Professional Documents
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MaxxForce 3.2H
Proconve P7 - EV
SERVICE MANUAL
SERVICE MANUAL
MaxxForce® 3.2H
Euro V
Model Year 2012 and Up
932H00602001
Euro V
MaxxForce® 3.2H
Model Year 2012 and Up
932H00602001
932H00602001
05/2012
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
ENGINE SERVICE MANUAL I
Table of Contents
Foreword.................................................................................................................................................................1
Service Diagnosis....................................................................................................................................................2
Safety Information...................................................................................................................................................3
Presentation............................................................................................................................................................5
Technical Data.......................................................................................................................................................17
Engine Block.........................................................................................................................................................69
Crankshaft.............................................................................................................................................................77
Lubrication System..............................................................................................................................................189
Cooling System...................................................................................................................................................211
Troubleshooting...................................................................................................................................................245
Appendix A .........................................................................................................................................................271
Appendix B..........................................................................................................................................................321
Appendix C..........................................................................................................................................................323
932H00602001
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ENGINE SERVICE MANUAL 1
NOTE: Photo illustrations identify specific parts or Technical Service Literature is revised periodically and
assemblies that support text and procedures; other mailed automatically to “Revision Service” subscribers.
areas in a photo illustration may not be exact. If a technical publication is ordered, the latest revision
will be supplied.
See vehicle manuals and Technical Service Information
(TSI) bulletins for additional information. NOTE: To order technical service literature, contact
your MaxxForce® dealer.
All marks are trademarks of their respective owners.
932H00602001
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© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
2 ENGINE SERVICE MANUAL
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
ENGINE SERVICE MANUAL 3
This manual provides general and specific maintenance • Wear protective safety glasses and shoes.
procedures essential for reliable engine operation and
• Wear correct hearing protection.
your safety. Since many variations in procedures, tools,
and service parts are involved, advice for all possible • Wear cotton work clothing.
safety conditions and hazards cannot be stated. • Wear sleeved heat protective gloves.
Read safety instructions before doing any service and • Do not wear rings, watches or other jewelry.
test procedures for the engine or vehicle. See related
application manuals for more information. • Restrain long hair..
Disregard for Safety Instructions, Warnings, Cautions,
and Notes in this manual can lead to injury, death or Vehicle
damage to the engine or vehicle. • Make sure the vehicle is in neutral, the parking
brake is set, and the wheels are blocked before
Safety Terminology servicing engine.
Four terms are used to stress your safety and safe • Clear the area before starting the engine.
operation of the engine: Warning, Caution, Attention
and Note. Engine
Warning: A warning describes actions necessary to • The engine should be operated or serviced only
prevent or eliminate conditions, hazards, and unsafe by qualified individuals.
practices that can cause personal injury or death. • Provide necessary ventilation when operating
engine in a closed area.
Caution: A caution describes actions necessary to
prevent or eliminate conditions that can cause damage • Keep combustible material away from engine
to the engine or vehicle. exhaust system and exhaust manifolds.
• Install all shields, guards, and access covers
Attention:An attention describes actions that require before operating engine.
a careful procedure necessary for correct and efficient
engine operation. • Do not run engine with unprotected air inlets or
exhaust openings. If unavoidable for service
NOTE: A note contains helpful information to reasons, put protective screens over all openings
determinate procedures or specifications. before servicing engine.
• Shut engine off and relieve all pressure in the
Safety Instructions system before removing panels, housing covers,
Work Área and caps.
• If an engine is not safe to operate, tag the engine
• Keep work area clean, dry and organized.
and ignition key.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit. Fire Prevention
• Make sure a First Aid Kit is available. • Make sure charged fire extinguishers are in the
work area.
Safety Equipment
NOTE: Check the classification of each fire
• Use correct lifting devices. extinguisher to ensure that the following fire types can
be extinguished.
• Use safety blocks and stands.
1. Type A — Wood, paper, textiles, and rubbish.
2. Type B — Flammable liquids.
3. Type C — Electrical equipment.
932H00602001
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4 ENGINE SERVICE MANUAL
• Always disconnect the main negative battery • Use extreme caution when working on systems
cable first. under pressure.
• Always connect the main negative battery cable • Follow approved procedures only.
last.
• Avoid leaning over batteries. Fuel
• Protect your eyes. • Do not over fill the fuel tank. Over fill creates a fire
hazard.
• Do not expose batteries to open flames or
sparks. • Do not smoke in the work area.
• Do not smoke in workplace. • Do not refuel the tank when the engine is running.
• Make sure all tools are in good condition. • Reinstall all safety guards, shields, and covers
after servicing the engine.
• Make sure all standard electrical tools are
grounded. • Make sure all tools, parts, and service equipment
are removed from the engine and vehicle after all
• Check for frayed power cords before using
work is done.
power tools.
932H00602001
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© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
PRESENTATION 5
Table of Contents
Introduction..............................................................................................................................................................6
Manual Content..................................................................................................................................................6
Section Content..................................................................................................................................................6
General Instructions................................................................................................................................................7
No. of Cylinders.....................................................................................................................................................10
Engine Accessories...............................................................................................................................................10
Alternador.........................................................................................................................................................10
Turbocharger....................................................................................................................................................12
Garrett Turbocharger...................................................................................................................................12
Starter Motor....................................................................................................................................................14
Injector Nozzle..................................................................................................................................................16
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6 PRESENTATION
Should any difference between this manual and the • General information about the component
engine appear, please contact an authorized MWM operation and an explanation of their main
INTERNATIONAL dealer or the manufacturer itself. changes.
The components used in the manufacture of MWM • Instructions of component disassembly, cleaning,
INTERNATIONAL engines are of the highest, last inspection and dimensions.
technology generation and a high level of quality.
When replacements parts are needed, use only Information on Metric System
genuine MWM INTERNATIONAL replacement parts. All dimensions are according to the International
Metric System (I.S.).
932H00602001
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PRESENTATION 7
932H00602001
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© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
8 PRESENTATION
Engine Serial Number Identification 1. On engine’s identification plate (left side of engine
block, viewed by the flywheel side) at intake
and Location manifold.
The engine serial number is stamped in two locations:
The engine serial number can be found on the data −− Engine displacement (liters);
plate.
−− Customer part number;
The information contained in the data plate is:
−− Idle speed (rpm);
−− Engine model; −− Serial number;
−− Emissions standard; −− Free maximum speed;
−− Bill of material; −− Manufacturing date.
−− Engine power (kW), at engine speed (rpm) and
valve lash (mm);
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PRESENTATION 9
Note 1 Note 2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
I II III IV I II III IV V
T 5 A Ø Ø Ø Ø 7 0 A 09 11 1 AUG
A I – Work Shift
T I - Family 09 II – Block Batch
5 II - Market configuration 11 III – Month Day
A III - Technology level 1 IV – Year
0 AUG Referring Month (In Portuguese)
0
0
IV - Serial number
0
7
0
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10 PRESENTATION
• Alternator;
• High Pressure Pump;
First Cylinder
• Turbocharger;
• Hydraulic Pump (Tandem);
• Distribution Tube (Rail);
• Starter Motor;
• Engine Control Module (ECM);
• Injector Nozzle.
Alternador
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PRESENTATION 11
932H00602001
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12 PRESENTATION
Turbocharger
Garrett Turbocharger
932H00602001
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PRESENTATION 13
932H00602001
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14 PRESENTATION
Starter Motor
932H00602001
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PRESENTATION 15
932H00602001
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16 PRESENTATION
Injector Nozzle
932H00602001
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TECHNICAL DATA 17
Table of Contents
Technical Data.......................................................................................................................................................20
Fuel System..........................................................................................................................................................20
Lubrication System................................................................................................................................................21
Cooling System.....................................................................................................................................................21
Thermostatic Valve................................................................................................................................................21
Engine Description................................................................................................................................................22
Features...........................................................................................................................................................22
Accessories Features.......................................................................................................................................22
System Constitution.........................................................................................................................................30
Engine Systems....................................................................................................................................................32
VGT Control.....................................................................................................................................................34
Turbocharger System............................................................................................................................................35
Internal Componentes......................................................................................................................................35
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18 TECHNICAL DATA
Table of Contents
Mechanical.......................................................................................................................................................36
Environmental Limits...................................................................................................................................36
Electrical...........................................................................................................................................................36
Voltage Characteristics...............................................................................................................................36
EGR Flow.........................................................................................................................................................38
Block Diagram..................................................................................................................................................40
Exhaust System....................................................................................................................................................43
2. Signal Conditioner...............................................................................................................................46
3. Microprocessor....................................................................................................................................46
Microprocessor Memory..............................................................................................................................46
ROM............................................................................................................................................................46
RAM............................................................................................................................................................46
4. Actuator Control..................................................................................................................................46
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TECHNICAL DATA 19
Table of Contents
Capacitor Sensor...................................................................................................................................................49
Magnetic Sensors..................................................................................................................................................50
Potentiometer........................................................................................................................................................52
Switches................................................................................................................................................................53
Clutch Switch....................................................................................................................................................53
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20 TECHNICAL DATA
Technical Data
Fuel System
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TECHNICAL DATA 21
Lubrication System
Cooling System
Description MaxxForce 3.2H
Coolant volume inside engine, without
5L
radiator
Coolant temperature
• Nominal 80 to 85°C
• Maximum 115°C
Thermostatic Valve
Opening start (°C) Total opening (°C) Maximum opening travel (mm)
77 to 81 ºC 94 8
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22 TECHNICAL DATA
Engine Description After filtering, fuel is pumped to the high pressure fuel
pump, then to the fuel rail and finally to the injectors.
Features The MWM INTERNATIONAL common rail high-
MaxxForce 3.2H Euro V series are in-line four cylinder pressure injection system includes a cast iron oil
engines. The engine displacements are 3.2 liters. manifold, fuel injectors and a high-pressure pump.
The firing order of the cylinders is 1-3-4-2 for the four The ECM sends pulse PWM (Pulse Signal Modulation)
cylinders. signal to actuate an EGR valve which pneumatically
controls an EGR flap from EGR cooler assembly to
The cylinder head has four valves per cylinder with regulate the cooled exhaust gases that recirculate
cross flow for improved air flow. The head gasket is through the inlet air stream. Cool exhaust gas
mated in metal-rubber. The fuel Injector is centrally increases engine tolerance for EGR, while reducing
located between the four valves and directs fuel smoke formed by gas dilution in the mixture.
over the piston bowl for improved performance and
reduced emissions. The overhead valve train includes The ECM is responsible for monitoring and controling
mechanical roller lifters, rocker arms, and dual valves the electronic engine systems.
that open using a valve bridge. To improve component The Water In Fuel (WIF) separation occurs when
durability and engine performance the engine uses a the filter element repels water molecules. The water
hot and cold side concept for component distribution. collects at the bottom of the element cavity in the fuel
filter housing.
Cold side (left engine side)
A Water In Fuel (WIF) sensor in the element cavity
• Fuel supply system; of the fuel filter housing detects water. When enough
water accumulates in the element cavity. The WIF
• Intake air manifold.
sensor sends a signal to the instrument panel. A fuel
Hot side (right engine side) drain valve handle on the housing can be opened to
drain water from the fuel filter housing.
• Turbocharger system;
• EGR system; Accessories Features
• Air compressor; The vacuum pump is commonly used for air brakes.
• Exhaust manifold. A hydraulic power steering pump is assembled with
the vacuum pump. In the MaxxForce 3.2H engines
A one piece oil pan withstands high-pressure loads both components are located in the hot side next to
during diesel operation. the powertrain.
