【EN】Maxxforce3.2 Engine Workshop Manual PDF

SERVICE MANUAL
MaxxForce 3.2H
Euro IV
SERVICE MANUAL
SERVICE MANUAL
MaxxForce® 3.2H
Euro IV
Model Year 2013 and Up
932H00602003
Euro IV
MaxxForce 3.2H
®
Model Year 2013 and Up
932H00602003
© 2013 Navistar, Inc. All rights reserved

Printed in Brazil
SERVICE MANUAL
ENGINE SERVICE MANUAL
932H00602003
07/2013
932H00602003
Read all safety instructions in the “Safety Information” section of this Manual before doing any procedures.
Follow all warnings, cautions, attention and notes.
© 2013 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.......................................................................................................................................................15
Operation and Maintenance..................................................................................................................................51
Engine Block.........................................................................................................................................................63
Crankshaft.............................................................................................................................................................69
Head and Camshaft..............................................................................................................................................89
Piston and Connecting Rods...............................................................................................................................129
Gear Housing and Gear Train.............................................................................................................................147
Flywheel and Flywheel Housing..........................................................................................................................163
Pulleys, Belts and Accessories............................................................................................................................169
Lubrication System..............................................................................................................................................181
Electronic Engine System...................................................................................................................................195
Cooling System...................................................................................................................................................203
Management Engine System..............................................................................................................................209
Intake and Exhaust Systems and Turbocharger.................................................................................................223
Troubleshooting...................................................................................................................................................233
Appendix A .........................................................................................................................................................259
Appendix B..........................................................................................................................................................307
Appendix C..........................................................................................................................................................309
932H00602003
ENGINE SERVICE MANUAL 1
Foreword Technical Service Literature
Navistar, Inc. is committed to continuous research 932H00604104 MaxxForce® 3.2H Engine

and development to improve products and introduce Operation and Maintenance
technological advances. Procedures, specifications, Manual
and parts defined in published technical service
literature may be altered. 932H00602003 MaxxForce® 3.2H Engine
Service Manual
This Engine Service Manual provides a general
sequence of procedures for out-of-chassis engine 932H00602204 MaxxForce® 3.2H Engine
overhaul (removal, inspection, and installation). For in- Diagnostic Manual
chassis service of parts and assemblies, the sequence 932H00602504 MaxxForce® 3.2H Engine
may vary. Electrical Diagram
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.
932H00602003
2 ENGINE SERVICE MANUAL
Service Diagnosis Technical Service Literature required for Effective

Diagnosis
Service diagnosis is an investigative procedure
that must be followed to find and correct an engine • Engine Service Manual.
application problem or an engine problem.
• Engine Diagnostic Manual.
If the problem is engine application, see specific
• Diagnostics Forms.
vehicle manuals for further diagnostic information.
• Electronic Control Systems Diagnostics Forms.
If the problem is the engine, see specific Engine
Diagnostic Manual for further diagnostic information. • Service Bulletins.
Prerequisites for Effective Diagnosis
• Availability of gauges, diagnostic test equipment,

and diagnostic software.
• Availability of current information for engine
application and engine systems.
• Knowledge of the principles of operation for
engine application and engine systems.
• Knowledge to understand and do procedures in
diagnostic and service publications.
932H00602003
ENGINE SERVICE MANUAL 3
Safety Information Protective Measures
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.
932H00602003
4 ENGINE SERVICE MANUAL
Batteries Fluids Under Pressure
• 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.
Tools Removal of Tools, Parts and Equipment
• 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.
932H00602003
PRESENTATION 5
Table of Contents
Introduction..............................................................................................................................................................6
How to Use This Manual.........................................................................................................................................6
Manual Content..................................................................................................................................................6
Section Content..................................................................................................................................................6
Information on Metric System.............................................................................................................................6
General Instructions................................................................................................................................................7
General Cleaning Instructions.................................................................................................................................7
Cleaning with Acids and Solvents......................................................................................................................7
Engine Serial Number Identification and Location..................................................................................................8
Engine Serial Number.............................................................................................................................................9
No. of Cylinders.....................................................................................................................................................10
Engine Accessories...............................................................................................................................................10
High Pressure Pump........................................................................................................................................ 11
Turbocharger....................................................................................................................................................12
Garrett Turbocharger...................................................................................................................................12
Common Rail....................................................................................................................................................12
Engine Control Module (ECM).........................................................................................................................13
Injector Nozzle..................................................................................................................................................14
IIC Codes Calibration Procedure................................................................................................................14
932H00602003
6 PRESENTATION
Introduction How to Use this Manual

This manual provides complete information and The development of this Manual was based on a
specifications for the disassembly and assembly of generic MaxxForce 3.2H engine, which has the
the MaxxForce 3.2H Euro IV engines, as well as same operation and maintenance procedures on all
all components manufactured by INTERNATIONAL models of this series. The illustrations can differ from
Indústria Automotiva. application to application notwithstanding.
Read and follow all safety instructions. Refer to All references regarding engine components are
WARNING item on General Safety Instructions on the divided in specific sections in this manual. For your
next section. convenience, the organization of the Manual is
compatible with MWM Service Bulletins.
The repair procedures as described in this manual
take for granted that the engine is properly supported.
Manual Content
Some of the assembly and disassembly procedures
require special tools. The Manual contains an index that can be used as a
quick reference for the access of each section.
Be sure that only the right tools have been used
according to the procedures.
Section Content
The assembly and disassembly procedures presented
in this manual are correct at the time of printing. Each section comprises the following information:
INTERNATIONAL Indústria Automotiva reserves the
right to make changes at any time without incurring in • Index page at the beginning of each section to
any obligation whatsoever. help in the location of desired information.
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.).
932H00602003
PRESENTATION 7
General Instructions General Cleaning Instructions

This engine has been manufactured with the latest Remove all gaskets and sealing rings. Remove all
technology and was designed to be repaired using deposits of sludge, carbon, etc with a wire brush or a
standard techniques together with quality norms. spatula before placing the parts in a cleaning tank. Be
careful not to damage the seating surfaces of sealing
• Use good quality fuel, free from water and devices.
dirtiness.
Flush all parts with warm water after cleaning. Dry
• Use only the recommended oil. throughout with compressed air. Remove water from
• In the event of a failure, seek only an MWM holes and lubrication galleries.
INTERNATIONAL or vehicle / equipment If the parts are not to be used right after cleaning,
manufacturer. Avoid unauthorized people to dip them in a suitable anti-oxidant compound. That
service the engine as that will void the warranty. compound must be removed from the parts before
• For jump start the engine, the current and voltage installation on the engine.
capacity of both batteries must be the same The following parts cannot be steam-cleaned:
to avoid overloading one of them. Standard
procedure is to connect the negative cable first, 1. Electric and electronics components;
and then the positive cable. Take care not to
2. Electric harness;
reverse polarity.
3. Fuel injectors;
• An improper removal of the battery cables can
cause loss of data on the ECM, erasing trouble 4. High pressure pump;
codes saved in the last engine start. It can also
5. Belts, tubes and hoses;
cause voltage spikes and ECM faults.
6. Retainers.
Cleaning with Acids and Solvents

MWM INTERNATIONAL Motores does not recommend
any specific cleaning agent for engine components.
932H00602003
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);
932H00602003
PRESENTATION 9
Engine Serial Number

Serial number on upper front area of the block.
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
932H00602003
10 PRESENTATION
No. of Cylinders Engine Accessories

The cylinder sequence starts on the flywheel, according The following engine accessories have manufacturer
to the figure below. identification tags or plates:
• High Pressure Pump;
• Turbocharger;
• Hydraulic Pump (Tandem);
First Cylinder
• Common Rail;
• Starter Motor;
• Engine Control Module (ECM);
• Injector Nozzle.
Identification tags or plates include useful information

and specifications for operators and technicians of the
vehicle.
The main bearing caps are numbered from the flywheel

towards the front of the engine.
932H00602003
PRESENTATION 11
High Pressure Pump
932H00602003
12 PRESENTATION
Turbocharger
Garrett Turbocharger
Common Rail
932H00602003
PRESENTATION 13
Engine Control Module (ECM)
932H00602003
14 PRESENTATION
Injector Nozzle
IIC Codes Calibration Procedure

The MaxxForce 3.2H engines‘ fuel injectors have Each fuel injector has a distinctive code which shall
a code stamped on its top part (according to figure be related to the cylinder where the fuel injector
above), which is related to the fuel injector calibration. is installed. This process will be done using the
This calibration aims a better usage of fuel injection, ServiceMaxx Diagnostic Tool.
helping to reduce the emission levels and improving
the engine’s performance.
932H00602003
TECHNICAL DATA 15
Table of Contents
Technical Data.......................................................................................................................................................18
Fuel System..........................................................................................................................................................18
Lubrication System................................................................................................................................................19
Cooling System.....................................................................................................................................................19
Thermostatic Valve................................................................................................................................................19
Engine Description................................................................................................................................................20
Features...........................................................................................................................................................20
Accessories Features.......................................................................................................................................20
Engine Component Location.................................................................................................................................21
Engine System Diagram...................................................................................................................................26
Air Management System.......................................................................................................................................27
EGR System View............................................................................................................................................27
Exhaust Gases EGR System................................................................................................................................28
System Constitution.........................................................................................................................................28
Engine Systems....................................................................................................................................................29
Air Flow ...........................................................................................................................................................29
Air Cooler ........................................................................................................................................................29
Variable Geometry Turbocharger VGT ............................................................................................................30
Closed Loop VGT System . .............................................................................................................................31
VGT Control.....................................................................................................................................................31
Closed Vanes ..................................................................................................................................................31
Open Vanes . ...................................................................................................................................................31
Turbocharger System............................................................................................................................................32
Internal Componentes......................................................................................................................................32
932H00602003
16 TECHNICAL DATA
Table of Contents
Turbo Technologies ..............................................................................................................................................33
Mechanical.......................................................................................................................................................33
Theory of Operation ...................................................................................................................................33
Environmental Limits...................................................................................................................................33
Electrical...........................................................................................................................................................33
Voltage Characteristics...............................................................................................................................33
Exhaust Gas Recirculation (EGR) System.......................................................................................................34
EGR Control Valve................................................................................................................................................35
EGR Flow.........................................................................................................................................................35
Valve for Exhaust Gas Recirculation................................................................................................................36
Block Diagram..................................................................................................................................................37
EGR Closed Loop Operation with Fault Management.....................................................................................39
Exhaust System....................................................................................................................................................40
Fuel Management System....................................................................................................................................41
Fuel Management Components.......................................................................................................................41
Fuel Flow Schematic........................................................................................................................................42
Electronic Control System.....................................................................................................................................43
Electronic Control System Components...........................................................................................................43
Operation and Function...............................................................................................................................43
1. Reference Voltage (VREF)..................................................................................................................43
2. Signal Conditioner...............................................................................................................................43
3. Microprocessor....................................................................................................................................43
Microprocessor Memory..............................................................................................................................43
ROM............................................................................................................................................................43
RAM............................................................................................................................................................43
4. Actuator Control..................................................................................................................................43
ECM Control of Engine Operation...............................................................................................................43
Engine and Vehicle Sensors.................................................................................................................................44
932H00602003
TECHNICAL DATA 17
Table of Contents
Resistor and Thermistor........................................................................................................................................45
Engine Coolant Temperature (ECT).................................................................................................................45
Manifold Air Pressure and Temperature (TMAP)..............................................................................................45
Engine Fuel Pressure (EFP) ...........................................................................................................................45
Switch....................................................................................................................................................................46
Magnetic Sensors..................................................................................................................................................47
Crankshaft Position (CKP) Sensor...................................................................................................................47
Hall Effect Sensors................................................................................................................................................48
CMP – Camshaft Position Sensor....................................................................................................................48
VSS – Vehicle Speed Sensor...........................................................................................................................48
Potentiometer........................................................................................................................................................49
Accelerator Position Sensor (APS)..................................................................................................................49
Switches................................................................................................................................................................50
Clutch Switch....................................................................................................................................................50
932H00602003
18 TECHNICAL DATA
Technical Data
Engine Data MaxxForce 3.2H

Engine type In-line vertical cylinders, 4-stroke
Injection type Direct
Cylinder bore 96 mm
Piston stroke 110 mm
Unitary displacement 0.8 dm3
Total displacement 3.200 dm3
No. of cylinders 4
Compression ratio 17:1
Firing order 1–3–4–2
Direction of rotation Counterclockwise (flywheel side)
Engine dry weight 275 Kg
Power @ 3000 rpm 160 CV
Torque 450 N.m
Emissions Euro IV
Intake System Turbo-charged and after-cooled
Fuel System
Description MaxxForce 3.2H

Minimum inlet pressure at high pressure pump 0.7 to 2.0 bar (abs)
Common Rail Pressure 1800 bar
Return Pressure 0.7 to 2.0 bar (abs)
Inlet Fuel Temperature Min. -30°C
Inlet Fuel Temperature Max. 70°C
932H00602003
TECHNICAL DATA 19
Lubrication System

Oil pressure
• At rated speed - Nominal 5.0 bar
• At idle speed - Minimum 0.7 bar
Oil temperature
• Normal 106 to 115°C
• Maximum 125°C
Oil capacity
• Minimum ( lowest mark on the
dipstick) 5.0 L
• Maximum (without filter) 8.6 L
• Maximum (with filter) 8.0 L
• Dry maximum (with filter) 8.5 L
• Oil Pressure to open the regulator

6+1.5 bar
valve in the oil pump
Cooling System
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
932H00602003
20 TECHNICAL DATA
Engine Description A low-pressure fuel supply pump draws fuel from the
fuel tank through a fuel filter assembly that includes
Features a strainer, prefilter, filter element, primer pump, drain
valves, and water in fuel (WIF) sensor.
MaxxForce 3.2H Euro IV series are in-line four cylinder
engines. The engine displacements are 3.2 liters. After filtering, fuel is pumped to the high pressure fuel
pump, then to the fuel rail and finally to the injectors.
The firing order of the cylinders is 1-3-4-2 for the four
cylinders. The MWM INTERNATIONAL common rail high-
pressure injection system includes a cast iron manifold,
The cylinder head has four valves per cylinder with fuel injectors and a high-pressure pump.
cross flow for improved air flow. The head gasket is
mated in metal-rubber. The fuel Injector is centrally EGR cooler regulates the cooled exhaust gases that
located between the four valves and directs fuel recirculates through the inlet air stream. Cool exhaust
over the piston bowl for improved performance and gas increases engine tolerance for EGR, while
reduced emissions. The overhead valve train includes reducing smoke formed by gas dilution in the mixture.
mechanical roller lifters, rocker arms, and dual valves The ECM is responsible for monitoring and controling
that open using a valve bridge. To improve component the electronic engine systems.
durability and engine performance the engine uses a
hot and cold side concept for component distribution. The Water In Fuel (WIF) separation occurs when
the filter element repels water molecules. The water
Cold side (left engine side) collects at the bottom of the element cavity in the fuel
filter housing.
• Fuel supply system;
A Water In Fuel (WIF) sensor in the element cavity
• Intake air manifold. of the fuel filter housing detects water. When enough
water accumulates in the element cavity. The WIF
Hot side (right engine side) sensor sends a signal to the ECM. A fuel drain valve
handle on the housing can be opened to drain water
• Turbocharger system;
from the fuel filter housing.
• EGR system;
• Air compressor; Accessories Features
• Exhaust manifold. The vacuum pump is commonly used for air brakes.
A hydraulic power steering pump is assembled with
A one piece oil pan withstands high-pressure loads the vacuum pump. In the MaxxForce 3.2H engines
during diesel operation. both components are located in the hot side next to
Manufactured in stamped steel, the oil pan has a the powertrain.
compact size and is lightweight. The starter motor is an electric motor that initiates
Five bearings support the crankshaft for MaxxForce rotational motion in an internal combustion engine to
3.2H engines. The rear oil seal carrier is part of the iniciate combustion. On the MaxxForce 3.2H engines
flywheel housing. The open oil pan breather assembly it’s located on the hot side, next to the Flywheel.
uses a road draft tube to vent oil pan pressure and an The high pressure pump supplies the injectors with
oil separator that returns oil to the oil pan. high pressure fuel. It’s located on the cold side next to
The crankshaft position sensor - CKP and camshaft the powertrain
position sensor - CMP are used by the ECM to The Turbocharger is an air compressor used for
calculate rpm, fuel timing, fuel quantity and duration forced-induction of an internal combustion engine.
of fuel injection. The purpose of a turbocharger is to increase the air
Manufactured with aluminum and new shape to mass entering the engine to create more power. On
improve its strength, the pistons are mated with the MaxxForce 3.2H engines it’s located on the hot
fractured cap joint connecting rods. side, next to the waterpipe and cooled EGR in the
upper position.
The oil pump is mounted onto the front of the engine
block, and is driven directly by the crankshaft. All
engines use an enlarged oil cooler.
932H00602003
TECHNICAL DATA 21
Engine Component Location
1. Fuel Rail Pressure Sensor 4. Fuel Injectors 6. Camshaft Position Sensor (CMP)
2. Water Inlet Tube to EGR 5. High-pressure Tubing 7. T-MAP Sensor
(Common Rail)
3. EGR 8. PCV Valve
932H00602003
22 TECHNICAL DATA
1. Thermostat 3. Intake Manifold 5. Cooling Fan

2. EGR Valve 4. Viscous Clutch 6. Oil Pan
932H00602003
TECHNICAL DATA 23
1. Accessories Belt 4. Engine Wire Harness 6. Oil Dipstick Tube

2. Intake Elbow 5. High-pressure Pump 7. Oil Pan Drain Plug
3. Intake Manifold
932H00602003
24 TECHNICAL DATA
1. Water Pump 4. Air Compressor 7. Oil Return Tube from Turbocharger

2. Air Outlet from Turbocharger 5. (Dumper) 8. Lubricating Oil Filter
3. Exhaust Elbow 6. EGR Water Inlet Tube 9. Crankshaft Position Sensor (CKP)
932H00602003
TECHNICAL DATA 25
1. Fuel Return to Fuel Tank 4. Engine Breather Tube 6. ECM (The Manufacturer of the vehicle is
responsible for installing and positioning
2. Lubricating Oil Filler Nozzle 5. Turbocharger
the ECM, check vehicle’s Service Manual
3. Coolant Temperature Sensor for more information.)
7. Flywheel
932H00602003
26 TECHNICAL DATA
Engine System Diagram
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.
932H00602003
TECHNICAL DATA 27
Air Management System

EGR System View
Air Management Components and Air Flow.
Air Management System (AMS).
5
4
8 9
6
1
2
1. Intake 5. Intake Air Filter 8. EGR Valve

2. Exhaust 6. Compressor 9. EGR Cooler
3. Air Cooler 7. Turbine
4. MAF
932H00602003
28 TECHNICAL DATA
Exhaust Gases EGR System System Constitution
The EGR system (Exhaust Gas Recirculation) is • Control valve;

constituted of a connection between the exhaust • Cooler;
manifold and intake manifold, which enables the
• Mixer;
recirculation of exhaust gases. This system reduces
the Nitrogen Oxides (NOx) emission levels that are • EGR tubes.
formed during the reaction between nitrogen and
oxygen at high temperatures during the combustion.
The function of recirculated gases inside the
combustion chamber is to reduce the temperature and
to decrease the oxygen available for the formation of
NOx.
932H00602003
TECHNICAL DATA 29
Engine Systems The turbocharger responds directly to the engine

loads. During heavy loads, a larger exhaust gases
The air management system includes the following: flow makes the turbine rotor VGT move more rapidly.
This increase of speed makes the compressor rotor
• Air filter assembly;
to move more quickly and provides more air to intake
• Air cooler; manifold.
• Variable geometry turbocharger On the other hand, when engine load is light, the
• Intake manifold; exhaust gases flow decreases and less air is directed
to intake manifold.
• Exhaust gases recirculation system (EGR);
• Exhaust system; Air Cooler
• Intake duct and EGR mixer;
• Engine brake.
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.
• If the EGR control valve was open, the exhaust

gases will mix themselves with the filtered intake
air and flow to the intake manifold; Air Cooler (typical)
• If the EGR control valve was closed, only the 1. Air Outlet
filtered air will flow to the intake manifold.
2. Air Cooler
After the combustion, the exhaust gas is forced 3. Air Inlet
through the exhaust manifold to the EGR cooler and
turbocharger. 4. Radiator
• 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.
932H00602003
30 TECHNICAL DATA
Variable Geometry Turbocharger VGT
Variable Geometry Turbocharger VGT
1. Turbine Housing Assembly 7. Actuator Assembly 12. Seal Ring

