PDF Service Manual NEW HOLLAND F5 Tier 4B Engine - 9 MB
This service manual provides complete repair and maintenance information for the New Holland F5 Tier 4B final and Stage IV engine.
It is an essential resource for technicians, containing detailed specifications, troubleshooting steps, and disassembly/assembly procedures.
With this guide, you can confidently diagnose and repair any issue, ensuring the engine meets emissions standards and performs reliably.
This is the definitive guide for servicing the F5 engine.
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--- Page 1 ---
SERVICE MANUAL
F5
Tier 4B (final) and Stage IV
Engine
See the following page for engine model numbers
Part number 47730922
Printed in U.S.A. 1st edition English
© 2015 CNH Industrial America LLC. All Rights Reserved.
Case, Case IH, New Holland, and Styer are trademarks registered in the United States and many other countries,
June 2015
owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.
--- Page 3 ---
INTRODUCTION
Basic instructions - Shop and assembly
Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals
For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CNH Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CNH Original Parts can offer this
guarantee.
When ordering spare parts, always provide the following information:
• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
47730922 29/06/2015
6
--- Page 4 ---
Contents
Engine - 10
Engine and crankcase - 001
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankcase
Bore - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(*) See content for specific models
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--- Page 5 ---
Contents
Engine - 10
Cylinder heads - 101
FUNCTIONAL DATA
Cylinder head
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Valve cover
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder head
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Valves
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Valve guide
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Valve seat
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
(*) See content for specific models
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--- Page 6 ---
Engine - Cylinder heads
5. Install the fuel injectors (1). Refer to Fuel injectors -
Install (10.218) for the proper procedure.
NHIL14ENG0591AA 3
NOTE: If your machine uses a remote mounted fuel filter base, skip steps 6 through 9.
6. Install the fuel filter base (3).
7. Install the two M8 x 45 bolts (2) to secure the filter base.
8. Connect the fuel supply line (4) to the filter base.
9. Connect the fuel return line (1) to the filter base.
NHIL14ENG0585AA 4
10. Install the clamp (1) to secure the fuel injector return
line.
NHIL14ENG0586AA 5
11. Use the M8 x 100 bolts (1) to install the common rail
(2) on the valve cover.
12. Torque the M8 x 100 bolts to 20 - 30 N·m (15 - 22 lb
ft).
NHIL14ENG0584AA 6
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--- Page 7 ---
Engine - Cylinder heads
23. Install the high pressure fuel lines (1) from the com-
mon rail to the fuel injectors.
NHIL14ENG1065AA 11
24. Position the wire harness over the valve cover.
25. Install the bolts (1) to secure the wire stands to the
valve cover.
26. Install the wire harness clamps (2).
NHIL14ENG1064BA 12
27. Install the Allen head bolt (1) to secure the main con-
nector harness.
NHIL14ENG1063AA 13
28. Connect the electrical connections and wire ties to the
following components:
• High pressure pump metering unit (1)
• Fuel pressure sensor (2)
• Oil pressure sensor (3)
• Fuel temperature sensor (4)
• Crankshaft speed sensor (5)
• Camshaft speed sensor (6)
• Fuel heater (if equipped)
NHIL14ENG1062FA 14
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--- Page 8 ---
Engine - Cylinder heads
Cylinder head - Disassemble
F5BFL413A*B001
F5BFL413A*B003
F5BFL413A*B007
F5BFL413A*B009
F5BFL413D*B002
F5BFL413D*B003
F5BFL413F*B002
F5BFL413F*B003
F5GFL413A*B003
F5GFL413A*B004
F5GFL413A*B006
F5GFL413A*B007
F5GFL413A*B012
F5GFL413A*B013
Prior operation:
Cylinder head - Remove (10.101)
1. Number the intake valves (1) and the exhaust valves (2)
before removal to ensure the correct orientation during
assembly.
NHIL14ENG1080AA 1
2. Remove the valve bridge (1).
3. Use the spring compressor tool 380000302 to com-
press the valve spring (4).
4. Remove the keepers (2).
5. Remove the spring compressor tool.
6. Remove the spring retainer (3), spring (4) and spring
cup (5).
7. Repeat steps 1 through 6 for each valve.
NHIL14ENG1081AA 2
8. Turn the cylinder head upside down and remove the
valves (1).
NHIL14ENG1082AA 3
Next operation:
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--- Page 9 ---
Index
Engine - 10
Cylinder heads - 101
Cylinder head - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder head - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder head - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder head - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cylinder head - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder head - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder head - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder head - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cylinder head - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder head - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Valve cover - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valve cover - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Valve cover - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve cover - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valves - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valves - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valves Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
(*) See content for specific models
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--- Page 10 ---
Engine - Pan and covers
Timing gear housing - Remove
Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the fuel injection pump (1). Refer to Injection
pump - Remove (10.218) for the proper procedure.
2. Remove the fan pulley bolts.
3. Remove the fan pulley (2).
NHIL14ENG0613AA 1
4. Remove the idler gear bolt (1).
5. Remove the idler gear (2).
6. Remove the camshaft gear bolts (3).
7. Remove the camshaft gear (4).
NHIL14ENG0617AA 2
8. Remove the three bolts (3) from the front of the oil pan.
9. Remove the bolts (2) from the timing gear housing.
10. Remove the timing gear housing (1) from the engine
block.