Manufactured in stamped steel, the oil pan has a The alternator is driven by the pulley system and the
compact size and is lightweight. belt accessories, used to charge the battery and to
power a vehicles electrical system when the engine is
Five bearings support the crankshaft for MaxxForce running. It’s located in the cold side, pulley side of the
3.2H engines. The rear oil seal carrier is part of the block (upper position).
flywheel housing. The open oil pan breather assembly
uses a road draft tube to vent oil pan pressure and an The starter motor is an electric motor that initiates
oil separator that returns oil to the oil pan. rotational motion in an internal combustion engine to
iniciate combustion. On the MaxxForce 3.2H engines
The crankshaft position sensor - CKP and camshaft it’s located on the cold side, next to the Flywheel.
position sensor - CMP are used by the ECM to
calculate rpm, fuel timing, fuel quantity and duration The high pressure pump supplies the injectors with
of fuel injection. high pressure fuel. It’s located on the cold side next to
the powertrain
Manufactured with forged steel and new shape to
improve its strength, the pistons are mated with The Turbocharger is an air compressor used for
fractured cap joint connecting rods. forced-induction of an internal combustion engine.
The purpose of a turbocharger is to increase the air
The oil pump is mounted onto the front of the engine mass entering the engine to create more power. On
block, and is driven directly by the crankshaft. All the MaxxForce 3.2H engines it’s located on the hot
engines use an enlarged oil cooler. side, next to the waterpipe and cooled EGR in the
A low-pressure fuel supply pump draws fuel from the upper position.
fuel tank through a fuel filter assembly that includes a
strainer, filter element, primer pump, drain valves, and
water in fuel (WIF) sensor.
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TECHNICAL DATA 23
1. Lubrication Oil Filling Cover 6. Wiring Harness 10. Camshaft Position Sensor
2. PCV Valve (Oil Separator) 7. Engine Coolant Temperature 11. Air Pressure and Temperature
Sensor Sensor
3. Fuel Injector
8. Valve Cover
4. EGR Cooler
9. Fuel High Pressure Rail
5. Intake Elbow
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24 TECHNICAL DATA
932H00602001
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TECHNICAL DATA 25
932H00602001
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Follow all warnings, cautions, attention and notes.
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26 TECHNICAL DATA
932H00602001
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Follow all warnings, cautions, attention and notes.
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TECHNICAL DATA 27
932H00602001
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28 TECHNICAL DATA
The different engine systems share some subsystems • The Lubrication System has different subsystems
or have a subsystem which adds up to their operation. for heat exchange between lubricating oil and
cooling system to provide lubrication and heat
• The Electronic Control System receives exchange with other systems.
information from the Air Management System and
controls the Fuel Management System. • The Fuel Delivery System supplies pressurized
fuel to injectors.
• The Cooling System has subsystems for both air-
to-air heat exchange, as well as Air Management
System heat exchange, and has a subsystem
for water and oil heat exchange for the engine
lubricating oil.
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TECHNICAL DATA 29
932H00602001
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30 TECHNICAL DATA
Exhaust Gases Post-treatment EGR The function of recirculated gases inside the
combustion chamber is to reduce the temperature and
System to decrease the oxygen available for the formation of
The EGR system (Exhaust Gas Recirculation) is NOx.
constituted of a connection between the exhaust
manifold and intake manifold, which enables the System Constitution
recirculation of exhaust gases. This system reduces
the Nitrogen Oxides (NOx) emission levels that are • Control valve;
formed during the reaction between nitrogen and • Cooler;
oxygen at high temperatures during the combustion. • Mixer;
• EGR tubes.
The system is designed to remove the diesel particulate Finally, clear air pass through the filter, burning the
material from exhaust gases. This is possible by soot generated due to the exhaust heat.
means of using the DOC (Diesel Oxidation Catalyst)
There are 3 main ways a Regen will be activated.
and CDPF (Catalysed Diesel Particulate Filter). First,
the system builds up and burns (regenerates) the 1. CDPF Soot Loading (Automatic).
particulate material (soot) from exhaust gases. After
that, the exhaust gas enters the catalytic converter 2. Maximum Distance Since Last Regen (Automatic).
(DOC), where it suffers an oxidation process. Then, 3. Stationary Regen (Driver Operated).
the gas flows through the filter (CDPF), a kind of
honeycomb that retains the soot.
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TECHNICAL DATA 31
1. CDPF Soot Loading The engine idle speed will rise automatically to a higher
than normal idle speed and the stationary regen cycle
The main automatic activation of Regen mode in this
begins. It is expected to take approximately 10mins to
strategy is when the CDPF soot quantity reaches a
completly clean the CDPF. Once complete the engine
certain calibratable level.
will return to a normal idle speed and the high soot
The ECM detects this accumulated soot quantity load lamp will switch off.
based on differential pressure accross the CDPF.
It will only be possible to innititate another Stationary
regen if the vehicle gets to the high soot load level
2. Maximum Distance Since Last Regen without managing to regen during normal driving
There is also a maximum distance since the last regen conditions.
activation for regen. To ensure a robust system this will This is a great function which allows a controlled regen
trigger a regen after a calibratable distance to ensure of the CDPF to be completed. If the driver ignores the
the filter is clean. lamp the vehicle will still continue to try to do a regen
automatically.
3. Stationary Regen *safe-place = Due to the hot exhaust gases and hot
There is also the possibilty to do a stationary Regen underfloor exhaust temperatures that are seen during
activated by the driver by a button on the dashboard. a stationary regen common sense should be applied.
This is only possible above a calibratable level of For example parking over dried grass or in a petrol
soot loading indicated to the driver by a light on the station where there is often split fuel would not be a
dashboard (the button will not work before). Then it good place to do the stationary regen due to a risk of
will only be possible if the vehicle is stationary and the fire.
accelerator pedal is not being pressed. Below is a table to show how the dashboard lights,
The vehicle documentation should be clear that when stationary and automatic regens are managed for
this lamp is lit, the driver should attempt a stationary different soot levels.
Regen to avoid the CDPF from eventually becoming The percentage soot loads used below are only to aid
blocked. the explanation of the strategy. These percentages are
To do a stationary Regen the vehicle should be parked fully calibrateble so other percentages can be chosen
in a safe-place* in neutral gear and at idle. Pressing to optimise the system.
the stationary regen button on the dashboard will then
activate the Stationary Regen cycle.
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32 TECHNICAL DATA
Air Flow
The air flows through the air filter and enters into the
variable geometry turbocharger VGT. The compressor
at turbocharger increases the pressure, temperature
and density of intake air before it enters into the air
cooler.
The compressed and cooled air flows from the air
cooler to the EGR mixer duct.
• Parte of exhaust gases is cooled at the EGR The air cooler is installed at upper part of radiator. The
cooler and flows through the EGR control valve to air that comes from the turbocharger passes through
the EGR mixer duct. When the exhaust gases mix a net of heat exchange tubes before entering the duct
themselves with the filtered air, the emissions of of EGR mixer.
nitrogen oxides (NOx) and the noise are reduced; The outside air that flows over the tubes and vanes
• The remaining portion of exhaust gases flows cools down the compressed air passing through the
to the turbocharger, descending in spiral and turbocharger. This air is colder and denser that the
expanding through the turbine rotor, varying the air not cooled; the colder and denser air improves the
pressure on turbocharger compressor side; air/fuel ratio during the combustion, resulting in better
control of gases emission and more power.
• The compressor rotor VGT, at the same shaft of
turbine rotor, compresses the mix of filtered air.
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TECHNICAL DATA 33
The key feature of variable geometry turbocharger The benefit is the capacity of controlling the internal
VGT is the driven vanes on turbine housing. The pressure according to the diverse motor speeds, as
vanes modify the characteristics of exhaust gases flow well as to the diverse loading conditions, thus reducing
through the turbine housing. the level of gases emission.
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34 TECHNICAL DATA
Closed Loop VGT System The drive vanes are installed around the internal
circumference of turbine housing.
One single ring unites all the vanes. When this ring is
moved, all the vanes are moved to the same position.
The ring movement occurs when the little crankshaft
on control module is moved. The flow of exhaust gas
can be adjusted, depending on back pressure required
by the engine speed and load.
Closed Vanes
The vanes are closed when the exhaust back pressure
is low.
The exhaust gases have to accelerate to pass through
the narrow vanes’ passages. The rising of exhaust
back pressure makes the gases to be recirculated to
Closed Loop VGT System
the EGR system.
VGT Control
Open Vanes
The vanes are opened when the exhaust back
pressure is high and there is a possibility of over-
speed. The open vanes result in low exhaust gases
flow and reduce the turbine speed.
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TECHNICAL DATA 35
Turbocharger System
Internal Components
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36 TECHNICAL DATA
932H00602001
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TECHNICAL DATA 37
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38 TECHNICAL DATA
The EGR system includes the following: Some exhaust from the exhaust manifold flows into
the EGR cooler. Exhaust from the EGR cooler flows
• EGR control valve; through the exhaust gas crossover to the EGR valve.
• EGR cooler; When EGR is actuated, the EGR control valve opens
allowing cooled exhaust gases to enter the EGR mixer
• Air intake manifold;
duct to be mixed with filtered intake air.
• Inlet and EGR mixer duct;
• Exhaust manifold;
• Exhaust gas crossover.
932H00602001
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TECHNICAL DATA 39
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
40 TECHNICAL DATA
Block Diagram
932H00602001
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TECHNICAL DATA 41
NOTE:
2. Peak of inrush current: Less Than 50A 5. Please see following control specifications for
more details.
(Battery Voltage: 24V Wire Harness resistance:
15m ohms). SB-N031-C B
3. Restriction of usage. (For Eletrical Circuit)
1) No load dump protection.
2) No protection against polarity reversal.
4. Join Connector
1) Part No. 6195-0021 (SUMITOMO Wiring
Systems).
2) The insertion power of the matching connector
is less than 100N.
932H00602001
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42 TECHNICAL DATA
The EGR is a closed loop system that uses exhaust gas recirculation position to provide feedback to the ECM.
932H00602001
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TECHNICAL DATA 43
932H00602001
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Follow all warnings, cautions, attention and notes.
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44 TECHNICAL DATA
932H00602001
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Follow all warnings, cautions, attention and notes.
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TECHNICAL DATA 45
Fuel Flow
The fuel filter housing includes the following
components:
• Fuel strainer;
• Fuel filtering element;
• Water separator;
• Water drain valve.
932H00602001
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46 TECHNICAL DATA
Electronic Control System Diagnostic strategies are also programmed into the
ECM. Some strategies monitor inputs continuously
Electronic Control System Components and command the necessary outputs to achieve the
correct performance of the engine.
Operation and Function
The Electronic Control Module (ECM) monitors and Microprocessor Memory
controls engine performance to ensure maximum
performance and adherence to emissions standards. The ECM microprocessor includes Read Only Memory
(ROM) and Random Access Memory (RAM).
The ECM has four primary functions:
• Provides Reference Voltage (VREF); ROM
• Conditions input signals; ROM stores permanent information for calibration
tables and operating strategies. Permanently stored
• Processes and stores control strategies; information cannot be changed or lost by turning the
• Controls actuators (output signals). ignition key OFF or when ECM power is interrupted.