2. Compressor Housing Assembly 8. Bracket, Actuator 13. Screw
3. Center Housing and Rotating Assembly 9. Bolt, Hex Head Flanged 14. Link Assembly
4. Bolt, Hex Head (THS) 10. Heat, Shield 15. Nut
5. Coupling, V-band CHS 11. Ring, Retaining 16. Socket Set Screw
6. Lock, Nut
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.
932H00602003
TECHNICAL DATA 31
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 intake back pressure
is low.
The intake gases have to accelerate to pass through
the narrow vanes’ passages. The rising of intake back
pressure makes the gases to be recirculated to the
Closed Loop VGT System
EGR system.
The variable geometry turbocharger VGT is a closed

loop system of uses an intake back pressure sensor to
provide a feedback to ECM. The ECM uses the Intake
Manifold Pressure Sensor and to adjust the cycle to
VGT, in order to meet the engine demands.
VGT Control
Open Vanes
The vanes are opened when the intake 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.
The VGT Control Module receives a modulated

signal from ECM. A microchip controls the step motor
according to the desired position. The step motor
rotates a little crankshaft, controlling the vane position.
932H00602003
32 TECHNICAL DATA
Turbocharger System
Internal Components
932H00602003
TECHNICAL DATA 33
Turbo Technologies Electrical
Mechanical Voltage Characteristics

The actuator is designed to operate within the following
Theory of Operation ranges:
This electric actuator (EA) consists of a 3phase
permanent magnet brushless motor and a spur gear Table 1 Operating Voltage Range
(ACME leadscrew) reduction which produces a linear
position and force output. The gear is stainless steel 24 V System
and lubricated for long life. The side of the actuator
presented to the hot turbo components are all rated for Normal Power
DC 16.0V~3.2.0V
high continuous temperatures; elastomers and PCB Supply Voltage
are protected from direct radiant heating. The rotor is Imputs
supported by ball-bearings ensure efficient transfer of CAN
Refer to ISO 11898
motor torque to the turbocharger with minimal losses. Communication
The actuator uses relative position sensing only, CAN

meaning the Hall effect sensors used for motor Outputs Refer to ISO 11898
Communication
commutation control are also the sensors used for shaft
position control. Thus, the actuator must operate from
a reference location, which is detected automatically The actuator is immune to short-to-ground and
during every power up and after correct CAN frames short-to-power events. Reverse voltage protection
are received. is integrated. The actuator should be powered either
from an ECM controlled relay or directly through the
ECM.
Environmental Limits
This actuator is qualified for the underhood
environment. This includes submersion, chemical
resistance, high pressure water spray, salt, dust, sand,
etc.
Notes about environmental limitations:
The actuator is not rated for full strength battery acid
exposure. When battery acid contacts the output shaft
silicon rubber boot, it can swell which could impact the
sealing ability of the boot. If the boot is compromised,
water could enter the actuator and cause subsequent
failures such as corrosion or electrical short circuits.
Gravel bombardment of the connector case assembly
(PCB chamber area, top of actuator) or output shaft is
not permitted. If gravel bombardment is an application
requirement, the actuator must be protected with a
shield.
Output shaft cover & nut corrosion resistant coating
(trivalent chrome) can visually degrade if exposed to
some types of engine cleaner.
932H00602003
34 TECHNICAL DATA
Exhaust Gas Recirculation (EGR) System
932H00602003
TECHNICAL DATA 35
EGR Control Valve EGR Flow
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.
The Exhaust Gas Recirculation (EGR) system

reduces Nitrogen Oxide (NOx) emissions. NOx forms
during a reaction between nitrogen and oxygen at high
temperature during combustion.
EGR works by recirculating a portion of the engine
exhaust gas back to the engine cylinders. Mixing the
incoming air with recirculated exhaust gas dilutes the
mixture with inert gas, lowering the adiabatic flame
temperature and reducing the amount of excess
oxygen. The exhaust gas also increases the specific
heat capacity of the mixture, lowering the peak
combustion temperature. Because NOx forms much
faster at high temperatures, EGR serves to limit the
generation of NOx.
932H00602003
36 TECHNICAL DATA
Valve for Exhaust Gas Recirculation
1. Housing 8. Bushing 14. Springholder

2. Valve Seat 9. Ring 15. Stopper
3. Valve 10. Plate 16. Plug
4. Rod 11. Plug 17. Spacer
5. Holder 12. Seal 18. Screw
6. Filter 13. Spring 19. DC Motor
7. Plate
932H00602003
TECHNICAL DATA 37
Block Diagram
932H00602003
38 TECHNICAL DATA
NOTE:
1. Wire Harness recomendations:

1) Wire Harness resistance: Lass Than
0.2 ohms (Including Power GND return line).
2) Wire Harness Routining.
PIN No. PIN Name Body Harness Plating

Reserved N.C Sn
CAN_Shld CAN Shield Sn
CAN_L Twisted pair wire Sn
CAN_H Twisted pair wire Sn
If possible, you should insert the wire harness into DC GND Sn
Motor from lower side in order to prevent permeation Power 12V or 24V Sn
water.
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.
932H00602003
TECHNICAL DATA 39
EGR Closed Loop Operation with Fault Management
The EGR is a closed loop system that uses exhaust gas recirculation position to provide feedback to the ECM.
932H00602003
40 TECHNICAL DATA
Exhaust System The exhaust system removes exhaust gases from

the engine. Exhaust gases exit from exhaust valves,
The exhaust system includes the following: through exhaust ports, and flow into the exhaust
manifold. Expanding exhaust gases are directed
• Exhaust valves;
through the exhaust manifold. The exhaust manifold
• Exhaust manifold; directs some exhaust gases into the Exhaust Gas
• Turbocharger; Recirculation (EGR) cooler.
• Exhaust piping;
• Muffler.
932H00602003
TECHNICAL DATA 41
Fuel Management System

Fuel Management Components
The fuel management system includes the following:
• Fuel supply system;

• Fuel injectors;
• Electronic control system.
932H00602003
42 TECHNICAL DATA
Fuel Flow Schematic
Fuel Flow
The fuel filter housing includes the following
components:
• Fuel strainer;
• Fuel filtering element;
• Water separator;
• Water drain valve.
932H00602003
TECHNICAL DATA 43
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.
932H00602003
44 TECHNICAL DATA
Engine and Vehicle Sensors
1. Electronic Control Module 6. Exhaust Gas Temperature Sensor 11. Engine Oil Pressure (EOP)
(ECM) (Outlet) (EGT2)
12. Temperature - Manifold Absolute
2. Accelerator Pedal (ACP) 7. Crankshaft Position Sensor (CKP) Pressure (T-MAP)
3. Can Controlled Turbo 8. Camshaft Position Sensor (CMP) 13. Engine Fuel Pressure (EFP)
4. EGR Control 9. Engine Fuel Temperature (EFT) 14. Manifold Air Flow (MAF)
5. Exhaust Gas Temperature 10. Engine Coolant Temperature (ECT) 15. Volumetric Control Valve (VCV)
Sensor (Inlet) (EGT1)
932H00602003
TECHNICAL DATA 45
Resistor and Thermistor Engine Fuel Pressure (EFP)
• ECT The ECM monitors the EFP signal to determine correct

fuel pressure for efficient engine operation.
• T-MAP (RESISTOR AND THERMISTOR UNIT
COMBINED) The EFP sensor is installed in the fuel rail.
• EFP
A thermistor sensor changes its electrical resistance

with changes in temperature. Resistance in the
thermistor decreases as temperature increases, and
increases as temperature decreases. Thermistors
work with a resistor that limits current in the ECM to
form a voltage signal matched with a temperature
value.
The top half of the voltage divider is the current limiting
resistor inside the ECM. A thermistor sensor has two
electrical connectors, signal return and ground. The
output of a thermistor sensor is a nonlinear analog
signal.
Engine Coolant Temperature (ECT) 1. Pressure sensor

The ECM monitors the ECT signal and uses this 2. Electronic Control Module (ECM)
information for the instrument panel temperature 3. Ground
gauge, coolant compensation, Engine Warning
Protection System (EWPS), and intake heater 4. Microprocessor
operation. The ECT sensor is installed in the water 5. Voltage reference (VREF)
pipe, close to the EGR cooler assembly.
Manifold Air Pressure and Temperature (TMAP)

The ECM monitors the TMAP signal for EGR operation
and determines intake manifold pressure (boost). This
information is used to control fuel rate and injection
timing.
The TMAP sensor is in the top side of the intake
manifold.
932H00602003
46 TECHNICAL DATA
Switch
• EOP
It is a sensor that reads the oil pressure and sends

this information to ECU through an analogue electrical
signal that is proportional to the pressure reading.
Inside the ECU there is a signal linearization map that
transforms the information into a pressure value again.
932H00602003
TECHNICAL DATA 47
Magnetic Sensors Crankshaft Position (CKP) Sensor
• CKP The CKP sensor provides the ECM with a signal

that indicates crankshaft speed and position. As the
A magnetic sensor generates an alternating frequency flywheel turns the CKP sensor detects several holes
that indicates speed. Magnetic sensors have a two made in the outside of the flywheel. All holes are
wire connection (signal and ground). This sensor has symmetric and spaced of 58 and 60. By comparing the
a permanent magnetic core surrounded by a wire coil. CKP signal with the CMP signal, the ECM calculates
The signal frequency is generated by the rotation of engine rpm and timing requirements. The CKP is
gear teeth that disrupt the magnetic field. installed in the top left side of the flywheel housing.
932H00602003
48 TECHNICAL DATA
Hall Effect Sensors This current is generated by a perpendicularly-applied

magnetic field to the Hall device. The ratio of average
CMP – Camshaft Position Sensor voltage by current intensity is known as Hall resistance
and it is a characteristic of the device material.
The CMP sensor is a “Hall-effect” sensor for the
engine position. It is assembled on the valve cover and
its function is to read the lobe position of the camshaft, VSS – Vehicle Speed Sensor
converting it into a signal and synchronizing the The VSS is normally installed at the transmission of
injection by the determination of the position of No. 1 the vehicle and supplies a signal to the ECM, tracking
cylinder, which is in the ignition cycle, and the position engine speed by use of a toothed wheel. Detected
of the cylinder piston. This information is used by the sinusoidal waves (AC) received by the ECM are
ECM for setting up of the injection synchronization. matched with tire size and rear axle ratio to calculate
NOTE: The Hall Effect refers to the difference of correct speed. See the Workshop Manual of the
potential (Hall potential) on opposite sides of a vehicle for VSS placement.
conductor or semiconductor material (Hall device)
where an electrical current flows through.
2 3
8
7
9
1. Crankshaft Position Signal 4. Camshaft Position Signal 7. Vehicle Speed Signal

2. Crankshaft Position Sensor 5. Camshaft Timing Disk 8. Electronic Control Module (ECM)
Timing Disk
6. Camshaft Position Sensor (CMP) 9. Vehicle Speed Sensor (VSS)
3. Crankshaft Position Sensor (CKP)
932H00602003
TECHNICAL DATA 49
Potentiometer Accelerator Position Sensor (APS)

The APS provides the ECM with a feedback signal
• APS
(linear analog voltage) that indicates the operator’s
A potentiometer is a variable voltage divider that demand for power. The APS is mounted in the
senses the position of a mechanical component. accelerator pedal.
A reference voltage is applied to one end of the
potentiometer. Mechanical rotary or linear motion
moves the wiper along the resistance material,
changing voltage at each point along the resistive
material. Voltage is proportional to the amount of
mechanical movement.
SENSOR
APS CIRCUIT #1
VCC1 C
SENSOR
#1
APS1 A
GND1 B
1
ISOLATION
ENGINE CONTROL UNIT
ISOLATION
1 SENSOR
APS CIRCUIT #2
VCC2 D
#2
APS2 F
GND2 E
2
1. Accelerator Position Sensor

(APS)
932H00602003
50 TECHNICAL DATA
Switches
• CPS (Clutch Pedal Switch)
• ECL (Engine Low Coolant Level Switch)
• LIS (Low Idle Switch)
• BPS (Brake Pedal Switch)
• Parking Brake Switch
• Switch oil
Switch sensors indicate position. They operate open

or closed, allowing or preventing the flow of current.
A switch sensor can be a voltage input switch or a
grounding switch. A voltage input switch supplies the
ECM with a voltage when it is closed. A grounding
switch grounds the circuit when closed, causing a
zero voltage signal. Grounding switches are usually
installed in series with a current limiting resistor.
Clutch Switch
The CPS determines if a vehicle is in gear for manual
transmissions. For automatic transmissions, the
neutral indicator switch functions as the CPS.
932H00602003
OPERATION AND MAINTENANCE 51
Table of Contents
Engine Operation..................................................................................................................................................53
Start / Stop.......................................................................................................................................................53
Cold Start.........................................................................................................................................................53
Turbocharger Precautions................................................................................................................................53
Break-in............................................................................................................................................................53
Fuel Specifications...........................................................................................................................................53
Diesel .........................................................................................................................................................53
Biodiesel......................................................................................................................................................54
Lubricating Oil..................................................................................................................................................54
Engine Oil Level Check...............................................................................................................................54
Oil Change..................................................................................................................................................54
Oil Filter Change.........................................................................................................................................54
Lubricating Oil.............................................................................................................................................54
Lubricating Oil Specifications......................................................................................................................54
Lubrication Oil Check..................................................................................................................................54
Coolant and Additive.............................................................................................................................................55
Level Check......................................................................................................................................................55
Topping up of the System............................................................................................................................55
Total System Capacity.................................................................................................................................55
MWM INTERNATIONAL Additive................................................................................................................55
Conservation for Long-inactive Engines................................................................................................................56
Engine Preparation for Return of Operation.....................................................................................................56
Engine Preparation................................................................................................................................................57
Engine Fluid Draining.......................................................................................................................................57
Oil Drain......................................................................................................................................................57
Lubricating System Preparation............................................................................................................................58
Recommended Method....................................................................................................................................58
932H00602003
52 OPERATION AND MAINTENANCE
Table of Contents
Oil Pan Plug..........................................................................................................................................................59
Adapter Plate of the Assembly and Engine Lifting................................................................................................60
Adapter Plate....................................................................................................................................................60
Engine Lifting....................................................................................................................................................60
Stand for Diesel Engines..................................................................................................................................60
Engine Assembly on Stand..............................................................................................................................60
932H00602003
Engine Operation Break-in

All MWM INTERNATIONAL engines are manufactured
Start / Stop and tested at the plant, assuring their ready operation.
Before starting the MaxxForce 3.2H engines, the However, a proper break-in is needed since the
following items must be checked: durability and life depend mostly on the care during
the initial operation phase.
• Coolant level;
As a general rule, the break-in period is considered
• Fuel level;
the initial 2000 km for vehicle applications and the
• Lubricating oil level; initial 50 hours for stationary, industrial and agricultural
• Right after engine start, warm it up in a no load, engines. An initial moderate operation is key for the
fair speed. Check lubricating oil pressure and durability, service safety and economy of the engine.
coolant temperature; During the initial period these key recommendations
• It is recommended not to accelerate during must be followed:
starting and to keep the engine at idle speed for • Carefully check for correct engine oil level;
30 seconds, as to start turbocharger lubrication;
• Carefully check for correct coolant level in the
• Before turning the engine off, leave it in idle for coolant system;
30 seconds to lower turbocharger revving speed.
• Avoid running the engine under high revving
Cold Start conditions, what means do not overload the
engine or, on vehicular applications, do not “hold”
A difficult starting can take place at very low room the gears;
temperatures as the filter can collapse due to paraffin
build up or non-ignition of the fuel. • Avoid overloads in low revving conditions;
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;
Turbocharger Precautions • Avoid operating the engine in constant speed for

long periods of time;
Almost all turbocharger failures are caused by poor
lubrication (delays, restriction or lack of oil, dirtiness, • Avoid operating the engine in idle speed for long
etc) and ingress of dirtiness into the intake manifold. periods of time;
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, or DIN EN 590:2009 for
• At low temperature or when the engine is being worldwide fuel.
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.
932H00602003
Biodiesel Oil Filter Change

The use of B5 (fuel composed of a mix of diesel and • Wipe the sealing area of the filter with a clean,
biodiesel*, in a proportion not higher that 5% biodiesel) lint-free cloth.
is allowed on MaxxForce 3.2H engines, according to
Brazilian Standard ANP No. 07, issued on Mar. 19, • Slightly lubricate the filter sealing with new oil
2008 – DOU of Mar. 20, 2008. and manually tighten up to the point the sealing
touches the head.
The use of a B5 fuel which does not meet manufacturer’s
recommended specifications can cause severe • Tighten manually from ¾ of a turn to one complete
damage to the internal components of the engine with turn.
a consequent void of warranty. • Top up with new oil. On a leveled vehicle, the oil
level must reach the upper mark of the dipstick.
* Biodiesel is understood as a renewable,
biodegradable fuel for internal combustion • Turn the engine on and check filter sealing and
engines derived from vegetal oil and/or animal fat, the oil pan plug.
whose ignition happens due to compression.
• Turn the engine off and 30 minutes later check
For complete fuel specification, consult ANP Standard again the oil level, filling up if necessary.
for Brazilian fuel or DIN EN 590:2009 for worldwide
fuel. Attention: Always use genuine MWM filters.
Lubricating Oil Lubricating Oil

The lubricating oil is very important for proper
Engine Oil Level Check
preservation of internal engine components.
• Turn the engine off and wait for 30 minutes so that Lubricating oils that are contaminated with sand, dust,
the oil can flow back to the oil pan. water or fuel cause problems to the engine.
• Be sure the vehicle is leveled. Check the appearance of the engine lubricating oil. A
• Before pulling the oil dipstick, clean around it. dark color and low viscosity mean the presence of fuel
in the lubricating oil. Bubbles or a milky color indicate
• If necessary, top up to the upper mark (MÁXIMO) presence of water in the oil.
(Maximum), without going over. Fill with the same
brand and type of oil.
Lubricating Oil Specifications
• Do not operate the engine if the indicated level is
below the lower mark (minimum). A multigrade lubricating oil that at least meets
specification SAE 10W30 API CI4 (or higher) and
• Use only the recommended lubricating oil. necessary viscosities must be used.
• Do not mix different types of oil.
Attention: Do not mix different types of oil. Once a
• Once chosen brand and type, use always the type is chosen, use always the same one.
same one.
Lubrication Oil Check
Oil Change
The condition of the lubricating oil is very important for
• The oil must be hot to ease draining. the proper preservation of internal engine components.
• Drain the oil by removing the oil pan drain plug Change lubricating oil according to the scheduled
and washer. Replace washer. maintenance.
• Wait until no more oil drips from the engine.
• Assemble the plug with a new washer and tighten
to specified torque.
• Top up with recommended lubricating oil up to the
upper level mark (MÁXIMO – Maximum) of the
dipstick.
932H00602003
Coolant and Additive Topping Up of the System

Top up the cooling system with the additive amount as
Level Check recommended in the chart.
Caution:
• Do not open the coolant reservoir cap while Total System Capacity
engine is hot.
• MaxxForce 3.2H – 5 liters (without radiator).
• Check level when the engine is cold.
• Check coolant level daily. Turn the engine on and wait until the normal
• If coolant level is not correct, top up the cooling operating temperature is reached. Top up with MWM
system with the additive amount as recommended INTERNATIONAL additive. After filling up the system,
in the chart. turn the engine on to check for any leakage.
• Carefully start turning the cap to relieve the vapor
pressure.
• Check for leakages on cooling system hoses.
MWM INTERNATIONAL Additive
MWMI No. 9.0193.05.6.0802 9.0193.05.6.0801

COOLING SYSTEM PROTECTOR – COOLING SYSTEM PROTECTOR –
Name
Environment-friendly Environment-friendly
Proprieties Anti-corrosion / Anti-boiling / Antifreeze Anti-corrosion / Anti-boiling / Antifreeze
Application Diesel / Gasoline / Ethanol / LPG Diesel / Gasoline / Ethanol / LPG
Color Fluorescent Red Fluorescent Red
Proportion READY TO USE READY TO USE
Replacement 12 months or according to the 12 months or according to the
period maintenance schedule maintenance schedule
Composition See package See package
Validity See package See package
Volume 1l 5l
932H00602003
Conservation for Long-inactive NOTES:

