin Value

Pin 1 5.0 V
Pin 2 Signal
Pin 3 Ground
Camshaft sensor electrical wiring/connection specification:
Connector pin Value

Pin 1 5.0 V
Pin 2 Signal
Pin 3 Ground
Tightening torque: 5.6 - 8.4 N·m (4.1 - 6.2 lb ft).
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Index

Engine timing sensors - Inspect - Crankshaft and camshaft revolution sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine timing sensors - Test - Speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine starting system - 201

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
TECHNICAL DATA
Engine starter
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine starting system

SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical test - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starter solenoid - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSTIC
Engine starter
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Electrical systems - Engine starting system
Engine starter - General specification

Manufacturer Denso Corporation
Model 2288000-5120
Current Draw
- Under Load 500 A @ 7.5 V
- No Load less than 110 A
No Load RPM 4000 RPM
No Load Voltage 11.5 V
Clutch System Overrunning Pinion Clutch
Brush Length
- New 15 mm (0.6 in)
- Wear Limit 12 mm (0.5 in)
Brush Spring Tension 26 - 35 N (5.8 - 7.9 lb)
Commutator Diameter
- New 35 mm (1.4 in)
- Wear Limit 34 mm (1.3 in)
Commutator Insulation Depth 0.2 - 0.85 mm (0.008 - 0.033 in)
Armature Runout
- Commutator 0.02 - 0.05 mm (0.001 - 0.002 in)
- Armature Shaft 0.02 mm (0.001 in)
- Ratings time 30 Sec
- Weight 4.6 kg
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Engine starting system - Dynamic description

Description of operation
The starting system consists of a starter motor equipped with an electromagnetic starter solenoid, a start relay, several
safety switches, and heavy-duty wiring.
Starter components
SEC55CH4PG28 1
(1) Reduction uni cover (9) Plunger

(2) Armature drive gear (10) Solenoid
(3) Motor/Field coil housing (Yoke) (11) Return spring
(4) Permanent magnet (12) Pinion clutch
(5) Field coil (13) Pinion
(6) Armature (14) Idler gear
(7) Brush spring (15) Idler gear roller bearing
(8) Brush
Starter motor assembly

The starter motor features a high-speed motor that utilizes a gear reduction unit, an overrunning pinion clutch, (12),
and permanent magnets, (4), in a field coil, (5), for magnetic field induction. The reduction unit consists of a small
drive gear, (2), on the motor armature, (6), which drives an idler gear, (14), in the reduction unit. The idler gear is
splined to the gear on the pinion clutch housing, (12). When the starter solenoid, (10), is energized, the solenoid
plunger, (9), pushes the pinion gear, (13), out, engaging with the engine flywheel. The starter motor then is turning
the flywheel, which rotates the engine. The use of the gear reduction unit allows use of the compact, high-speed
motor and provides more torque and power to turn the engine flywheel. The sliding pinion mechanism is enclosed,
resulting in a more durable mechanism.
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Starter solenoid
The starter solenoid is an electromagnetic type solenoid
that is located on the bottom of the starter motor assem-
bly. The solenoid contains two coils, a pull-in coil, (1)
and a hold-in coil (2) When the key switch is turned to
the "START" position and the safety start relay is closed
(safety switches closed), current from the battery will en-
ergize the solenoid's two coils. With the coils energized,
the solenoid plunger, (3) pushes a spring (4) which will
then push the pinion gear out to engage the flywheel. At
the same time, a set of contacts (5), on the solenoid be-
come closed, allowing current to flow to the starter motor.
Closing the contacts also supplies current to both ends
of the solenoid pull in coil which makes the coil become
non-energized. The hold-in coil continues to engage the
pinion gear with the flywheel. SEC55CH4PG29_1 2
Pinion clutch
To prevent the engine from driving the starter motor once
the engine is running, the pinion gear is equipped with an
overrunning clutch. The clutch will disengage the pinion
gear from the rest of the starter components once the en-
gine has been started and the key switch is in the "START"
position. The clutch consists of an outer gear/shell, (1), a
cam with tapered notches, (2), rollers, (3), roller springs,
(4), a splined pinion collar/tube that acts as a clutch hub,
(5), and the pinion shaft, (6). As the starter motor engages
and rotates, the rollers are locked against the pinion collar
with the tension provided by the roller springs. While the
rollers are locked, the clutch assembly is locked, allowing
the pinion gear to rotate the flywheel. When the engine
starts, the flywheel moves faster than the starter motor
and this causes the rollers to become unlocked. With the SEC55CH4P29_2 3
rollers unlocked, the clutch assembly is unlocked, allow-
ing the pinion gear and shaft to turn independently of the A- Engaged, B - Disengaged
starter motor.
(1) Clutch gear

(2) Cam
(3) Roller
(4) Spline tube - inner (pinion collar)
(5) Pinion shaft
(6) Roller spring
The clutch is not serviceable and is replaced as a com-
plete assembly.
Once the engine is started and the key switch is released

from the "START" position, the solenoid's pull in coil be-
comes energized, pulling the solenoid plunger in, which
disengages the pinion from the flywheel.
SEC55CH4P29_3 4
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Engine starter - Remove

1. Disconnect the wiring harness connections (3) from the
starter motor (1).
2. Remove the bolts (2) which secure the starter assembly
(1) to the engine.
SEC55CH4P30_1 1
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Engine starter - Disassemble
SEC55CH4PG30_2 1
(1) Felt washer (9) Solenoid housing

(2) Armature (with front bearing) (10) Return spring
(3) Rear armature bearing (11) Steel ball
(4) Motor/Field coil housing (12) Pinion clutch
(5) Brush spring (13) Reduction unit housing
(6) Brush holder (14) Idler gear roller bearing
(7) Brush cover (15) Roller
(8) Through bolt (16) Idler gear
1. Remove the field coil wire (3) the solenoid terminal (4).
2. Remove the long through bolts (2) securing the motor
assembly (1) to the gear reduction unit housing.
SEC55CH4P47_2 2
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3. Slide the motor assembly (2) from the gear reduction

unit housing (1).
4. Remove the screws (3) which secure the brush cover
(4), to the motor/field coil housing (5).
SEC55CH4PG31_2 3
NOTE: Before removing the brush holder scribe aligning

marks on the brush holder and the motor/field coil housing.
5. Use a suitable pair of pliers to remove the insulated ar-
mature commutator brushes (2) from the brush holder
(3).
6. Slide the brush holder (3) from the armature commuta-
tor (1).
SEC55CH4PG31_3 4
7. Remove the armature (4) from the motor/field coil hous-

ing (3). The rear armature bearing (2) is a light press fit
and it may be necessary to pull the armature from the
housing, gripping on the front bearing (1).
SEC55CH4PG32_1 5
8. Use an impact tool (2) to remove the two screws (1) se-
curing the gear reduction cover (3) to the starter hous-
ing.
SEC55CH4P32_2 6
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NOTE: The pinion gear (1) and idler gear with roller bear-
ings (2) will be free to fall out when the gear reduction unit
cover (3) is removed from the starter assembly (4). Use
care not to lose any of these pieces.
9. Carefully remove the reduction unit cover (3) from the
starter assembly (4).
SEC55CH4PG32_3 7
10. Pull the pinion clutch assembly (1) from the reduction
unit cover or the starter motor assembly.
SEC55CH4PG33_1 8
11. Remove the steel ball (1) from the center of the pinion
clutch.
SEC55CH4PG33_2 9
NOTE: When removing the idler gear and bearing, be care-

ful not to lose the bearing rollers contained in the bearing.
12. Remove the idler gear and bearing (1) and pinion gear
from the reduction unit cover, if they were not removed
when the reduction unit cover and the starter motor
housing was separated.
SEC55CH4PG33_3 10
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13. Remove the return spring (1) from the electromagnetic

solenoid.
SEC55CH4PG34_1 11
14. Remove the screws (1) securing the solenoid cover