ROM includes the following:
1. Reference Voltage (VREF) • Vehicle configuration, modes of operation and
The ECM supplies a 5 volt VREF signal to input options;
sensors in the electronic control system. By comparing • Engine Family Rating Code (EFRC);
the 5 volt VREF signal sent to the sensors with their
respective returned signals, the ECM determines • Engine warning and protection modes.
pressures, positions and other variables important to
engine and vehicle functions. RAM
The ECM supplies two independent circuits for VREF: RAM stores temporary information for current engine
conditions. Temporary information from RAM is lost
• VREF A supplies 5 volts to engine sensors; when the ignition key is turned to OFF or when ECM
• VREF B supplies 5 volts to vehicle sensors. power is interrupted. RAM information includes the
following:
2. Signal Conditioner • Engine temperature;
The signal conditioner in the internal microprocessor • Engine rpm;
converts analog signals to digital signals, squares up
sine wave signals, or amplifies low intensity signals to • Accelerator pedal position.
a level that the ECM microprocessor can process.
4. Actuator Control
3. Microprocessor The ECM controls the actuators by applying a low
level signal (low side driver) or a high level signal (high
The ECM microprocessor stores operating instructions side driver). When switched on, both drivers complete
(control strategies) and value tables (calibration a ground or power circuit to the actuator.
parameters). The ECM compares stored instructions
and values with conditioned input values to determine Actuators are controlled in three ways, determined by
the correct operating strategy for all engine operations. the kind of actuator.
Continuous calculations in the ECM occur at two • A duty cycle (percent time on/off).
different levels or speeds: Foreground and Background.
• A controlled pulse width.
• Foreground calculations are much faster than
• Switched on or off.
background calculations and are normally more
critical for engine operation. Engine speed control
is an example. ECM Control of Engine Operation
• Background calculations are normally variables The ECM controls engine operation through the
that change at lower rates. Engine temperature following actuators:
is an example.
• Turbocharger control module;
Diagnostic Trouble Codes (DTC´s) are generated by • EGR control module and control valve;
the microprocessor, when inputs or conditions do not
comply with expected values. • Fuel Pressure valve;
• Injectors.
932H00602001
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TECHNICAL DATA 47
1. Electronic Control Module 7. Exhaust Gas Temperature Sensor 13. Engine Oil Pressure (EOP)
(ECM) (Outlet) (EGT2)
14. Temperature - Manifold Absolute
2. Accelerator Pedal (ACP) 8. Diesel Particulate Filter Delta Pressure (T-MAP)
Pressure Sensor (CDPF)
3. Can Controlled Turbo 15. Engine Fuel Pressure (EFP)
9. Crankshaft Position Sensor (CKP)
4. EGR Control 16. Throtle Valve
10. Camshaft Position Sensor (CMP)
5. Diesel Oxydation Catalyst 17. Manifold Air Flow (MAF)
Temperature (DOCT) 11. Engine Fuel Temperature (EFT)
18. Volumetric Control Valve (VCV)
6. Exhaust Gas Temperature 12. Engine Coolant Temperature (ECT)
Sensor (Inlet) (EGT1)
932H00602001
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48 TECHNICAL DATA
932H00602001
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TECHNICAL DATA 49
Capacitor Sensor
• EOP
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50 TECHNICAL DATA
932H00602001
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Follow all warnings, cautions, attention and notes.
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TECHNICAL DATA 51
932H00602001
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Follow all warnings, cautions, attention and notes.
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52 TECHNICAL DATA
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
TECHNICAL DATA 53
Clutch Switch
The CPS determines if a vehicle is in gear for manual 1. Accelerator pedal
transmissions. For automatic transmissions, the
2. Low Idle Switch (LIS)
neutral indicator switch functions as the CPS.
3. Voltage source with current limiting resistor
932H00602001
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54 TECHNICAL DATA
NOTES
932H00602001
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Follow all warnings, cautions, attention and notes.
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OPERATION AND MAINTENANCE 55
Table of Contents
Engine Operation..................................................................................................................................................57
Start / Stop.......................................................................................................................................................57
Cold Start.........................................................................................................................................................57
Turbocharger Precautions................................................................................................................................57
Break-in............................................................................................................................................................57
Fuel Specifications...........................................................................................................................................57
Diesel .........................................................................................................................................................57
Biodiesel......................................................................................................................................................58
Lubricating Oil..................................................................................................................................................58
Oil Change..................................................................................................................................................58
Lubricating Oil.............................................................................................................................................58
Level Check......................................................................................................................................................59
Engine Preparation................................................................................................................................................61
Oil Drain......................................................................................................................................................61
Recommended Method....................................................................................................................................62
932H00602001
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56 OPERATION AND MAINTENANCE
Table of Contents
Oil Filter.................................................................................................................................................................64
Fuel Filter..............................................................................................................................................................65
Adapter Plate....................................................................................................................................................66
Engine Lifting....................................................................................................................................................66
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OPERATION AND MAINTENANCE 57
The following action must be observed: • Avoid overloading the engine while not yet in the
normal operating temperature;
• Use winter fuel that does not cause paraffin build • Avoid operations above ¾ (75%) of the maximum
up at low temperatures. load limit of the vehicle or equipment;
For a maximum turbocharger life, the following • Rigorously follow the maintenance manual;
precautions must be followed: • By following these recommendations, the engine
life will be longer.
• Do not accelerate the engine right after starting;
• Wait for 30 seconds in idle speed before turning Fuel Specifications
the engine off;
• Rev the starter motor some times before starting Diesel
the engine. After that, leave the engine in idle The diesel fuel used on MWM INTERNATIONAL
speed for a period of time to set up a throughout engine must meet Brazilian Standard ANP No. 32,
oil circulation and full pressure before revving up issued on Oct. 16, 2007 – DOU [The Federal Official
and loading the engine; Gazette] of Oct. 16, 2007.
• At low temperature or when the engine is being
started after a long inoperative period, start the
engine and leave it in idle speed before operating
in high speed;
• Avoid engine operation in idle for a long time.
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58 OPERATION AND MAINTENANCE
932H00602001
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Follow all warnings, cautions, attention and notes
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OPERATION AND MAINTENANCE 59
932H00602001
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Follow all warnings, cautions, attention and notes.
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60 OPERATION AND MAINTENANCE
8. Drain the coolant and oil from the oil pan. The fuel 7. Drain the fuel mix and top up the reservoir with
mix can stay in the system; new fuel;
9. Remove cylinder head valve covers and spray 8. Change fuel filter.
protection oil over springs and rocker arms.
Reattach valve covers;
10. Apply protective grease on joints;
11. Apply protection oil over machined surfaces;
12. Remove belt(s);
13. Cover all engine holes to avoid ingress of dust
and water.
932H00602001
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OPERATION AND MAINTENANCE 61
932H00602001
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Follow all warnings, cautions, attention and notes.
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62 OPERATION AND MAINTENANCE
932H00602001
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OPERATION AND MAINTENANCE 63
Remove the oil pan plug and discard the washer. Drain Assemble the oil pan plug with a new washer.
used oil from the engine and discard it, according to Tighten the plug with a 55 to 75 Nm torque and fill in
local existing laws. with new engine oil up to the dipstick maximum mark.
932H00602001
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64 OPERATION AND MAINTENANCE
Oil Filter
Remove the oil filter. For the assembly, pay attention to the correct
positioning of the O-ring and follow the installation
procedures found in this chapter.
932H00602001
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OPERATION AND MAINTENANCE 65
Fuel Filter
To remove the fuel filter, loosen the support attaching For the assembly, apply a torque of 7 to 9 Nm and
bolt and the fuel inlet and outlet hose connector. connect the fuel inlet and outlet hoses.
932H00602001
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66 OPERATION AND MAINTENANCE
Adapter Plate of the Assembly and NOTE: An oil pan is an important engine stand
accessory, since it ALWAYS grabs the oil that drips
Engine Lifting from the engine when you are working on it, keeping
the floor dry. Thus, the staff will not walk or slide over
Adapter Plate the oil pools, taking the oil all over the workshop.
Warning: To avoid serious personal injuries or
damages to the engine or vehicle, use a 3-ton chain Engine Assembly on Stand
crane equipped with safety hooks to lift the engine by Lift the engine with special lifting equipment and using
the lifting eyelets. MWM special tool No. 9.610.0.690.011.6 (adapter
Warning: To avoid serious zonal injuries, possible plate kit), an engine stand and M12 x 45 bolts. Visually
death or damages to the engine or vehicle, use only align the adapter plate with the bolt holes at the right
10.9 metric or SAE grade B bolts to attach the adapter side of the engine for the determination of the adapter
plate for the assembly of the engine, as well as on an plate position in relation to the engine stand.
engine stand.
NOTE: Leave all bolts untightened to ease assembly
of adapters to engine and stand plate. Tighten to
Engine Lifting torque only after all bolts have been fitted to the plate
Keep in mind that safety is the primary concern when and engine.
choosing engine lifting equipments, which are needed
on safety lifting of heavy engine and parts. Engine side support adapter (3 holes for attachment).
932H00602001
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OPERATION AND MAINTENANCE 67
932H00602001
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Follow all warnings, cautions, attention and notes.
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68 OPERATION AND MAINTENANCE
NOTES
932H00602001
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Follow all warnings, cautions, attention and notes
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ENGINE BLOCK 69
Table of Contents
Engine Block.........................................................................................................................................................70
Cylinder Block.......................................................................................................................................................71
Block Machining...............................................................................................................................................71
Machining Procedure.......................................................................................................................................71
Additional Information.......................................................................................................................................72
Cylinder Specifications..........................................................................................................................................73
Measurement..............................................................................................................................................74
Instalation.........................................................................................................................................................75
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70 ENGINE BLOCK
Engine Block
932H00602001
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ENGINE BLOCK 71
Cylinder Block
Block Machining
Please find below the recommended procedures for
cylinder machining of the MaxxForce 3.2H engine.
Machining Procedure
Assemble and tighten block bearings at specified
torque.
Check general condition of the engine block for cracks
and deformations.
Bore the cylinder.
Hone the cylinder as specified.
Steps Torque
Cylinder internal diameter (standard): 1 30 ± 3 Nm
2 60 ± 3 Nm
96H6 (96.000 to 96.022 mm)
3 90° + 10°
NOTE: Machining dimensions must be made in steps 4 (Loosen) -100° + 10°
of 0.25 mm.
5 60 ± 3 Nm
Attention: To perform machining procedures and 6 100 ± 3 Nm
dimensional verification of liners and cylinders, the 7 60° + 10°
torque plate must be used (Appendix A), duly bolted
8 90° + 10°
to the block simulating tightening of the head. This
avoids the procedure is done on a block that is out of
the normal operating position. Hone liners.
Honing angle:
90° to 120°
Roughness:
Rpk: 0.3 (maximum)
Rv: 0.4 to 1.6
Rvk: 1.3 to 3.6
Mr1: 2% to 14%
Mr2: 65% to 85%
Before assembling the torque plate, assemble the Out-of-roundness and tapering after honing:
head gasket, position the torque plate and tighten to 0.020 mm (maximum)
specified torque in the recommended sequence using
the head bolts.
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72 ENGINE BLOCK
Stone Data
Supplier Nagel Sunnen
SCG80KKE 7046S (20’)
Code H27 – 6 – AV – AV – EJ – 6C
GOS 250 + 10
Dimensions 10 x 10 x 80 (mm) 10 x 10 x 80 (mm)
Additional Information
Block upper surface roughness: • If the parts will remain disassembled for a long
period, lubricate them to avoid corrosion.
