9 612 0 006 716 4

WORKSHOP MANUAL
MaxxForce 4.8H / 7.2H

Euro IV
Workshop Manual
MaxxForce 4.8H / 7.2H
Euro IV
MWM INTERNATIONAL Motores

Customer Service
Av. das Naes Unidas, 22.002
ZIP CODE - 04795-915 - So Paulo - SP - Brasil
web site: www.mwm-international.com.br

e-mail: assistencia@navistar.com.br
9.612.0.006.716.4 - 08/11
Workshop Manual
MaxxForce 4.8H / 7.2H - Euro IV
INDEX
1
INTRODUCTION
11
12
2
TECHNICAL DATA
OPERATION AND MAINTENANCE

13 3
ENGINE BLOCK
14 4
CRANKSHAFT 5 5
CAMSHAFT
16 6
PISTONS AND CONNECTING RODS

17 7
CYLINDER HEADS
18 8
GEAR HOUSING
19 9
FLY WHEEL AND FLY WHEEL HOUSING 10

1 10
BALANCER UNIT 11 11
LUBRICATION SYSTEM 12
1 12
ENGINE ELECTRICAL 13
1 13
COOLING SYSTEM 14
1 14
FUEL INJECTION SYSTEM 15
1
INTAKE, EXHAUST AND TURBOCHARGER SYSTEM 16 15
TROUBLESHOOTING 17 16
17

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INTRODUCTION
1-1
Presentation
2
Introduction ............................................................................................................................................... 1-2
How to Use this Workshop Manual ........................................................................................................... 1-2

3
Important Safety Remarks ........................................................................................................................ 1-3
General Instructions ................................................................................................................................. 1-4 4
Cleaning General Instructions .................................................................................................................. 1-5

5
Engine Serial Number Identication and Location.................................................................................... 1-6
Cylinder Numbering .................................................................................................................................. 1-7

6
Engine Identication ................................................................................................................................. 1-8
10
11
12
13
14
15
16
17

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1-2
Introduction
This manual contains complete information and specications necessary to assemble and disassemble
MaxxForce 4.8H/7.2H Euro IV engines and all components manufactured by MWM INTERNATIONAL Motores.
Read and follow all safety instructions. Consult the item WARNING in the Safety General Instructions, in the next
section.
The repair procedures, described in this manual assume that the engine is positioned on an appropriate stand.
Some of the assembly and disassembly procedures require special tools.
Make sure that the correct tools are used according to the procedures.
The assembly and disassembly specications and information presented in this manual are accurate of the date
of publication. INTERNATIONAL Indstria Automotiva da Amrica do Sul Ltda. Reserves the right to make
changes, at any time. INTERNATIONAL Indstria Automotiva da Amrica do Sul Ltda. Reserves the right to
make changes in the product at any time without incuring any further obligation. In case of any discrepancy in
the engine or information of this manual, contact an MWM Authorized Distributor or the service center.
The components used in MWM engine production are produced with latest generation technology and with a high
level of quality. When part changes are necessary, it is recommended that only genuine MWM spare parts are
used.
How to Use this Manual
This Manual was created based on a MaxxForce 4.8H/7.2H Euro IV engine, which has the same operation and
maintenance for all models of this series. The illustrations therefore, could differ from application to application.
All references to the components of the engine in this manual are divided in 19 specic sections. For your
convenience, the organization of the Manual is consistent with MWM Service Bulletins.
MANUAL CONTENT
The Manual contains an index that can be used as a quick reference to access each section.
SECTIONS CONTENT
Each section contains the following information:
v Index page at the beginning of each section to help locate the desired information.
v General information about the operation of the component and an explanation of their specications.
v Component disassembly, cleaning, inspection and dimentional specications.
Information on Metric System

All dimensions are expressed in the International Metric System (I.S.).