(2) to the starter housing. Pry the cover from the hous-
ing.
SEC55CH4PG34_2 12
15. Remove the solenoid plunger and spring assembly (2)

from the starter housing (1).
SEC55CH4PG34_3 13
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Engine starter - Inspect
SEC55CH4PG35 1
(1) Normal wear pattern (4) Milled condition excessive wear on 2 or 3 teeth.
(2) Small wear pattern (5) Milled tooth-metal buildup - Will not permit
engagement
(3) Milled gears
1. Inspect the gear splines on the pinion clutch, the pinion,

the armature, and the intermediate gear for damaged
or missing splines. Replace any damaged parts.
2. Hold the pinion clutch housing and rotate the pinion.
The pinion should rotate smoothly, although not neces-
sarily easily, in one direction only. If the pinion can spin
in both directions, the clutch is defective and needs re-
placed.
3. Inspect the motor housing, brush cover, gear reduction
unit, and starter housing for damage such as cracks,
fatigue, wear, etc. Replace any damaged parts.
4. Inspect the brush terminals, battery terminals, and mo-
tor terminals for corrosion, loose connections or dam-
age. Repair or replace any damaged parts.
5. Clean and inspect the solenoid plunger contact ring (1)
and solenoid contacts (2). Dirty contacts or pitting may
be cleaned with fine grit sandpaper or a fine abrasive
pad.
6. Inspect that all bearings rotate freely when rotated
manually by hand and are not damaged or have ex-
cessive play. Replace any damaged bearings.
20002308 2
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7. Inspect the armature windings (1) for burnt, broken or

loose connections.
8. Inspect the commutator contacts (2) for burnt seg-
ments, indicating an open winding.
20002279 3
9. Use a suitable measuring device to measure the com-

mutator diameter. The minimum commutator diameter
is 34.0 mm (1.339 in). If the commutator is worn be-
yond these specifications, replace the armature.
SEC55CH4PG36_3 4
10. Inspect the mica insulating valleys, (1) between the

commutator contacts (2) for uneven wear. Use a suit-
able measuring device to check the distance (3) be-
tween the top of the contact to the bottom of the in-
sulating valley. The distance should be 0.5 - 0.8 mm
(0.020 - 0.031 in). If the distance is not within these
specifications or there is uneven wear, the insulating
valleys may be undercut with a suitable file.
20002267A 5
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NOTICE: If not previously removed, the armature bearings

will need to be removed for this test.
11. Place the armature (3) in a set of precision V-blocks
(4) and use a dial indicator (2) to measure commutator
(5) runout and shaft (1) runout. Commutator runout
should not be more than 0.2 mm (0.008 in). Shaft
runout should not be more than 0.5 mm (0.002 in)
20002266 6
NOTICE: When measuring the brush length, remove the

brush from the brush support and measure the middle por-
tion of the brush.
12. Use a suitable measuring device to measure the
length of the armature brushes. Compare the mea-
surement of each brush with brush length specifica-
tions. If the brush is not within specifications or is
damaged in any way, replace the brushes.
SEC55CH4PG37_3 7
13. Test the brush spring tension by connecting a spring

balance to the brush spring and pulling until the spring
moves. Observe the reading indicated on the spring
balance. If the reading is between 26 - 35 N (5.8 -
7.9 lb), the spring tension is within specifications. Oth-
erwise, replace the brush springs
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SEC55CH4P38_1 8
Standard tension = (A) 26 - 35 N (5.8 - 8 lb)
(1) Spring scale (3) Brush

(2) Hook (4) Brush spring
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Engine starter - Electrical test

Armature
1. Use a growler (1) to inspect the armature coil (2) for
short circuits. Replace if the armature is shorted.
SEC55CH4PG38_2 1
2. Use an ohmmeter to test for continuity in the armature

coil (2).
3. Touch one ohmmeter test probe to a commutator con-
tact (1). Touch the ohmmeter test probe to an adjacent
commutator contact.
4. Observe the ohmmeter. Repeat the test on each ad-
jacent commutator contact. Little or no resistance in-
dicates that there is continuity and the armature coil is
good. High resistance indicates that the armature is
defective and needs replaced.
20002280 2
5. If the armature is tested OK, touch one ohmmeter test

probe to a commutator contact (1). Touch the other test
probe to the armature shaft (2).
6. Observe the ohmmeter. A high resistance reading in-
dicates the armature is good. Little or no resistance
indicates that the armature is defective and needs to
be replaced.
SEC55CH4PG39_1 3
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Brush holder
1. Use an ohmmeter and touch one test probe to the in-
sulated brush holder (1) and the other test probe to the
brush holder plate (2).
2. Observe the ohmmeter. Repeat the test for the oppo-
site insulated brush holder.
3. A reading high resistance indicates no continuity and
the brush holder is good. Little or no resistance indi-
cates that there is continuity and the brush holder is
SEC55CH4PG39_2 4
Field coil
1. Use an ohmmeter to test the field coil.
2. Touch one ohmmeter test probe to one of the field coil
brushes. Touch the other test probe to the remaining
field coil brush.
3. Observe the ohmmeter. Little or no resistance indicates
continuity and that the field coil is functioning properly.
High resistance indicates the field coil is defective and
needs replaced.
SEC55CH4PG39_3 5
NOTICE: Paint on the field coil/motor housing will give

a false reading when testing to see if the field coil is
grounded. Be sure to remove paint from the field coil/mo-
tor housing.
4. If the previous test indicated the field coil was not de-
fective, touch one ohmmeter test probe to one of the
field coil brushes (1). Touch the other test probe to the
field coil housing (2).
5. Observe the ohmmeter. If the reading shows high re-
sistance, indicating no continuity, the field coil is not
grounded and is functioning properly. If there is little or
no resistance indicating continuity, the field coil is de- SEC55CH4PG40_1 6
fective and needs replaced.
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Engine starter - Assemble
20002285 1

NOTE: Use white lithium grease to lubricate parts indi-

cated.
1. Install the solenoid plunger (2) to the starter housing
(1).
SEC55CH4PG34_3 2
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2. Install the solenoid cover and gasket to the starter

housing. Install the screws (1) securing the solenoid
cover (2) and gasket to the starter housing.
20002306 3
3. Grease and install the return spring (1) to the solenoid.
SEC55CH4PA34_1 4
4. Grease and install the steel ball (1) into the center of
the pinion clutch.
SEC55CH4PA33_2 5
5. Grease and install the pinion clutch (4) in the starter

housing. Make sure the rear clutch bearing is com-
pletely seated in the housing.
6. Grease the idler gear bearing and gear and install the
gear (2) and bearing onto the starter housing. Align
the bearing and gear so that it meshes with the pinion
clutch and is aligned with the hole in the housing for the
pin which the bearing rides on.
7. Install the drive gear (1) in the proper recess in the
reduction unit cover (3) as the cover is being installed
onto starter motor housing.
SEC55CH4PA32_3 6
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8. Secure the gear reduction cover (2) with the retaining

screws (1).
20002277A 7
20002287 8
(1) Front armature bearing (5) Brush spring (9) Brush cover
(2) Armature (6) Brush holder (10) Brush
(3) Rear armature bearing (7) Screws
(4) Motor/Field coil housing (8) Through bolt
9. If removed, install the front and rear bearings (1) and

(3) to the armature (2).
10. Install the armature (2) to the motor/field coil housing
(4). Be sure that the rear bearing (3) is properly seated
in the motor housing.
NOTE: When installing the field coil brushes be sure that
the aligning marks made on the brush holder and motor/
field coil housing will line up when the brush holder is in-
stalled onto the armature commutator.
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11. Install the field coil brushes (6) into the brush holder
(7) holding the brush springs (5) away as the brush is
being inserted into the insulated brush holder.
12. Install the brush holder (7) onto the armature commu-
tator.
13. Secure the brush cover (8) to the brush holder (7)
using the retaining screws (9).
NOTE: Be sure the aligning marks made on the starter

housing and motor/field coil housing line up when installing
the motor assembly to the starter assembly.
14. Install the motor assembly (2) into the starter housing
assembly (1).
SEC55CH4P31_2 9
15. Secure the motor assembly (1) to the starter housing

assembly using the long through bolts (2).
SEC55CH4PG47_2 10
16. Install the field coil wire (2) the solenoid terminal (1).
SEC55CH4PG47_3 11
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Engine starter - Electrical test - No load
SEC55CH4P48_1 1
(1) Ammeter (3) Voltmeter

(2) Switch (4) Battery
NOTE: Before installing the starter motor to the engine, it is recommended that a no load test be performed on the
starter motor.
NOTE: Do not operate the starter for more than 30 seconds at a time.
1. Connect a battery and switch to the battery terminal of

the starter and the 'S' terminal of the solenoid.
2. Connect an ammeter between the positive (+) battery
terminal of the battery and the battery terminal of the
starter solenoid.
3. Connect a voltmeter, after the ammeter, between the
positive (+) lead from the battery and the negative (-)
lead from the battery.
4. Close the switch and record the readings indicated on
the ammeter and voltmeter.
5. Test starter components if any abnormal operation is
noted.
6. Service limits are 11.5 V, 110 A maximum at
4000 RPM.
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Engine starter - Install

1. Install the starter motor (1) to the engine and secure us-
ing the retaining bolts (2). Be sure all ground terminals
are connected to the bottom starter bolt.
2. Connect the wiring harness connections to the starter
(3).
SEC55CH4PA30_1 1
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Engine starter Starter solenoid - Electrical test
20002285 1