Rz: 16
932H00602001
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ENGINE BLOCK 73
Cylinder Specifications
Cylinder Specifications
Dimension (mm)
Maximum Wear 0.06
Out-of-roundness 0.000 to 0.022
Internal Ø 96H6 (96.000 to 96.022)
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74 ENGINE BLOCK
Measurement
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ENGINE BLOCK 75
932H00602001
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76 ENGINE BLOCK
NOTES
932H00602001
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Follow all warnings, cautions, attention and notes.
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CRANKSHAFT 77
Table of Contents
Crankshaft.............................................................................................................................................................78
Removal...........................................................................................................................................................79
Installation........................................................................................................................................................79
Removal...........................................................................................................................................................82
Specifications........................................................................................................................................................83
Crankshaft........................................................................................................................................................83
Journal Specifications...........................................................................................................................................84
Clearance..............................................................................................................................................................87
Fillet Radius...........................................................................................................................................................88
Visual Inspection...................................................................................................................................................89
Plain Bearings.......................................................................................................................................................90
Bearing Out-of-roundness................................................................................................................................91
Bearing Pre-tensioning..........................................................................................................................................93
Assembly..........................................................................................................................................................93
Axial Play...............................................................................................................................................................96
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78 CRANKSHAFT
Crankshaft
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CRANKSHAFT 79
Removal
Remove all dirtiness from the oil pan gasket and clean.
932H00602001
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80 CRANKSHAFT
Apply Dow Corning 780 silicone sealer or equivalent Assemble the oil pan tightening bolts to the specified
to the 4 junction points and housing before assembly torque transversally from the center to the outer edges.
of the oil pan and gasket.
932H00602001
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CRANKSHAFT 81
1. Pan Assy, Lubrication Oil 4. Pipe, Suction Lubrication Oil 7. Hexagon Socket Screw
M8 x 25 - 8.8
2. Gasket, Oil Pan 5. O`Ring
8. Intermediary Pipe
3. Hexagon Flanged 6. Hexagon Flanged Bolt
Bolt M8 x 16 - 8.8 M10 x 45 - 8.8
932H00602001
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82 CRANKSHAFT
932H00602001
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CRANKSHAFT 83
Specifications
Crankshaft
Gear
Diameter mm
Seat 80.032 - 80.051
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84 CRANKSHAFT
Journal Specifications
Journals
Diameter mm
Standard 69.981 to 70.000
1st Repair 69.731 to 69.750
2nd Repair 69.481 to 69.500
3rd Repair 69.231 to 69.250
4th Repair 68.981 to 69.000
932H00602001
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CRANKSHAFT 85
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86 CRANKSHAFT
A
D
C
B
Maximum Out-of-roundness mm
A x C and B x D 0.01
Maximum Tapering mm
A x C and B x D 0.01
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CRANKSHAFT 87
Clearance
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88 CRANKSHAFT
Fillet Radius
Fillet Radius mm
Nominal 3.30 to 3.50
932H00602001
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CRANKSHAFT 89
Maximum warpage:
0.15 mm.
Remove the crankshaft and clean the main bearing
and journal surfaces throughout.
932H00602001
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90 CRANKSHAFT
Plain Bearings
Engine block
Diameter (mm)
Without bearings 75.000 to 75.019
Engine block
(Inner) Diameter (mm)
Standard 70.036 to 70.079
1st Repair 69.786 to 69.829
2nd Repair 69.536 to 69.579
3rd Repair 69.286 to 69.329
4th Repair 69.036 to 69.079
Pre-tensioning 0.015 to 0.060
932H00602001
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CRANKSHAFT 91
1st Step 60 to 66 Nm
Sintered bearing cap 2 Step
nd
80 to 90°
Bolt: M14 x 95 – 10.9 class
Torque:
1st step: 60 to 66 Nm
Bearing Out-of-roundness
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92 CRANKSHAFT
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CRANKSHAFT 93
Pre-tension:
0.015 to 0.060 mm
Assembly
Start assembly with the oil pump, flywheel housing
and timing gears removed.
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94 CRANKSHAFT
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CRANKSHAFT 95
1st Step 60 to 66 Nm
2 Step
nd
80° to 90°
Read the comparator gauge.
Attention: Bearing caps are not interchangeable;
If needed, an oversize thrust washer can be used, as
thus, they must be assembled on their original position.
to obtain the correct axial clearance.
After assembling the central bearing with thrust
washers, measure the axial clearance according to the Crankshaft Thrust Washers
procedure below.
Width (mm)
Standard 2.42 to 2.47
Oversize 2.67 to 2.72
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96 CRANKSHAFT
Axial Play
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HEAD AND CAMSHAFT 97
Table of Contents
Removal.........................................................................................................................................................100
Installation......................................................................................................................................................100
Valve Cover.........................................................................................................................................................101
Removal.........................................................................................................................................................101
Inspection.......................................................................................................................................................101
Inspection.......................................................................................................................................................106
Disassembly...................................................................................................................................................107
Specifications......................................................................................................................................................108
Camshaft Specifications.................................................................................................................................108
Valve Specifications.............................................................................................................................................109
Valve Seats....................................................................................................................................................109
Valve Springs.......................................................................................................................................................113
Valve Diagram.....................................................................................................................................................115
Camshaft Bearings..............................................................................................................................................117
Camshaft........................................................................................................................................................ 117
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98 HEAD AND CAMSHAFT
Table of Contents
Intermediate Bearings.........................................................................................................................................118
Assembly........................................................................................................................................................122
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HEAD AND CAMSHAFT 99
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100 HEAD AND CAMSHAFT
Removal
Installation
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HEAD AND CAMSHAFT 101
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102 HEAD AND CAMSHAFT
Loosen bolts from the valve cover and remove it. For
more details about the valve cover procedure, see
Valve Cover, in this chapter.
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HEAD AND CAMSHAFT 103
Loosen and remove turbocharger oil inlet and outlet Lock the camshaft by installing the MWM
tubes. No. D7002304C1 special tool.
Before locking the camshaft, check if the “PMS” (TDC) Pay attention to the perfect seating of the tool over
mark on camshaft is turned upwards. the head.
Remove the O-ring to assure the perfect seat of the
hard tool.
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104 HEAD AND CAMSHAFT
NOTE: If the engine is not set at the right timing, the See the correct procedure to remove the inspection
special tool will not touch (seat on) the head, causing cover in the following illustration.
clearances.
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HEAD AND CAMSHAFT 105
Remove the inspection cover. Using lifting straps, carefully remove the head with a
winch.
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106 HEAD AND CAMSHAFT
Inspection
Keep the head lubrication hole well cleaned. The head gasket for electronic engines is a metallic,
blade-type, 1.4 mm width gasket (the only size
available for service).
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HEAD AND CAMSHAFT 107
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108 HEAD AND CAMSHAFT
Specifications
Camshaft Specifications
Journals (C)
Standard Φ 49.873 – 49.897
Bearing Clearance
Axial 0.05 – 0.19
Radial 0.093 – 0.183
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HEAD AND CAMSHAFT 109
Valve Specifications
Valve Seats
D
C
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110 HEAD AND CAMSHAFT
C B
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HEAD AND CAMSHAFT 111
Valve Guides
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112 HEAD AND CAMSHAFT
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HEAD AND CAMSHAFT 113
Wire Ø: 3.50mm
Load (N) Load Length
A 312.0 A 37.60
B 588.5 B 28.60
C 0 C 50
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114 HEAD AND CAMSHAFT
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HEAD AND CAMSHAFT 115
Valve Diagram
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116 HEAD AND CAMSHAFT
Measure the gear seat and camshaft bearing The values are the same for the MaxxForce 3.2H
diameters. engines.
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HEAD AND CAMSHAFT 117
Camshaft Bearings
Camshaft
Measure the internal diameter of the support bearing that must be assembled and tightened to the specified
torque, and check radial clearance.
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118 HEAD AND CAMSHAFT
Intermediate Bearings
Camshaft Gear Intermediate Bearing
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HEAD AND CAMSHAFT 119
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120 HEAD AND CAMSHAFT
For the measurement of camshaft warpage, do as Check if the rocker arm does not show excessive wear
follows: install and lubricate just the outer support or cracks in the shaft housing or in the valve stem
bearings and carefully position the camshaft. Turn contact area. After removing the rocker arms, check
the camshaft and check warpage with a comparator for signs of seizure.
gauge on the central bearing. Visually check the condition of springs, valves and
inserts. Replace if needed.
Maximum warpage: 0.08 mm
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HEAD AND CAMSHAFT 121
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122 HEAD AND CAMSHAFT
Assembly
Attention:
• All parts must be clean before assembly.
• Use new sealing rings, gaskets and washers.
• Use genuine parts for replacement.
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HEAD AND CAMSHAFT 123
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124 HEAD AND CAMSHAFT
Caution:
• The bearing on the outer edges of the camshaft
(pulley and gear sides) are not interchangeable
and are different from the central bearings.
• The central bearings are interchangeable.
• The upper and lower bearing pairs are matched
and cannot be changed.
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HEAD AND CAMSHAFT 125
Lubricate the camshaft journals and install the upper Use the special device and measure the camshaft
bearings, checking the parity with the lower ones. axial play.
Tighten bearing bolts to torque, following the tightening
sequence and recommended torque values.
10 6 1 4 8
9 5 2 3 7
1st step 9 to 11 Nm
2 step
nd
58 to 62°
For the rocker arm installation, position the rocker arm
shaft with the shoulder turned up.
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126 HEAD AND CAMSHAFT
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HEAD AND CAMSHAFT 127
The tool must be mounted in the camshaft. Measure the idle gear radial clearance.
Install the special tool No. D7002303C1 in the idle Check the idle gear axial play.
gear.
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128 HEAD AND CAMSHAFT
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HEAD AND CAMSHAFT 129
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130 HEAD AND CAMSHAFT
Step Torques
1 30 ± 3 Nm
2 60 ± 3 Nm
3 90o + 10o
4 (Loosen) - 100o + 10o
5 60 ± 3 Nm
6 100 ± 3 Nm
7 60o + 10o
8 90o + 10o
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HEAD AND CAMSHAFT 131
Check the clearance of the camshaft gear. Install the valve cover.
Assemble the glow plugs (on vehicles with cold Apply petrolatum on the camshaft sensor CMP
start auxiliary system only) applying a torque of housing.
16 to 18 Nm. Apply Loctite 242 thread locker or equivalent to the
valve cover attaching bolts.
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132 HEAD AND CAMSHAFT
Tighten cover attaching bolts to a torque of NOTES: The long bolts that hold the rail and valve
23 to 27 Nm. cover to the cylinder head need to be installed before
the perimeter bolts and removed after the perimeter
Install the CMP sensor per CMP – camshaft position
bolts.
sensor, in this chapter.
The long rail bolts need to be removed carefully or the
valve spring pressure is pushing one end of the cover
away from the cylinder head. This could damage the
valve cover.
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HEAD AND CAMSHAFT 133
Install fuel nozzles and high pressure pump return and Install the fuel high pressure tubes of injector nozzles,
connections. tightening the nuts to a torque of 24 to 30 Nm.
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134 HEAD AND CAMSHAFT
Crankshaft to Camshaft
Synchronization Check
Timing synchronization of MaxxForce 3.2H engines is
performed using special tools to set synchronization
between camshaft and crankshaft.
The accuracy of those tools is important for a good
engine performance.
The gears do not feature assembly marks, just
production ones.
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HEAD AND CAMSHAFT 135
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136 HEAD AND CAMSHAFT
Remove the camshaft gear. 1st cylinder in compression position (flywheel side).
Place the bolt on the camshaft and turn it to adjust
valve lash according to compression cycle, without the
drive gear. Valve lash adjustment can be performed
at the vehicle or on a cylinder head that is out of the
engine.