NHIL14ENG0618AA 3
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--- Page 11 ---
Engine - Crankshaft and flywheel
Flywheel housing - Install
F5B
F5DFL463A*F007
F5DFL463A*F013
F5DFL463A*F014
F5DFL463A*F019
F5DFL463A*F020
F5DFL463B*F003
F5DFL463B*F004
F5DFL463B*F006
F5DFL463C*F001
F5DFL463C*F002
F5DFL463C*F004
F5HFL463A*F001
F5HFL463A*F002
F5HFL463A*F003
F5HFL463A*F004
F5HFL463A*F005
F5HFL463A*F006
F5HFL463A*F007
F5HFL463A*F008
F5HFL463B*F001
F5HFL463B*F002
F5HFL463C*F001
F5HFL463C*F002
F5HFL463D*F001
F5HFL463D*F004
F5HFL463D*F005
F5HFL463D*F006
Prior operation:
Flywheel housing - Remove (10.103)
1. Clean the sealing surfaces (1) of the flywheel housing.
NHIL14ENG0626AA 1
2. Clean the sealing surface (1) of the engine block.
3. Apply LOCTITE® 5970™ sealant in a consistent 1.5 mm
(0.059 in) bead around the sealing surface of the fly-
wheel housing.
NOTICE: Be sure there are no lumps, air bubbles or gaps.
Do not use too much sealer as it could squeeze from the
surface and obstruct lubrication passages.
NHIL14ENG0627AA 2
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--- Page 12 ---
Engine - Crankshaft and flywheel
7. Remove the main bearing caps.
8. Compare the widest point of the plastic gauge to the
scale on the package (1).
9. The width of the wire should be between:
• 0.064 - 0.095 mm (0.0025 - 0.0037 in) for journals
1, 2, 3, 4
• 0.059 - 0.100 mm (0.0023 - 0.0039 in) for journal 5
10. Replace the bearings if the values above cannot be
obtained and perform the procedure again.
73092846A 4
Connecting rod journals
1. Clean the crankshaft journals and connecting rod bear-
ings.
2. Place a piece of plastic gauge (3) on the surface of the
journal (2) as shown.
3. Install the connecting rod caps (1).
73092867 5
4. Lubricate the rod cap bolts (1) with clean engine oil.
5. Install the rod cap bolts (1).
6. Torque the bolts to 45 - 55 N·m (33 - 41 lb ft).
73092868 6
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--- Page 13 ---
Engine - Connecting rods and pistons
Connecting rod and piston - Assemble
Prior operation:
Connecting rod and piston - Disassemble (10.105)
1. Install the piston pin (1) through the piston and the con-
necting rod.
NOTE: Use the markings on the piston (2) to correctly ori-
ent the piston on the connecting rod. The (→) marks the
front of the engine as viewed from the top.
NHIL13ENG1209AA 1
2. Use snap ring pliers (1) to install the snap rings (2) that
secure the assembly together.
NHIL13ENG1208AA 2
3. Use the pliers 380000324 (2) to install the piston rings
(1) on the piston (4).
4. The rings need to be mounted with the marking (3)
facing upwards.
5. Direct the ring openings so they are staggered 120 °
apart.
NHIL14ENG0636AA 3
Next operation:
Connecting rod and piston - Install (10.105)
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--- Page 14 ---
Engine - Valve drive and gears
Camshaft bushings - General specification
NHIL14ENG0650AA 1
Camshaft bore inside diameter
(1) 59.222 - 59.248 mm (2.3316 - 2.3326 in)
(2), (3), (4) 50.069 - 50.119 mm (1.9712 - 1.9732 in)
(5) 40.069 - 40.119 mm (1.5775 - 1.5795 in)
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Engine - Valve drive and gears
Camshaft - Remove
Prior operation:
Timing gear housing - Remove (10.102)
NOTE: This procedure is best performed with the engine block rotated upside down to keep the tappets from inter-
fering with removal of the camshaft.
1. Remove the camshaft retainer plate bolts (2).
2. Remove the camshaft retainer plate (1).
NHIL14ENG0643AA 1
3. Slide the camshaft (1) out of the engine block.
NOTICE: Be sure not to damage the bushings during re-
moval.
NHIL14ENG0644AA 2
Next operation:
Camshaft - Install (10.106)
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--- Page 16 ---
Engine - Valve drive and gears
Next operation:
Engine block cover Front - Install (10.102)
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--- Page 17 ---
Engine - Fuel filters
Fuel filters - Install
Prior operation:
Fuel filters - Remove (10.206)
1. Install the fuel filter base (2) onto the valve cover.
2. Install the M8 x 45 bolts (1) to secure the fuel filter base.
3. Torque the M8 x 45 bolts to 25 N·m (18 lb ft).
NHIL14ENG0659AA 1
4. Connect the fuel filter inlet line (3).
5. Connect the fuel filter outlet line (1).
6. Connect the electrical connector (2).
NHIL14ENG0658AA 2
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--- Page 18 ---
Engine - Fuel injection system
Fuel injection system - Bleed
WARNING
Pressurized system!
Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines
to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.
Failure to comply could result in death or serious injury.
W0285A
Machines with a primer button.
1. Remove the fuel bleed screw (1) from the top of the fuel
filter housing.
2. Press the primer button on the machine.
3. Install the bleed screw (1) when fuel is present at the
top of the filter.
4. Crank the engine.
NOTICE: Only crank the engine for 20 s at a time. Allow
the starter to cool for 30 s before cranking again.
NHIL14ENG0660AA 1
Machines without a primer button.
5. Turn the key to the ON position.
6. Allow the pump to run approximately 30 s.
7. Turn the key to the OFF position.
8. Loosen the bleed screw (1) on top of the filter base to
purge the air from the system.
9. Tighten the bleed screw (1).
10. Crank the engine.
NOTICE: Only crank the engine for 20 s at a time. Allow
the starter to cool for 30 s before cranking again.
11. Repeat steps 5 through 10 if the engine will not start.
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--- Page 19 ---
Engine - Fuel injection system
Fuel injection system - Troubleshooting
NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure
sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See
Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary.
NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure
Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
NOTE: If a fuel injector is replaced, a new IMA code must be programmed. The IMA code may be hidden under the
paint on the fuel injector. For more information regarding programming IMA codes, see Fuel injectors - Configure
- IMA codes (10.218).
Problem Possible Cause Correction
Dark, hazy fuel color Poor fuel quality or contamination. Hazy 1. Drain the fuel tank and replace with new
looking fuel typically is a sign of water con- diesel fuel.
tamination. Dark fuel is usually indicative
of oxidation, possibly from being stored for
too long, and is a far more severe stage of
diesel fuel contamination.
Diesel fuel leakage Loose or improperly connected fittings, 1. Inspect all hoses, clamps and fittings. If
damaged seals or damaged fuel lines. any fittings or clamps are loose or im-
Leakage from fuel filters. properly installed, repair as necessary.
2. Inspect all fuel filters for leakage. If
the filter is damaged or there is leakage
from the seal, replace the failed fuel fil-
ter.
3. Inspect all fuel lines for leakage or dam-
age. If there is any leakage or damage
present, repair as necessary.
4. Inspect the fuel tank for damage or cor-
rosion. If there is any failures found, re-
pair or replace as necessary.
5. Inspect all fuel system components for
diesel fuel leakage. If any leakages are
present, repair or replace as necessary.
Low fuel system pressure Low fuel system pressure can be caused 1. Perform a fuel system pressure test to
by clogged fuel filters, a faulty electric lift verify the low pressure condition. The
pump (if applicable), a faulty mechanical fuel pressure at the main fuel filter, af-
fuel pump, a faulty fuel metering unit, or ter the mechanical gear pump, should
leakages present in the system. be approximately 5.0 bar (72.5 psi). If
the pressure is too low, continue to trou-
bleshoot the low pressure side of the
fuel system to isolate the failed compo-
nent. If the pressure is not too low, con-
tinue to Step 2.
2. Use the Electronic Service Tool (EST)
to check for active fault codes related
to the fuel metering unit. If any faults
are active, diagnose them first and then
continue troubleshooting the fuel sys-
tem.
Fuel system pressure too Too high fuel pressure can be caused by 1. Check the operation of the fuel meter-
high a faulty fuel metering unit, a stuck closed ing, pressure relief valve and the rail
pressure relief valve, or a faulty rail pres- pressure sensor. Use the appropriate
sure sensor. section of the engine service manual, if
necessary. Repair or replace as neces-
sary.
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--- Page 20 ---
Engine - Turbocharger and lines
10. Connect the bottom fitting of the oil supply line (1) to
the engine block.
NOTE: If the fitting (2) was removed, install the fitting and
torque to 40 N·m (30 lb ft).
NHIL14ENG0702AA 5
11. Install the hose (1) from the turbocharger to the Throt-
tle Valve Actuator (TVA).
NHIL14ENG0697AA 6
12. Install the hose (2) that runs from the turbocharger to
the boost pressure modulator valve.
13. Install the hose (1) that runs from the wastegate actu-
ator to the boost pressure accumulator.
NHIL14ENG0696AA 7
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--- Page 22 ---
Engine - Intake and exhaust manifolds and muffler
Intake manifold - Remove - Spacer
Prior operation:
Intake manifold - Remove (10.254)
1. Remove the intake manifold spacer bolts (1).
2. Remove the air intake manifold spacer (2).
3. Remove the intake manifold spacer gaskets.
NHIL14ENG0712AA 1
Next operation:
Intake manifold - Install - Spacer (10.254)
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--- Page 23 ---
Engine - Engine lubrication system
Engine oil pump - Overview
73092739 1
(1) Drive shaft (5) Housing
(2) Main gear (6) Cover
(3) Secondary shaft (7) Internal rotor
(4) Secondary gear (8) External rotor
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--- Page 24 ---
Engine - Engine lubrication system
Engine oil pump - Install
Prior operation:
Engine oil pump - Remove (10.304)