NOTE: Use white lithium grease to lubricate parts indi-

cated.
1. Install the solenoid plunger (2) to the starter housing
(1).
SEC55CH4PG34_3 2
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2. Install the solenoid cover and gasket to the starter

housing. Install the screws (1) securing the solenoid
cover (2) and gasket to the starter housing.
20002306 3
3. Grease and install the return spring (1) to the solenoid.
SEC55CH4PA34_1 4
4. Grease and install the steel ball (1) into the center of
the pinion clutch.
SEC55CH4PA33_2 5
5. Grease and install the pinion clutch (4) in the starter

housing. Make sure the rear clutch bearing is com-
pletely seated in the housing.
6. Grease the idler gear bearing and gear and install the
gear (2) and bearing onto the starter housing. Align
the bearing and gear so that it meshes with the pinion
clutch and is aligned with the hole in the housing for the
pin which the bearing rides on.
7. Install the drive gear (1) in the proper recess in the
reduction unit cover (3) as the cover is being installed
onto starter motor housing.
SEC55CH4PA32_3 6
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8. Secure the gear reduction cover (2) with the retaining

screws (1).
20002277A 7
20002287 8
(1) Front armature bearing (5) Brush spring (9) Brush cover
(2) Armature (6) Brush holder (10) Brush
(3) Rear armature bearing (7) Screws
(4) Motor/Field coil housing (8) Through bolt
9. If removed, install the front and rear bearings (1) and

(3) to the armature (2).
10. Install the armature (2) to the motor/field coil housing
(4). Be sure that the rear bearing (3) is properly seated
in the motor housing.
NOTE: When installing the field coil brushes be sure that
the aligning marks made on the brush holder and motor/
field coil housing will line up when the brush holder is in-
stalled onto the armature commutator.
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11. Install the field coil brushes (10) into the brush holder
(6) holding the brush springs (5) away as the brush is
being inserted into the insulated brush holder.
12. Install the brush holder (6) onto the armature commu-
tator.
13. Secure the brush cover (9) to the brush holder (6)
using the retaining screws (7).
NOTE: Be sure the aligning marks made on the starter

housing and motor/field coil housing line up when installing
the motor assembly to the starter assembly.
14. Install the motor assembly (2) into the starter assem-
bly (1).
SEC55CH4P31_2 9
15. Secure the motor assembly (1) to the starter assembly

using the long through bolts (2).
SEC55CH4PG47_2 10
16. Install the field coil wire (2) the solenoid terminal (1).
SEC55CH4PG47_3 11
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Engine starter - Troubleshooting

Pinion shaft fails to Wiring: Open circuit battery, and switch ter- Repair or replace.
advance minal connections.
Wiring: Open circuit, fuse. Replace fuse.
Key switch: No contact. Repair or replace.
Starter motor: Sleeve bearing burnt out. Repair or replace.
Starter motor: Lever broken. Replace.
Solenoid: Plunger movement defective or Repair or replace.
coil open or shorted.
Pinion motor rotates but Starting motor: Clutch defective. Replace.
no rotation transmitted to
engine
Starting motor: Orbital gear or planetary Replace.
gears damaged.
Motor rotates before Starter motor: Shift lever damaged. Replace.
pinion meshes with ring
gear
Starter motor: :Shift lever damaged Replace.
Starter motor: Slip ring defective. Replace.
Starter motor: Pinion teeth worn. Replace.
Starter motor: Pinion push out position de- Adjust.
fective.
Engine: Ring gear worn. Replace.
Solenoid defective Replace.
Pinion meshes with ring Wiring: Line connecting solenoid to battery Repair or replace.
gear but starting motor broken or defective ground.
fails to turn
Wiring: Lead wire connecting solenoid to Repair or replace.
motor tightened improperly.
Starting motor: Ball bearing locked. Replace.
Starting motor: Brush worn. Replace.
Starting motor: Improper installation. Reinstall.
Starting motor: Brush spring defective. Replace.
Starting motor: Commutator dirty. Clean.
Starting motor: Armature of field coil defec- Repair or replace.
tive.
Starting motor: Field coil-to-brush connec- Replace.
tion defective.
Solenoid: Contact not touching properly. Replace.
Solenoid: Contact contacting surface Replace.
roughened.
Battery: In discharge state. Recharge or replace.
Motor fails to stop after Key switch: defective. Replace.
engine starts and key
switch is turned off
Defective solenoid. Replace.
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Index

Engine starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine starter - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine starter - Electrical test - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine starter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starter - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine starter - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine starter Starter solenoid - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine starting system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Alternator - 301

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
Alternator - 301
TECHNICAL DATA
Alternator
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Alternator
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Alternator
Preliminary test - Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical test - Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical test - Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical test - Bench check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Electrical systems - Alternator
Alternator - General specification

Manufacturer Mitsubishi
Model A007T03877
Polarity Negative ground
Rotational direction (viewed from Clockwise
pulley side)
Drive belt tension 10 - 15 mm (0.39 - 0.59 in) deflection @ 9 - 11 kg (20 - 25 lb) of force
Adjusting voltage 14.5 - 15.0 V
Load characteristics
- Terminal voltage 13.5 V
- Current 30 A minimum at 2500 RPM
Brush length
- Wear limit (min. length) 5 mm (0.20 in)
- Original 18.5 mm (0.728 in)
Brush contact rings
- Wear limit (min. diameter) 22.1 mm (0.871 in)
- Original diameter 22.7 mm (0.894 in)
Bearing
- Front ECSC8
- Rear 6303DDG
Stator coil resistance less than 1.0 Ω
Rotor coil resistance 2.8 Ω
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Alternator - Static description
T1530CHARGCIR2 1
Alternator
Description of operation
The 40 A output alternator is equipped with an integrated circuit (IC) regulator, meaning voltage is regulated internally
and electronically within the alternator.
The principle components of the alternator are the stator (5) the rotor (2) the rectifier assembly (7) and the IC regulator
(1).
The rectifier assembly (7) consist of two heat sinks, one positive (+) and one negative (-) and a diode trio.
The diode trio is used as a field supply diode and is connected to terminal 'L' on the alternator.
The IC regulator (1) is a solid state unit and can only be serviced as an assembly.
The internal components of the alternator are housed in a two-piece frame, which is divided into a drive end (front)
frame (4) and a rear frame (6). The frame contains open slots to allow for cooling of the alternator.
The alternator is rotated in the frame by using a belt-driven pulley (3) which is powered off of the engine crankshaft
pulley by a belt.
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T1530CHARGCIRA 2
Charging circuit
The charging circuit and internal connections are shown. The charging system consists of an IC voltage regulator (6)
(enclosed with dotted lines), a battery (5) and connecting wires. Because of the use of IC, the voltage regulator is
very compact and is built into the alternator.
The IC voltage regulator (6) limits the field current to flow directly from the diode trio (2) to the field coil (7) without
passing through the external circuit. Consequently, there are no voltage drops caused by the key switch or the external
wiring as with conventional vibrating-contact regulators mounted separately from the alternator. To aid in initial voltage
buildup when the engine is started the field current is supplied through the indicator lamp (3) from the battery (5).
Since the frequency pulse output of 1/10 the alternator speed develops on the 'P' terminal, this terminal is used for
speed detection.
Principle of IC regulator
The basic function of the IC voltage regulator is to make the terminal voltage constant by detecting the generated
voltage and increasing/decreasing the field current.
As indicated, the regulator consists of two basic sections: a voltage control device and an output device to handle
the field current. The voltage control device includes the voltage divider network, R1 and R2, a zener diode, DZ, for
voltage reference, and a single amplifying transistor, Tr1. The output device is a darlington-type amplifier which is
called power transistor, Tr2. The power transistor, Tr2, is placed in series with the alternator field coil and ground.
The signal amplifying transistor, Tr1, senses the generated voltage and turns the power transistor, Tr2, on and off
many times per second most of the time the engine is in operation.
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The basic operating principles are explained as follows, see Figure 2:

1. When the key switch (4) is closed current from the battery (5) flows through the indicator lamp (3) and resistor R6,
which are in parallel to the field coil (7). From here it continues to flow on through the field coil (7), to the ground
completing the circuit back to the battery (5).
2. When the alternator begins to rotate, AC voltages are generated by the stator coil (1). The diodes in the rectifier
assembly change the stator AC voltages to DC voltage which appears between ground and the 'B' terminal.
3. The stator also supplies DC field current through the diode trio (2), the field coil (7), the power transistor, Tr2, and
then through the diodes in the rectifier assembly back to the stator.
4. When the generated voltage is low, no current flows in the zener diode, DZ, since the voltage at point 'A' is lower
than the zener voltage.
5. As the speed and voltage increase, the voltage at point 'A' also increases until it reaches the limiting value set at
the factory. As the zener diode, DZ, breaks down, current flows through R1, DZ, and the base-emitter circuit of
Tr1 to ground. This renders Tr1 conductive, so that much of the current flows through the collector emitter circuit
of Tr1. This reduces the base current of Tr2 thereby reducing the field current. This means that Tr1 turns on and
Tr2 turns off.
6. When the generated voltage decreases, the zener diode, DZ, again turns off and Tr1 also turns off. This cycle
repeats many times per second, and the alternator output voltage is, therefore, regulated within a narrow limit.
In other words, the action is similar to the conventional vibrating-contact regulator, in that current to the field coil
(7) is varied to limit the output voltage, but in place of the voltage coil and spring system there is a voltage divider
network, R1and R2, and a zener diode, DZ
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Alternator - Preliminary test - Alternator Output