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PISTON AND CONNECTING RODS 137
Table of Contents
Disassembly...................................................................................................................................................139
Check.............................................................................................................................................................139
Identification Code....................................................................................................................................139
Piston Grooves....................................................................................................................................................140
Connecting Rods.................................................................................................................................................143
Inspection.......................................................................................................................................................146
Identification..............................................................................................................................................149
Piston Rings........................................................................................................................................................150
Removal.........................................................................................................................................................150
Inspection.......................................................................................................................................................150
Assembly........................................................................................................................................................150
Bearing Diagnostic.........................................................................................................................................153
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138 PISTON AND CONNECTING RODS
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PISTON AND CONNECTING RODS 139
Piston, Flat Bearing and Rings NOTE: Crashing or heating pistons is not required.
Disassembly
After removing the crankcase and cylinder head,
place the engine in an upright position to remove the
connecting rods. Remove the connecting rod caps.
The bolts should be alternately loosened in steps.
Check
Identification Code
Only the “Y” mass range connecting rods are available
for service. Those are used to replace the connecting
rods of every other range.
NOTE: Do not assemble “X” and “Z” mass range
connecting rods in the same engine, as those
connecting rods exceed the maximum mass difference.
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140 PISTON AND CONNECTING RODS
Piston Grooves
1º
2º
3º
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PISTON AND CONNECTING RODS 141
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142 PISTON AND CONNECTING RODS
Internal Ø (mm)
Standard 58.767 to 58.800
1st Repair 58.517 to 58.550
2nd Repair 58.267 to 58.300
3rd Repair 58.017 to 58.050
4th Repair 57.767 to 57.800
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PISTON AND CONNECTING RODS 143
Connecting Rods
B
A
Internal Ø (mm)
A (with connecting rod bearing) 58.767 to 58.800
B (without connecting rod bearing) 62.433 to 62.446
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144 PISTON AND CONNECTING RODS
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PISTON AND CONNECTING RODS 145
Ø A – Piston Pin
Diameter (mm)
Nominal 37.994 to 38.000
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146 PISTON AND CONNECTING RODS
Inspection
Check connecting rod for possible damages, wear or
dents. Damages to the rod (I-beam) can cause cracks
or breaks.
Check for dents, scratches or excessive wear on the
piston pin.
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PISTON AND CONNECTING RODS 147
Connecting Rod to Journal Clearance Transfer the previous measurement of the journal to a
micrometer caliper.
1st step 20 to 23 Nm
2 step
nd
90 to 100°
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148 PISTON AND CONNECTING RODS
• At 30° and at 30° + 90° from the connecting rod Place the micrometer caliper at 90° from the con-
partition. necting rod partition and set comparator gauge to null.
Loosen one of the bolts and check the new micrometer
caliper reading. The difference is the pre-tension.
Pre-tension: 0.06 – 0.12.
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PISTON AND CONNECTING RODS 149
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150 PISTON AND CONNECTING RODS
Piston Rings Measure the ring end gap by inserting a ring inside the
piston cylinder and perform the measurement using a
Removal feeler gauge
Assembly
Inspection
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PISTON AND CONNECTING RODS 151
Measure the gap between the rings and piston Assemble the bearings on connecting rods and caps.
grooves. Be sure that they are correctly positioned. Lubricate
the bearing inner surfaces and place the piston /
connecting rod assembly to the block. Take care not to
damage the cylinder.
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152 PISTON AND CONNECTING RODS
Install the ring compression belt and tighten with the Turn the crankshaft for the proper fit of the remaining
tool. connecting rods.
Push the piston and connecting rod assembly inside
the cylinder with the help from a plastic bar as to not
damage the piston.
If the piston is seized at the beginning of the course,
the rings may have opened, and thus, the belt was not
duly closed.
In this case, remove and retighten the belt.
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PISTON AND CONNECTING RODS 153
Step Torque
1 20 ± 3 N.m
2 130º - 5º
Bearing Diagnostic
Check connecting rod bolt length. Bolts with out of
specification lengths must be discarded and replaced. By the condition or failure type of the bearings, it is
possible to identify problems like excessive play, out-
Maximum length: 56.5 mm. of-roundness or tapering of the bearings. For more
information, refer to chapter 16 of this manual.
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154 PISTON AND CONNECTING RODS
NOTES
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GEAR HOUSING AND GEAR TRAIN 155
Table of Contents
Removal.........................................................................................................................................................157
Installation......................................................................................................................................................158
Pre-assembly Inspection................................................................................................................................161
Gear Assembly...............................................................................................................................................165
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156 GEAR HOUSING AND GEAR TRAIN
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GEAR HOUSING AND GEAR TRAIN 157
Gear Housing Cover and Pulse Loosen the housing inner bolts and remove the cover.
Wheel Sensor (CKP)
Removal
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158 GEAR HOUSING AND GEAR TRAIN
Using a plastic or rubber hammer, hit slightly on the Attach the sensor applying a torque of 7.5 to 9.5 Nm.
indicated point until the housing metallic gasket is
loosened.
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GEAR HOUSING AND GEAR TRAIN 159
Apply Dow Corning 780 gasket maker on equivalent to Install the cover and its inner bolts.
the appropriate place.
Tighten bolts to a torque of 34 to 46 Nm.
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160 GEAR HOUSING AND GEAR TRAIN
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GEAR HOUSING AND GEAR TRAIN 161
Pre-assembly Inspection
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162 GEAR HOUSING AND GEAR TRAIN
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GEAR HOUSING AND GEAR TRAIN 163
Measure the difference on the gear inner bushing to Install the idle gear attaching bolt.
obtain the working play.
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Follow all warnings, cautions, attention and notes.
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164 GEAR HOUSING AND GEAR TRAIN
It is possible to assemble all gears, control the Measure the axial play with a magnetic base and a dial
clearances, and then remove the gears for the indicator.
assembly of the gear housing.
932H00602001
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Follow all warnings, cautions, attention and notes.
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GEAR HOUSING AND GEAR TRAIN 165
Gear Assembly
1st Step 34 to 46 Nm
2 Step
nd
87 to 93°
932H00602001
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Follow all warnings, cautions, attention and notes.
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166 GEAR HOUSING AND GEAR TRAIN
1st Step 34 to 46 Nm
2 Step
nd
87 to 93°
932H00602001
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Follow all warnings, cautions, attention and notes.
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GEAR HOUSING AND GEAR TRAIN 167
932H00602001
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Follow all warnings, cautions, attention and notes.
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168 GEAR HOUSING AND GEAR TRAIN
932H00602001
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Follow all warnings, cautions, attention and notes.
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GEAR HOUSING AND GEAR TRAIN 169
932H00602001
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Follow all warnings, cautions, attention and notes.
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170 GEAR HOUSING AND GEAR TRAIN
932H00602001
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Follow all warnings, cautions, attention and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 171
Table of Contents
Removal.........................................................................................................................................................172
Inspections.....................................................................................................................................................174
Installation......................................................................................................................................................174
Verification......................................................................................................................................................176
932H00602001
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172 FLYWHEEL AND FLYWHEEL HOUSING
Flywheel, Retainer and Race Check the procedure in the “Starter motor” section, in
this manual.
Removal
Remove the starter motor.
After start motor removal, install the MWM No. NOTE: This tool can be used on several MIM engines,
D7000600C1 special tool to lock the engine and as such, the right holes indicated in the illustration
crankshaft. must be used for the correct adjustment in each
engine.
932H00602001
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Follow all warnings, cautions, attention and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 173
932H00602001
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Follow all warnings, cautions, attention and notes.
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174 FLYWHEEL AND FLYWHEEL HOUSING
Rigid Flywheel When assembling the race retainer race to the flywheel,
check the correct assembly side with the inscription
‘VOLANTE FLYWHEEL” facing the flywheel.
Install the flywheel race retainer striking it with a plastic
hammer up to touching the bottom.
Inspections
Visually check the flywheel housing for cracks or any
other damage.
Visually check the flywheel and the flywheel ring gear. Install a new flywheel retainer using the MWM
No. 9.407.0.690.037.6 special tool.
Visually check the flywheel for any cracks,
deformations and wear signals on the flywheel ring
gear teeth.
Failures on starter motor gears can be caused by a
broken ring gear or damaged teeth.
Check if the sensor holes are clean and in good
condition.
932H00602001
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Follow all warnings, cautions, attention and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 175
NOTE: To position the flywheel correctly, note that Tighten bolts to the torque as specified in the
there is a calibrated hole (hole with an offset positioning) sequence below.
that coincides with the respective crankshaft calibrated
hole.
Torque:
932H00602001
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Follow all warnings, cautions, attention and notes.
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176 FLYWHEEL AND FLYWHEEL HOUSING
Verification
Turn the crankshaft / flywheel assembly 360° for the
verifications below.
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 177
Table of Contents
Removal.........................................................................................................................................................179
Inspections.....................................................................................................................................................180
Instalation.......................................................................................................................................................182
Belt Assembly......................................................................................................................................................185
Removal.........................................................................................................................................................186
Inspection.......................................................................................................................................................186
Installation......................................................................................................................................................186
Starter Motor.......................................................................................................................................................188
Removal.........................................................................................................................................................188
Installation......................................................................................................................................................188
932H00602001
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Follow all warnings, cautions, attention and notes.
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178 PULLEYS, BELTS AND ACCESSORIES
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 179
932H00602001
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Follow all warnings, cautions, attention and notes.
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180 PULLEYS, BELTS AND ACCESSORIES
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 181
Remove the air-conditioning compressor. Hold the pulley nut with a wrench and later loosen the
remaining pulley bolts.
Remove the air compressor. See “Air Compressor -
REMOVAL” in this Manual.
932H00602001
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Follow all warnings, cautions, attention and notes.
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182 PULLEYS, BELTS AND ACCESSORIES
Loosen the 4 attaching bolts and remove the damper Install the fan pulley hub.
pulley from the crankshaft.
Instalation
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 183
Install the alternator and air compressor support Install the alternator attaching the upper and lower
assembly attaching the bolts with the specified torque. bolts with the specified torque.
Install the oil return tube from the support assembly Install the idle pulley and tensioner from the accessory
attaching the hollow bolt with the specified torque. belt.
932H00602001
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Follow all warnings, cautions, attention and notes.
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184 PULLEYS, BELTS AND ACCESSORIES
Install the accessory belt. Install the tensioner attaching the bolts with the
specified torque.
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 185
Belt Assembly
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Follow all warnings, cautions, attention and notes.
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186 PULLEYS, BELTS AND ACCESSORIES
Inspection
Check if the bushing is free from scratches, dents or
dirtiness before installing it on the crankshaft front
pulley.
Also check the pulley housing where the bushing will
Insert a spatula under the bushing until it does not be installed for damages or dirtiness. Apply gasket
make any contact with the seat. Take care not to maker on inner side of the bushing and press it against
damage the seat and the bushing. the pulley.
Installation
NOTE: A faulty bushing (race) replacement can cause Apply the gasket maker over all surfaces of the inner
lack of lubrication on crankshaft bearings and, on more side of the bushing.
severe cases, even lock the crankshaft.
932H00602001
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Follow all warnings, cautions, attention and notes.
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PULLEYS, BELTS AND ACCESSORIES 187
Assemble the bushing on the pulley using a press. Be sure that the oil pump front retainer has no damages
or seepage. Otherwise, it must be replaced by a new
one. Assemble the crankshaft retainer bushing and
pulley. Carefully assemble the vibration damper as
to not damage the retainer. Check if the bushing is
correctly fitted and the cylindrical pin which serves as
a guide is in its correct position.