Engines • Renew conservation procedure every 8 months of
inactivity.
MWM INTERNATIONAL engines are manufactured for
a protected inactivity of 6 months maximum. When an • For new engines, do not consider items 1, 2
engine remains inactive for a long period, the following and 3.
actions are necessary:
Engine Preparation for Return of Operation
1. Clean external parts of the engine;
Before turning on a long inactive engine, the following
2. Turn the engine on until it reaches normal procedures must be followed:
operating temperature;
1. Clean the external part of the engine;
3. Drain the cooling and lubricating oil systems;
2. Fill up the cooling system with MWM additive;
4. Top up the radiator with MWM additive;
3. Change the engine lubricating oil filter;
5. Top up the oil pan with SAE 20W20 protection oil;
4. Top up the oil pan with new recommended
6. Drain the fuel system (reservoir, low pressure lubricating oil per recommendations;
system);
5. Assemble belt(s) and adjust tensioning;
7. Turn the engine on for 15 minutes at 2/3 nominal
speed, no load, using a mix of fuel with 15% SAE 6. Remove valve covers and lubricate rocker arms
20W20 protection oil; with engine oil. Reattach valve covers;
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.
932H00602003
Engine Preparation Engine Fluid Draining
Warning: To avoid serious injuries and even death Oil Drain

or damages to the vehicle or engine, read all safety
1. Place a suitable container beneath the oil pan
instructions in “Safety Information”, in this manual.
plug to collect oil.
Warning: To avoid serious injuries and even death, 2. Remove the plug from the oil pan (R ½ “) and the
or damages to the vehicle or engine, be sure that washer. Drain the oil and dispose of used motor
the transmission is in neutral, the parking brake is according with existing laws.
engaged and the wheels are choked before performing
3. Discard the washer, check and replace the plug if
diagnostic procedures or service the engine or the
necessary. Assemble a new washer on the plug
vehicle.
and assemble it on the oil pan. Tighten to 25 to
1. Cover all turbocharger openings and manifolds to 40 N.m torque.
avoid that water and degreasing agents enter into
any component of the engine.
2. Cover exposed electrical components and the
ECM with plastic and adhesive tape.
3. Use a suitable detergent mixed to the correct
proportion of water and apply it to the engine using
warm water and a moderate pressure machine or
a similar cleaning equipment.
NOTE: Do not use high pressure or excessively hot

Torque
water, as those can damage engine components.
1) 18 ± 1 Nm +
2) 36º ± 2º
NOTE: Do not use solvents, thinners or any other
petroleum-derived product, because those can
damage the wiring harnesses and other plastic-made
components.
932H00602003
Lubricating System Preparation The following procedure is the recommended method

for preparation of the lubrication system
Caution: To avoid damage to the engine, be sure that
all internal moving components were well lubricated 1. Check engine lubricating oil level before starting.
during assembly. 2. Disconnect the CMP sensor connector and turn
the starter motor on. Thus, there will be lubrication
Recommended Method of the system without starting the engine.
After the engine has been assembled, lubricate 3. After checking the oil pressure in the lubrication
the engine with oil before starting. This prepares system, connect again the CMP sensor connector
the internal components with suitable lubrication and start the engine.
requirements during the initial critical first start.
932H00602003
Oil Pan Plug
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 25 to 40 Nm torque and fill in
local existing laws. with new engine oil up to the dipstick maximum mark.
932H00602003
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).
Assemble the recommended adapter plate to engine

stand and attach it using grade 8 bolts and nuts.
NOTE: Leave all bolts untightened to ease assembly

of the adapters to the engine and stand plate. Tighten
to torque only after all bolts have been fitted to the
plate and engine.
Stand for Diesel Engines

A good engine stand is one of the key points for an easy
engine assembly, eliminating the need of excessive
efforts to assemble the engine on a bench or on the
ground. A recommended stand for diesel engines must
have good strength, be stable, with a pan to keep
engine oil out of the ground, an easy 360° rotation
capability and a floor locking for safety reasons and to
keep a firm position during repairs is recommended.
932H00602003
Using the lifting equipment, line up the engine stand

to match the engine adapter plate, swivel stand and/or
lift the engine to coincide with the adapter plate. Attach
one bolt and, if necessary, turn the stand to tighten
remaining bolts.
Use metrical 10.9 M12 x 45 bolts or better to attach the
engine to the adapter plate.
Tighten bolts to the normal torque value (General
Torque Guidelines).
Remove hooks from the engine lifting eyelets.
932H00602003
NOTES
932H00602003
ENGINE BLOCK 63
Table of Contents
Engine Block.........................................................................................................................................................64
Cylinder Block.......................................................................................................................................................65
Block Machining...............................................................................................................................................65
Machining Procedure.......................................................................................................................................65
Engine Block Preassembly Inspection and Measurement...............................................................................66
Measurement..............................................................................................................................................66
Engine Block Plug.................................................................................................................................................67
Instalation.........................................................................................................................................................67
932H00602003
64 ENGINE BLOCK
Engine Block
932H00602003
ENGINE BLOCK 65
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
Attention: To perform machining procedures and 1 30 ± 3 Nm
dimensional verification of liners and cylinders, the
2 60 ± 3 Nm
torque plate must be used (Appendix A), duly bolted
to the block simulating tightening of the head. This 3 90° + 10°
avoids the procedure is done on a block that is out of 4 (Loosen) -100° + 10°
the normal operating position. 5 60 ± 3 Nm
6 100 ± 3 Nm
7 60° + 10°
8 90° + 10°
Hone liners.
Before assembling the torque plate, assemble the

head gasket, position the torque plate and tighten to
specified torque in the recommended sequence using
the head bolts.
932H00602003
66 ENGINE BLOCK
Engine Block Preassembly Inspection and

Measurement
Measurement
NOTE: Always use calibrated instruments.
Measure liner internal diameter, tapering and out-of-

roundness.
Insert the gauge on liner inner walls, find a point
for reference, set gauge to null and then perform
measurements on equidistant points. For out-of-
roundness determination, choose points 90° apart.
For tapering, use 3 points. Take note of the values and
calculate tapering and out-of-roundness.
Measure the liner inner diameter in 3 points along its
length, as illustrated below.
932H00602003
ENGINE BLOCK 67
Engine Block Plug

Instalation
Torque 12 ± 2 Nm
Apply Loctite 567 Thread Sealant or equivalent when installing threaded plugs to the block. Inside Exaust Manifold.
Plug M101
Torque 12 ± 2 Nm
(Use Sealant - Loctite 567)
Torque 25 - 3 Nm
Torque 5 ± 1 Nm
Torque 5 ± 1 Nm
Apply Loctite 567 Thread Locker or equivalent on water pump oil inlet threaded plug.
932H00602003
68 ENGINE BLOCK
NOTES
932H00602003
CRANKSHAFT 69
Table of Contents
Crankshaft.............................................................................................................................................................70
Oil Pan and Suction Pump....................................................................................................................................71
Removal...........................................................................................................................................................71
Installation........................................................................................................................................................71
Crankshaft and Bearings.......................................................................................................................................74
Removal...........................................................................................................................................................74
Specifications........................................................................................................................................................75
Crankshaft........................................................................................................................................................75
Journal Specifications...........................................................................................................................................76
Connecting Rod Journals......................................................................................................................................77
Out-of-roundness and Tapering.............................................................................................................................78
Clearance..............................................................................................................................................................79
Fillet Radius...........................................................................................................................................................80
Visual Inspection...................................................................................................................................................81
Plain Bearings.......................................................................................................................................................82
Bearing Out-of-roundness................................................................................................................................83
Clearance Between Bearings and Crankshaft......................................................................................................84
Bearing Pre-tensioning..........................................................................................................................................85
Assembly..........................................................................................................................................................85
Axial Play...............................................................................................................................................................88
932H00602003
70 CRANKSHAFT
Crankshaft
932H00602003
CRANKSHAFT 71
Oil Pan and Suction Pump Installation
Removal
Clean and check the oil suction tube for cracks or

obstructions. Replace oil suction tube sealing ring.
Loosen oil pan bolts from outer ends to the center.
Remove oil pan.
Carefully assemble the oil suction tube with the new

sealing ring (O-Ring).
Remove suction tube and clean. Take care not to let the sealing ring fall inside the
suction gallery.
Tighten attaching bolts with 17 to 23 Nm torque.
Remove all dirtiness from the oil pan gasket and clean.
932H00602003
72 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.
Assemble a new oil pan gasket. Do not apply

adhesives to the gasket.
932H00602003
CRANKSHAFT 73
NOTE: Follow the tightening sequence below.
7
8 Torque 20 ± 3 Nm
4
9
Torque 40 ± 6 Nm 6
Torque 40 ± 6 Nm
17 11 9 3 1 5 7 13 15
2
19 21
23
1
20 24
22 3
18 10 2 8 16 Torque
12 4 6 14 1) 18 ± 1 Nm +
2) 36º ± 2º
Tightening sequence
1. Pan Assy, Lubrication Oil 4. Tube, Lubrication Oil Suction 7. Hexagon Socket Screw
M8x25 - 8.8
2. Gasket, Oil Pan 5. O`Ring
8. Intermediate Duct, Lubrication
3. Hexagon Flanged 6. Hexagon Flanged Bolt
Oil Suction Tube
Bolt M8x20 - 8.8 M10x45 - 8.8
9. Hexagon Flanged Bolt
M10x20 - 8.8
932H00602003
74 CRANKSHAFT
Crankshaft and Bearings

Removal
After removal of the oil pan, pistons, connecting rods,
flywheel, pulley and gearing housing, position the
engine over the stand in a vertical position and loosen
the bearing caps.
Carefully remove the crankshaft, taking care not to hit

any part of the engine block and damage it.
To remove bearing caps, use attaching bolts.
Once removed, the crankshaft must always stand in

a vertical position, using the flywheel as a base, thus
avoiding any chance of warpage.
Remove axial thrust washers from bearing #3.
932H00602003
CRANKSHAFT 75
Specifications
Crankshaft
Gear
Diameter mm
Seat 80.032 - 80.051
932H00602003
76 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
932H00602003
CRANKSHAFT 77
Connecting Rod Journals
Connecting Rod Journals

Diameter mm
Standard 58.725 - 58.745
1st Repair 58.475 - 58.495
2nd Repair 58.225 - 58.245
3rd Repair 57.975 - 57.995
4th Repair 57.725 - 57.745
932H00602003
78 CRANKSHAFT
Out-of-roundness and Tapering
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
932H00602003
CRANKSHAFT 79
Clearance
Clearance (except central bearing) mm

Nominal 0.036 to 0.098
932H00602003
80 CRANKSHAFT
Fillet Radius
Fillet Radius mm
932H00602003
CRANKSHAFT 81
Visual Inspection Measure the crankshaft. The measurements must be

made twice, 90° apart.
The crankshaft, as well as the bearings, can be
visually inspected.
Checks for overheating evidences, deep scratches,
cracks or other kind of damages as needed.
Depending on the kind of damage to the plain bearings,
it is possible to identify what the engine problem is:
excessive play, out-of-roundness, etc.
Lack of or excessive play can also be detected by the
reduction of lubricating oil pressure.
Extensive use in a low oil pressure condition can
cause premature vibrations and knocks on crankshaft
and a consequent deterioration of bearings.
For the measurement of crankshaft warpage, do as

follows: install and lubricate just the first and last main
bearings and carefully position the crankshaft. With a
comparator gauge over the central main bearing, turn
the crankshaft and check warpage.
Maximum warpage:
0.15 mm.
Remove the crankshaft and clean the main bearing
and journal surfaces throughout.
Measure fillet radius with a radius gauge.

Fillet radius measurement can also be done with a
ball gauge.
932H00602003
82 CRANKSHAFT
Plain Bearings
Engine block
Diameter (mm)
Without bearings 75.000 to 75.019
Engine block
(Inner) Diameter (mm)
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
932H00602003
CRANKSHAFT 83
Before performing any check on main bearing and

bearing caps, be sure that the engraved number on
engine block matches the one on bearing cap.
Assemble the bearing caps without bearings and apply

torque as follows.
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
2nd step: 80 to 90°
Bearing Out-of-roundness
The first measurement must be taken on the bearing

center.
Measure the bearing with a gauge on 30° left and 30°
right starting from the central position.
After checking out-of-roundness, a replacement of the
block must be decided.
NOTE: Machining of the block is not recommended.
932H00602003
84 CRANKSHAFT
Clearance Between Bearings and

Crankshaft
Remove bearing caps and reassemble with the
plain bearings applying working torque. Start the
measurements to control clearance and pre-tensioning.
NOTE: For the measurement of the bearings with the

plain bearings, the bearing caps must be well cleaned
to avoid errors due to component seating problems
caused by dirtiness.
Bolt holes must also be cleaned. The holes must be

completely free of dirtiness and residues of oil.
Transfer the measurement to a micrometer caliper.
Assemble bearing cap plain bearings, noting the

correct side (lubrication holes) and locks.
With bearings tightened to working torque, perform the
measurement comparing with the crankshaft.
The difference between measurements is the
clearance.
Clearance:
0.04 to 0.11 mm.
With a micrometer, measure the crankshaft journal

diameter in relation to its respective bearing. Lock the
micrometer with the obtained measurement.
932H00602003
CRANKSHAFT 85
Bearing Pre-tensioning Install piston cooling oil nozzles with a torque of

8.5 to 11.5 Nm.
Check if the nozzles are correctly assembled on block
holes.
For the pre-tensioning measurement, tighten

bearings, place the comparator gauge 90° from the
plain bearing partition at the crankshaft housing, set
the guide and set the comparator gauge to null. Be sure that all bearings are clean to avoid seating
Loosen one of the bolts on the opposite side of the problems due to dirtiness when installing the plain
guide and repeat the measurement with the gauge. bearings.
The difference between the measurements is the pre-

tension.
Pre-tension:
0.015 to 0.060 mm
Assembly
Start assembly with the oil pump, flywheel housing
and timing gears removed.
Before assembling the plain bearings, check the width

of the bearing which is being used.
932H00602003
86 CRANKSHAFT
The axial clearance adjustment bearing is the central

one, where the thrust washers are.
Those washers have a proper assembly position,
being one side with the part dimension identification
and the other one which has the lubrication grooves
and assembly facing the shaft.
Take care when assembling thrust washers as they
can cause severe damages to the engine.
There are 4 thrust washers, being two on block bearing
and two on bearing cap.
Clean the plain bearing housing with a solvent that

does not harm metals and assemble bearings in their
housings without applying oil.
Apply a small amount of lubricating oil and position the
crankshaft.
NOTE: Assemble bearing caps noting the correct side

(lubrication holes) and locks.
Note the correct positioning of the washers.
Carefully install the crankshaft.
Check bolt length before assembling the bearings.

Bolts whose length is out of specified limit must be
discarded and replaced.
Maximum length = 95.7 mm
932H00602003
CRANKSHAFT 87
Position the comparator gauge and set it to null.

Loosen the attaching bolt at one side of the cap.
Using a screwdriver, displace the crankshaft to the
gear side.
Apply specified torque on bearings from the center to

the outer edges.
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)
Oversize 2.67 to 2.72
932H00602003
88 CRANKSHAFT
Axial Play
Axial Play (mm)

932H00602003
HEAD AND CAMSHAFT 89
Table of Contents
Head and Camshaft..............................................................................................................................................91
CMP – Camshaft Position Sensor.........................................................................................................................92
Removal...........................................................................................................................................................92
Installation........................................................................................................................................................92
Valve Cover...........................................................................................................................................................93
Removal...........................................................................................................................................................93
Inspection.........................................................................................................................................................93
Head, Gasket and Bolts........................................................................................................................................94
Complete Head Removal.................................................................................................................................94
Inspection.........................................................................................................................................................98
Disassembly.....................................................................................................................................................99
Specifications......................................................................................................................................................100
Camshaft Specifications.................................................................................................................................100
Valve Specifications.............................................................................................................................................101
Valve Seats....................................................................................................................................................101
Valves and Springs..............................................................................................................................................102
Valve Guides.......................................................................................................................................................103
Distance to Head Surface...................................................................................................................................104
Valve Springs.......................................................................................................................................................105
Valve Diagram.....................................................................................................................................................107
Inspection and Measurement..............................................................................................................................108
Camshaft Bearings..............................................................................................................................................109
Camshaft........................................................................................................................................................109
932H00602003
90 HEAD AND CAMSHAFT
Table of Contents
Intermediate Bearings.........................................................................................................................................110
Camshaft Gear Intermediate Bearing............................................................................................................. 110
Intermediate Bearing (Intermediate Gears, Except Camshaft Gear)............................................................. 111
Assembly........................................................................................................................................................ 114
Camshaft Gear Backlash Adjustment.............................................................................................................120
932H00602003
Head and Camshaft
932H00602003
CMP – Camshaft Position Sensor Apply Vaseline to the silicone base.
Removal
Install the CMP sensor.
Loosen CMP sensor attaching bolt.
Tighten the sensor attaching bolt to a torque of

7.5 to 9.5 Nm.
Loosen sensor.
Installation
932H00602003
Valve Cover Inspection

The gasket and cover feature a guide for fitting, thus
Removal allowing that they not leave their housing even after
the cover is removed.
Wipe off the excess of oil and visually check for
damages on the gasket.
If the gasket is not damaged, reuse it.
Clean the internal vent system, clearing the galleries
with a degreaser which does not cause deterioration
of the rubber.
Loosen valve cover bolts.

Remove valve cover.
Remove valve cover sealing gasket.
932H00602003
Head, Gasket and Bolts

Attention: Before starting disassembly, drain all engine
coolant and lubricating oil.
Complete Head Removal
Loosen bolts from the valve cover and remove it. For
more details about the valve cover procedure, see
Valve Cover, in this chapter.
To ease the operation, the head can be removed

from the block, together with manifolds, turbocharger,
camshaft, injector nozzles, etc.
To accomplish that, loosening and removal of some
block-to-head interface components is needed,
according to the procedure below.
Loosen the fuel high pressure tubes from injectors.
Remove the CMP sensor. See CMP – Camshaft

Position Sensor, in this chapter.
Loosen the fuel return connection from nozzles and

the high pressure pump return.
932H00602003
Loosen and remove turbocharger oil inlet and outlet Lock the camshaft by installing the MWM
tubes. No. D7002304C1 special tool.
Remove the O-ring to assure the perfect seat of the Pay attention to the perfect seating of the tool over
hard tool. the head.
Place the tool to the camshaft using the same valve

cover attaching bolts.
932H00602003
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.
NOTE: Do not remove the inspection cover as shown

in the following illustration, due the risc of component
damage.
Install the MWM No.D7000600C1 special tool to lock

the engine crankshaft.
Loosen the inspection cover using a screw driver.
932H00602003
Remove the inspection cover. Using lifting straps, carefully remove the head with a
winch.
Loosen the idle gear bolt.

Attention: Assure that the glow plugs have been
removed because, the glow plugs are salient with
regard to the cylinder head.
Loosen and remove the cylinder head attaching bolts.