NOTICE: Start-up current can exceed ammeter capacity. Do not attempt to start the engine without first shorting the
wires between the ammeter leads. Failure to comply could damage testing components.
NOTE: Use the following methods if an alternator/charging system analyzer is unavailable.
1. Connect a 50 A capacity test ammeter between the
positive (+) battery cable and the key switch.
2. Connect a voltmeter to the battery terminal (1) of the
alternator and to a ground source.
20098354 1
(A) Alternator
(B) Voltmeter
(C) Key switch
(D) Ammeter
(E) Battery
3. Observe the voltmeter. The meter should indicate bat-

tery voltage. If the voltmeter does not read battery volt-
age, the wiring between the alternator and the battery
may be faulty and should be repaired or replaced.
4. Use a jumper wire to short the test ammeter leads and
start the engine.
5. After the engine is started, remove the jumper wire be-
tween the test leads of the ammeter.
6. Increase the engine speed to approximately 2000 RPM
and observe the ammeter reading.
7. If the ammeter indicates 5 A or less, observe the volt-
meter reading. The voltmeter is indicating adjusting
voltage, which is the amount of increased voltage the
alternator supplies to the battery. The reading should
indicate a higher voltage than what is indicated when
voltage is taken at the battery. If the reading is not
higher, the alternator is not generating enough voltage
and a component may be malfunctioning.
8. If the ammeter indicated more than 5 A, continue to
charge the battery until the ammeter reading falls below
5 A. If the reading does not fall below 5 A, test the bat-
tery or replace the battery with one that is fully charged.
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SECT55C04PG10B 2
NOTE: Bench testing the alternator will achieve the best

results for the following tests (see alternator bench testing).
9. If the previous test was satisfactory, open the key
switch (OFF) and connect an ammeter between the
battery terminal (B) of the alternator and the battery
wire, as shown.
10. Connect the positive (+) lead of a voltmeter to the (B)
terminal on the alternator. Connect the negative (-)
lead to a suitable ground. Confirm that the voltmeter
indicated battery voltage.
11. Apply the parking brake and start the engine. Turn
on all 12 V powered accessories such as headlight
and indicator lights. Immediately raise engine speed
to 2000 RPM or more to record the maximum value
indicated on the ammeter.
12. If the amperage value is more than 70 % of the nomi-
nal alternator output, as described in alternator spec-
ifications, the alternator is considered to be working
satisfactorily.
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Alternator - Remove
1. Disconnect the negative (-) battery cable from the neg-
ative battery terminal.
2. Disconnect all wiring (2) from the rear of the alternator.
3. Loosen the alternator mounting bolts (1) and remove
the V-belt (3) from the alternator drive pulley.
4. Remove the alternator mounting bolts (1) and remove
the alternator from the engine.
SECT55C04PG9_2D 1
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Alternator - Disassemble
NOTICE: Heat from a soldering gun can damage diodes. To avoid damage to diodes, use a pair of needle-nose pliers
to remove excess heat from the area being soldered. Hold the pliers just below the solder joint to remove excess
heat. Use a damp cloth to cool the components once they have been joined or separated. Failure to comply could
damage diode.
SECT55C04P11_2 1
1. Alternator assembly 9. Rear rotor assembly

2. Pulley nut 10. Stator
3. Pulley assembly 11. Rear alternator frame assembly
4. Bolt 12. Terminal assembly
5. Front alternator frame assembly 13. IC Regulator assembly
6. Bolt 14. Rotor brush and spring
7. Front rotor bearing 15. Rectifier
8. Rotor assembly
1. Mark the front alternator frame (5) the rear alternator

frame (11) and the stator (10) with scribe marks to in-
sure that the alternator is assembled as taken apart.
2. Remove the alternator frame retaining bolts (4).
3. Carefully separate the front frame (2) and the rear
frame and stator (1). The rotor assembly (5) and the
pulley (3) , will be removed with the front frame (2).
SECT55C04PG12_1 2
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4. To remove the pulley nut (1) use an impact wrench or

place the rotor (3) into a soft jaw vice and use a wrench.
Remove the washer (6), the pulley (5), spacer (4) and
the front frame (2) from the rotor (3).
SECT55C04PG12_2 3
NOTICE: When removing the rear rotor bearing from the

rotor, be sure to apply even pressure to the rear rotor bear-
ing.
5. The rear rotor bearing (3) may be removed from the
rotor (1) by using a bearing puller (2).
SECT55C04PG12_3 4
6. Remove the screws (1) which secure the regulator/rec-

tifier assembly (2) to the rear alternator frame.
SEC55CH4PG13_1 5
7. Remove the battery terminal nut (1) from the rear of the
alternator frame.
8. Carefully remove the stator and the regulator/rectifier
assembly from the rear alternator frame.
SECT55C04PG13_2 6
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NOTICE: Heat from a soldering gun can damage diodes.

To avoid damage to diodes, use a pair of needle-nose pliers
to remove excess heat from the area being soldered. Hold
the pliers just below the solder joint to remove excess heat.
Use a damp cloth to cool the components once they have
been joined or separated. Failure to comply could damage
diode.
9. Unsolder the stator leads (2) and remove the stator (1)
from the rectifier/regulator assembly (3).
SEC55CH4PG13_3 7
10. Unsolder the IC regulator assembly (1) from the recti-

fier assembly (2) at the solder joints (3).
SEC55CH4PG14_1 8
11. Remove the screws (4) from the front alternator frame
(1). Remove the retaining plate (3) and the front rotor
bearing (2).
SECT55C04PG14_2 9
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Alternator - Electrical test - Stator

1. Use an ohmmeter and touch the ohmmeter test probes
to different leads of the stator coil.
2. Observe the ohmmeter. The ohmmeter should read a
resistance of less than 1 Ω for each of the phase wires,
indicating continuity.
3. If there is no continuity, inspect the lead wire connection
for breaks. The lead wire may be repaired with solder
if damage is not excessive. If the lead wire is good, the
stator coil is faulty and needs replaced.
SEC55CH4PG15_1 1
4. Use an ohmmeter and touch one of the ohmmeter test

probes to the stator coil and the other test probe to the
stator core.
5. Observe the ohmmeter. Resistance should be high,
indicating no continuity between the coil and the core.
If there is continuity, the stator is defective and needs
replaced.
SEC55CH4PG15_2 2
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Alternator - Electrical test - Rotor

1. Inspect the rotor brush contacts (1) for pitting, rough-
ness and dirt. If necessary use # 600 grit fine sandpa-
per to clean dirt off of the contacts. If the contacts are
pitted or damaged excessively, replace the rotor.
SEC55CH4PG16_1 1
2. Use a suitable measuring device to determine the outer

diameter of each brush contact. The minimum outer
diameter of the brush contacts is 22.1 mm (0.871 in).
SEC55CH4PG16_2 2
3. Use an ohmmeter and touch one ohmmeter test probe

to a brush contact. Touch the other test probe to the
remaining brush contact.
4. Observe the ohmmeter. The ohmmeter resistance
reading should be approximately 3 Ω. If the reading
is not as specified, the rotor is defective and needs
replaced.
SEC55CH4PG16_3 3
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NOTICE: When testing the resistance between the brush