NOTE: Always use a new retainer for the assembly.
Apply petrolatum.
1st Step 27 to 33 Nm
2 Step
nd
100º + 10º
3 Step
rd
25º + 5º
932H00602001
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Follow all warnings, cautions, attention and notes.
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188 PULLEYS, BELTS AND ACCESSORIES
Removal
Remove the bolt of the starter motor.
932H00602001
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 189
Table of Contents
Lubrication System..............................................................................................................................................191
Cooling System...................................................................................................................................................192
Oil Cooler............................................................................................................................................................193
Removal.........................................................................................................................................................193
Disassembly...................................................................................................................................................195
Cleaning.........................................................................................................................................................195
Inspection.......................................................................................................................................................196
Installation......................................................................................................................................................196
System Bleeding............................................................................................................................................198
Oil Pump..............................................................................................................................................................199
Removal.........................................................................................................................................................199
Inspection.......................................................................................................................................................199
Installation......................................................................................................................................................200
Oil Filter...............................................................................................................................................................202
Removal.........................................................................................................................................................202
Installation......................................................................................................................................................202
932H00602001
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Follow all warnings, cautions, attention and notes.
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190 LUBRICATION SYSTEM
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 191
Lubrication System
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Follow all warnings, cautions, attention and notes.
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192 LUBRICATION SYSTEM
Cooling System
932H00602001
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 193
932H00602001
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Follow all warnings, cautions, attention and notes.
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194 LUBRICATION SYSTEM
Remove the housing assembly and oil radiator. Remove the oil radiator and thermostat assembly.
Remove and discard the sealing gaskets.
932H00602001
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 195
Thermostatic Valve Test Compare obtained values with chart. Replace the
thermostatic valve if the initial opening temperature is
If necessary, the thermostats can be tested with a out of specified values and/or the total operation range
suitable device, as follows: is below specification.
Install the thermostatic valve in a container and fill in
with water until the valve is fully immersed. Caution:
• Never operate the engine without a thermostatic
valve, as the engine will not reach the correct
working temperature, shortening engine life and
causing higher fuel consumption.
• The sealing rings of disassembled components
must be always replaced.
Disassembly
Necessary Equipments:
932H00602001
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196 LUBRICATION SYSTEM
Inspection
Check the oil cooler housing for clogged holes and
damaged threads.
Replace the housing if required.
Installation
932H00602001
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 197
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Follow all warnings, cautions, attention and notes.
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198 LUBRICATION SYSTEM
Precautions Before Starting the Bleed air in the system through the plug in the water
hose nozzle.
Engine
• Loosen the plug and run the engine for about
Attention: To get the best performance of the cooling 1 min.
system, all water passages inside the engine must be
duly filled. Air in the cooling system can cause high Caution: Non-conformance to this procedure can
temperature points on head surfaces and engine cause severe damages to the engine.
block, with resulting cracks on components and burns
on head gaskets. To draw air from the system, the
following procedure must be followed.
System Bleeding
Whenever the oil and water cooler module is removed,
the following procedure must be followed:
• Start the engine to allow the oil and cooling fluid to
flow inside galleries of the cooler;
• Disconnect the M-PROP valve and turn the
starter motor on for some moments to allow an oil
circulation on the cooler module;
• Connect the M-PROP valve again.
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 199
Removal
2
Remove the fan with viscous clutch, accessory belt
and crankshaft damper pulley. For more details, see
accessories and pulleys – removal.
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Follow all warnings, cautions, attention and notes.
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200 LUBRICATION SYSTEM
Installation
932H00602001
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Follow all warnings, cautions, attention and notes.
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LUBRICATION SYSTEM 201
1st Step 13 to 17 Nm
2 Step
nd
57º to 63º
932H00602001
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Follow all warnings, cautions, attention and notes.
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202 LUBRICATION SYSTEM
Removal
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Follow all warnings, cautions, attention and notes.
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ELECTRONIC ENGINE SYSTEM 203
Table of Contents
ECM.....................................................................................................................................................................205
Removal.........................................................................................................................................................206
Inspection.......................................................................................................................................................206
Installation......................................................................................................................................................207
Sensor Identification............................................................................................................................................208
Engine Sensors..............................................................................................................................................208
Fuel Injectors.............................................................................................................................................210
Vehicle Sensors..............................................................................................................................................210
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Follow all warnings, cautions, attention and notes.
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204 ELECTRONIC ENGINE SYSTEM
932H00602001
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Follow all warnings, cautions, attention and notes.
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ELECTRONIC ENGINE SYSTEM 205
ECM
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Follow all warnings, cautions, attention and notes.
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206 ELECTRONIC ENGINE SYSTEM
932H00602001
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Follow all warnings, cautions, attention and notes.
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ELECTRONIC ENGINE SYSTEM 207
Installation
932H00602001
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Follow all warnings, cautions, attention and notes.
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208 ELECTRONIC ENGINE SYSTEM
932H00602001
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Follow all warnings, cautions, attention and notes.
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ELECTRONIC ENGINE SYSTEM 209
Engine Coolant Temperature Sensor (ECT) This sensor consists of a piezoresistive pressure
sensor element and the temperature sensor is a NTC-
resistor in a circuit designed to amplify temperature
signal and compensation in an integrated silicon chip.
The TMAP sensor is assembled on the intake manifold
at the left side of the engine.
Installation: The O-Ring seals the sensor from the
environment and just a light coat of engine oil (5W20)
may be applied as lubricant. Do not use silicone-based
lubricants.
932H00602001
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Follow all warnings, cautions, attention and notes.
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210 ELECTRONIC ENGINE SYSTEM
Vehicle Sensors
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Follow all warnings, cautions, attention and notes.
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COOLING SYSTEM 211
Table of Contents
Cooling System...................................................................................................................................................212
Water Pump.........................................................................................................................................................213
Introduction.....................................................................................................................................................213
Diagnostics.....................................................................................................................................................213
Removal.........................................................................................................................................................213
Installation......................................................................................................................................................214
932H00602001
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212 COOLING SYSTEM
Cooling System
932H00602001
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Follow all warnings, cautions, attention and notes.
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COOLING SYSTEM 213
932H00602001
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Follow all warnings, cautions, attention and notes.
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214 COOLING SYSTEM
Installation
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Follow all warnings, cautions, attention and notes.
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COOLING SYSTEM 215
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Follow all warnings, cautions, attention and notes.
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216 COOLING SYSTEM
NOTES
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 217
Table of Contents
Fuel Filter............................................................................................................................................................218
Removal.........................................................................................................................................................219
Removal.........................................................................................................................................................222
Injectors...............................................................................................................................................................224
Removal.........................................................................................................................................................224
Installation......................................................................................................................................................224
Removal.........................................................................................................................................................227
Installation......................................................................................................................................................227
Removal.........................................................................................................................................................228
Installation......................................................................................................................................................229
Removal.........................................................................................................................................................231
Installation......................................................................................................................................................232
932H00602001
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Follow all warnings, cautions, attention and notes.
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218 FUEL INJECTION SYSTEM
Fuel Filter
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 219
932H00602001
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Follow all warnings, cautions, attention and notes.
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220 FUEL INJECTION SYSTEM
Disconnect the connectors of the injectors. Remove the fuel regulator valve (VCV) connector.
Disconnect the engine fuel pressure sensor (EFP) Remove the CKP sensor by loosening the attachment
connector. to block bolt.
Disconnect the turbo pressure modulator connector. To remove the ECM connector, move the releasing
lever first.
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 221
Remove the ECM connector. Disconnect the engine coolant temperature sensor
(ECT) connector.
932H00602001
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Follow all warnings, cautions, attention and notes.
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222 FUEL INJECTION SYSTEM
Removal
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 223
Loosen and remove the distribution tube (Rail). Attention: Cover all distribution tube inlets to prevent
ingress of debris.
932H00602001
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Follow all warnings, cautions, attention and notes.
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224 FUEL INJECTION SYSTEM
Injectors Installation
Sub-Assembly Injector Nozzle:
Removal
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 225
NOTE:
1. Assemble the washer (4) in the cylinder head
injector housing and insert the sub-assembly 1.
2. Assemble the injector clamp (3), bolt (2) and apply
torque.
3. Apply in two steps torque of 12 Nm ±1 + 120º ± 5º
to the fuel injector clamp bolt (2).
4. Position the cover and bolts (1) and apply torque.
932H00602001
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Follow all warnings, cautions, attention and notes.
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226 FUEL INJECTION SYSTEM
Install the fuel distribution tube to the valve cover. Install new high pressure fuel tubes to the distribution
Tighten the attaching bolts to a torque of 24 to 30 Nm. tube and tighten with 24 to 30 Nm torque.
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 227
Installation
Install a new sealing ring (O-ring) on the high pressure
pump.
932H00602001
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Follow all warnings, cautions, attention and notes.
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228 FUEL INJECTION SYSTEM
Power Steering Pump and Vacuum Loosen the vacuum pump tube at the housing and
remove the lubrication tube.
Pump (TANDEN)
Removal
Properly drain and dispose all the hydraulic system
fluid before removing the assembly.
Remove the fluid reservoir. Unscrew the hydraulic pump attaching bolts.
Loosen the attachments of the hydraulic pump tubes. Remove the pump oil return hose.
932H00602001
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Follow all warnings, cautions, attention and notes.
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FUEL INJECTION SYSTEM 229
Installation
Before starting the installation, clean the hydraulic
system throughout to remove dirtiness, taking care
there is no water or other substances in the tubes or
reservoir before filling them with a new fluid. Install the lubrication tube and the vacuum pump tube
in the housing.
NOTE: Renew the hydraulic fluid whenever the system
is disassembled.
932H00602001
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Follow all warnings, cautions, attention and notes.
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230 FUEL INJECTION SYSTEM
Tighten the attachment of the hydraulic pump to a Assemble the oil reservoir, tightening the attaching
torque of 2 to 3 Nm. bolts of the head support to a torque of 17 to 23 Nm.
Then, tighten the reservoir belt attachment bolts to a
torque of 3 to 7 Nm.
Top up with new fluid, bleed the hydraulic system and
pre-lubricate the pump. For these procedures, see the
owner’s manual of the vehicle.
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
FUEL INJECTION SYSTEM 231
Removal
932H00602001
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232 FUEL INJECTION SYSTEM
Remove the wiring harness glow plug. Install wiring harness glow plug. Apply 1.5 to 2.5Nm
torque.
932H00602001
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FUEL INJECTION SYSTEM 233
Install the exhaust gas recirculation duct and tighten to Install the exhaust gas recirculation cooler outlet tube
16 to 20Nm torque. and tighten 5 to 7 Nm torque.
932H00602001
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234 FUEL INJECTION SYSTEM
NOTES
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INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 235
Table of Contents
Intake Manifold....................................................................................................................................................236
Removal.........................................................................................................................................................236
Installation......................................................................................................................................................237
Removal.........................................................................................................................................................239
Cleaning.........................................................................................................................................................239
Installation......................................................................................................................................................240
Exhaust Manifold.................................................................................................................................................242
Removal.........................................................................................................................................................242
Cleaning.........................................................................................................................................................242
Inspection.......................................................................................................................................................242
Installation......................................................................................................................................................242
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236 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
• Do not smoke;
• Keep away from fire or sparks.