Untightening sequence starts on outer ends to the
center. Remove the head gasket.
It is advisable to use a long socket wrench.
932H00602003
Inspection
1.4 mm metallic gasket (replacement part).
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).
Keep the coolant passage holes well cleaned.
Head gasket guide in its housing.
932H00602003
Disassembly To remove valve locks, spring and spring retainers, use

the MWM No. D7000597C1 special tool positioned on
Turn the camshaft through the gear attaching bolt.
the holes of the valve cover attaching bolts.
Never use the shaft hexagon. Identify the camshaft
bearings to keep them at the same position when Pay attention to keep the valves in their original
assembling. position if the seats and guides were not repaired.
Visually check camshaft for uneven wear or pitting
buildup on cams.
Visually check overall condition of the head for
damages or cracks. Perform tightness tests.
Check flatness on lower side of the head and seating
surface of the camshaft bearings longitudinally and
transversely.
Head height: 107.95 – 108.05 mm
Remove camshaft upper bearings starting from the

outer edges to the center and then remove camshaft
and support it in a upright position using the camshaft
gear as a base.
932H00602003
Specifications
Camshaft Specifications
Gear Seat (A)

Nominal Φ 51.990 – 51.97’
Axial Clearance Limiting Groove (B)

Width 7.100 – 7.190
Journals (C)
Standard Φ 49.873 – 49.897
Bearing Clearance
Axial 0.05 – 0.19
Radial 0.093 – 0.183
932H00602003
Valve Specifications
Valve Seats
D
C
Ø Housing (A) (mm)

Intake (STD) 33.988 - 34.008
Exhaust (STD) 30.963 to 30.988
Ø External Seat (B) (mm)

Intake (STD) 34.043 to 34.059
Exhaust (STD) 31.043 to 31.059
Seat width (C) (mm)

Intake 1.541 to 1.940
Exhaust 2.037 to 2.423
Seat angle (D) Degrees (°)

Intake 44º 45’ - 45º
Exhaust 44º 45’ - 45º
932H00602003
Valves and Springs
C B
Ø Stem (A) (mm)

Intake (STD) 5.936 - 5.950
Exhaust (STD) 5.923 - 5.937
Head height (B) (mm)

Intake 1.30
Exhaust 2.15
Seat width (C) (mm)

Intake 5.88
Exhaust 2.64
Ø Head (D) (mm)

Intake 31.9 - 32.1
Exhaust 28.9 - 29.1
932H00602003
Valve Guides
Ø After pressing (A) (mm)

Nominal 5.975 - 6.000
Ø External (B) (mm)

Nominal 12.050 - 12.060
Ø Housing (C) (mm)

Nominal 12.021 - 12.043
Stem clearance (D) (mm)

Intake (STD) 0.025 - 0.064
Exhaust (STD) 0.038 - 0.077
932H00602003
Distance to Head Surface
Closed valve to head face distance (mm)

Intake (STD) 0.7 ± 0.05
Exhaust (STD) 0.7 ± 0.15
932H00602003
Valve Springs NOTE: The MaxxForce 3.2H engine features 4 valves,

two for intake and two for exhaust.
Tests and measurements on valve springs must
be performed using an appropriate device for the
measurement of spring free height, and after applying
a load to the spring per attached chart, the height is
measured.
Wire Ø: 3.50mm
Load (N) Load Length
A 312.0 A 37.60
B 588.5 B 28.60
C 0 C 50
932H00602003
Special device for spring measurement.
932H00602003
Valve Diagram
Valve Clearance 0.0 Valve Clearance 1.0 Allowable Tolerance

Intake
Open 28° 36’ TDC (B) 15° 10’ TDC (B)
Close 71° 24’ BDC (A) 10° 57’ BDC (A)
± 3°, measured on
engine
Exhaust
Open 63° 23’ BDC (C) 16° 53’ BDC (C)
Close 46° 37’ TDC (D) 13° 56’ TDC (D)
932H00602003
Inspection and Measurement
Measure the gear seat and camshaft bearing The values are the same for the MaxxForce 3.2H
diameters. engines.
Theoretical Valve Timing

Valve Clearance Valve Clearance:
Intake I: 0.0 Intake I: .1.0
Exhaust E: 0.0 Exhaust E: 1.0
Crankshaft
Opens Closes Opens Closes
(Angle)
Intake I 28° 36’ ATDC 71° 24’ ABDC 15° 10’ ATDC 10° 57’ ABDC Allowable tolerance of
Exhaust E 63° 23’ BBDC 46° 37’ BTDC 16° 53’ BBDC 13° 56’ BTDC ± 3° measured on engine.
932H00602003
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.
Camshaft Bearings (C), (D) e (E)

Internal Ø standard (A) 28.000 – 28.021
Thrust ring seat Ø (B) 36.000 – 36.100
Thrust ring seat width (C) 3.020 – 3.080
932H00602003
Intermediate Bearings
Camshaft Gear Intermediate Bearing
Gear seat Ø (A) 34.984 – 35.000

Clearances
Radial clearance 0.020 to 0.076
Axial clearance 0.100 to 0.500
932H00602003
Intermediate Bearing (Intermediate Gears, Except Camshaft Gear)
Gear seat Ø (A) 34.979 – 34.995

Clearances
Radial clearance (gear / bearing) 0.025 to 0.081
Axial clearance (gear / bearing) 0.100 to 0.600
932H00602003
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
Measure valve stem diameter in three different

Measure the camshaft gear intermediate bearing positions: top, center and bottom.
diameter.
Measure the width of valve contact surface.
Bearing diameter: 34.984 to 35.000 mm
932H00602003
Attention: Do not measure the lower end diameter of

the guide.
Measure valve guide internal diameter and check the

clearance between guide and valve. Measure in two
positions close to upper and lower ends.
Measure the diameter of the valve guide housing.
Measure the external diameter of the valve guide.

Measure the diameter of the assembled valve guide.
Measure the external diameter of the valve guide.

Measure the width of the valve guide seat.
Measure the height of the valve guide assembly in
relation to the head surface.
932H00602003
Assembly
Attention:
• All parts must be clean before assembly.
• Use new sealing rings, gaskets and washers.
• Use genuine parts for replacement.
Check the length of the head attaching bolts. Bolts

beyond the specification length limit must be discarded
and replaced.
Maximum length: 150.5 mm.
Assemble the valves with lubricated stems.
Replace the valve guides and seats if necessary. Ship

the head to an accredited machining workshop.
Caution: Insert lower spring retainers.

• Valve guides must be replaced together with valve
seats to assure concentricity.
• If the valve seats and guides were not replaced,
keep the valves in their original positions.
• Head machining is not recommended.
932H00602003
Assemble the device on the valve.
Measure valve lift in relation to head surface. Check the

sealing between seats and valves, per the procedure
Assemble valve retainers. below.
1. Thoroughly clean the seat and put a small amount
of oil.
2. Inject air through the head intake ducts.
3. Air bubbles indicate poor sealing.
Carefully assemble new retainers with the MWM

No. D7000597C1 special tool.
NOTE: Use new retainers every new assembly.
The bearings are fractured-type ones and the parity

between base and cap is made by the surface
roughness.
Assemble springs, retainers and locks with the MWM

No. D7000597C1 special tool positioned over the valve
cover attaching holes.
932H00602003
Install head gasket as shown. Position the gasket on

the block by using the guide pins. The “TOP” mark of
the gasket must be facing upwards.
Install the head on the block with help of a hoist.

During installation, position the camshaft idle gear
to the intake manifold side to avoid “choking” the
clearance between idle and transfer gears. Slightly
tighten the idle gear attaching bolt.
Apply Loctite 518 Gasket Maker or equivalent.
932H00602003
Tighten the bolts according sequence and values below:
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
NOTE: Each step must be applied to all bolts before

starting the next step.
– Tightening sequence ( V= flyweel side)
932H00602003
The separation is done by breaking and can be

performed with locking pliers or a rubber hammer.
Position the idle gear on the cylinder head.
The uneven surface after separation will assure parity,

thus preventing any incorrect assembly.
Lubricate the bearings.
Assemble the camshaft lower bearings with lower

lubrication grooves facing the gear side, and install the
camshaft lower thrust half-washer.
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.
Position the camshaft on the cylinder head and install

the bearing with the upper thrust half-washer without
tightening.
932H00602003
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.
932H00602003
Camshaft Gear Backlash Adjustment Using the valve cover attaching bolt, attach the tool to
the camshaft.
NOTE: Before to make the procedure below, remove
the valve bridge to avoid it falls and cause some NOTE: If the engine is not in the right position, the
damage to the engine. special tool will not touch (seat on) the head, causing
clearances.
During installation, position the camshaft idle gear
to the intake manifold side to avoid “choking” the
Valve Bridge clearance between idle and transfer gears. Slightly
tighten the idle gear attaching bolt.
Use the MWM No. 9.407.0.690.029.4 special tool to

lock the engine.
Lock the camshaft by installing the MWM No.

D7002304C1 special tool over the shaft hexagon. Pay
attention to the perfect tool seating over the head.
Tool fitted to housing hole and flywheel.
932H00602003
The tool must be mounted in the camshaft.
Lock the camshaft by installing the MWM No.

D7002307C1, special tool over the shaft hexagon. Pay
Hand thread the special tool, as indicated in the
attention to the perfect tool seating over the head.
illustration above, assuring that the tool is well fixed.
Tight the special tool bolts as indicated.

Adjust manually the idle gear in order to prepare the
NOTE: If the engine is not in the right position, the gear (rough adjustment).
special tool will not touch (perfectly) the head, causing
clearances.
Without the gear, install the special tool No.
D7002307C1 as shown in the illustration below.
Pre-Tightening the gear bolt, to ensure that the gear

bolt is firm.
932H00602003
Install the dial indicator magnetic base.
Lock the
G
Indicate Gear
H
D
J I B
Lock the indicated gear with screwdriver.
NOTE: Lock the indicated gear is a very important point to do the backlash adjustment.
932H00602003
Measuring the camshaft idle gear backlash Install the camshaft gear and tight the bolt with the
hands.
Specification: 0.05 a 0.12mm
If the backlash is within specification, tight the camshaft
idle gear bolt and measure again.
Torque: 40Nm + 6Nm

90º + 3º
Install the dial indicator with magnetic base.
Remove the special tool.
932H00602003
Lock the
G
Indicate Gear
H
D
J I B
Lock the camshaft idle gear and measure the camshaft gear backlash.
Specification: 0.05 a 0.12mm
If the camshaft gear is according to specification, tighten the bolt and measure again.
Torque: 30Nm + 3Nm

45º + 5º
932H00602003
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.
Install the valve cover.
932H00602003
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.
932H00602003
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.
932H00602003
NOTES
932H00602003
PISTON AND CONNECTING RODS 129
Table of Contents
Piston and Connecting Rods...............................................................................................................................130
Piston, Flat Bearing and Rings............................................................................................................................131
Disassembly...................................................................................................................................................131
Check.............................................................................................................................................................131
Connecting Rod Mark...............................................................................................................................131
Identification Code....................................................................................................................................131
Piston Grooves....................................................................................................................................................132
Ring end Gap Specifications...............................................................................................................................133
Connecting Rod Flat Bearing Specifications.......................................................................................................134
Connecting Rods.................................................................................................................................................135
Connecting Rod Specification........................................................................................................................135
Bearing Shell Connecting Rod Specification..................................................................................................136
Connecting Rod Warpage...................................................................................................................................137
Piston and Pin.....................................................................................................................................................138
Inspection.......................................................................................................................................................139
Inspection and Measurement.........................................................................................................................139
Connecting Rod Pin to Bushing Clearance...............................................................................................139
Connecting Rod to Journal Clearance......................................................................................................141
Connecting Rod Out-of-roundness...........................................................................................................141
Connecting Rod Pre-tension.....................................................................................................................141
Warpage and Torsion................................................................................................................................142
Preparation of the Fractured Connecting Rod..........................................................................................142
Identification..............................................................................................................................................142
Piston Rings........................................................................................................................................................143
Removal.........................................................................................................................................................143
Inspection.......................................................................................................................................................143
Assembly........................................................................................................................................................143
Bearing Diagnostic.........................................................................................................................................146
932H00602003
130 PISTON AND CONNECTING RODS
Piston and Connecting Rods
932H00602003
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.
Attention: Do not loosen a bolt completely on one

side and then loosen the other one.
Pay attention not to damage the ejectors when
removing the connecting rods.
Use the MWM No. 9.408.0.690.001.4 special tool to

remove the connecting rod bushings.
Check
Connecting Rod Mark
Before removing the piston, clean the inner part of

the cylinder to remove carbon deposits and dirtiness.
Take care when removing the piston/connecting rod
assembly through the upper part of the engine.
Caution: When removing the piston and connecting

rod, pay attention to the position of the oil ejector to
avoid crashes and damages.
The body / cap pair of the fractured connecting rod is

made up by the matching of engraved digits on the rod
with the 4 initial digits engraved on the cap.
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.
Remove the circlips of the piston pin. The piston pins

must move freely.
932H00602003
Piston Grooves
1º
2º
3º
NOTE: The rings of MaxxForce 3.2H engines are

identified by a stripe over the outer diameter.
Dimensions and Clearances of the rings in the Grooves (Standard)

Ring Dimensions (Diameter x Height x Width) (mm) Clearance (mm) Stripe Color
1st 96.0 x 2.5 x 3.85 to 4.15 0.078 to 0.137 Black
2nd 96.0 x (1.970 to 1.990) x (3.85 to 4.15) 0.070 to 0.110 Lilac
96.0 x 2.975 to 2.990 x 2.3 to 2.6 (without spring)
3rd 0.030 to 0.065 Yellow
3.50 a 3.75 (with spring)
932H00602003
Ring end Gap Specifications
End gap (mm)

1st Groove 0.30 a 0.50
2nd Groove 0.30 a 0.55
3 Groove
rd
0.30 a 0.55
932H00602003
Connecting Rod Flat Bearing Specifications
Internal Ø (mm)
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
932H00602003
Connecting Rods
Connecting Rod Specification
Radial Clearance
0.03 to 0.088
Ø Internal
A (with Connecting Rod Bushing) 58.767 – 58.800
B (without Connecting Rod Bushing) 62.433 – 62.446
Axial Clearance
0.2 to 0.5
932H00602003
Bearing Shell Connecting Rod Specification
Ø Internal Standard 58.767 – 58.800

Ø Internal 1 Repair
st
58.517 – 58.550
nd
58.267 – 58.300
rd
58.017 – 58.050
Ø Internal 4th Repair 57.767 – 57.800
Bearing Shell Thickness
Thickness standard 1.823 – 1.833
932H00602003
Connecting Rod Warpage
Maximum warpage (mm) Maximum Torsion (mm)

0.03 0.40
932H00602003
Piston and Pin
Ø A – Piston Pin
Diameter (mm)
Nominal 37.994 to 38.000
Ø B – Connecting Rod Bushing (assembled)

Diameter (mm)
Nominal 38.020 to 38.035
Ø C – Connecting Rod Bushing (housing)

Diameter (mm)
Nominal 42.650 to 42.675
D – Piston Pin to Connecting Rod Bushing Clearance

Diameter (mm)
932H00602003
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.
Transfer pin diameter to a micrometer caliper.
Measure the length of the connecting rod attaching

bolt. Replace bolts that exceed the maximum length.
Maximum length: 60.58 mm
Inspection and Measurement
Connecting Rod Pin to Bushing Clearance
Transfer the micrometer caliper measurement to

the assembled connecting rod bushing to check the
clearance between the connecting rod bushing and
piston pin.
Measure the piston pin housing diameter with the
assembled bushing.
Measure the bushing seat diameter and out-of-
roundness.
Measure the connecting rod bushing inner out-of-
roundness.
For bushing replacement, use the MWM No.
9.407.0.690.034.6 special tool.
Measure the pin diameter. Check tapering and out-of-

roundness.
932H00602003
Connecting Rod to Journal Clearance Transfer the previous measurement of the journal to a
micrometer caliper.
Before performing any measurement, check the code

marks on the connecting rod and cap. Those codes
indicate parity between the connecting rod and cap,
assuring a perfect seating of the bearing assembly.
Assemble the bearings on the connecting rod and

tighten attaching bolts to indicated torque.
1st step 26 - 2N.m

2 step
nd
84º - 4o
Place the micrometer caliper with the previous

measurement and compare the values of the
crankshaft and the internal diameter of the connecting
rod bearing. The difference on the values is the radial
clearance.
To check the crankshaft to connecting rod clearance,
first measure the journal diameter with a micrometer.
932H00602003
Connecting Rod Out-of-roundness Connecting Rod Pre-tension

Loosen the connecting rod bolts and disassemble the
connecting rod and cap.
Loosen the connecting rod cap, position the bearings,

assemble the cap again and tighten the connecting
rod to specified torque.
Assemble the connecting rod cap without the bearing
to specified torque. Measure the inner diameter of
1st step 26 - 2N.m
the bearing housing at two points, checking out-of-
roundness: 2 step
nd
84o - 4o
• 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.
Warpage and Torsion
Check warpage of the connecting rod.

Remove connecting rod cap, install the bearing and
assemble the bearing cap again to the specified Maximum warpage:
torque. 0.03 mm
Measure the inner diameter of the installed bearing in
Check the torsion of the connecting Rod.
two positions:
Maximum torsion:
• 30° and at 30° + 90° from the connecting rod
partition. 0.40 mm
932H00602003
Preparation of the Fractured Connecting Rod
NOTE: Never invert the connecting rod cap fit-ting

assembly, as that can cause deformations in the
Hold the connecting rod in a vise with aluminum jaws. seating area and permanently damage the part.
Be sure that the component is well supported. Loosen
bolts and slightly tap the connecting rod cap with a
rubber hammer, taking the two pieces apart. Identification
Attention: Loosen bolts e leave them on place, not

tightening them, hol-ding the connecting rod cap
to avoid its fall after separation and damages to the
contact to rod surface.
Pay attention to the numbers on the cap and con-

necting rod that assure a perfect match.
Caution: Avoid the inversion of the cap or assembling

the cap from ano-ther connecting rod, as that can
Be sure that the rod/cap assembly is free from dir- damage the fractured contact and the part must be
tiness, especially on fractured surfaces. replaced.
NOTE: The fractured surface between the rod and

cap should not receive any kind of crashes during
the loosening process. If is there any damage in the
surfaces, the assembly must be discarded.
932H00602003
Piston Rings Measure the ring end gap by inserting a ring inside the
piston cylinder and perform the measurement using a
Removal feeler gauge
Gap between ends (mm)

1st Groove 0.30 to 0.50
2 Groove
nd
0.30 to 0.55
3rd Groove 0.30 to 0.55
Assembly
Remove the rings with the help of slip-joint pliers,

taking care not to damage them.
Inspection
Install the rings with the help of the slip-joint pliers.
Markings “CTOPW”, CTOPK” and CTOP” must face

upwards.
932H00602003
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.
Assemble one of the piston connecting rod set, making

sure that the marks on the piston head and at the side
of the connecting rod are facing the same side. Check
if the connecting rod moves freely on pin. Place the piston / connecting rod assembly paying
attention that the piston head arrow faces the flywheel
side.
Lubricate with oil, clean the cylinder and then lubricate

again.
Before assembling the piston compression belt, lu-
bricate it in the ring area. Place the rings ends 180°
from each other, alternating them towards the piston
pin.
932H00602003
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.
Caution: Do not hit the piston head.
Assemble the connecting rod cap taking care not to

invert its positioning, and tighten bolts alternately, in
steps, to the specified torque.
It is advisable to turn the camshaft to place twin pistons
at TDC and tighten the bolts.
Attention: If necessary, remove the piston and push

the cap with a plastic hammer as to not damage the
fractured area of the component.
932H00602003
Do the 1st tightening step with a torque meter and the

2nd step with a goniometer, as specified.
Step Torque
1 26 - 2N.m
2 84o - 4o
Measure the connecting rod axial play with a feeler

gauge or a comparator gauge.
Play with feeler gauge: 0.2 to 0.5 mm.
Check the free movement of the connecting rod;
otherwise disassemble and fix it.
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.
932H00602003
GEAR HOUSING AND GEAR TRAIN 147
Table of Contents
Gear Housing and Gear Train.............................................................................................................................148
Gear Housing Cover and Pulse Wheel Sensor (CKP)........................................................................................149
Removal.........................................................................................................................................................149
Installation......................................................................................................................................................150
Distribution Gears and Gear Housing.................................................................................................................152
Gear Disassembly and Removal....................................................................................................................152
Gear Housing Removal..................................................................................................................................152
Pre-assembly Inspection................................................................................................................................153
Measurement of the New Distribution Gear Shafts........................................................................................154
Gear Assembly and Measurement.................................................................................................................155
Gear Housing Installation...............................................................................................................................157
Gear Assembly...............................................................................................................................................157
Shaft to Stop Clearance Control.....................................................................................................................158
Camshaft Idle Drive Gear Back-lash Adjustment Procedure..........................................................................159
Gear Backlash Verification........................................................................................................................159
Spur Gear Train...................................................................................................................................................161
932H00602003
148 GEAR HOUSING AND GEAR TRAIN
Gear Housing and Gear Train
932H00602003
Gear Housing Cover and Pulse Loosen the housing inner bolts and remove the cover.
Wheel Sensor (CKP)
Removal
Attention: To remove the housing, the engine speed

sensor must also be removed.
NOTE: There are bolts with different lengths; being

so, the position of every bolt must be checked
during removal, and it is recommended that they are
organized as to ease the assembly.
Loosen and remove the crankshaft sensor (CKP)

attaching bolt.
Loosen housing outer bolts.
Remove the sensor.
Install two long bolts, as shown.
932H00602003
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.
Check for damages on the gear teeth and the distance

between teeth and sensor with a feeler gauge.
Remove the gear housing cover.
Teeth to sensor distance: 0.5 to 1.5 mm
Installation Attention: If the distance is out of specification, check

if the sensor is a genuine MWM International one or
check for damages on the component fitting area or
toothed wheel.
Apply petrolatum to the silicone base.
932H00602003
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.
NOTE: There are bolts with different lengths; being

so, the position of every bolt must be observed during
assembly.
932H00602003
Distribution Gears and Gear Housing Gear Housing Removal
Gear Disassembly and Removal
Remove the gear housing.

Leave two long bolts pre-attached to the housing and
Loosen bolts and remove the gears together with the move the housing from the guides using a plastic
shafts. Manually and carefully dislodge them up to hammer to avoid damaging it.
their removal, so that the shaft does not fall and gets
damaged.
Remove the housing without having to remove the

pulse wheel.
Use the bolts as supports for the gear removal.
Remove the gear assembly.
932H00602003
Pay attention to the lubrication groove during

assembly.
Remove the gear from its shaft. Visually check the

condition of the gear bushing and perform some
measurements. If necessary, replace the bushing.
Special tools for gear bushing assembly.
Pre-assembly Inspection
Check the distribution gear condition for cracks,

deformations and signs of teeth wear.
Attention is needed during assembly not to invert the

lubrication groove of the washer and shaft.
Gear bushing replacement using the MWM No.