contacts and rotor poles, be sure that the ohmmeter test
probe touching the rotor pole is not insulated by paint.
5. Use an ohmmeter and touch one ohmmeter test probe
to one of the rotor brush contacts (1) and the other test
probe to one of the rotor poles (2).
6. Observe the ohmmeter. Resistance should be high,
indicating no continuity between the rotor poles and
brush contacts. If there is continuity, the rotor is de-
fective and needs replaced.
SEC55CH4PG17_1 4
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Alternator - Inspect
Alternator brushes
SEC55CH4PG18_2 1
(1) New brush, (2) Used brush, and (3) Wear limit.
1. Carefully clean the alternator brushes with a soft, dry
cloth and electrical component cleaner, if available.
2. Inspect the brushes and brush springs for corrosion,
damage, stretched springs, or a damaged brush holder.
If damaged, replace the brush assembly.
3. Use a suitable measuring device to measure brush
wear. The minimum brush length is 5 mm (0.020 in).
If either brush is worn beyond specifications, replace
the brush assemblies.
Alternator bearings
4. Inspect the alternator bearings for smooth operation by
spinning the bearing. Replace bearings that are rough
and do not rotate smoothly.
5. Inspect the bearings for grease leakage between the
bearing seal (3) and races (1) and (2).
6. Inspect the inner race (2) and the outer race (1) for
signs of spinning in the alternator frame or on the rotor
shaft.
7. Replace bearings that are damaged in any way.
SEC55CH4P18_3 2
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Drive pulley
8. Inspect the drive pulley for a worn, bent, cracked, or
otherwise damaged belt groove (1).
9. A polished surface in the bottom of the belt groove in-
dicates a worn pulley.
SEC55CH4PG19_1 3
Alternator frames
10. Inspect the bearing housing bores (2) for scoring,
cracks or evidence that the bearing was spinning
inside the bore.
11. Inspect the frames for cracked or broken mounting
bosses (1) or any other distortion or damage.
SEC55CH4PG19_2 4
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Alternator - Assemble
NOTICE: When installing the rear rotor bearing, be sure that top sleeve used to press the bearing onto the rotor
contacts the inner race of the bearing only.
1. Install the rear rotor bearing (3) and spacer onto the
rotor by using a press (1) and sleeves, such as tubing
or 15 mm (0.6 in) deep sockets (2). The bottom sleeve
will support the rotor as the top sleeve presses the rear
bearing spacer onto the rotor.
SEC55CH4PG19_3 1
2. Install the front rotor bearing (3) and front bearing re-
taining plate (2) into the front alternator frame (4) and
secure using the four retaining screws (1).
SEC55CH4PG20_1 2
3. Install the washer (2), pulley (6), spacer (5) and front
frame (4) onto the rotor (3).
4. To install the pulley nut (1) use an impact wrench or
place the rotor (3) into a soft jaw vice and use a wrench
to tighten the pulley assembly to the rotor.
SEC55CH4PG20_2 3
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5. Use the following guidelines when soldering alternator

components.
• Clean all terminals to be soldered and remove ex-
cess solder.
• Preheat the soldering iron and use rosin-core solder
to solder terminals and/or wires. To avoid damage to
the rectifier diodes, use a pair of needle nose pliers
to remove excess heat from the area being soldered.
Hold the pliers just below the solder joint on the rec-
tifier to remove excess heat.
• Make good, solid, solder joints for best alternator
performance.
• After soldering, quickly cool the solder joint with a SEC55CH4PG21_1 4
damp cloth.
6. Solder the IC regulator (1) and rectifier (2) together.
SEC55CH4PG21_2 5
7. Solder the stator leads (1) to the terminals on the rec-

tifier/regulator assembly (2).
SEC55CH4PG21_3 6
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NOTICE: Secure the regulator/rectifier assembly to the

rear alternator frame before pressing the stator into the
rear frame.
8. Secure the regulator/rectifier assembly (2) the rear al-
ternator frame using the retaining screws (1). Manually
press the stator assembly into the rear alternator frame.
SEC55CH4P13_1 7
9. Install the battery terminal nut (1) to the rear of the

alternator frame.
SECT55C04P13_2 8
10. Push the brushes (1) and springs (2) to the brush
holder and insert a piece of wire (3) through the rear of
the alternator frame and into the brush holder to hold
the brushes out of the way while the alternator halves
are being assembled.
SEC55CH4PG22_3 9
11. Assemble the front alternator frame (2) and rear alter-
nator frame (1) together. Be sure to align the scribe
marks made when the alternator was disassembled to
insure proper reassembly. Use the bolts (3) to secure
the front and rear frames together.
SECT55C04P12_1 10
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Alternator - Electrical test - Bench check
SEC55CH4PG23_2 1
(1) Voltmeter (4) Load resistor

(2) Ammeter (5) Battery
(3) Switch (6) Alternator
1. Connect the alternator to a testing circuit, as shown.

Set the load resistance to zero
NOTICE: Alternator rotation direction is clockwise, as
viewed looking at the pulley.
2. Slowly increase the alternator rotational speed and ob-
serve the voltage reading indicated on the voltmeter.
3. If the voltage is uncontrolled when increasing alternator
speed and increases above 15.5 V, disassemble and
check the alternator for malfunctioning components.
4. If the voltage reading is below 15.5 V, set alternator's
rotational speed to 5000 RPM and set the load resis-
tance to achieve maximum output from the alternator.
5. If the amperage value is more than 70 % of the nomi-
nal alternator output as described in alternator specifi-
cations, the alternator is considered to be working sat-
isfactorily.
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Alternator - Install
1. Align the alternator with the alternator mounting holes
located on the engine block and brackets. Use the
adjusting/mounting bolts (1) to secure the alternator to
the mounting brackets. Be sure to install the v-belt (3)
into the drive pulley.
2. Connect all wire terminals (2) rear of the alternator.
SECT55C04P9_2 1
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Index
Alternator - 301
Alternator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alternator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternator - Electrical test - Bench check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alternator - Electrical test - Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Alternator - Electrical test - Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Alternator - Preliminary test - Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cold start aid - 202

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
FUNCTIONAL DATA
Cold start aid

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Glow plug system

Cold start aid - Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cold start aid - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cold start aid - Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Cold start aid
Cold start aid - Overview
NHIL12ENG0173AA 1
A glow plug typically comprises a heating coil in a metal tube closed at one end and filled with electrically insulating
ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head
into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface
temperature of more than 1000°C within a few seconds. The air-fuel spray generated by the injection ignites close to
the glow plug and initiates combustion.
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Cold start aid - Remove - Glow plug

1. Disconnect the negative battery cable from the battery.
2. Loosen the screw terminals on each glow plug (2).
3. Remove the power supply (3) from the terminal.
4. Remove the glow plug connector bar (1).
NHIL12ENG0222AA 1
5. Remove glow plugs (1).
NHIL12ENG0220AA 2
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Cold start aid - Test

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
1. Clean the carbon from the sheath end of the glow plug.
NOTE: Do not test resistance using the glow plug sheath.
2. Use an ohmmeter and touch one test probe to the glow
plug electrode.
3. Touch the other test probe to the glow plug body.
4. A resistance reading of 1 Ω is normal for the standard
glow plug. If the resistance is too high, the glow plug is
NHIL13ENG0027AA 1
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Cold start aid - Install - Glow plug

1. Install the glow plugs (1) and torque to 15 - 20 N·m (11
- 14.5 lb ft).
NHIL12ENG0221AA 1
2. Attach the glow plug connector bar (1) to the screw

terminals on the glow plugs.
3. Attach the power supply (3) to the screw terminal.
4. Tighten the screw terminals (2) on the glow plugs until
the connector is tight on all glow plugs.
5. Connect the negative battery cable to the battery.
NHIL12ENG0222AA 2
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Index

Cold start aid - Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cold start aid - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cold start aid - Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cold start aid - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
SERVICE

Electrical test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel shutoff solenoid
Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Fuel injection system
Fuel injection system - Electrical test

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Check the Suction Control Valve (SCV).

• Use the Service Tool D to check the following param-
eters. See Electrical system Computer support
tools - Overview Data Monitoring Screen (55.000)
for how to set up data monitoring.
• Target Rail Pressure
• Actual Rail Pressure
• Target SCV Current
• Pump Learning Condition
• Pump Difference Learning Correction Value
2. Start the engine, and allow it to warm up.
3. Change the accelerator, and monitor the graph.
• Target SCV Current
• Actual SCV Current
• (A) Accelerator ON.
• (B) Accelerator OFF.
NHIL13ENG0088AA 1
Engine Condition Value

Engine idling at 1,000 RPM. 1700 - 1900 mA
Accelerator to 100 %. 1100 - 2500 mA
The "Pump Difference Learning Correction Value" is +/-

450 mA or less.
When monitoring the graph the "Target Rail Pres-
sure" and "Actual Rail Pressure" will drop 100 bar
(1450.0 psi) or less within 20 s if:
• The accelerator is depressed and the position
abruptly goes from 0 - 100 %.
• The accelerator position abruptly returns to 0 %
while driving. (Clutch is engaged to create a state
of non injection.)
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Fuel shutoff solenoid - Inspect – Linear solenoid and rack position

sensor
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The linear solenoid is a device controlled by the Engine

Control Unit (ECU), a variety of plunger positions may de-
termine the engine speed. The plunger position also as-
sists with engine start up or shut down.
1. Remove the linear solenoid.
• Check the body of the solenoid for damage.
• Check for damage to the wiring harness and connec-
tor.
If there is visible damage, repair or replace as needed.
NHIL13ENG0195AA 1
2. Disconnect the linear solenoid connection (1).