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INTRODUCTION
1-3
Important Safety Remarks
! Warning: Incorrect procedures and lack of care can cause burns, cuts, mutilation, asphyxia or other 2
injuries and even death.
Carefully read all safety procedures and remarks before performing any repair in the engine. The following list 3
presents the general cautions that must be followed to guarantee your personal safety. Special safety measures
can be presented with the procedures, if necessary.
4
v Make sure that the work area around the engine is dry, well lightened, ventilated, organized, without tools and
loosened parts, ignition sources and dangerous substances. Check for dangerous conditions can happen and
avoid them.
5
v Always use individual protection equipments (safety eyeglasses, gloves, shoes, etc.) while you are working.
v Remember that parts in movement can cause cuts, mutilation and strangling.
6
v Do not use loosen or ripped clothes. Remove jewellery and watches before working.
v Disconnect the battery (negative cable rst) and discharge the capacitors before beginning the repairs.
7
v In case the repair is being made in the vehicle, disconnect the starter motor to avoid an accidental start of the
engine. In case of industrial engines, place a Do Not Operate warning in the operator compartment or on the
controls.
8
v To manually rotate the engine, use ONLY the recommended procedures. Never try to rotate the crankshaft with
the fan. This practice can cause serious personal injuries or damages to the fan blades, causing the premature
failure of the component.
9
v If the engine was in operation and the cooling uid is hot, leave the engine to cold down before slowly open
the cover of the reservoir to relief the pressure of the cooling system.
v Do not work with materials that are lifted by jacks or cranes. 10
v Always use correct blocks, stands or brackets to position the engine before performing any repair.
v Relief the pressure of the pneumatic (brakes), lubrication and cooling systems before removing or disconnect 11
any piping, connections or other elements. Pay attention to the pressure existence before to disconnect any
item of a pressurized system. Do not check pressure leakages with the hand. Oil or fuel at high pressure can
cause injuries. 12
v To avoid injuries, use a crane, or ask for help to lift components which weight more than 20 kg. Make sure that
all lift equipments as chains, hooks or belts are in good conditions and have the correct load capacity. Make
sure that hooks are correctly positioned. Always use an extension when necessary. The lift hooks must not 13
receive side loads.
v Never leave the engine operating in a closed and non ventilated area. The engine exhaust gases are harmful 14
to health.
v The MWM coolant has alkaline substances. Avoid the contact with the eyes. Avoid the prolonged or repetitive
contact with the skin. Do not ingest. In case of contact with the skin, wash immediately with water and soap. 15
In case of contact with the eyes, abundantly wash with water for, at least 15 minutes. CALL MEDICAL HELP
IMMEDIATELY. KEEP AWAY FROM THE REACH OF THE CHILDREN AND ANIMALS.
16
17

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1-4 v Cleaning solutions and solvents are inammable materials that must be handled with a lot of care. Follow
the manufacturer instructions to use these products. KEEP AWAY FROM THE REACH OF CHILDREN AND
ANIMALS.
v To avoid burns, pay attention to hot spots on engines that have just been stopped and to hot piping and com-
partments.
v Always use tools in good conditions. Make sure that you know how to handle the tools before beginning any
repair. Use ONLY genuine MWM spare parts.
v Some international public health institutions prove that used lubricant oil can be cancerous and contaminates
the human reproducer system. Avoid inhaling vapours, ingesting or keeping prolonged contact with these
substances.
v People with pacemaker must avoid standing close to the engine electronic injection system.
General Instructions
This engine has been manufactured with the latest technology and, it was designed to be repaired using regular
techniques in conjunction with good maintenance and repair practices.
! Attention: v Use good quality fuel, free of water and impurities.
v Use only recommended oil.
v In the event of a failure, seek only an authorized dealer or service center. Unauthorized
ized service ou repair void the warranty.
v If multiple batteries wired in parallel are used, the amperages of both batteries must be the
same. Always connect the negative cable rst, then the positive cable. Do not reverse the
polarity.
v The imprope removal of the battery cables may cause the loss of data from ECM, erasing
the fault codes saved from the last start of the engine. It can also cause voltage spikes,
causing the ECM to break down.

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INTRODUCTION
1-5
Cleaning General Instructions
CLEANING WITH ACIDS AND SOLVENTS

2
MWM INTERNATIONAL Motores does not recommend any specic cleaning agent for engine components.
Remove all gaskets, sealing rings, and with a brush of steel or rasper, the sludge deposits, carbon, etc., before
placing the parts in the cleaning tank. Be careful not to damage the sealing surfaces. 3
Flush all parts with hot water after cleaning. Completely dry them with compressed air. Remove water from screw
holes and oil galleries.
4
If the parts will not be used soon after cleaning, dip them in an appropriate anti-oxidation compound. That
compound must be removed from the parts before installation on the engine.
The following parts cannot be steam-cleaned:
5
1. Electric and electronics components;
2. Electric harness; 6
3. Fuel injectors;
4. High pressure pump; 7
5. Belts, pipes and hoses;

8
6. Bearings.
10
11
12
13
14
15
16
17

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1-6
Engine Serial Number Identication and Location
The engine identication and serial number can be found in the following places:
1. Identication plate on the water pipe.
2. Engraving on the right side of the engine block, close to the cylinder heads.
6. 12 T C E
Electronic
Aftercooler
Turbocharged
Series
Cylinders numbers

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INTRODUCTION
1-7
Cylinders Numbering
The cylinder order starts from the ywheel, according to the illustration below.
2
3
First cylinder
9
During the assembly, check the numbers on the block (A) and on the bearings (B), these numbers, must correspond
to the block.
10
The bearing number must start from ywheel to front side.
11
B
12
13
1 2 3 4 5 A 14
15
16
17

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1-8
Engine Identication
ENGINE SERIAL NUMBER

The engine serial number is engraved in the right side of the engine block. In the upper side, close to the cylinder
head gasket.
ENGINE ACCESSORIES
The following engine accessories have manufacturers labels or identication plates:
v Air compressor;
v Alternator;
v Turbocharger;
v Power steering pump;
v Starter motor;
v High Pressure Fuel Pump.
Labels or identication plates include information and specications helpful to vehicle operators and technicians.
Air Compressor

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INTRODUCTION
Alternator 1-9
High Pressure Pump

7
10
11
12
13
14
15
16
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1-10 Turbocharger
ECM Electronic Control Module