9.407.0.690.034.6 special tool.
932H00602003
Measurement of the New Distribution Gear Shafts
Adjustment washer sizes.
Inspect and measure for excessive wear.

Ring Measurement (mm)
Outer diameter: 34.984 – 35.000 mm.
940704330014 2.47
Procedure for current shaft control:
940704330024 2.52
Measure the diameter of the shaft.
940704330034 2.58
Compare on the micrometer caliper.
Assemble the idle gear applying oil to the thrust washer

and bearing.
Pay attention to the lubrication groove, which must be
as shown on illustration.
932H00602003
Measure the difference on the gear inner bushing to Install the idle gear attaching bolt.
obtain the working play.
Gear Assembly and Measurement
Apply the specified torque to the bolt.
The shaft must be assembled to the block together

with the gear, washer and bolt for clearance control.
Pay attention to the correct shaft assembly side, so
that the lubrication groove does not stay away from
the gear bushing.
932H00602003
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.
932H00602003
Gear Housing Installation

Clean the engine block and housing. Apply Dow
Corning 780 over the housing contact surface. Avoid
applying sealer to the block due to risk of penetrating
into the bolt holes.
Assemble the housing to the engine block and tighten
the attaching bolts to a torque of 34 to 46 Nm.
Install the rear retainer with the MWM No.
9.407.0.690.037.6 special tool.
Before assembling the gears, install the hydraulic

pump lubrication tubes, tightening the hollow bolts to a
torque of 8.5 to 11.5 Nm.
Gear Assembly
Clean the housing and apply sealer (gasket maker)

over the support point, contouring the bolt holes and
install it on the block.
NOTE: Do not apply sealer to the block as that can

enter into the bolt holes and cause shimming on final
torque.
With the first and last piston at TDC, assemble the

gears starting by the crankshaft idler gear, tightening
the attaching bolt to the indicated torque.
2 Step
nd
87 to 93°
Install the housing on the block and tighten attaching

bolts to a torque of 34 to 46 Nm.
932H00602003
Shaft to Stop Clearance Control

Assemble the gear to the shaft together with the
thrust washer and cover and attach the assembly to
a vise, making sure the gear movement is free. Then
measure the side clearance, what can be done with a
feeler gauge within specified values or a dial indicator.
Assemble the hydraulic pump drive gear tightening the

attaching bolt to the specified torque.
2 Step
nd
87 to 93°
Check gear clearance. Use the thrust washer to adjust

to the desired value.
Assemble the camshaft idle drive gear and tighten to

specified torque.
1st Step 34 to 46 Nm Apply Loctite 271 thread locker or equivalent to the

2nd Step 87 to 93° attaching bolt.
932H00602003
NOTE: For the following measurements, the dial

indicator probe must always be positioned at the end
of the gear teeth to be measured.
NOTE: For the measurement the other gear

(matching pair) must be locked. The other gear can be
locked by the hands, a wrench or any other tool. Non-
conformance to this instruction will generate incorrect
backlash results.
Tighten the attaching bolt to a torque of 34 to 46 Nm.
The gear backlash measurement can be performed

with assembled gear train housing.
On the second step, tighten to a torque-angle of

87o to 93°.
Camshaft Idle Drive Gear Back-lash Adjustment

Procedure
Gear Backlash Verification
932H00602003
Camshaft idle gear radial clearance. Camshaft gear.
Camshaft idle gear axial play.
932H00602003
Spur Gear Train
G - Camshaft
F - Camshaft Iddle
D - Iddle Cam and
E - High High Pressure Pump
Pressure Pump
H - Water
Pump G
B/C - Iddle
A - Crank
E
J - Hidraulic
H
Pump D
C
I - Iddle to
Hidraulic Pump
J I B
ID Name Radial Clearance (mm) Axial Play (mm)

A Crankshaft - -
B Water Pump Idle 0.020 to 0.066 0.10 to 0.60
C High Pressure Idle Drive 0.020 to 0.066 0.10 to 0.60
Camshaft Idle / High Pressure Pump
D 0.020 to 0.066 0.10 to 0.60
Drive
E High Pressure Pump - -
F Camshaft Idle 0.020 to 0.066 0.10 to 0.50
G Camshaft - -
H Water Pump - -
I Hydraulic Pump Idle 0.020 to 0.066 0.10 to 0.60
J Hydraulic Pump - -
932H00602003
Gears Circumference clearance between teeth (m)

A and B 0.05 to 0.20
C and D 0.05 to 0.25
B and H 0.05 to 0.25
D and E 0.05 to 0.25
D and F 0.05 to 0.12
F and G 0.05 to 0.12
I and J 0.05 to 0.25
A and I 0.05 to 0.20
Attention: Apply Dow Corning 780 gasket maker or equivalent to

the flywheel housing surface which will be in contact
• While the engine is working there should be no
with the gear housing.
gear noise.
Both surfaces must be dry, clean and free from gasket
• A noisy operation indicate excessive backlash
residues.
between gear teeth, excessive wear o damaged
teeth.
Assemble the rotation sensor and tighten bolt to a

7.5 to 9.5 torque.
Assemble all bolts, checking the length and tightening

to a torque of 34 to 46 Nm.
932H00602003
FLYWHEEL AND FLYWHEEL HOUSING 163
Table of Contents
Flywheel, Retainer and Race..............................................................................................................................164
Removal.........................................................................................................................................................164
Flywheel Ring Gear.............................................................................................................................................166
Dual-mass Flywheel and Rigid Flywheel........................................................................................................166
Inspections.....................................................................................................................................................166
Installation......................................................................................................................................................166
Verification......................................................................................................................................................168
932H00602003
164 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.
932H00602003
Loosen the flywheel attaching bolts. Remove the race retainer.
Remove the flywheel assembly. Remove the retainer using a wrench.
Remove the race retainer and then the retainer using

the MWM No. 9.407.0.690.045.6 special tool.
932H00602003
Flywheel Ring Gear Installation
To remove the ring gear from the flywheel, use a plastic

hammer and a brass bar, hitting in a cross pattern until
the whole gear comes apart.
To install the ring gear to the flywheel, it must be
previously heated to a temperature of about 250° C.
Carefully assemble it taking care with the position
of the V-form teeth, which must be facing the starter
motor side.
Dual-mass Flywheel and Rigid Flywheel

The MaxxForce 3.2H has a rigid flywheel.
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.
932H00602003
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:
Install the flywheel. 1. 30 ± 3 Nm

2. 100° + 10°
Lock the flywheel with the MWM No. D7000600C1

special tool.
932H00602003
Verification
Turn the crankshaft / flywheel assembly 360° for the
verifications below.
Measure off center.

Off center: 0.40 mm
Measure the parallelism of the flywheel.

Parallelism: 0.30 mm
Measure the flywheel waviness.

Waviness: 0.30 mm
932H00602003
PULLEYS, BELTS AND ACCESSORIES 169
Table of Contents
Pulleys, Belts and Accessories............................................................................................................................170
Accessories and Pulleys.....................................................................................................................................171
Removal.........................................................................................................................................................171
Disassembling Notes ....................................................................................................................................171
Inspections.....................................................................................................................................................172
Instalation.......................................................................................................................................................174
Belt Assembly......................................................................................................................................................177
Vibration Damper and Crankshaft Front Retainer Bushing (Race Retainer).......................................................178
Removal.........................................................................................................................................................178
Inspection.......................................................................................................................................................178
Installation......................................................................................................................................................178
932H00602003
170 PULLEYS, BELTS AND ACCESSORIES
Pulleys, Belts and Accessories
932H00602003
Accessories and Pulleys Disassembling Notes

For replacing of the belt, turn the automatic tensioner
Removal pulley bolt clockwise.
Hold the fan shaft using a wrench and loosen the For removal of the pulley, lock the engine flywheel with
attaching bolt. the special tool MWM no. 9.407.0.690.036.6.
NOTE: This illustration is for procedure only and the
vehicle fan could differ from this presented.
Carefully remove the fan and viscous clutch assembly,

taking care not to damage the heat sensor.
NOTE: This illustration is for procedure only and the

vehicle fan could differ from this presented.
932H00602003
Inspections Release the tensioner with a ½” square wrench to

remove the accessory belt.
Check condition of the belt after removing it from
engine. Check for cracks, cuts and dryness.
Remove the idle pulley and the tensioner from the

accessory belt.
Inspect the engine vent tube for clogging, cracks and
dents. Remove the air-conditioning compressor.
Remove the air compressor. See “Air Compressor -
REMOVAL” in this Manual.
932H00602003
Remove the hollow bolt and oil return tube from the Hold the pulley nut with a wrench and later loosen the
support assembly. remaining pulley bolts.
Loosen and remove the fan pulley hub.
Remove the attaching bolts of the tensioning pulley

and air compressor support assembly.
Install the MWM No. D7000600C1 special tool to

preclude crankshaft movement.
932H00602003
Loosen the 6 attaching bolts and remove the air

compressor drive pulley from the damper pulley.
Install the damper pulley from the cranckshaft tighten

the bolts with the specified torque.
Loosen the 4 attaching bolts and remove the damper

pulley from the crankshaft.
Instalation
Install the fan pulley hub.
Install the MWM No. D7000600C1 special tool to

preclude crankshaft movement.
932H00602003
2
Mount the item 2 with silicone
grease DC111 on item 1
Install the air compressor drive pulley.
Torque 10 ± 2 Nm
932H00602003
Apply Loctite 271 thread locker or equivalent to the 4 Install the idle pulley and tensioner from the accessory
pulley attaching bolt holes. belt.
Install the accessory belt.

Install the tensioner attaching the bolts with the
specified torque.
Install the air compressor support assembly attaching

the bolts with the specified torque.
932H00602003
Belt Assembly
1. Idle Pulley 4. Idle Pulley 7. Damper

2. Automatic Tensioner Pulley 5. Air-conditioner Pulley
3. Alternator Pulley 6. Idle Pulley
932H00602003
Vibration Damper and Crankshaft

Front Retainer Bushing (Race
Retainer)
Removal
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
Once there is some space between the bushing and

the seat, insert a wrench there and carefully force the
bushing to completely remove it. Use Loctite® 601 gasket maker or equivalent.
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.
932H00602003
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.
Check if the bushing was pressed up to the final stop

on the bushing surface. Remove any excess of gasket
maker.
Install the MWM No. D7000600C1 special tool to lock

the flywheel.
Apply petrolatum.
Tighten the pulley bolts to the indicated torque.
2 Step
nd
100º + 10º
3 Step
rd
25º + 5º
932H00602003
NOTES
932H00602003
LUBRICATION SYSTEM 181
Table of Contents
Lubrication System of the Engine........................................................................................................................182
Lubrication System..............................................................................................................................................183
Cooling System...................................................................................................................................................184
Oil Cooler............................................................................................................................................................185
Removal.........................................................................................................................................................185
Thermostatic Valve Test......................................................................................................................................187
Disassembly...................................................................................................................................................187
Cleaning.........................................................................................................................................................187
Inspection.......................................................................................................................................................188
Installation......................................................................................................................................................188
Precautions Before Starting the Engine..............................................................................................................190
System Bleeding............................................................................................................................................190
Oil Pump..............................................................................................................................................................191
Removal.........................................................................................................................................................191
Inspection.......................................................................................................................................................191
Installation......................................................................................................................................................192
Oil Filter...............................................................................................................................................................193
Removal.........................................................................................................................................................193
Installation......................................................................................................................................................193
932H00602003
182 LUBRICATION SYSTEM
Lubrication System of the Engine
932H00602003
Lubrication System
932H00602003
Cooling System
932H00602003
Oil Cooler Warning: To avoid serious personal injuries or even

death, as well as damages to the engine or vehicle,
Removal be sure that the transmission is in neutral, the parking
brake is applied and the wheels are choked before
Warning: To avoid serious personal injuries or even performing repair procedures in the vehicle.
read all safety instructions on “Safety Instructions”, in Attention: Never operate the engine without a
this manual. thermostatic valve, as the engine will not reach the
correct working temperature. The sealing rings of
disassembled components must always be replaced.
932H00602003
Remove the housing assembly and oil radiator. Remove the oil radiator and thermostat assembly.
Remove and discard the sealing gaskets.
Remove the M6x16 bolt as shown.
Attention: The “Torx” type bolts for the oil radiator

attachment require a special wrench for their removal
and must only be removed if the heat exchanger plates
are replaced.
Caution: To avoid damages to the engine when

removing the oil cooler from its cover, do not
press excessively the aluminum cooler plate to
break it from the cover. Do not apply any force
to the oil cooler fins.
932H00602003
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:
−− Dial indicator; Remove the Allen attaching bolts.

−− Thermometer; Caution: To avoid damages to the fin assembly when
−− Heater; removing the oil cooler from its housing, do not press
the oil cooler fins excessively.
−− Thermostat attaching device.
Remove gasket residues, thus avoiding damages to
Position the dial indicator over the thermostatic valve the housing.
rod and adjust it with a 1 mm pre-load.
Install a thermometer with 0 to 100° C scale immersed Cleaning
in the water.
Caution: Whenever there are locking or shear on flat
Heat up the water gradually. bearings, an inner cleaning of the fins or oil cooler
Record the initial and final temperatures of the replacement must be performed, since such dirtiness
thermostatic valve opening (dial indicator movement is difficult to remove and can cause damages to the
start and end), and the total final deviation of the dial engine.
indicator (completely open).
Check if the opening movement is linear. Sudden Caution: Do not clean the oil fins with solvents, as that
movements during the opening hint to valve problems. will stay in the cooler and can damage the regulator
and thermal valve assembly.
Values to be observed during thermostatic valve tests.
Clean the oil system module housing with dry, filtered
Maximum and clean compressed air.
Opening Fully
Opening Remove all residues of gaskets from the cover and
Start (°C) Open (°C)
Excursion (mm) engine block in the cooler housing.
79 ± 2 94 8
932H00602003
Dip the disassembled oil cooler cover in a suitable

cleaning agent.
Wash and drain the oil cooler cover to remove
any residue. Dry all components with filtered
compressed air.
Inspection
Check the oil cooler housing for clogged holes and
damaged threads.
Replace the housing if required.
Installation
Assemble the cooler, tightening assembly bolts to a

torque of 21 to 29 Nm.
NOTE: If an inspection of the valves is required,

remove them from the housing and perform the
“thermostatic valve test procedure”, in this manual.
Check the lubricating oil cooler for cracks and

damages.
Install a new gasket between the cooler head and

engine block.
Replace the gasket if an oil cooler disassembly is

required.
932H00602003
The oil cooler must be clean and dry before installation.

Torque 7 ± 2 Nm
Torque 8.5 ± 1 Nm
Torque:
Torque: 1) 15 ± 5 Nm
1) 15 ± 5 Nm 2) 25º ± 2º
2) 25º ± 2º
Assemble the oil cooler.

Apply torque as specified, following the tightening
sequence in the figure below.
932H00602003
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.
932H00602003
Oil Pump Inspection
Removal
2
Remove the fan with viscous clutch, accessory belt
and crankshaft damper pulley. For more details, see
accessories and pulleys – removal.
Check the general condition of the oil pump and the

lubricating oil pump inlet (1) and outlet (2) for dirtiness.
Remove the oil pump front retainer with an adequate

tool.
Placement of the oil pressure regulating valve.
Loosen the oil pump attaching bolts.
Disassemble the pressure regulating valve.
Remove the oil pump.
932H00602003
Installation
Check the condition of the spring and regulating valve

piston.
Install the lubricating oil pump.
If the engine has low oil pressure, check the valve

components for damages or wear. When installing, take care not to damage or distort the
retainer rubber material.
Replace the oil pump assembly, if required.
When installing a new oil pump or reinstalling
it after check and cleaning, lubricate the gear
housing through the oil inlet hole with approximately
10 ml of oil.
This procedure is required to prevent oil-less operation
of the pump gears after first engine start, which can
cause wear and reduction of component life.
Tighten the bolts in a cross pattern to the indicated

torque.
2 Step
nd
57º to 63º
932H00602003
Oil Filter
Removal
Wipe the sealing area of the filter with a clean, lint-free

cloth.
Loosen and remove the oil filter.
Installation
Slightly lubricate the filter sealing with new oil.
Manually tighten the filter, following instructions on it.

Do not use a strap as that can damage the filter.
Manually tighten up to the point the sealing touches
the head.
932H00602003
Torque 30 ± 4.5 Nm
Torque 20 ± 5 Nm
Torque 36 ± 4 Nm
Mark on the position of one complete and 3/4. Install two bolts and applying the torque of 30 ± 4.5Nm.
Tighten manually from ¾ of a turn to one complete

turn.
932H00602003
ELECTRONIC ENGINE SYSTEM 195
Table of Contents
Common Rail Electrical System..........................................................................................................................196
ECM.....................................................................................................................................................................198
Electronic Control Module (ECM)........................................................................................................................199
Removal.........................................................................................................................................................199
Inspection.......................................................................................................................................................199
Installation......................................................................................................................................................199
Sensor Identification............................................................................................................................................200
Engine Sensors..............................................................................................................................................200
Phase Sensor or Camshaft Position Sensor (CMP).................................................................................200
Rotation Sensor or Crankshaft Position Sensor (CKP).............................................................................200
Engine Oil Pressure Sensor (EOP)...........................................................................................................200
Engine Coolant Temperature Sensor (ECT)..............................................................................................201
Temperature Manifold Air Pressure Sensor (TMAP).................................................................................201
Engine Fuel Pressure (EFP) – Common Rail...........................................................................................201
Electronic Control Module (ECM)..............................................................................................................201
Fuel Injectors.............................................................................................................................................202
Vehicle Sensors..............................................................................................................................................202
Throttle Position Sensor (TPS).................................................................................................................202
Vehicle Speed Sensor (VSS)....................................................................................................................202
Clutch Pedal Sensor (CPS).......................................................................................................................202
Brake Pedal Sensor (BPS)........................................................................................................................202
932H00602003
196 ELECTRONIC ENGINE SYSTEM
Common Rail Electrical System
1. Bracket Wiring Harness 3. Hex. Flanged Bolt M8x12 8.8 4. Wiring Harness, Engine
2. Hex. Flanged Bolt M6x12 8.8
932H00602003
932H00602003
ECM
932H00602003
Electronic Control Module (ECM) Installation
Removal
Install the ECM module, tightening to a torque of

5 to 7 Nm.
Unscrew the attaching nuts of the ECM support to the
engine, and then remove the assembly. Unscrew the
bolts and remove the module from the support.
Inspection
Visually check the harness and connector pins for
rust, dirtiness, damages and water ingress. Clean or
replace components as required.
Attention: Never open an ECM module as that can

damage the internal components.
932H00602003
Sensor Identification Warning: To avoid serious personal injuries or even

Engine Sensors read all safety instructions on “Safety Instructions”, in
this manual.
Phase Sensor or Camshaft Position Sensor (CMP)
Warning: To avoid serious personal injuries or even
be sure that the transmission is in neutral, the parking
performing repair procedures on the vehicle.
NOTE: For information about the removal or installation

of adjacent components, refer to the following types of
service in other parts of this manual: This section must
be used for identification and placement of the sensors.
For a more detailed description of the electronic sensors,
refer to Engine and Vehicle Sensors in “Introduction”, in
this manual or in the diagnostic manual.
Engine Oil Pressure Sensor (EOP)
The CMP sensor is a “Hall-effect” sensor for the

engine position. It is assembled on the valve cover and
its function is to read the lobe position of the camshaft,
converting it into a signal and synchronizing the
injection by the determination of the position of No. 1
cylinder, which is in the ignition cycle, and the position
of the cylinder piston.
Rotation Sensor or Crankshaft Position Sensor

(CKP)
1. Engine Oil Pressure sensor (EOP)
The Engine Oil Pressure (EOP) is a switch used to

The Crankshaft Position Sensor is an induction-type monitor the oil pressure in the lubricating system and
sensor and is located at the fl ywheel housing. The sends out a signal. A warning light in the vehicle lights
sensor signal reads the engine speed and the exact up when the engine starts and low oil pressure is
position of the cylinder pistons. The information is detected.
used by the ECM for the determination of the injection Installation: Place the EOP sensor with a new washer.
start angle. This requires a special socket for removal. Apply the
torque of 9 to 13 N.m.
932H00602003
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.
Engine Fuel Pressure (EFP) – Common Rail
The ECT sensor is a termistor-type sensor and is

assembled.
Temperature Manifold Air Pressure Sensor (TMAP)
The EFP sensor consists of a piezoresistive pressure

element.
NOTE: The obtained signal is proportional to the

pressure applied to the sensor and is processed by
an integrated circuit. The EFP sensor is assembled on
the fuel common rail.
Electronic Control Module (ECM)
The TMAP sensor measures the absolute pressure

and temperature of the air.
932H00602003
Fuel Injectors Vehicle Speed Sensor (VSS)
Vehicle Sensors The VSS sensor is designed to measure vehicle

speed.
Throttle Position Sensor (TPS) It is assembled on the vehicle; refer to the vehicle
service manual for more information.
Clutch Pedal Sensor (CPS)