932H00602001
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INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 237
Installation
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238 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
Intake Manifold
1. Gasket, Intake Manifold 3. Bolt, Hex with Flange 8.8 5. Bracket, Exhaust Gas
M8x50 Organo Recirculation Mixer
2. Manifold, Intake
4. Bolt, Hex with Flange 8.8 6. Bolt, Hex with Flange 8.8
M8x80 Organo M8x20 Organo
Intake Elbow
1. Mixer Exhaust Gas Recirculation 3. Bolt, Hex with Flange 8.8 4. Bolt, Hex with Flange 8.8
M6x25 Organo M6x30 Organo
2. O-ring
To install the intake elbow, tightening the attaching Assemble the remaining components in the reverse
bolts to the indicated torque. order of the disassembly procedure.
932H00602001
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INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 239
Removal
Remove the attaching bolt of the feeding tube.
Cleaning
Clean the tubing between the turbocharger and the air
filter. Use filtered compressed air to dry the tubes.
Clean the air inlet tubes and connection hoses.
Clean the oil inlet and drain tubes.
Clean any material residue on the turbine housing
surfaces and exhaust manifold assembly.
Loosen the oil return tube bolt. Loosen the return tube
hose and remove the tube.
932H00602001
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240 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
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INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 241
Before installing the oil inlet tube, lubricate the NOTE: This procedure is important to avoid damages
turbocharger shaft with new engine oil through the oil due to lack of turbo lubrication on the first start of the
inlet hole. Use new washers on the turbo oil inlet. engine.
932H00602001
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242 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
Installation
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INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 243
932H00602001
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244 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
NOTES
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TROUBLESHOOTING 245
Table of Contents
Symptom Chart...................................................................................................................................................246
Bearing Diagnostics............................................................................................................................................256
Excessive Clearance.................................................................................................................................257
Solid Particles...........................................................................................................................................258
Crankcase Out-of-roundness....................................................................................................................260
Offset Cap.................................................................................................................................................263
Bent Crankshaft........................................................................................................................................264
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246 TROUBLESHOOTING
Symptom Chart
The ECM enters into the Safe Mode: Limited engine RPM;
59-65-67-68-69-75-113-131-199
engine stops
10-11-12-13-14-30-31-33-35-38-50-51-52-53-
Engine does not start 56-57-70-90-134-150-151-152-170-171-175-
190-191
10-11-12-13-14-31-33-35-38-50-51-52-53-56-
Hard start – engine takes long to start 57-70-90-134-150-151-152-170-171-175-190-
191
31-33-35-38-50-51-52-53-56-57-58-70-71-72-
Low power / poor performance 73-84-90-130-132-134-150-151-152-170-171-
172-190-191-197-198
31-50-53-56-57-58-63-71-72-90-116-132-137-
Excessive fuel consumption
150-151-152-171-172-191-197-198
31-50-53-56-57-58-63-71-72-90-116-150-151-
Excessive black smoke
171-191
31-50-58-70-71-74-110-112-116-130-150-153-
Excessive white smoke
154-170-176-179-191-195
932H00602001
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TROUBLESHOOTING 247
111-113-116-117-124-134-136-140-151-152-
Excessively noisy engine or internal knocks 154-157-158-170-171-175-190-191-193-194-
196-198
37-50-53-56-71-124-125-134-151-152-153-
Excessive vibration
154-155-158-177-191-192-193-194-196
37-53-56-63-90-116-121-125-130-137-138-
Boiling
140-141-150-158-171-175-190-191
Overheating 131-158
70-75-76-90-110-116-122-123-130-153-
Excessive oil pan pressure with possible oil leakage (blow-by)
155-170-176-178
57-58-70-90-110-130-134-150-152-153-
Low compression in one of the cylinders
170-175
31-63-70-74-110-112-123-125-153-155-158-
High lubricating oil consumption
170-176-178-179
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248 TROUBLESHOOTING
Tank electric pump running but with no Check: clogged pump, open return valve, faulty pump
32
pressure motor, blown fuse.
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TROUBLESHOOTING 249
Replace the fuel. Check the fuel tank and feeding line for
35 Inadequate fuel.
contamination. Clean and replace as required.
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250 TROUBLESHOOTING
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TROUBLESHOOTING 251
76 Clogged air filter If it is contamination by oil, check for excessive oil return
to the filter. In this case, check the oil pan return valve, oil
pan oil level and working conditions of the turbocharger.
Repair or replace.
Visually check for oil in the core. Perform a leak test with
84 Air leakage on aftercooler the aftercooler immersed in water and using pressurizing
the air.
112 High lubricating oil level in the oil pan Check, repair or replace.
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252 TROUBLESHOOTING
Oil pump pressure relief valve spring stuck Check the condition of the spring, ball and obstruction of
117
opened the groove on pump housing. Repair or replace.
136 Excessively noisy fan Check for viscous clutch locked on. Replace if necessary.
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TROUBLESHOOTING 253
932H00602001
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254 TROUBLESHOOTING
932H00602001
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TROUBLESHOOTING 255
Improper clearance between the CKP sensor Check clearance using a feeler gauge. Follow the
199
and the pulse wheel specifications and procedures of the service manual.
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256 TROUBLESHOOTING
Causes
Lack or dilution of the lubricating oil film between
the bearing and shaft, which cases wear of the
electrodeposited layer, is normally caused by:
• Insufficient vertical clearance;
• Dilution of the lubricating oil;
• Engine running in idle for long periods of time.
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TROUBLESHOOTING 257
Corrections
Excessive Clearance
Appearance
Causes
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258 TROUBLESHOOTING
Corrections
Solid Particles
Appearance
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TROUBLESHOOTING 259
Causes
Dust, dirt, abrasives or metal particles in the oil encrust
over the bearings surfaces, displacing the antifriction
alloy. Tips of the alloy or particle can come to the shaft,
creating friction points and causing disruption of the oil
film, as shown in the images below.
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260 TROUBLESHOOTING
Causes
Corrections
• Assemble new bearings, carefully following the Particles between the bearing housing and bearing
recommended cleaning instructions; prevent proper contact and can stop the heat flow.
• Grind the shaft if necessary; Heating and localized loads cause fatigue in this area
and the material is taken off.
• Change the lubricating oil and oil filter at
recommended intervals and keep the air filter and Corrections
oil vent tube clean.
• Carefully clean the bearing housing throughout,
removing all burrs, dirtiness or solid particles
Dirtiness on Bearing Housing before installing new bearings;
Appearance • Check the condition of the journals and grind them
if required.
Crankcase Out-of-roundness
Appearance
Excessive wear areas near the bearing partition lines.
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TROUBLESHOOTING 261
Causes
The tightening is not sufficient enough for setting up a
radial pressure that holds the bearings in the housing.
Corrections
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262 TROUBLESHOOTING
Causes
When a bearing is placed over its connecting rod
housing, it sticks out of the partition line (seat
height).
When tightening cap bolts, the bearings are pressed
against the housing, thus assuring a good contact.
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TROUBLESHOOTING 263
Causes
Causes The bearing cap has been displaced, pressing one
side of each cap against the shaft. That can happen
due to:
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264 TROUBLESHOOTING
Bent Crankshaft
Appearance
• A well-defined wear band can be seen on upper
central main bearing or on lower ones;
• The amount of wear is different for each bearing,
but in general, it is more pronounced on central
main bearings.
Causes
• A bent crankshaft causes excessive loads to the
central main bearings, the highest pressures are
where the bending is highest.
Corrections
• Choose the right wrench and alternately tighten
the bolts for proper cap seating;
• Make sure that the cap position is correct;
Corrections
• Check if the cap centering system is not changed
or damaged and replace it if necessary; • Check if the shaft is bent with an appropriate
• Replace the connecting rod / bearing bolts per procedure.
recommendations; • Replace the crankshaft if required.
• Machine the crankshaft per specifications.
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TROUBLESHOOTING 265
Appearance
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266 TROUBLESHOOTING
Causes
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TROUBLESHOOTING 267
Appearance
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268 TROUBLESHOOTING
An uneven wear band at the bearing. According to Excessively worn areas alongside the bearing side
places subject to higher pressures, there are three surfaces.
main aspects that correspond respectively to the
defects of journal shapes, as shown. Causes
Incorrect fillet radius on journals, causing metal-to-
metal contact alongside the bearing lateral surfaces.
This leads to excessive wear and a localized
premature fatigue.
Causes
Non-cylindrical journals impose an irregular distribution
on the bearing surface, generating higher heat and
accelerating wear in certain areas. Clearances may
become insufficient and metal-to-metal contact can Corrections
appear between the bearings and crankshaft journals.
• Machine journals, taking care to correctly make
In other cases the clearances will be excessive. The the radiuses;
tapered, concave or convex profiles of crankshaft
journals and even a tapering of the connecting • Do not leave sharp edges, as that will weaken the
rod bearing housing is always caused by incorrect shaft due to stress concentration in an already
machining. stressed area.
Appearance
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TROUBLESHOOTING 269
Causes
The torque applied to the block attaching studs / bolts
causes deformation and consequently metal-to-metal
contact when the specification is exceeded. This
contact generates enough heat to cause melting and
dragging of the material. Another factor that leads to
fusion is a partial obstruction of the external lubrication
groove due to adhesive build up.
Corrections
• Periodically check / calibrate the torque wrench;
• Tighten to recommended torque;
• Assemble the engine following recommendations.
Inadequate shims.
Exchanged bearings.
932H00602001
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270 TROUBLESHOOTING
932H00602001
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 271
Table of Contents
Alternator.............................................................................................................................................................275
Alternator Bracket................................................................................................................................................276
Belt Tensioner......................................................................................................................................................277
Camshaft.............................................................................................................................................................278
Crankcase...........................................................................................................................................................279
Crankshaft ..........................................................................................................................................................281
Cylinder Head......................................................................................................................................................282
EGR System........................................................................................................................................................285
Exhaust Manifold.................................................................................................................................................288
Fan Drive.............................................................................................................................................................289
Flywheel..............................................................................................................................................................290
Flywheel Housing................................................................................................................................................292
Glow-Plug............................................................................................................................................................296
Intake Manifold....................................................................................................................................................297
Intermediate Gear...............................................................................................................................................298
Lifting Eyes..........................................................................................................................................................300
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272 APPENDIX A
Table of Contents
Oil Dipstick...........................................................................................................................................................306
Rocker Arm..........................................................................................................................................................311
Sensors...............................................................................................................................................................312
Starter Motor.......................................................................................................................................................313
Tandem Pump.....................................................................................................................................................314
Timing Case........................................................................................................................................................315
Turbocharger.......................................................................................................................................................316
Turbocharger Lubrication....................................................................................................................................317
Turbocharger Tub................................................................................................................................................318
Water Pump.........................................................................................................................................................320
932H00602001
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 273
1. Mixer Exhaust Gas Recirculation 3. Bolt, Hex With Flange 8.8 M6x25 4. Bolt, Hex With Flange 8.8 M6x30
Organo Organo
2. O’Ring
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Follow all warnings, cautions, attention and notes.
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274 APPENDIX A
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 275
Alternator
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Follow all warnings, cautions, attention and notes.
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276 APPENDIX A
Alternator Bracket
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 277
Bel Tensioner
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Follow all warnings, cautions, attention and notes.
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278 APPENDIX A
Camshaft
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 279
Crankcase
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Follow all warnings, cautions, attention and notes.
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280 APPENDIX A
NOTE: The contact faces of the parts must be oiled Steps M14x95 – 10.9
with lubricant oil.
1 60 N.m + 6
Bolt, Bering Cap: 2 90° + 10°
−− Insert the bolt, manually in the bearing cap. Discart bolt after X > 96.5mm.