3. Test the solenoid from pin 1 to pin 2.
Temperature (Degrees) Resistance (ohms)

20 °C (68 °F) 3.7 - 4.1 Ω
If the resistance is incorrect, replace the solenoid. See

Electrical system Computer support tools - Overview
— Engine configuration parameters (55.000) to calibrate
the new component.
4. Test the position sensor.
• Leave the position sensor (2) connected to the wiring
harness.
• Press the plunger into the solenoid body.
• Monitor the voltage output on the diagnostic screen.
• The range should be between 1.0 - 4.0 V.
If the range is incorrect, replace the sensor. See Electrical
system Computer support tools - Overview — Engine
configuration parameters (55.000) to calibrate the new
component.
Fuel solenoid electrical wiring/connection specification:
Connector pin Value

Pin 1 Ground
Pin 2 12.0 V
Rack position sensor electrical wiring/connection specifica-

tion:
Connector pin Value

Pin 1 (B) 5.0 V reference
Pin 2 (A) Ground
Pin 3 (C) Signal output 1.0 - 4.0 V
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Fuel shutoff solenoid - Inspect – Linear solenoid and rack position

sensor
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The linear solenoid is a device controlled by the Engine

Control Unit (ECU), a variety of plunger positions may de-
termine the engine speed. The plunger position also as-
sists with engine start up or shut down.
1. Remove the linear solenoid.
• Check the body of the solenoid for damage.
• Check for damage to the wiring harness and connec-
tor.
If there is visible damage, repair or replace as needed.
NHIL13ENG0195AA 1
2. Disconnect the linear solenoid connection (1).

3. Test the solenoid from pin 1 to pin 2.
Temperature (Degrees) Resistance (ohms)

20 °C (68 °F) 3.7 - 4.1 Ω
If the resistance is incorrect, replace the solenoid. See

Electrical system Computer support tools - Configure
- Fuel pump actuator (55.000) to calibrate the new com-
ponent.
4. Test the position sensor.
• Leave the position sensor (2) connected to the wiring
harness.
• Press the plunger into the solenoid body.
• Monitor the voltage output on the diagnostic screen.
• The range should be between 1.0 - 4.0 V.
If the range is incorrect, replace the sensor. See Electri-
cal system Computer support tools - Configure - Fuel
pump actuator (55.000) to calibrate the new component.
Fuel solenoid electrical wiring/connection specification:
Connector pin Value

Pin 1 Ground
Pin 2 12.0 V
Rack position sensor electrical wiring/connection specifica-

tion:
Connector pin Value

Pin 1 (B) 5.0 V reference
Pin 2 (A) Ground
Pin 3 (C) Signal output 1.0 - 4.0 V
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Index

Fuel injection system - Electrical test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine intake and exhaust system - 014

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
FUNCTIONAL DATA
Throttle Valve Actuator (TVA)

SERVICE
Boost pressure sensor

Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Throttle Valve Actuator (TVA)
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical test - Intake throttle system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inlet air temperature sensor
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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CONSUMABLES INDEX

Loctite® ODC-Free Cleaner Throttle Valve Actuator 55.7 / 8
and Degreaser
47632293 16/09/2014
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Electrical systems - Engine intake and exhaust system
Throttle Valve Actuator (TVA) - Dynamic description

N4LDI-TA-45SL
N4LDI-TA-50SL
The throttle valve assembly controls the throttle opening position according to engine condition, water temperature
and barometric pressure, which supplies the set amount of air in the combustion chamber. It is used to reduce and
control the emission gases and may rise the exhaust gas temperature at low idle speeds to activate the Diesel Oxi-
dation Catalyst (DOC) function.
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Boost pressure sensor - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The boost pressure sensor measures the induction of pres-

sure in the intake system.
1. Check the wiring harness to the boost pressure sensor.
as needed.
NHIL13ENG0165AA 1
Boost pressure sensor electrical wiring/connection specifi-

cation:
Connector pin Value

Pin 1 5.0 V
Pin 2 Ground
Pin 3 Signal
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Throttle Valve Actuator (TVA) - Remove

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Disconnect the electrical connection from the Throttle

Valve Assembly (TVA).
2. Remove the four retaining bolts (1).
3. Remove the TVA (2) and gasket (3) from the intake
manifold.
NOTICE: The throttle valve is very delicate. Do not drop,
shock, damage or get wet.
NOTICE: Do not dismantle the throttle valve and stop
screw.
NHIL13ENG0052AA 1
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Throttle Valve Actuator (TVA) - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
Prior operation:
Throttle Valve Actuator (TVA) - Remove (55.014)
1. Visually check the intake valve.

• Check for debris build up.
• Check the valve (flap) is not seized.
• See Throttle Valve Actuator (TVA) - Cleaning
(55.014). If the valve is seized and can not be
cleaned, replace the intake throttle valve.
NHIL12ENG0144AA 1
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Throttle Valve Actuator (TVA) - Cleaning

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: When cleaning the intake valve do not spray the valve directly with any kind of a chemical cleaner.
1. Spray LOCTITE® ODC-FREE CLEANER AND DEGREASER
or equivalent onto a cloth.
2. Wipe the intake valve clean.
3. If the intake valve can not be cleaned, or the valve (flap)
is seized, replace the intake throttle valve.
NHIL12ENG0144AA 1
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Throttle Valve Actuator (TVA) - Install

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTICE: The throttle valve is very delicate. Do not drop, shock, damage or sprinkle water.
2. Install the Throttle Valve Actuator (TVA) (2) and secure
with the four retaining bolts (1).
3. Torque retaining bolts (1) to 10 - 13 N·m (7.4 - 10 lb ft).
4. Connect the electrical connection.
NHIL13ENG0052AA 1
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Throttle Valve Actuator (TVA) - Electrical test - Intake throttle system

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: ETC = Electronic Throttle Control

1. Verify the intake throttle system status
• Target Idle Speed or Accelerator Angle
• Engine Speed
• Target Intake Throttle Position
• Actual Intake Throttle Position
• Intake Throttle Position Sensor Output Voltage
• (1) Key switch On and engine OFF. “Intake Throttle
Position” is at - 8 %.
• (2) Engine running. “Intake Throttle Position” is at
0 %.
• (3) Engine start up.
• (4) Accelerator OPEN.
• (5) Accelerator CLOSE.
• (6) Key switch OFF.
• (7) Engine stopped.
NHIL13ENG0090AA 1
4. Use the Service Tool D to observe the waveform for

intake throttle valve motor terminals B57 and B44.
• The graph should look like this when monitoring con-
nector X-002B pin 44 (ETC-) accelerator fully closed
(idling).
NHIL13ENG0091AA 2
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The graph should look like this when monitoring connector

X-002B pin 57 (ETC+) and connector X-002B pin 44 (ETC-)
accelerator at 2800 RPM.
NHIL13ENG0094AA 3

X-002B pin 57 (ETC+) accelerator fully open.
NHIL13ENG0092AA 4
5. Run the active test “Intake Throttle Check Function”.

See Electrical system Computer support tools -
Overview — Active Test (55.000).
• (A) Target Intake Throttle Position
• (B) Actual Intake Throttle Position
• (C) Intake Throttle Position Sensor Output Voltage
NHIL13ENG0093AA 5
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Inlet air temperature sensor - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Measure the resistance of the inlet air temperature sen-

sor from pin 1 to pin 2.
NHIL13ENG0180AA 1
Temperature Voltage output

0 °C (32 °F) 5.74 Ω
20 °C (68.0 °F) 2.54 Ω
40 °C (104.0 °F) 1.15 Ω
60 °C (140.0 °F) 0.58 Ω
80 °C (176.0 °F) 0.31 Ω
Tightening torque: 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)
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Index

Boost pressure sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inlet air temperature sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Throttle Valve Actuator (TVA) - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Throttle Valve Actuator (TVA) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Throttle Valve Actuator (TVA) - Electrical test - Intake throttle system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Throttle Valve Actuator (TVA) - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Throttle Valve Actuator (TVA) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Throttle Valve Actuator (TVA) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Exhaust Gas Recirculation (EGR) electrical system - 989

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
47632293 16/09/2014
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Contents
SERVICE
Exhaust Gas Recirculation (EGR) electrical system

Electrical test - EGR system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust Gas Recirculation (EGR) temperature sensors
Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspect - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspect - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 27
Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 28
Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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CONSUMABLES INDEX

Loctite® ODC-Free Cleaner Exhaust Gas Recirculation 55.8 / 7
and Degreaser
47632293 16/09/2014
55.8 [55.989] / 3
Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) electrical system - Electrical test

- EGR system
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Verify the Exhaust Gas Recirculation (EGR) system

status
• Target Idle Speed or Accelerator Angle
• Engine Speed
• Target EGR Position
• Actual EGR Position
• EGR Position Sensor Output Voltage
• (A) Target Idle Speed
• (B) Engine Speed
• (C) see graph 2 below.
NHIL13ENG0098AA 1
Detailed graph for:

• Target EGR Position
• Actual EGR Position
• EGR Position Sensor Output Voltage
NHIL13ENG0095AA 2
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4. Use the Service Tool D to observe the waveform for

EGR motor connector X-002B pin 58 and pin 45.
• The graph should look like this when monitoring con-
nector X-002B pin 58 (EGR+) accelerator fully open.
NHIL13ENG0099AA 3

X-002B pin 45 (EGR-) accelerator closed, at idle.
NHIL13ENG0100AA 4

X-002B pin 45 (EGR-) accelerator at 2800 RPM.
NHIL13ENG0096AA 5
5. Run the EGR active test “EGR Check Function”.