The CPS sensor is a normally-open switch. It is
assembled on the clutch pedal.
See the vehicle workshop manual for more information.
Brake Pedal Sensor (BPS)

The BPS sensor is a normally-open switch. It is
assembled on the brake pedal.
See the vehicle workshop manual for more information.
932H00602003
COOLING SYSTEM 203
Table of Contents
Cooling System...................................................................................................................................................204
Water Pump.........................................................................................................................................................205
Introduction.....................................................................................................................................................205
Diagnostics.....................................................................................................................................................205
Removal.........................................................................................................................................................205
Installation......................................................................................................................................................206
932H00602003
204 COOLING SYSTEM
Cooling System
932H00602003
COOLING SYSTEM 205
Water Pump Removal

Caution: Never perform any service on a cooling
Introduction system component while engine is working.
Caution: Avoid touching the cooling system

components right after engine operation, as that can
cause severe burns.
Caution: The cooling system fluid may splatter and

cause burns if the water reservoir cap is removed
while the system is still hot. To remove the reservoir
cap let the system cool down, turn the cap up to the
first phase and wait for the pressure to be relieved.
The water pump is located externally on the engine

block and is driven by the timing gear.
There are currently two types of pump: one with
aluminum housing and another one with cast iron
housing, the assembly procedure for both being the
same.
The lower hole is intended to indicate failure of the
pump sealing ring. Whenever there is a leakage in the
hole, the pump must be replaced.
Loosen and remove the pump attaching bolts to the
Diagnostics gear housing and block.
Attention: The bolts have different lengths.
Check for water leakages through the indicated hole. If

so, the pump must be replaced.
932H00602003
206 COOLING SYSTEM
NOTE: Before installing the water pump, check the

housing condition for erosion or cavitation. Clean it
throughout and replace the sealing rings.
NOTE: The water pump is not serviceable, the

assembly must be replaced as a unit and, if the
housing is in good condition, the pump may be
replaced keeping the old housing.
Installation
Remove the pump and housing assembly together

with the sealing rings.
Replace the 3 pump sealing O-rings and apply

petrolatum to the silicone base of new rings before
installing them on the housing.
Disassemble the water pump assembly (rotor) from

the housing.
Install the pump with attaching the mouting bolts with

17 to 23 Nm torque.
Disassemble the pump rotor, remove and discard the

sealing rings.
932H00602003
COOLING SYSTEM 207
Install the pump with attaching the mouting bolts with

17 to 23 Nm torque.
932H00602003
208 COOLING SYSTEM
NOTES
932H00602003
MANAGEMENT ENGINE SYSTEM 209
Table of Contents
Engine Wiring Harness........................................................................................................................................210
Removal.........................................................................................................................................................210
High Pressure Fuel Tubes (Rail).........................................................................................................................213
Removal.........................................................................................................................................................213
Injectors...............................................................................................................................................................215
Removal.........................................................................................................................................................215
Installation......................................................................................................................................................215
High Pressure Fuel Pump...................................................................................................................................218
Removal.........................................................................................................................................................218
Installation......................................................................................................................................................218
EGR System and Glow Plug...............................................................................................................................219
Removal.........................................................................................................................................................219
Installation......................................................................................................................................................220
932H00602003
210 MANAGEMENT ENGINE SYSTEM
Engine Wiring Harness Removal
Caution: NOTE: To remove the wiring harness at the

connectors, care must be taken as to not pull the
• Never perform any service on a cooling system harness by the cables or stress with tools, as that can
component while engine is running. damage the connections and will lead to a possible
• Do not smoke while repairing the fuel system or replacement of the whole wiring harness.
any other system of the engine.
• Avoid contact with electrical components which
can generate sparks.
• Always check tanks, tubes, hoses and other
system components to detect fuel leakages.
• Do not touch injector connectors while engine
is running. The high voltage can cause serious
injuries or even death.
• Do not bleed the management engine system
while engine is running.
• The high pressure in the system can cause
serious injuries if disassembled.
• Under no condition the ECM can be disassembled
for any kind of service. Disconnect the phase sensor (CMP) connector.
• Only an authorized Bosch service can check or
repair failures in this component after verification
with an electronic diagnostic equipment. A faulty
repair will void component warranty and, as a
consequence, the warranty of the engine as a
whole.
• Before start assembling the electrical wiring
harness to the ECM, be sure that the battery
cables are disconnected.
• Repairs on the injection system can only be
performed 30 seconds after the engine was
stopped, a required time to assure a complete
reduction of the common rail pressure (fuel
distribution tube).
Disconnect the temperature manifold air pressure

sensor (TMAP).
932H00602003
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.
932H00602003
Remove the ECM connector. Loosen the wiring harness at the injectors and remove
the upper part of the harness.
NOTE: When loosening the sensors, carefully remove
the cables to avoid damages to connectors or wiring
harness.
Disconnect the engine coolant temperature sensor

(ECT) connector.
932H00602003
High Pressure Fuel Tubes (Rail)

read all safety instructions on “Safety Instructions” in
this manual.

be sure that the transmission is in neutral, the parking
performing repair procedures in the vehicle.

death, as well as damages to the engine or vehicle
when draining the fuel, observe the following: Loosen and remove the high pressure tubes from the
• Do not smoke. common rail.
• Keep away from fire or sparks.
• Drain all the water from the fuel filter in a suitable
container before removing the assembly.
Attention: Discard all fuel high pressure tubes after

their removal.
Warning: Do not reuse the fuel high pressure tubes

to avoid serious injuries or even death, as well as
damages to the engine or to the injection system.
Removal
Loosen the high pressure tube from the pump.
Cover all holes of the common rail holes (Rail) during

the removal. Removal of connectors and fuel tube
supports:
• Loosen all connectors of the common rail to
injectors; Loosen the rail return clamp.
• Loosen connectors of the high pressure pump to
the fuel common rail on both sides;
• Loosen and remove the attaching bolts of the fuel
common rail support;
932H00602003
Loosen and remove the common rail. Attention: Cover all common rail inlets to prevent
ingress of debris.
932H00602003
Injectors Installation
Sub-Assembly Injector Nozzle:
Removal
Loosen and remove the injector fastening system

(clamps).
1. Pre-assemble manually the injector (1) retainer

(2), cover (3) and gasket (4) corresponding to the
sub-assembly.
Remove the injector nozzle carriers using the MWM

No. 9.407.0.690.052.4.
932H00602003
After the assembly the injector nozze, install then

follow the torques of figure below.
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.
932H00602003
Install the fuel distribution tube to the valve cover. Install new high pressure fuel tubes to the common rail
Tighten the attaching bolts to a torque of 24 to 30 Nm. and tighten with 24 to 30 Nm torque.
Install a new high pressure pump fuel tube to the fuel

common rail and tighten with 24 to 30 Nm torque.
932H00602003
High Pressure Fuel Pump Caution:

• High pressure pumps shall never be disassembled.
Removal
• Any violation will void warranty.
The pump can be removed together with the gear.
• If a pump repair is required, it must be sent to an
authorized Continental dealer.
Installation
Install a new sealing ring (O-ring) on the high pressure
pump.
Clean the surface and apply a coat of petrolatum over

the O-Ring contact area with the intermediate part
housing.
Install the high pressure pump in the gear housing.
Tighten bolts in a cross pattern as to not damage the
O-Rings (cuts) on the side of the pump.
Position the pump with bolts up to the back wall in the
gear housing and apply 24 to 30 Nm torque.
After loosening and removing the tubes, unscrew the Be sure that the pump sits properly in the gear housing.
bolts of the high pressure pump attaching bolts from
the gear housing.
The removal must be done carefully. Friction between
the O-Ring and the pump housing may hinder its
removal. Since it is a component that requires extreme
care, the fuel inlet and outlet holes must be covered
and the component stored in a safe place, away from
accidents.
To remove the pump gear, loosen and remove the
attaching nut. Remove the gear with a suitable puller.
932H00602003
EGR System and Glow Plug
Removal
Remove the exhaust gas recirculation cooler-water

inlet tube.
Remove the exhaust gas recirculation cooler outlet

tube.
Remove the exhaust gas recirculation duct.
Unscrew the sensor ECT (engine coolant temperature).
Remove EGR system.
932H00602003
Remove the wiring harness glow plug. Install wiring harness glow plug. Apply 1.5 to 2.5Nm
torque.
Remove the glow plug.

Install the EGR system. Tighten 16 to 18Nm torque in
the bolts.
Installation
Install Install the exhaust gas recirculation cooler-

Install the glow plug and tighten 16 to 18 Nm torque.
water inlet tube and tighten to 19 to 25Nm torque.
932H00602003
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.
Install the sensor ECT (engine coolant temperature)

and tighten 16 to 20 Nm torque.
932H00602003
NOTES
932H00602003
INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER 223
Table of Contents
Intake Manifold....................................................................................................................................................224
Removal.........................................................................................................................................................224
Installation......................................................................................................................................................225
Turbocharger and Tubing....................................................................................................................................227
Removal.........................................................................................................................................................227
Cleaning.........................................................................................................................................................227
Installation......................................................................................................................................................228
Exhaust Manifold.................................................................................................................................................230
Removal.........................................................................................................................................................230
Cleaning.........................................................................................................................................................230
Inspection.......................................................................................................................................................230
Installation......................................................................................................................................................230
932H00602003
224 INTAKE AND EXHAUST SYSTEMS AND TURBOCHARGER
Intake Manifold Warning: To avoid serious personal injuries or even

Removal be sure that the transmission is in neutral, the parking
Remove the fuel common rail, high pressure tubing, performing diagnostic or service procedures on the
alternator and coolant outlet tube. See the specific engine or vehicle.
procedures in this manual for more information.
observe the followin:
• Do not smoke;
• Keep away from fire or sparks.
Remove the fuel common rail.

See the specific procedure in this manual for more
information.
Remove the air mixer attaching bolts.
Remove the manifold attaching bolts.
Position the intake manifold and then remove it as
shown.
Loosen the intake tube attaching bolts. Discard the manifold gaskets and remove all gasket
residues along the head and intake manifold holes.
Caution: To avoid damages to the engine, do not try to

machine the intake manifold to correct warpage.
Clean the intake manifold with and adequate, non-
caustic solvent.
After cleaning, dry with filtered compressed air.
Replace the intake manifold, if necessary.
Removal of the intake manifold.

this manual.
932H00602003
Installation
Tighten the intake manifold bolts according to the

indicated sequence and torque.
Install the gasket maker in the intake manifold.
Install the manifold and bolts and manually tighten up

to the end of the thread.
932H00602003
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.
932H00602003
Turbocharger and Tubing

this manual.
• Be sure that the engine has cooled down enough

before removing the turbocharger assembly.
Removal
Remove the attaching bolt of the feeding tube.
Remove and discard the turbocharger to exhaust

manifold attaching nuts.
Discard and replace the sealing ring.
Loosen and remove the turbocharger.
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.
Loosen the oil return tube bolt. Loosen the return tube
Clean the oil inlet and drain tubes.
hose and remove the tube.
Clean any material residue on the turbine housing
surfaces and exhaust manifold assembly.
932H00602003
Installation NOTE: The previous procedure is necessary as there

is no room to tighten the bolts with a torque wrench
with an installed supercharger.
Torque 70±5 N.m
Torque 10±2 N.m
Assemble the turbocharger and return tube on the

Torque 10±2 N.m
exhaust manifold.
If a replacement of the studs is required, Loctite 648

thread locker or equivalent must be applied and then
new studs installed.
With the turbocharger removed, apply Loctite 242

thread locker or equivalent on both threads.
Install the return tube and two attaching bolts,
tightening to the torque of 13 to 17 Nm.
932H00602003
Torque 70±5 N.m
Torque 25+5 N.m
Torque 25±3 N.m Torque 10±2 N.m
Torque 11±1 N.m
Install four new turbo attaching nuts, tightening to the

torque of 65 to 75 Nm.
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.
932H00602003
Exhaust Manifold Cleaning

Remove gasket residues form the manifold holes and
Warning: To avoid serious personal injuries or damages
carefully clean the exhaust manifold.
to the engine or vehicle, be sure that the engine has
cooled down enough before removing any component. Scrap excesses of carbon and rust from the manifold
surfaces.
Removal After cleaning, dry the parts with filtered compressed
air.
Untighten the bolts, remove the exhaust tube and
gaskets.
Inspection
Check the exhaust manifold for cracks and damages.
Replace the part if necessary.
Check for warpage.
Installation
Attention: After the manifold cleaning and inspection

procedures, assemble new gaskets to the manifold.
Replace the attaching bolts.
Loosen and remove the manifold attaching bolts.
Tighten the nuts and studs of the exhaust manifold.

The bolts must be tightened to torque from the center
to ends in a cross pattern.
Remove the exhaust manifold and metallic gaskets.
932H00602003
1. Air Intake Curve 2. O-ring 3. V Clamp
932H00602003
NOTES
932H00602003
TROUBLESHOOTING 233
Table of Contents
Symptom Chart...................................................................................................................................................234
Bearing Diagnostics............................................................................................................................................244
Bearing Premature Failures Due to Malfunction............................................................................................244
Lack of Oil on Bearings.............................................................................................................................244
Excessive Clearance.................................................................................................................................245
Premature Failure of Bearings Due to Faulty Assembly.................................................................................246
Insufficient end Play..................................................................................................................................246
Solid Particles...........................................................................................................................................246
Dirtiness on Bearing Housing....................................................................................................................248
Crankcase Out-of-roundness....................................................................................................................248
Insufficient Seat Height.............................................................................................................................249
Excessive Seat Height..............................................................................................................................250
Twisted or Bent Connecting Rod...............................................................................................................251
Offset Cap.................................................................................................................................................251
Bent Crankshaft........................................................................................................................................252
Bent Engine Block.....................................................................................................................................253
Non-cylindrical Journal Bearings...............................................................................................................255
Incorrect Fillet Radius...............................................................................................................................256
Incorrect Torque and Adhesive Application...............................................................................................256
Incorrect, Careless Assembly....................................................................................................................257
932H00602003
234 TROUBLESHOOTING
Symptom Chart
Symptom Probable Causes
The ECM enters into the Safe Mode: Limited engine RPM;
59-65-67-68-69-75-113-131-199
engine stops
Cylinder working failure 56-65
Excessive fuel pressure on rail: Idle and Nominal Speed 38-56-61-65-67
Low fuel pressure on rail 34-38-53-54-55-60-65-67
Excessive air pressure on intake manifold 65-81
Low air pressure on intake manifold 83-77-65
Intermittent failures generating several different trouble codes

at the same time and the instrument panel warning light 10-13-15-16-17-18-38-65
switches on.
Low starting revolution 10-12-13
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
Sudden stalls while engine is running 38-63-64-65-191-195
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
Low lubricating oil pressure 50-110-111-116-117-119-120-123-124-158
932H00602003
TROUBLESHOOTING 235
Symptom Chart (Continuation)
Symptom Probable Causes
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
High oil pressure 110-114-118-120-122-124
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
Engine starts and stops 38-51-52-53-56-90
Engine run up 50-53-178
31-63-70-74-110-112-123-125-153-155-158-
High lubricating oil consumption
170-176-178-179
Coolant fluid mixed with lubricant oil 130-177
Oil mixed to coolant fluid 194
Rough idle 33-35-50-52-90-123-151
Engine stalls when vehicle stops 30-33-50-51-52-151
Engine misfiring 50-52-151
932H00602003
236 TROUBLESHOOTING
No. Probable Cause What to do
Check: current leakage, alternator working condition,

10 Low charge battery battery condition and corrosion on battery and cable
terminals. Repair or replace.
Check: current leakage, alternator working condition,

11 Low starting voltage battery condition and corrosion on battery and cable
terminals. Repair or replace.
Check condition of the starter motor and solenoid.
12 Faulty starter motor Check for corrosion on wiring harness contacts to the
starter motor. Repair or replace.
Check for changes or damages on grounding points,
13 Poor contact on electrical connections connections or wiring harness due to previous repairs or
service. Repair or replace.
14 Sticky or limited movement accelerator Check, repair or replace
Check battery for low charge.

15 Inconstant voltage ECM supply Check the fuse box and wiring harness from the battery
to ECM. Repair or replace.
Check the loading condition of the alternator and its
16 Faulty or no load alternator connections for good contact and no corrosion. Repair
or replace.
17 Poor grounding connections or wiring harness due to previous repairs or
18 Terminals with poor or no contact connections or wiring harness due to previous repairs or
30 Empty fuel tank Top up with recommended fuel.
31 Fuel tank with clogged venting Check, repair or replace.
Tank electric pump running but with no Check: clogged pump, open return valve, faulty pump
32
pressure motor, blown fuse.
Check clogging causes like: improper fuel, fuel filter not

33 Clogged fuel feed tube replaced, dirty fuel tank.
Clean and replace as required.
Using a pressure gauge, check the pressure on the low
pressure line right after the fuel filter.
If the pressure is below specification, check the condition
34 No feeding on low pressure fuel line of the feeder pump (if available), electric tank pump
and return valve, or any obstruction in the fuel line due
to: improper fuel, fuel filter not replaced, dirty fuel tank
or electric tank pump pre-filter. Clean and replace as
required.
932H00602003
TROUBLESHOOTING 237
Replace the fuel. Check the fuel tank and feeding line for
35 Inadequate fuel.
contamination. Clean and replace as required.
Check for anomalies caused by previous repairs or

service.
36 Overloaded engine
Check problems related to excessive compression,
friction on gear train and pulleys. Repair or replace.
Check the condition of the engine mounts for correct

assembly. Replace damaged mounts, paying attention
37 Faulty engine mounts
to the correct sequence and torque tightening on the
vehicle’s service manual.
Check the fuse and feeding wiring harness up to the

pump. Check if accessories like alarms or immobilizers
38 Faulty electric pump that block the vehicle through shutdown of the electric
pump have been installed. Check the electric pump and
replace if necessary
Check for faults with a diagnostic scanner.
Check battery for low charge or other problems related
50 Faulty electronic injection system
to the feed system components.
Repair or replace.
Check causes of the clogging like: improper fuel, fuel
51 Clogged fuel filter filter not replaced, dirty fuel tank. Clean or replace as
required.
Check if the electric pump is pressurizing the system.

52 Air in the fuel system
Repair or replace.
Check if the fault was caused by dirtiness in the fuel line

such as: improper fuel, fuel filter not replaced, dirty fuel
53 Faulty high pressure pump tank.
Clean or replace as required.
If the engine was kept inactive for a long period of time,
54 High pressure pump locked an overhaul and cleaning of the pump in an authorized
service can be necessary.
High pressure pump contaminated by such as: improper fuel, fuel filter not replaced, dirty fuel
55 tank.
dirtiness
Clean or replace as required.
such as: improper fuel, fuel filter not replaced, dirty fuel
56 Clogged or faulty injectors. tank. If necessary, send the injectors to an authorized
service for analysis and cleaning in proper devices or to
replace the injectors.
932H00602003
238 TROUBLESHOOTING
Check fuse, wiring harness and glow plug. Repair or

57 Cold start system inoperative
replace.
58 Incorrect high pressure tubes Check and replace.
Check operation of the high pressure pump, rail pressure

59 Excessive fuel pressure on rail sensor and rail relief valve.
Repair or replace.
60 VCV valve locked open Check, repair or replace.
61 VCV valve locked closed Check, repair or replace.
62 Faulty rail relief valve Check, repair or replace.
If the sensor is not faulty after verification, check if the

CKP sensor to pulse wheel distance is correct, as well
63 Faulty CKP sensor as damages on the pulse wheel causing faulty readings
or damages on the sensor wiring harness.
Repair or replace.
If the sensor is not faulty after verification, check if the
CMP sensor to camshaft lobe distance is correct or if
64 Faulty CMP sensor. there are damages on the sensor wiring harness.
Check, repair or replace.
65 Faulty wiring harness Check, repair or replace.
67 Faulty rail pressure sensor Check, repair or replace.
Faulty oil pressure and temperature sensor

68 Check, repair or replace.
(EOPT)
Faulty engine coolant temperature sensor
(ECT)
70 Restrictions in the air intake system Check, repair or replace.
Turbocharger that is damaged or in need

of a cleaning
Leaking gaskets on turbocharger and exhaust
manifold
73 Low supercharger air pressure Check, repair or replace.
74 Leaky supercharger oil retainers Check, repair or replace.
75 Excessive air pressure on intake manifold Check, repair or replace.
932H00602003
TROUBLESHOOTING 239
If those are obstructions due to dirtiness ingress, check if

the driver follows the heavy duty maintenance schedule.
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.
77 Clogged intercooler Check, repair or replace
Check if the problem is associated with loss of power,

turbocharger operation or air leakages in tubes and
78 Low air pressure on intake manifold
hoses. Check for wrong readings of the T-MAP sensor.
Repair or replace.
83 Holes on aftercooler hoses Check, 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.
90 Obstructed exhaust Check, repair or replace.
Check if the exhaust was correctly assembled, paying

91 Cracked exhaust
attention to the correct sequence and tightening torques.
Check and replace by the oil recommended in the

110 Improper lubricating oil
manufacturer’s operation manual.
Top up and check for oil leakages on the block or oil

111 Low lubricating oil level in the oil pan
cooler, or oil consumption between rings and cylinders.
112 High lubricating oil level in the oil pan Check, repair or replace.
Check the wear condition of the oil pump, pump pressure

113 Low pressure lubricating oil regulator spring and oil passage obstructions (suction
tube, crankshaft and others). Repair or replace.
114 High pressure lubricating oil Check, repair or replace.
Check for oil leakages on gaskets or oil in the air filter.