−− Tighten the bolt in 2 steps, as indicated below:
932H00602001
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APPENDIX A 281
Crankshaft
NOTE: The contact faces of the parts must be oiled Item Clearance
with lubricant oil.
4 Crankshaft /
Radial 0.036 to 0.098
5 Bering Shells
Crankshaft /
6 Axial 0.080 to 0.251
Bering Shells
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Follow all warnings, cautions, attention and notes.
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282 APPENDIX A
Cylinder Head
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 283
932H00602001
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Follow all warnings, cautions, attention and notes.
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284 APPENDIX A
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 285
EGR System
1. Cooler, Exhaust Gas 6. Bolt Hex. with Flange 10. Thermostatic, Valve
Recirculation M8x25 – 8.8 Organo
11. O`Ring
2 Bolt Hex. with Flange 7. Valve, Exhaust Gas
12. Tube, EGR Cooler Outlet Wather
M8x90 – 8.8 Organo ecirculation
13. Bolt Hex. with Flange M8x35 –
3. Bracket, EGR Cooler 8. Valve, Exhaust Gas
8.8 Organo
Recirculation
4. Valve, Throttle
14. Grease Based on Silicone DC 111
9. O`Ring
5. Bolt Hex. with Flange
M6x40 – 8.8 Organo
932H00602001
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Follow all warnings, cautions, attention and notes.
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286 APPENDIX A
1. Gasket, EGR Tube to EGR Valve 7. Tube, Water Outlet 13. O`Ring
2 Elbow, EGR Valve Air Inlet 8. Bolt Hex. with Flange M8x16 14. O`Ring
Organo
3. Bolt Hex. with Flange M8x25 15. Tube, Exhaust Gas Recirculation
Organo 9. O`Ring Cooler Water Inlet
4. Clamp – PEB 5164 10. Gasket, Exhaust Manifold to EGR 16. Hose, Assy Oil Cooler Water Inlet
Cooler
5. Hose, Exhaust Gas Recirculation 17. Spring Clamp DN 47 - DIN 3021
Valve 11. Duct, Exhaust Gas Recirculation
18. Spring Clamp DN 35 - DIN 3021
6. Tube, Exhaust Gas Recirculation 12. Bolt Hex. with Flange for Hight
Cooler Outlet Temp
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APPENDIX A 287
Engine Breather
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288 APPENDIX A
Exhaust Manifold
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Follow all warnings, cautions, attention and notes.
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APPENDIX A 289
Fan Driver
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
290 APPENDIX A
Flywheel
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 291
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
292 APPENDIX A
Flywheel Housing
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 293
NOTE: Apply lub oil No 901922002037 on the lip Attention: Mount opposite side of lip.
the seal during mounting process of the bushing
crankshaft. NOTE: Apply liquid seal on the indicated area.
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
294 APPENDIX A
1. Pump, Fuel High Pressure 6. Bolt, Left Hand Thread 11. Lower Clamp, Injection Pipe
2. Adapter Flange, Pump Fuel 7. Pipe Assy, Fuel High Pressure 12. Spacer, Injection Pipe
High Pressure
8. Rail, Fuel High Pressure 13. Upper Clamp, Injection Pipe
3. Chart, O`Ring
9. Hexalobular Socket Pan Head 14. Bolt, Hex with Flange 8.8 M6x16
4. Gear, Pump Fuel High Pressure Screw M8x105 Organo
5. Washer, Pump Fuel High 10. Pipe Assy, Fuel High Pressure 15. Bolt, Hex with Flange 8.8 M8x40
Pressure Organo
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 295
Fuel Injector
1. Nozzle, Fuel Injector 5. Washer, Fuel Injector 7. Bolt, Fuel Injector Clamp
2. Seal , Fuel Injector 6. Bolt, Hex with Flange 8.8 8. Clamp, Fuel Injector
M6x20 Organo
3. Cover, Fuel Injector Clamp
4. Gasket, Fuel Injector Clamp
Cover
NOTE: Pre-assembly manually the injector (1), NOTE: To install the injectors in accordance in the
retainer (2), cover (3) and gasket (4) corresponding original position.
to the sub-assembly 1. Assemble the washer (5) in
the cylinder head injector housing and insert the sub-
assembly 1. Assemble the injector clamp (8), bolt (7)
and apply torque. Apply in two steps 12Nm ± 1 + 120
± 5° to the fuel injector clamp bolt (7). Positioning the
cover (3) and bolt (6) aplly torque.
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
296 APPENDIX A
Glow-Plug
1. Glow Plug 2. Wiring Harness, Glow Plug 3. Hexagon Flange Nut M4x0.7
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 297
Intake Manifold
1. Gasket, Intake Manifold 3. Bolt, Hex with Flange 8.8 5. Bracket , Exhaust Gas Recirculation
M8x50 Organo Mixer
2. Manifold, Intake
4. Bolt, Hex with Flange 8.8 6. Bolt, Hex with Flange 8.8 M8x20
M8x80 Organo Organo
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
298 APPENDIX A
Intermediate Gear
1. Intermediate Gear Assy, 5. Bering Assy, Intermediate Gear 9. Gear Double, Transference
Camshaft
6. Gear Intermediate, Fuel High 10. Intermediate Gear, Steering Pump
2. Bering Intermediate Gear Pressure Pump
3. Ring, Gear Bering 7. Retainer, Gear Pump
4. Hexagon Flanged Bolt M12x65 8. Hexagon Flanged Bolt Oiled
DIN 6921 10.9 M10x60 DIN 6921 10.9
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 299
NOTE: Mount Cylinder Head in Crankase, position the Assemble the item 8 with fastener Loctite 271 (item 1)
device, intermediate gear in the Camshaft, after tighten on items 6 and 9.
the bolt DIN 6921 M14x80 fixation of the intermediate
Manually insert the bolt.
gear camshaft and verify clearance specified.Case
it does anchieve the specified clearance you must Tighten the bolt in two stages, acording to showed.
remove the gear and assembly the gear again,
pulling up the device manually to the side needed and
tightening the bolt of the gear then checking again
the clearance, case if does achieve the specified
clearance to repeat the process again.
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
300 APPENDIX A
Lifting Eyes
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 301
1. Tube Assy, Fuel Return 6. Fuel Filter 11. Bracket Fuel Inlet Return Tubes
2. Clamp 7. Bracket Fuel Filter 12. Bolt Hexagon with Flange 8.8
M6x12 Organo
3. Tube Assy, Fuel Filter High 8. Double Pipe Clip
Pressure Pump 13. Clamp
9. Bracket Fuel Inlet Return Tubes
4. Spring Clamp DN14 – DIN3021
10. Tube Assy, Fuel Filter Inlet
5. Bolt Hexagon with Flange 8.8
M10x20 Organo
932H00602001
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© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
302 APPENDIX A
NOTE: * Mount the item 8 in this place. ** Mount the items 6 and 7 with the items 9.
932H00602001
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© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 303
NOTE: Lubricate slighy the oil filter gasket (item 2). * Assemble O’Ring (items 4, 5 and 6 with grease
(item 7).
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
304 APPENDIX A
1. Pan Assy, Lubrication Oil 4. Pipe, Suction Lubrication Oil 7. Hexagon Socket Screw
M8x25– 8.8
2. Gasket, Oil Pan 5. O’Ring
8. Intermediary Pipe
3. Hexagon Flanged Bolt 6. Hexagon Flanged Bolt
M8x16 – 8.8 M10x45 – 8.8
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 305
1. Gasket, Lubrication Oil Pump 3. Oil Seal, Side Oil Pump 4. Hexagon Flanged Bolt M8x1.25
2. Pump Lubrication Oil
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
306 APPENDIX A
Oil Dipstick
1. Tube Assy, Oil Dipstick 4. Hexagon Flanged Bolt, 6. Sealing Washer DIN
M10x45 – 8.8 7603 – A16x20 – AI
2. Oil Dipstick
5. Hollow Bolt M16x1.5x28
3. Hexagon Flanged Bolt,
M8x16 – 8.8
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 307
1. Piston Assy, Ring and 2. Upper Bearing Shell, 3. Piston Assy, Ring and
Connecting Rod Connecting Rod Connecting Rod
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
308 APPENDIX A
Steps Torque
1 20 ± 3 Nm
2 130° - 5°
Clearance
Axial 0.20 to 0.50
Bearing Shell Connecting Rod / Crankshaft
Radial 0.030 to 0.088
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 309
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
310 APPENDIX A
Mounting Instruction:
−− Apply Chemical Lock (item 5) on Front Bushing
inside surface (item 3) before assembling.
−− Mounting the bushing (item 3) on pulley (item 1).
−− Mounting the pulley (item 1) on crankshaft.
−− Tighten bolts (item 2) according to tightening
sequence.
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 311
Rocker Arm
1. Shaft, Rocker Arm 2. Rocker Arm, Inlet (Options 3. Rocker Arm, Exhaust (Options
Structure) Structure)
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
312 APPENDIX A
Sensors
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 313
Starter Motor
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
314 APPENDIX A
Tandem Pump
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 315
Timing Case
F1 = Maximum 0.05
Step in the assembly between the timing
case and crankcase
F2 = Maximum 0.15
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
316 APPENDIX A
Turbocharger
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 317
Turbocharger Lubrication
NOTE: Assemble Tube (2) in Crankcase, with Seal (1) Assemble Washer (12) and Spacer (10) at
and Tight. Turbocharger.
Assemble Hose (3) and Clamp (4) in Tube. Assemble Tube (11), Washer (2) and Bolt (8) in Spacer
Assemble Tube (6), Gasket (7) and Bolt (5) at (10).
Turbocharger. Assemble Tube (11), Washer (9) and Bolt (8) in Head
Assemble Hose (3) in Tube (2) and Position Clamp Filler. Tight Bolt (8).
(13).
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
318 APPENDIX A
Turbocharger Tub
NOTE: Assemble the Tube (2), Washer (1/7) and Bolt Assemble the Tube (4), Washer (1) and Bolt (3) on
(3) on EGR. Turbocharger.
Assemble the Tube (2), Washer (1) and Bolt (3) on Assemble the Tube (4), Washer (5) and Bolt (3) on
Turbocharger. Timing Case.
Tight the Bolts (3). Tight the Bolts (3/6).
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX A 319
Valve Cover
1. Gasket, Valve Cover 5. Sealing Washer 11. Tube, Lubrication Oil Fill Cover
2. Cover, Valve 6. Plug Thread M22 12. O-ring
3. Hexagon Flanged Bolt M8x25 7. Hexagon Socket Set Screw 13. Chemical Lock Loctite 242
4. Cover, Lubrication Oil Fill 9. Hexalobular Socket Pan Head 14. Grease Based Silicon DC111
Screw M8x1.25x105
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
320 APPENDIX A
Water Pump
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX B 321
Standard Torque Chart for Regular Steel Bolts (According to DIN Standard No. 2230)
NOTE: This chart values apply only when the torque is not indicated in the Service Manual. For all other conditions,
the supplied special torque values prevail on related procedures.
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
322 APPENDIX B
NOTES
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX C 323
Special Tools
MWM CODE TOOL TYPE COMPONENT IMAGE
Camshaft Gear
D7002303C1 Adjuster Device
Clearance adjustment
932H00602001
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Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
324 APPENDIX C
Piston height
9.610.0.690.062.4 Dial indicator support
measuring
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
APPENDIX C 325
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
326 APPENDIX C
NOTES
932H00602001
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Produced by:
ASC Comunicação Técnica
www.asccomunicacao.com.br