• (A) Target EGR Position
• (B) Actual EGR Position
• (C) EGR Position Sensor Output Voltage
NHIL13ENG0101AA 6
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Exhaust Gas Recirculation (EGR) electrical system - Inspect

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Remove the Exhaust Gas Recirculation EGR) valve

pipe.
2. Remove the electrical connection.
NHIL12ENG0151AA 1
3. Remove the valve.
NHIL13ENG0068AB 2
4. Visually check the EGR valve.

• Check for debris build up.
• Check the valve (flap) is not seized.
• See Exhaust Gas Recirculation (EGR) electrical
system - Cleaning (55.989). If the valve is seized
and can not be cleaned, replace the EGR valve.
NHIL12ENG0154AA 3
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Exhaust Gas Recirculation (EGR) electrical system - Cleaning

N4LDI-TA-45SL
N4LDI-TA-50SL
NOTE: When cleaning the Exhaust Gas Recirculation (EGR) valve do not spray the valve directly with any kind of a
chemical cleaner.
1. Spray LOCTITE® ODC-FREE CLEANER AND DEGREASER
onto a cloth.
2. Wipe the EGR valve clean.
3. If the EGR valve can not be cleaned, or the valve (flap)
is seized, replace the EGR valve.
4. Erase the fault codes.
5. Use Service Tool D to conduct the “EGR Maintenance
Time ½ Initialization”. See Electrical system Com-
puter support tools - Overview — Utility (55.000).
6. Use Service Tool D to conduct the “EGR Default Learn-
ing Value Initialization”. See Electrical system Com-
puter support tools - Overview — Utility (55.000).
NHIL12ENG0154AA 1
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Exhaust Gas Recirculation (EGR) electrical system - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The Exhaust Gas Recirculation (EGR) valve recirculates a

portion of exhaust gas to the induction port. This process
effectively burns the recirculated gas and fuel mixture in
the combustion chamber, which reduces the temperature
and Nox as well.
1. Remove and then inspect the EGR valve.
2. Check and clean the following items every 1500 h.
• EGR valve (1)
• EGR cooler (2)
• Piping for EGR (3)
• Intake manifold (4)
NHVM13ENG0197AA 1
3. Active test.
drop down menu.
• Select “EGR Actuator Control Command”.
menu.
If there is a clicking sound and the test is OK, the valve is
good. If the test fails, replace the EGR valve.
4. Measure the EGR valve electrical resistance.
• Test the solenoid from pin 1 to pin 2.
• The resistance should be approximately 7.9 - 8.7 Ω
at 20.0 °C (68.0 °F).
• EGR valve (1) shown.
If the resistance is incorrect, replace the EGR valve.
NHIL13ENG0169AA 2
EGR valve electrical wiring/connection specification:
Connector pin Value

Pin 1 12.0 V
Pin 2 Ground
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Exhaust Gas Recirculation (EGR) temperature sensors - Remove -

Diesel Oxidation Catalyst (DOC) Inlet temperature sensor
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Disconnect the wire harness connector (2).

2. Remove the temperature sensor (1) by turning counter-
clockwise.
NOTICE: Mark the position of the wire harness. If wires
are not routed correctly, wire damage may occur.
NHIL13ENG0012AA 1
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Exhaust Gas Recirculation (EGR) temperature sensors - Inspect -

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Use a multimeter to inspect the resistance of the inlet

sensor (1). If the resistance is not within range, replace
the sensor.
NHIL13ENG0012AA 1
Temperature (Degrees) Resistance (Ohms)

200 °C (392 °F) 4.0 kΩ +/- 15 %
650 °C (1202 °F) 164.8 Ω +/- 5 %
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Exhaust Gas Recirculation (EGR) temperature sensors - Install -

N4LDI-TA-45SL
N4LDI-TA-50SL
1. Apply a high temp anti seize compound such as LOC-

TITE® 8150™ or equivalent to the threads of the sen-
sor.
2. Install the sensor (1) into the Diesel Oxidation Catalyst
(DOC).
3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).
4. Connect the wire connector (2) to the wire harness.
NOTICE: Ensure the wiring is routed properly in the engine
bay to avoid damage.
NHIL13ENG0012AA 1
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Diesel Oxidation Catalyst (DOC) Outlet temperature sensor
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Disconnect the wire harness connector (2).

clockwise.
NHIL13ENG0012AA 1
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N4LDI-TA-45SL
N4LDI-TA-50SL
1. Use a multimeter to inspect the resistance of the sensor

(1). If the resistance is not within range, replace the
sensor.
NHIL13ENG0012AA 1

200 °C (392 °F) 4.0 kΩ +/- 15 %
650 °C (1202 °F) 164.8 Ω +/- 5 %
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N4LDI-TA-45SL
N4LDI-TA-50SL

sor.
(DOC).
4. Connect the wire connector (2) to the wire harness.
NHIL13ENG0012AA 1
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Diesel Oxidation Catalyst (DOC) Differential pressure sensor
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Disconnect the wire harness connector.

2. Remove the hose clamps (2).
3. Carefully remove the hoses.
4. Remove retaining bolts from the sensor and remove
sensor (1).
NOTICE: Take care when removing the hoses from the
sensor connections, they are fragile.
NHIL13ENG0012AA 1
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Exhaust Gas Recirculation (EGR) temperature sensors - Inspect –

N4LDI-TA-45SL
N4LDI-TA-50SL

nections.
NHIL13ENG0012AA 1
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N4LDI-TA-45SL
N4LDI-TA-50SL
1. Install the retaining bolts to secure the sensor (1).

2. Carefully install the hoses and secure with hose clamps
(2).
NOTICE: Take care when installing the hoses to the sensor
connections, they are fragile.
3. Connect the wire harness connector.
NHIL13ENG0012AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Disconnect the wire harness connector (not shown).

clockwise.
NHIL13ENG0168AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sensor.
NHIL13ENG0168AA 1

200 °C (392 °F) 4.0 kΩ +/- 15 %
650 °C (1202 °F) 164.8 Ω +/- 5 %
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sor.
(DOC).
4. Connect the sensor wire connector to the wire harness.
NHIL13ENG0168AA 1
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Diesel Particulate Filter (DPF) Inlet temperature sensor
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

clockwise.
NHIL13ENG0168AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sensor.
NHIL13ENG0168AA 1

200 °C (392 °F) 4.0 kΩ +/- 15 %
650 °C (1202 °F) 164.8 Ω +/- 5 %
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sor.
(DOC).
NHIL13ENG0168AA 1
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Diesel Particulate Filter (DPF) Outlet temperature sensor
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

clockwise.
NHIL13ENG0168AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sensor.
NHIL13ENG0168AA 1

200 °C (392 °F) 4.0 kΩ +/- 15 %
650 °C (1202 °F) 164.8 Ω +/- 5 %
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

sor.
(DOC).
NHIL13ENG0168AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Disconnect the wire harness connector.

2. Remove the hose clamps.
3. Carefully remove the hoses (1).
4. Remove retaining bolts from the sensor and remove
sensor (2).
NOTICE: Take care when removing the hoses from the
sensor connections, they are fragile.
NHIL13ENG0168AA 1
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Exhaust Gas Recirculation (EGR) temperature sensors - Inspect –

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

nections.
NHIL13ENG0168AA 1
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N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Install the retaining bolts to secure the sensor (1).