Check oil consumption between rings and cylinders:
115 High consumption of lubricating oil faulty machined cylinders, poorly aligned or worn rings,
worn cylinders, poor head compression. Repair or
replace.
116 Internally worn lubricating oil pump Check and replace.
932H00602003
240 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.
Oil pump pressure relief valve spring stuck

closed
Check the suction tube for clogginess, assembly and

119 Faulty oil pump suction tube tube to block sealinng.
Repair or replace
120 Obstructed lubricating oil filter Check and replace.
121 Clogged engine vent tube Check, repair or replace.
122 Damaged PCV valve Check, repair or replace.
123 Leaky oil cooler Check, repair or replace.
124 Faulty tandem pump Check, replace or send to an authorized service.
Check engine installation, supports and vehicle mounts.

125 Improper engine inclination angle
Repair.
Check thermostatic valve actuation, system hose con-

130 Boiling dition, water pump pressure and operation condition,
burnt head gasket, water in oil mix. Repair or replace.
Check thermostatic valve actuation, air in the system

hoses, condition of the system hoses, water pump
131 Overheating (high coolant fluid temperature) pressure and operation condition, burnt head gasket,
water in oil mix, excessive turbocharger pressure,
advanced timing of the fuel injection. Repair or replace.
Check thermostatic valve actuation. Replace if necessary.

132 Engine too cold
Also check for loss of power. Repair or replace.
Faulty thermostatic valves (stuck open or

133 Check and replace.
closed)
134 Damaged fan Check causes of damage and replace.
Check if the fan RPM reaches 70% to 80 % of the engine

135 No actuation of viscous clutch RPM when fully engaged (warm engine) if not, replace
fan.
136 Excessively noisy fan Check for viscous clutch locked on. Replace if necessary.
Cylinder liner / block water passageways

137 Check, clear passageways or replace component.
obstructed
932H00602003
TROUBLESHOOTING 241
Check if only the radiator is clogged or if are

there obstructions or crusting in the hose and water
Internally clogged radiator (obstructed tubes or passageways. Repair or replace the radiator and other
138 affected components.
tanks)
Check if the right fluid and water are being used and in
the correct ratio for the cooling system.
Check for fin obstruction causes. Clean the fins
139 Radiator externally clogged (obstructed fins)
throughout or replace the radiator.
If there is cavitation, check for air in the system. Replace

the pump and bleed the system.
140 Faulty water pump In case of a leaky retainer, check if the right coolant fluid
in the right ratio and specification is being used. Replace
the pump. For other faults, replace the pump.
Check for damages and fluid leakages in the overflow
reservoir, overflow cap valve, hoses, connections,
141 Lack of fluid in the cooling system
gaskets, stains from leakages in the water / oil cooler
and cylinder head gasket.
Check: poorly aligned or worn rings, worn cylinders, and
150 Low compression
poor cylinder head compression. Repair or replace.
Check with a micrometer caliper if the wear is concentrated
in a region and/or in a specific cylinder.
151 Cylinder wear Check for correct machining of the cylinders, evidences
of wear on cylinder liners and rings as related to assembly
or machining problems. Repair and replace.
Check for signs of overheating or improper assembly.
152 Broken, worn or stuck rings Check if the liner is within specifications.
Replace damaged components.
Check for faulty assembly of the piston or if the specified
153 Stuck piston clearances between liner and piston or pin are correct.
Repair or replace.
Check for damages or torsion in the block. Check the
154 Damaged or worn bearings assembly of the bearings, flat bearings and crankshaft.
Repair or replace.
155 Improper seating of piston rings. Check, repair or replace.
156 Improper piston to block surface height Check, repair or replace.
157 Cracked or broken liners Check, repair or replace.
Abnormal wear of bearing or connecting rod

158 Use the bearing diagnostic chart in this manual.
flat bearings
932H00602003
242 TROUBLESHOOTING
Check for engine overheating, burnt cylinder head

gasket, engine compression too high, faulty valve lash
170 Burnt valves and valve seats
between valve and valve guide, lack of lubrication from
the camshaft to the valves. Repair or replace.
Check for insufficient valve lash between the valve and
171 Stuck valves valve guide, lack of lubrication from the camshaft to the
valves. Repair or replace.
Check for engine overheating. Check warping of the
172 Leaky cylinder head gasket head and / or block, incorrect protrusion (with the liner).
Repair or replace.
Check the clearance between the valve stem and guide.
174 Worn valve stems and guides Check lubrication from the camshaft to the valves. Repair
or replace.
175 Broken valve springs Check, repair or replace.
176 External leakages (gaskets, retainers, etc) Check, repair or replace.
Check if caused by overheating or improper assembly.

177 Broken rocker arms
Repair or replace.
178 Leaking valve guide retainers Check, repair or replace.
Check for retainer replacement on previous repairs.

179 Loose valve guide retainers
Replace using suitable special tools. Repair or replace.
Check belt condition and adjust the tensioner according

190 Loose accessory belt
to the service manual.
Check camshaft to crankshaft timing following the

191 Improper gear timing service manual procedure and using the recommended
special tools. Correct timing.
Check flywheel to flywheel housing misalignment fol-

192 Misaligned flywheel or flywheel housing
lowing the service manual procedure. Repair or replace.
Check for displacement of the pulley and damper.

193 Faulty vibration damper
Replace the component.
194 Faulty gears Check, repair or replace.
195 Loose pulse wheel Check, repair or replace.
Check for excessive wear on gear teeth or bushings.

196 Excessive backlash on timing gears Replace worn or damaged components. Assemble and
check backlash according to the service manual.
932H00602003
TROUBLESHOOTING 243
Check if the cylinder head was previously machined causing

excessive contact between the idle gear and camshaft
Insufficient backlash between camshaft and drive gear teeth. Replace the affected components.
197
idle gears Check for excessive wear of gear teeth or bushings.
Replace worn or damaged components. Assemble and
Check for excessive wear of gear teeth or bushings.
198 Insufficient backlash on timing gears Replace worn or damaged components. Assemble and
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.
932H00602003
244 TROUBLESHOOTING
Bearing Diagnostics When a bearing failure occurs due to lack or dilution

of the lubricating oil, its surface can become shiny. In
Most of the bearing wear takes place during engine the case of total lack of lubrication, it shows excessive
start or at the beginning of the operation. After that wear due to the shoveling of material by the shaft
there is still wear but on a lower scale. If the scheduled in contact with the bearing slipping surface with the
maintenance is performed just smaller particles, crankshaft journal.
those not retained in the oil filter, will be present in
the abrasion process of the bearing surface. Under
this condition the bearings shall have a considerably
longer life.
The strongest evidence that the bearing lifetime has
been exceeded is the appearance of noises in the
engine (“thuds”) and a decrease on lubricating oil
pressure.
A normal wear is commonly indicated by a small
amount of scratches on the bearing surface caused
by foreign particles not retained by the filter. Those
scratches are not problems once the base alloy is not
reached and the scratches can even disappear under
continuous operation.
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.
Lack of lubricating oil, which causes a metal-to-metal

contact of the bearing and crankshaft journal, which
in its turn causes excessive wear as the anti-friction
material is shoveled, is normally caused by:
Bearing Premature Failures Due to Malfunction • Partially obstructed oil passageways;

• Faulty choice of oversize bearing;
Lack of Oil on Bearings
• Inverted assembly of central main bearing (lower
Appearance part instead of the upper part);
• Faulty oil pump or relief valve.
932H00602003
TROUBLESHOOTING 245
Corrections
• Check the journal dimensions to choose new

bearings,
• Machine crankshaft journals, if necessary;
• Check if the oil pump and relief valve are working
correctly. If necessary, overhaul or replace them;
• Check if the bearing lubrication holes are aligned
up with existing ones on block and connecting rod
bearings;
• Avoid running the engine in idle for long periods
of time;
• Check the lubricating oil for dilution by the fuel or
coolant fluid.
Excessive Clearance
Appearance
• The part shows scratches caused by particles

and/or deformation/migration of the anti-friction
alloy to the area close to the bearing side edge.
Causes
• If the dimensions of the bearings or main

bearings are below the minimum recommended
dimensions, and if the bearing housing diameter
is above the maximum recommended diameter,
those facts will provide an excess of lubricating oil Corrections
that is above the maximum allowed. The excess
quantity will not generate a hydrodynamic support • Check the diameter dimensions of main bearings,
to the shaft. Thus, there is contact of the shaft connecting rods and crankshaft bearing journals;
and bearing surface, what can cause melting and • Always tighten the bolts to the correct torque and
surface deformation of the bearing antifriction replace them whenever required;
alloy, as shown in the figures below.
• Use the correct lubricating oil that meets the
specifications in this manual.
932H00602003
246 TROUBLESHOOTING
Premature Failure of Bearings Due to Faulty Causes

Assembly Insufficient end play caused by a faulty assembly or
positioning of the disk and plate, that presses the
Insufficient end Play crankshaft against the bearing flange to the point that,
Appearance due to the generated friction and lack of an oil film,
there is a temperature rise to the point that the alloy
lead is separated from copper, with a consequent total
damage of those areas.
Corrections
• Follow the specified assembly clearance;

• Check for the correct positioning of the
transmission elements between engine and
transmission.
Solid Particles
Appearance
Foreign particles can become stuck to the antifriction

alloy, causing material displacement. Scratches over
Excessive wear on bearing side flange and in an inner the bearing surface can also be found.
surface, heaviest axial load side, while the other side
presents a normal working order. There are melting
points and loosening of antifriction alloy on worn areas.
932H00602003
TROUBLESHOOTING 247
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.
932H00602003
248 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.
Punctual wear area on the alloy surface related to a

mark made by a foreign particle on the reverse side of
the bearing.
932H00602003
TROUBLESHOOTING 249
Causes Insufficient Seat Height

Bending of the rod due to alternating loads can cause Appearance
out-of-roundness of the crankcase. The bearings tend
to keep this format, hence resulting in a non-cylindrical
inner surface. The gap near the partition line becomes
very small due to crankcase deformation and there
may be metallic contact of the antifriction alloy with the
shaft journal.
Bright (polished) areas are visible on bearing back

and, in some cases, also on the partition surface.
Causes
The tightening is not sufficient enough for setting up a
radial pressure that holds the bearings in the housing.
Corrections
• Check the bearing housing roundness on

crankcase;
• Check the shaft journal and machine it if required.
932H00602003
250 TROUBLESHOOTING
The contact is inadequate, heat conduction is worsened Excessive Seat Height

and at the same time, the extra friction caused by
pulsation of the bearings increases the generated Appearance
heat. The causes of an insufficient seat height are:
• Metal filings on bearing parting surfaces;

• Cover moved away due to dirt or burrs on the
surface partition;
• Insufficient torque;
• Bolt touching the bottom of a non-through hole;
• Bearing housing with a diameter larger than
specified.
An excessively worn area close to the partition line on

both bearings or just one.
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.
Corrections In case of excessive seat height, the resulting radial

pressure can cause bearing buckling alont the partition
• Clean partition surfaces before tightening line.
bolts;
• Check dimensions, housing condition and Common causes are:
overhaul them, if necessary;
• Machined housing partition surface;
• Apply the recommended torque when tightening
nuts and bolts. • Excessive torque.
932H00602003
TROUBLESHOOTING 251
Corrections A connecting rod twisting can happen due to a forced

pin placement, tightening of cap bolts on a incorrectly
• If a cap, block or connecting rod partition surface attached connecting rod to a vise, or vapor lock.
had been machined, replace the part;
• Use Prussian Blue or another adequate process Corrections
(micrometer caliper, etc) to check if out-of-round-
• Check the connecting rod and replace if
ness is within the allowed range after the right
necessary;
tightening to cap bolts with a torque wrench has
been applied; • Avoid twists on the connecting rod.
• Tight bolts or nuts to the recommended torque.
Offset Cap
Twisted or Bent Connecting Rod Appearance
Appearance
• Excessively worn areas on diagonally opposed

sides of each bearing.
Excessively worn areas on opposite sides of the

connecting rod, close to the partition line.
Causes
Causes The bearing cap has been displaced, pressing one
side of each cap against the shaft. That can happen
due to:
• Inadequate wrench for bolt tightening;

• Reversal of the cap;
• Changed holes, pins or other cap centering
systems;
• Offset crankshaft due to machining;
• Reuse of connecting rod and/or bearing bolts.
In a twisted or bent rod the housings are not aligned

up, thus creating high pressure areas and even
metal-to-metal contact between the bearing and
crankshaft journal.
932H00602003
252 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.
On those points the gap is also reduced and a metal-

to-metal contact can happen between the bearing and
crankshaft journal. The crankshaft can be bent due to
inadequate handling, storage or to severe operating
conditions.
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.
932H00602003
TROUBLESHOOTING 253
Bent Engine Block
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.
932H00602003
254 TROUBLESHOOTING
Causes
Sudden warm up and cooling down of the engine is Corrections

a reason for block distortions when running without
a thermostatic valve. Block deformation can also be • Check for deformation with an adequate process;
caused by: • Replace the block if the deformation is confirmed;
• Unfavorable conditions of use (for example, • Assemble a thermostatic valve.
engine overload);
• Incorrect tightening procedures of the cylinder
head bolts.
932H00602003
TROUBLESHOOTING 255
Non-Cylindrical Journal Bearings
Appearance
932H00602003
256 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.
Corrections Incorrect Torque and Adhesive Application
• Correctly machine the surfaces if necessary. Appearance
Incorrect Fillet Radius
Appearance
The part is dented at the housing splitting area and

with an external lubrication groove partially clogged
with adhesive.
932H00602003
TROUBLESHOOTING 257
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.
Reversed or exchanged connecting rod caps.
An incorrect positioning / displacement of the lock can

also cause part deformation, hindering the oil gap.
Corrections
• Periodically check / calibrate the torque wrench;
• Tighten to recommended torque;
• Assemble the engine following recommendations.
Inadequate shims.
Incorrect, Careless Assembly

The bearings will not work properly if they are not
correctly assembled or if their design is changed. An
incorrect assembly almost always causes a premature
bearing failure.The figures below show the most
common assembly errors.
Exchanged bearings.
Asymmetrical connecting rod.
932H00602003
258 TROUBLESHOOTING
Unmatched centering bosses. Lubricating hole not aligned.
932H00602003
APPENDIX A 259
Table of Contents
Air Inlet Elbow......................................................................................................................................................261
Turbocharger to Air Radiator Elbow....................................................................................................................262
Alternator Bracket................................................................................................................................................263
Belt Tensioner......................................................................................................................................................264
Camshaft.............................................................................................................................................................266
Crankcase...........................................................................................................................................................267
Crankshaft ..........................................................................................................................................................269
Cylinder Head......................................................................................................................................................270
EGR System........................................................................................................................................................272
EGR System Tubes.............................................................................................................................................273
Engine Breather .................................................................................................................................................274
Exhaust Manifold.................................................................................................................................................275
Fan Drive.............................................................................................................................................................276
Flywheel..............................................................................................................................................................277
Flywheel Housing................................................................................................................................................279
Fuel High Pressure..............................................................................................................................................281
Fuel Injector . ......................................................................................................................................................282
Glow-Plug............................................................................................................................................................283
Intake Manifold....................................................................................................................................................284
Intermediate Gear...............................................................................................................................................285
Lifting Eyes..........................................................................................................................................................287
Low Pressure Fuel..............................................................................................................................................288
Lubricant Oil Cooler Module................................................................................................................................289
932H00602003
260 APPENDIX A
Table of Contents
Lubrication Oil Filter............................................................................................................................................290
Lubrication Oil Pan..............................................................................................................................................291
Lubrication Oil Pump...........................................................................................................................................292
Oil Dipstick...........................................................................................................................................................293
Piston and Connecting Rod.................................................................................................................................294
Pulley and Vibration Damper . ............................................................................................................................296
Rocker Arm..........................................................................................................................................................298
Sensors...............................................................................................................................................................299
Power Steering Pump.........................................................................................................................................300
Timing Case........................................................................................................................................................301
Turbocharger.......................................................................................................................................................302
Turbocharger Lubrication....................................................................................................................................303
Turbocharger Tub................................................................................................................................................304
Valve Cover ........................................................................................................................................................305
Water Pump.........................................................................................................................................................306
932H00602003
APPENDIX A 261
Air Inlet Elbow
1. Mixer, Exhaust Gas Recirculation 3. Bolt, Hex with Flange 8.8 M6x25 Organo 5. Elbow, Air Intake
2. O’Ring 4. Bolt, Hex with Flange 8.8 M6x30 Organo
932H00602003
262 APPENDIX A
Turbocharger to Air Radiator Elbow
1. Elbow, Turbocharger to Air Radiator 2. O’ Ring 3. V Clamp
932H00602003
APPENDIX A 263
Alternator Bracket
1. Pin Guide 4. Hex. Flanged Bolt M8x70 – 8.8 6. Tensioner, Pulley

2. Bracket, Power Take Off 5. Hex. Flanged Bolt M8x40 – 8.8 7. Hex. Flanged Bolt M10x20 – 8.8
3. Hex. Flanged Bolt M8x95 – 8.8
932H00602003
264 APPENDIX A
Belt Tensioner
1. Belt, Poly V 3. Seal Flat 5. Tensioner Pulley

2. Lever, Belt Tensioner 4. Hex. Flanged Bolt M8x35 – 8.8 6. Hex. Flanged Bolt M10x20 – 8.8
932H00602003
APPENDIX A 265
Belt Tensioner (Continued)
Belt tension control region
Torque 18 ± 2 Nm 2
Torque 18 ± 2 Nm 3
Torque 40 ± 6 Nm 5
1
6
4
Tightening Sequence 7 1 - Apply pre-torque: 12 ± 2 Nm (according to

tightening sequence)
3 1 2 - Apply angular tightening of 25º ± 2º (according
to teghtening sequence)
8
5 6
2 4
1. Lever, Belt Tensioner 4. Seal Flat 7. Hex. Flanged Bolt M8x45 – 8.8
2. Hex. Flanged Bolt M8x30 – 8.8 5. Pulley, Tensioner 8. Belt, Poly V
3. Hex. Flanged Bolt M8x35 – 8.8 6. Pulley
NOTE: Mouting tension of the belt 520 ± 70N on

indicated region.
932H00602003
266 APPENDIX A
Camshaft
1. Camshaft, Assy 2. Gear, Camshaft 3. Hexagon Flanged Bolt M14x1.5x40 - 10.9
NOTES:
−− Axial and radial clearance of the camshaft:

Axial: 0.05 - 0.29 mm
Radial: 0.12 - 0.165 mm
−− Fastening Gear, Camshaft/Camshaft:

Before assembly, use the degreasing to eliminate
the oiliness between the gear camshaft and the
support face of camshaft.
Set the gear camshaft, with the camshaft in
position of the TDC of the engine.
Manually insert the bolt.
Tighten the bolt in two stages, according to
showed *...
932H00602003
APPENDIX A 267
Crankcase
1. Plug 5. Plug, Metallic 3/8” x 18 NPTF 8. Hollow Screw

2. Crankcase Assy 6. Plug 9. Ejector, Piston Lubrication Oil
3. Pin Guide 7. Pin Guide 10. Anaerobic Sealant Loctite 567
4. Pin Guide
932H00602003
268 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:
932H00602003
APPENDIX A 269
Crankshaft
1. Bushing, Rear Crankshaft 4. Upper Bearing Sheels, 7. Washer Lower, Thrust

Crankshaft
2. Hexagon Socket Head Cap 8. Crankshaft Assy
Screw 5. Lower Bearing Sheels, Crankshaft
9. Chemical Lock Loctite 242
3. Pulse Wheel 6. Washer Upper, Thrust
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
932H00602003
270 APPENDIX A
Cylinder Head
1. Head Assy, Cylinder 5. O’Ring 8. Cover, Inspection

2. Bolt, Cylinder Head 6. Pin, Dowel 9. Hexagon Flanged Bolt M8x16 - 8.8
3. Pin Backing, Fuel Injector Clamp 7. O’Ring 10. Gasket, Cylinder Head
4. Bridge, Valves Drive
X - Distance between Crankcase face and a top of X Y Z GASKET

Piston in TDC.
0.53 - 0.63 0.79 - 0.94 1.42 - 1.47 7001672C3
Y - Distance between Cylinder Head face and a top
of Piston in TDC.
Z - Distance between Crankcase face and Cylinder
Head face with gasket compressed.
932H00602003
APPENDIX A 271
NOTE: Steps Torque

** Gasket cylinder head assembly according to 1 30 ± 3 Nm
detail. 2 60 ± 3 Nm
YS Fastening Cylinder Head / Crankcase: 3 90° + 10°
4 (Loosen) - 100° + 10°
−− Manually insert bolts on cylinder head.
5 60 ± 3 Nm
−− Tighten the bolts according sequence and values
below: 6 100 ± 3 Nm
7 60° + 10°
8 90° + 10°
NOTE: Each step must be applied to all bolts before

starting the next step.
Tightening Sequence (V = flyweel side)
Discart bolt after L > 150.5mm.
Mount the item 7 with silicone grease DC 11 in item 8.
932H00602003
272 APPENDIX A
EGR System
1. Cooler, Exhaust Gas 5. Bolt Hex. with Flange 9. O´Ring

Recirculation M8x25 – 8.8 Organo
10. Tube EGR Cooler Outlet Wather
2 Bolt Hex. with Flange 6. Valve, Exhaust Gas
11. Bolt Hex. with Flange M8x35 –
M8x90 – 8.8 Organo Recirculation
8.8 Organo
3. Bracket, EGR Cooler 7. Gasket, EGR Valve
12. Grease Based on Silicon DC 111
4. Bracket, Deaeration Tube 8. Thermostatic, Valve
932H00602003
APPENDIX A 273
EGR System Tubes
1. Gasket, EGR Tube to EGR Valve 6. Tube, Exhaust Gas Recirculation 11. Duct, Exhaust Gas Recirculation
Cooler Outlet
2 Elbow, EGR Valve Air Inlet 12. Bolt Flanged Hexagon Head HT
7. Bolt Hex. with Flange M8x16 8.8 M8X25 10.9 Organo
3. Bolt, Hex. with Flange M8x25
Organo
8.8 Organo 13. Tube, EGR Cooler Water Inlet
8. Tube, EGR Cooler Water Outlet
4. Clamp – PEB-5164 14. O’Ring
9. O’Ring
5. Hose, Exhaust Gas Recirculation 15. O’Ring
Valve 10. Gasket, Exhaust Manifold to EGR
Cooler
932H00602003
274 APPENDIX A
Engine Breather
1. Separator, Lube Oil 5. Spring Clamp DN25 - DIN3021 9. Hose, Engine Breather
2 Bolt Hex. Socket Screw 6. Hexagon Flanged Bolt 10. Tube Assy., Engine Breather
M6x20 – 8.8 M6x12 – 8.8 Organo
11. Plastic Clamp
3. Hose, Engine Breather 7. Hexagon Flanged Bolt
12. Insulock Clamp
M6x20 – 8.8 Organo
4. Tube, Engine Breather
8. Bracket, Breather Tube
932H00602003
APPENDIX A 275
Exhaust Manifold
1. Stud M8 3. Exhaust, Manifold 5. Stud M10

2. Gasket, Exhaust Manifold 4. Stover Nut M8
932H00602003
276 APPENDIX A
Fan Drive
1. Adapter, Fan Drive Bracket 3. Bracket Assy, Fan 5. Hex. Flanged Bolt M6x12 8.8
2. Hex. Flanged Bolt M8x25 8.8 4. Pulley Fan 6. Locker, Chemical TR 314 C2 TM
NOTE: Apply chemical locker (item 6) on indicated

bolts.
932H00602003
APPENDIX A 277
Flywheel
1. Flywheel Assy 3. Dowel Pin 5. Bearing

2. Bolt, Flywheel M12x55 4. Adapter, Flywheel 6. Flanged Hexagon Bolt M8x30 – 8.8
932H00602003
278 APPENDIX A
NOTE:
−− Bolt reuse in the assembly line:

During the assembly process, each bolt must not
be tightened more than three times.
−− Bolt reuse in the field:

The bolt must be scrapped when its lenght is 1mm
larger than the nominal lenght.
−− Before fixing the Flywheel on the engine is

necessary to mount the retainer on the flywheel
housing.
932H00602003
APPENDIX A 279
Flywheel Housing
1. Rear Seal, Crankshaft 5. Liquid Seal (Dow Corning 780) 9. Bracket, Crankcase Flywheel
Housing LS
2. Housing, Flyweel 6. Pin Guide
10. Hexagon Flanged Bolt M10x35
3. Hexagon Flanged Bolt 7. Lubricantion Oil
8.8 Organic-metallic
M10x100 8.8 Organic-metallic
8. Bracket, Crankcase Flywheel
11. Protection Cover
4. Hexagon Flanged Bolt Housing RS
M10x45 8.8 Organic-metallic
932H00602003
280 APPENDIX A
NOTE: Apply lub oil No 901922002037 on the lip Attention: Mount opposite side of lip.
of the seal during mounting process of the bushing
crankshaft. NOTE: Apply liquid seal on the indicated area - Detail
item 5.
932H00602003
APPENDIX A 281
Fuel High Pressure
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
NOTE: Assemble manually the nuts of each tube on

its respective end before appllying the torque. The
high pressure pipes are allowed to be assembled only
once. Part must be replaced if disassembled.
932H00602003
282 APPENDIX A
Fuel Injector
1. Nozzle, Fuel Injector 4. Gasket, Fuel Injector Clamp Cover 7. Bolt, Fuel Injector Clamp
2. Seal , Fuel Injector 5. Washer, Fuel Injector 8. Clamp, Fuel Injector
3. Cover, Fuel Injector Clamp 6. Bolt, Hex with Flange 8.8
M6x20 Organo
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.
932H00602003
APPENDIX A 283
Glow-Plug
1. Glow Plug 2. Wiring Harness, Glow Plug 3. Hexagon Flange Nut M4x0.7
932H00602003
284 APPENDIX A
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
932H00602003
APPENDIX A 285
Intermediate Gear
1. Intermediate Gear Assy, 5. Bering Assy, Intermediate Gear 8. Hexagon Flanged Bolt Oiled
Camshaft M10x60 DIN 6921 10.9
6. Gear Intermediate, Fuel High
2. Bering Intermediate Gear Pressure Pump 9. Gear Double, Transference
3. Ring, Gear Bering 7. Retainer, Gear Pump 10. Intermediate Gear, Steering Pump
4. Hexagon Flanged Bolt M12x65
DIN 6921 10.9
932H00602003
286 APPENDIX A
Gearing Blacklash Between Teeth

1 and 6 0.05 to 0.12
6 and 9 0.05 to 0.25
Item Description Teeth No Radial Clearance Axial Clearance

Intermediate Gear Assy,
1 50 0.020 to 0.066 0.10 to 0.50
Camshaft
Gear Intermediate, Fuel High
6 75 0.020 to 0.066 0.10 to 0.60
Pressure Pump
9 Gear Double, Tranference 70 and 28 0.020 to 0.066 0.10 to 0.60
Intermediate Gear,
10 49 0.020 to 0.066 0.10 to 0.60
Steering Pump
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.
932H00602003
APPENDIX A 287
Lifting Eyes
1. Eye, Lifting Front 3. Hexagon Flaged Bolt 4. Hexagon Flaged Bolt

M8x20 – 8.8 M8x25 – 8.8
2. Eye, Lifting Rear
932H00602003
288 APPENDIX A
Low Pressure Fuel
1. Tube Assy, Fuel Return 3. Clip, Double Pipe 4. Bracket, Fuel Inlet and Return Tubes
2. Clamp
932H00602003
APPENDIX A 289
Lubricant Oil Cooler Module
1. Cooler Assy, Lub Oil 3. Stud M8x30 5. Nut, Special M8x1.25

2. Gasket, Oil Cooler 4. Hexagon Flanged Bolt M8x30 6. Hexagon Bolt M6X16
932H00602003
290 APPENDIX A
Lubricant Oil Filter
1. Head Assy, Lubrication Oil 5. O’Ring 103x3.55 8. Hexagon Flanged Bolt

Filter M10x25 - 8.8
6. O’Ring 31.5x2.65
2. Hexagon Flanged Bolt 9. Hexagon Flanged Bolt
7. Bracket, Head Lubrication
M10x50 - 8.8 M10x20 - 8.8
Oil Filter
3. Filter, Lubrication Oil 10. Silicone Grease DC 111
4. O’Ring 13.2x1.8
NOTE:
−− Lubricate lightly the oil filter gasket (item 3).
−− Assemble o-ring (items 4, 5 and 6) with grease
(item 10).
932H00602003
APPENDIX A 291
Lubricant Oil Pan
1. Pan Assy, Lubrication Oil 4. Tube, Lubrication Oil 7. Hexagon Socket Screw
Suction M8x25– 8.8
2. Gasket, Oil Pan
5. O’Ring 8. Intermediate Duct, Lubrication
Oil Suction Tube
M8x20 – 8.8 6. Hexagon Flanged Bolt
M10x45 8.8 9. Hexagon Flanged Bolt
M10x20 - 8.8
932H00602003
292 APPENDIX A
Lubricant Oil Pump
1. Gasket, Lubrication Oil Pump 3. Oil Seal, Side Oil Pump 4. Hexagon Flanged Bolt M8x1.25
2. Pump Lubrication Oil
NOTE: Apply vaseline NP 0800013 at the item 3 for

assembly.
Step in the assembly between the oil pump and

Crankcase F = Maximum 0.15
Oil Pump and Crankase
932H00602003
APPENDIX A 293
Oil Dipstick
1. Hexagon Flanged Bolt, 3. Dipstick, Oil Level 4. Locker, Chemical TR314:1998

M8x35 – 8.8 B2 TM 1G
2. Tube, Oil Dipstick
NOTE: Apply chemical locker (item 4) on the thread of

the dipstick tube assembly nipple.
932H00602003
294 APPENDIX A
Piston and Coneccting Rod
1. Piston Assy, Rings and 2. Upper Bearing Shell, 3. Lower Bearing Shell,
Connecting Rod Connecting Rod Connecting Rod
Clearance
Axial 0.20 to 0.50
Bearing Shell Connecting Rod / Crankshaft
Radial 0.030 to 0.088
932H00602003
APPENDIX A 295
NOTES:
The contact faces connecting rod/bearing shell must be oiled with lubrificant oil.
YS Fastening Connecting Rod Cover/Shank:

−− Manually insert bolts on connecting rod cap.
−− Tighten the bolts according sequence and values below:
Steps Torque
1 26 - 2 N.m
2 84o - 4o
Discard bolt after x > 60.58 mm.
932H00602003
296 APPENDIX A
Pulley and Vibration Damper
1. Pulley, Vibration Damper 3. Front Bushing, Crankshaft 5. Chemical Lock

2. Cylindrical Dodecagon Bolt 4. Expansion Bushing
Socket M12x50
932H00602003
APPENDIX A 297
NOTE: Bolt reuse in the assembly line: During the

assembly process, each bolt must not be tightened
more than three times.
Bolt reuse in the field: The bolt must be scraped when
it lenght is 1 mm larger then the nominal lenght.
Discard bolt after X > 56.5 mm.
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.
932H00602003
298 APPENDIX A
Rocker Arm
1. Shaft, Rocker Arm 2. Rocker Arm, Inlet (Options 3. Rocker Arm, Exhaust (Options
Structure) Structure)
NOTE: The contact faces of the parts must be oiled

with lubricant oil.
932H00602003
APPENDIX A 299
Sensors
1. Sensor, Air Pressure and 4. Sensor, Camshaft Position 7. Sensor, Rotational Speed
Temperature
5. Hexagon Flanged Bolt M5x12 - 8. Clamp
2. Seal Flat Washer DIN Organo
9. Hexagon Socket Screw M6x12 8.8
125 - 4.3
6. Sensor, Coolant and Oil
10. Sensor Oil Pressure
3. Hexagon Socket Screw Temperature
M4x16 8.8
932H00602003
300 APPENDIX A
Power Steering Pump
1. Pump, Power Steering 2. Hex. Flanged Bolt M8x25 8.8
932H00602003
APPENDIX A 301
Timing Case
1. Guide Pin 5. Sealing Washer 8. Protection Plug, TDC Lock

Pin Hole
2. Timing Case 6. Tube, Fuel Lift Pump
Lubrication 9. Dow Corning 780
M10x25 - 8.8 7. Hollow Screw M8x1
F1 = Maximum 0.05
Step in the assembly between the timing
case and crankcase
F2 = Maximum 0.15
932H00602003
302 APPENDIX A
Turbocharger
1. Turbocharger 5. Nut M8x1.25 8. Lower Bracket, Turbocharger

2. Stud M10x25 6. Bolt, Flanged Hexagon Head 9. Spacer, High Temperature
High Temperature
3. Nut, Stover M10 10. Stud, M10x45
7. Bolt, Hexagon Flanged M6x25 10.9
4. Upper Bracket, Turbocharger
932H00602003
APPENDIX A 303
Turbocharger Lubrication
1. Seal, IR 314.D1:1998 6. Tube Turbocharger Lubrication 10. Spacer, Turbocharger

Return
2. Tube Lubrication Oil Return 11. Tube, Turbocharger Lub Inlet
Hose LNG 7. Gasket, Turbocharger
12. Washer Sealing
Lubrication
3. Hose, Turbocharger Oil Return
13. Spring Clamp, DN30-DIN3021
8. Hollow Screw M14x1.5x26
4. Spring Clamp, DN27-DIN3021
Organo
5. Bolt Hexagon with Flange 8.8
9. Washer Sealing
Organo
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).
932H00602003
304 APPENDIX A
Turbocharger Tub
1. Washer, Sealing 4. Tube, Turbocharger 6. Hollow Screw, M20x1.5

Water Inlet
2. Tube, Turbocharger 7. Washer, Sealing
Water Outlet 5. Washer, Sealing
3. Hollow Screw Organo
M14x1.5 - DIN7643
932H00602003
APPENDIX A 305
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
E NOTE: Use chemical lock TR 314:1998 B2

(item 13) where specified.
Apply grase based silicon DC111 (item 14) on assembly
of O-ring (item 12).
932H00602003
306 APPENDIX A
Water Pump
1. O-ring 4. Bolt M8x35 6. Bolt M8x20

2. O-ring 5. Plug M20x10 7. Sealant Loctite 567
3. Pump Assy, Water
Gearing Backlash Between Teeth

Gear, Water Pump / Gear Double, Transference 0.05 to 0.25
NOTE: Mount the items 1 and 2 with silicone grease

DC 111 on item 3.
Apply item 7 on item 5 to ensure sealing.
932H00602003
APPENDIX B 307
Standard Torque Chart for Regular Steel Bolts (According to DIN Standard No. 2230)
Bolt Class (Nm)

Nominal Size
8.8 10.9 12.0
M5 6±1 9±1 10 ± 1.5
M6 10 ± 1.5 15 ± 2 18 ± 3
M8 25 ± 4 37 ± 6 43 ± 7
M10 50 ± 8 73 ± 11 84 ± 13
M12 86 ± 13 124 ± 19 145 ± 22
M14 135 ± 20 198 ± 30 231± 35
M16 207 ± 31 304 ± 46 325 ± 49
M18 298 ± 45 424 ± 64 497 ± 75
M20 418 ± 63 595 ± 89 696 ± 104
M22 569 ± 85 810 ± 122 948 ± 142
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.
932H00602003
308 APPENDIX B
NOTES
932H00602003
APPENDIX C 309
Special Tools
MWM CODE TOOL TYPE COMPONENT IMAGE
Camshaft Gear
D7002303C1 Adjuster Device
Clearance adjustment
D7002304C1 Locker Camshaft Locker
4 Valve spring remover

D7002305C1 Remover device
3.2 engine
D7000600C1 Lock Engine flywheel
Oil seal installer tool,

D7002299C1 Cylinder head
engine
Front oil seal

9.407.0.690.035.6 Centering tool
Power take-off
932H00602003
310 APPENDIX C
9.610.0.690.011.6 Adapter Engine stand
Piston height
9.610.0.690.062.4 Dial indicator support
measuring
Spring compressor Valve spring - one per

D7000382C1
individual time
9.407.0.690.029.4 Timing locker-pin Engine flywheel 3.2
Rear oil seal

9.407.0.690.037.6 Assembling device
Guide bush
Crankshaft rear oil seal

9.407.0.690.045.6 Puller
race
932H00602003
APPENDIX C 311
9.407.0.690.050.6 Holder Camshaft gear
D7000601C1 Adapter Engine stand
NOTE: Pictures are illustrative, the real parts may differ.
932H00602003
312 APPENDIX C
NOTES
932H00602003
Produced by:
ASC Comunicação Técnica
www.asccomunicacao.com.br

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SERVICE MANUAL

© 2013 Navistar, Inc. All rights reserved

ENGINE SERVICE MANUAL

Operation and Maintenance..................................................................................................................................51

Head and Camshaft..............................................................................................................................................89

Piston and Connecting Rods...............................................................................................................................129

Gear Housing and Gear Train.............................................................................................................................147

Flywheel and Flywheel Housing..........................................................................................................................163

Pulleys, Belts and Accessories............................................................................................................................169

Electronic Engine System...................................................................................................................................195

Management Engine System..............................................................................................................................209

Intake and Exhaust Systems and Turbocharger.................................................................................................223

Foreword Technical Service Literature

Navistar, Inc. is committed to continuous research 932H00604104 MaxxForce® 3.2H Engine

Service Diagnosis Technical Service Literature required for Effective

Prerequisites for Effective Diagnosis

• Availability of gauges, diagnostic test equipment,

Safety Information Protective Measures

Batteries Fluids Under Pressure

Tools Removal of Tools, Parts and Equipment

How to Use This Manual.........................................................................................................................................6

Information on Metric System.............................................................................................................................6

General Cleaning Instructions.................................................................................................................................7

Cleaning with Acids and Solvents......................................................................................................................7

Engine Serial Number Identification and Location..................................................................................................8

Engine Serial Number.............................................................................................................................................9

High Pressure Pump........................................................................................................................................ 11

Engine Control Module (ECM).........................................................................................................................13

IIC Codes Calibration Procedure................................................................................................................14

Introduction How to Use this Manual

General Instructions General Cleaning Instructions

Cleaning with Acids and Solvents

Engine Serial Number

No. of Cylinders Engine Accessories

Identification tags or plates include useful information

The main bearing caps are numbered from the flywheel

High Pressure Pump

Engine Control Module (ECM)

IIC Codes Calibration Procedure

Engine Component Location.................................................................................................................................21

Engine System Diagram...................................................................................................................................26

Air Management System.......................................................................................................................................27

EGR System View............................................................................................................................................27

Exhaust Gases EGR System................................................................................................................................28

Air Flow ...........................................................................................................................................................29

Air Cooler ........................................................................................................................................................29

Variable Geometry Turbocharger VGT ............................................................................................................30

Closed Loop VGT System . .............................................................................................................................31

Closed Vanes ..................................................................................................................................................31

Open Vanes . ...................................................................................................................................................31

Turbo Technologies ..............................................................................................................................................33

Theory of Operation ...................................................................................................................................33

Exhaust Gas Recirculation (EGR) System.......................................................................................................34

EGR Control Valve................................................................................................................................................35

Valve for Exhaust Gas Recirculation................................................................................................................36

EGR Closed Loop Operation with Fault Management.....................................................................................39

Fuel Management System....................................................................................................................................41

Fuel Management Components.......................................................................................................................41

Fuel Flow Schematic........................................................................................................................................42

Electronic Control System.....................................................................................................................................43

Electronic Control System Components...........................................................................................................43

Operation and Function...............................................................................................................................43

1. Reference Voltage (VREF)..................................................................................................................43