2. Carefully install the hoses (1) and secure with hose
clamps.
NOTICE: Take care when installing the hoses to the sensor
connections, they are fragile.
3. Connect the wire harness connector.
NHIL13ENG0168AA 1
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Index

Exhaust Gas Recirculation (EGR) electrical system - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust Gas Recirculation (EGR) electrical system - Electrical test - EGR system (*) . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust Gas Recirculation (EGR) electrical system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust Gas Recirculation (EGR) electrical system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Inlet tempera-
ture sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Inlet tempera-
ture sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Outlet temper-
ature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Particulate Filter (DPF) Inlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Particulate Filter (DPF) Outlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential
pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential
pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Differential pres-
sure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Differential pres-
sure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Inlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Inlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Outlet tempera-
ture sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Particulate Filter (DPF) Inlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Particulate Filter (DPF) Outlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Differential
pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Differential
pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Inlet temper-
ature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Inlet temper-
ature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Outlet tem-
perature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Particulate Filter (DPF) Inlet temperature
sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Particulate Filter (DPF) Outlet tempera-
ture sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
SERVICE
Engine coolant temperature sensor

Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine cooling system
Engine coolant temperature sensor - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
1. Measure the resistance of the coolant temperature sen-

sor from pin 1 to pin 2.
NHIL13ENG0180AA 1
Temperature Voltage output

0 °C (32 °F) 5.74 Ω
20 °C (68.0 °F) 2.54 Ω
40 °C (104.0 °F) 1.15 Ω
60 °C (140.0 °F) 0.58 Ω
80 °C (176.0 °F) 0.31 Ω
Tightening torque: 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)
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Index

Engine coolant temperature sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine oil system - 013

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
FUNCTIONAL DATA
Engine oil pressure sensor and switch

Dynamic description - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine oil pressure sensor and switch

Remove – Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect – Pressure switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Engine oil system
Engine oil pressure sensor and switch - Dynamic description

- Pressure switch
The oil pressure switch is located on top of the cylinder head. The engine oil pressure switch closes (circuit completed)
when engine oil pressure is less than 27.6 kPa (4.0 psi). This illuminates the indicator light on the instrument panel.
The engine oil pressure switch is closed before the engine is started. If the switch does not work after the engine is
started, the oil level inside the engine may be low or there may be a problem with the oil pump.
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Engine oil pressure sensor and switch - Remove – Pressure switch

1. Disconnect the wire.
2. Remove the oil pressure switch (1) from the cylinder
head.
NHIL12ENG0224AA 1
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Engine oil pressure sensor and switch - Install - Pressure switch

1. Install the oil pressure switch (1) into the cylinder head.
2. Torque the pressure switch to 14.7 - 19.6 N·m (10.8 -
14 lb ft).
3. Connect the wire.
NHIL12ENG0224AA 1
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Engine oil pressure sensor and switch - Inspect – Pressure switch

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
NOTE: See Oil pressure valve - Dynamic description — Pressure switch (10.304) for pressure switch description.
NOTE: See Engine lubrication system - Pressure test — Engine oil (10.304) for lubrication system pressure test.
1. Inspect the wiring harness to the oil pressure switch.
as needed.
2. Measure the resistance of the switch.
• Use a multimeter to check for continuity from the oil
pressure switch pin 1 to pin 2.
• There should be continuity.
• If there is no continuity, the switch has failed. Re-
place the switch.
NHIL13ENG0175AA 1
Oil pressure switch electrical wiring/connection specifica-

tion:
Connector pin Value

Pin 1 12.0 V
Pin 2 Ground
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Index

Engine oil pressure sensor and switch - Dynamic description - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure sensor and switch - Inspect – Pressure switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pressure sensor and switch - Install - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pressure sensor and switch - Remove – Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electronic modules - 640

N844L-F-34 , N844L-F-36SL , N844LT-F-45SL
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Contents
SERVICE
Electronic module
Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Electronic modules
Electronic module - Electrical test Engine Control Unit (ECU)

verification
N4LDI-TA-45SL
N4LDI-TA-50SL
1. Locate the Engine Control Unit (ECU).

• Disconnect the harness from the ECU.
Place the key switch ON.
2. Use a multimeter to check the power supply and ground
reference circuits.
• ECU harness connector X-002B pin 47 to connector
X-002B pin 3.
X-002B pin 4.
X-002B pin 31.
X-002B pin 1.
X-002B pin 2.
X-002B pin 18.
The multimeter should read between 8 - 18 V.
A. If any of the readings are incorrect, continue with
3.
B. If the readings are correct continue with 5.
3. Check the power supply circuits of the Engine Control
Unit (ECU) at the engine harness connector.
Use a multi-meter to measure the voltage from the har-
ness side of:
• ECU harness connector X-002B pin 47 to chassis
ground.
ground.
ground.
ground.
ground.
A. If any of the readings are incorrect. Repair or re-
place the circuit to the ECU connector.
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4. Check the ground circuits of the Engine Control Unit

(ECU) at the engine harness connector.
Place the key switch OFF.
Use a multi-meter to check for continuity from the har-
ness side of:
ground.
ground.
ground.
ground.
ground.
ground.
There should be continuity.
5. Use the Service Tool D to check the software level.
• If the incorrect software level is installed. Install the
correct software level. Test the system for proper
operation.
• If the correct software level is installed, replace the
ECU. Install the current software level. Test the sys-
tem to verify repairs.
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Electronic module - Inspect

N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL
The Engine Control Unit (ECU) monitors and control vari-

ous components within the engine bay.
1. Always make sure the electrical connections are se-
cure and tight. Loose connections can cause problems.
2. The ECU contains an internal atmospheric pressure
sensor and is very delicate. Please handle with care.
3. Do not block the vent (1).
NHIL13ENG0200AA 1
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verification
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

2. Use a multi-meter to measure the voltage from the har-
ness side of:
• ECU harness connector X-002 pin 1 to connector
X-002 pin 20.
X-002 pin 39.
X-002 pin 39.
X-002 pin 80.
X-002 pin 79.
X-002 pin 60.
X-002 pin 59.
X-002 pin 59.
X-002 pin 59.
X-002 pin 59.
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3.
ness side of:
• ECU harness connector X-002 pin 1 to chassis
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
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ness side of:
ground.
ground.
ground (EH units only).
ground (Mechanical units only).
ground.
ground.
ground.
ground.
5. Use the Service Tool I to check the software level.
operation.
NOTE: For mechanical unit schematic, see Wiring harnesses - Electrical schematic sheet 10 Engine ISM IDI -
Mechanical Units (55.100).
NOTE: For EH unit schematic, see Wiring harnesses - Electrical schematic sheet 06 Engine ISM - EH Units
(55.100).
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verification
N843LT-F-27
N843T-F-24
N844L-F-30
N844L-F-34
N844L-F-36SL
N844LT-F-45SL

2. Use a multi-meter to measure the voltage from the har-
ness side of:
X-9100 pin 20.
X-9100 pin 39.
X-9100 pin 39.
X-9100 pin 80.
X-9100 pin 79.
X-9100 pin 60.
X-9100 pin 59.
X-9100 pin 59.
X-9100 pin 59.
X-9100 pin 59.
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3.
ness side of:
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
ground.
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ness side of:
ground.
ground.
ground (where populated).
ground (where populated).
ground.
ground.
ground.
ground.
5. Use the Service Tool I to check the software level.
operation.
NOTE: For schematic, see Wiring harnesses - Electrical schematic sheet 04 – Engine Control Unit (ECU) –
machine connector (55.100).
47632293 16/09/2014
55.11 [55.640] / 11
Index

Electronic module - Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic module - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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55.11 [55.640] / 13
17557
PRINTED IN U.S.A.
47632293 16/09/2014
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

FNH00120 [Oil Pump Port Engine - Compression test 10.1 / 16
Block Installer Adapter]
FNH00120 [Oil Pump Port Engine - Compression test 10.1 / 17
Block Installer Adapter]
OEM Reference PAGE
OEM1074 [Compression Engine - Compression test 10.1 / 16
Gauge]
OEM1074 [Compression Engine - Compression test 10.1 / 17
Gauge]
47632293 16/09/2014
17557
PRINTED IN U.S.A.
47632293 16/09/2014
EN

Service Manual Engine Case

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N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 ,

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

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

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

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

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

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

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

[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

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

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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

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

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

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

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

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

[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

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

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

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

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

Foreword - Ecology and the environment

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

Basic instructions - Important notice regarding equipment servicing

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

Basic instructions - Shop and assembly

Rotating shaft seals

Protecting the electrical/electronic systems during charging or welding

To avoid damage to the electronic/electrical systems, always observe the following:

By using these tools, repair personnel will benefit from:

Torque - Minimum tightening torques for normal assembly

METRIC FLANGED HARDWARE

Metric Hex head and carriage bolts, classes 5.6 and up

Metric Hex nuts and locknuts, classes 05 and up

INCH NON-FLANGED HARDWARE

INCH FLANGED HARDWARE

Inch Bolts and free-spinning nuts

SAE Grade Identification

Inch Lock Nuts, All Metal (Three optional methods)

Consumable Reference PAGE

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 ,

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

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

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

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

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

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

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

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

[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

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

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

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

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16