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TECHNICAL DATA
1
Technical Data
2-1
Technical Specication ............................................................................................................................. 2-2
Fuel System ............................................................................................................................................. 2-2

3
Lubrication System .................................................................................................................................. 2-3
Cooling System ........................................................................................................................................ 2-3 4
Thermostat ............................................................................................................................................... 2-3

5
Engine Description ................................................................................................................................... 2-4
Engine Component Locations .................................................................................................................. 2-6

6
Engine Systems ..................................................................................................................................... 2-12
7
Air Management System ........................................................................................................................ 2-14
Turbocharger System ............................................................................................................................. 2-16

8
EGR Control Valve ................................................................................................................................. 2-20
Exhaust System ..................................................................................................................................... 2-24 9
Fuel Management System ..................................................................................................................... 2-25

10
Electronic Control System ..................................................................................................................... 2-28
Engine and Vehicle Sensors .................................................................................................................. 2-30

11
Resistor and Thermistor......................................................................................................................... 2-31
12
Capacitor Sensor ................................................................................................................................... 2-33
Magnetic Sensors .................................................................................................................................. 2-34

13
Potentiometer......................................................................................................................................... 2-35
Switches ................................................................................................................................................ 2-36 14
15
16
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Technical Specication
2-2 Engine Data 4.8 7.2

Engine type Vertical cylinders in line, 4 strokes
Injection type Direct with electronic management Common Rail
Cylinder bore 105 mm
Cylinder stroke 137 mm
Cylinder displacement 1.2 l
Total displacement 4.745 litres 7.118 litres
Quantity of cylinders 4 6
Compression ratio 16.9:1
Firing order 1-3-4-2 1-5-3-6-2-4
Direction of rotation Counter clockwise (seen by ywheel side)
Engine weight (dry) 441 kg (EGR) 551Kg (EGR)
185 CV 225 CV
Power @ 2200 rpm
138 KW (EGR) 165 KW (EGR)
700 N.m 861 N.m
Torque @ 1200 ~ 1500 rpm
(71.4 (kgf.m) (87.7 (kgf.m)
Valve clearance (cold) 0.20 a 0.40 mm
Emissions EURO IV / PROCONVE P6
Waste Gate Intercooler Waste Gate Intercooler
Intake system
Cooled EGR Cooled EGR
Cylinder Head Individual cylinder head with 4 valves per cylinder and cross ow
Fuel System
Description 4 Cylinders 6 Cylinders

Maximum fuel inlet restriction
0.6 to 1.2 bar
(for gears pump)
Rail pressure 350 to 1800 bar
Fuel pressure range in the
fuel lter outlet (at crank 9.7 to 12.8 bar
speed)
Range of fuel pressure in fuel
lter fuel inlet (at operation 10.5 to 13 bar
speed)
Maximum pressure load
0.8 bar
reduction in the fuel lter

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TECHNICAL DATA
1
Lubrication System
Description 4.8 7.2 2-3

Oil pressure
v Nominal speed 5.3 bar (hot engine)
v Idling speed 3.5 bar (hot engine) 3
Oil temperature
v Nominal 90 - 110 C
4
v Maximum 120 C
Oil capacity
v Cooler module 1.75 l 1.75 l 5
v Minimum (without lter) 11.9 l 14.8 l
v Maximum (without lter) 14.1 l 17.3 l
v Minimum (with lter) 15.4 l 18.6 l
6
v Maximum (with lter) 16.9 l 20.3 l
v Variation pressure of the
oil lter to open by-pass 0.12 to 0.28 bar
7
Cooling System 8
Description 4.8 7.2

9
Engine coolant capacity,
7l 9l
without radiator (*)
Water temperature 10
v Nominal 80 - 90 C
v Maximum 100 C
11
* To total volume (Engine + Radiator), see the Vehicle Manual.
Thermostat 12
Opening Total Maximum opening

Thermostat 13
beginning opening course
9.229.0757.0046 75 2C 90C 10.0 mm
14
15
16
17

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Engine Description
FEATURES
2-4
MaxxForce 4.8H and 7.2H Euro IV series are in-line four and six cylinder engines. The engine displacements are
4.8 liters and 7.2 liters.
The ring order of the cylinders is 1-3-4-2 for the four cylinders and 153624 for the six cylinders.
The cylinder head has four valves per cylinder with cross ow for improved air ow. The head gasket is mated in
metal-rubber and is individual for each cylinder head. The fuel Injector is centrally located between the four valves
and directs fuel over the piston bowl for improved performance and reduced emissions. The overhead valve train
includes mechanical roller lifters, push rods, rocker arms, and dual valves that open using a valve bridge.
To improve component durability and engine performance the engine uses a hot and cold side concept for
component distribution.
Cold side (left engine side)

v fuel supply system
v intake air manifold
Hot side (right engine side)

v Turbocharger system
v EGR system
v Air compressor
v Exhaust manifold
A one piece oil pan withstands high-pressure loads during diesel operation.
Manufactured in stamped steel, the oil pan has a compact size and is lightweight.
Five and seven main bearings support the crankshaft for MaxxForce 4.8H and MaxxForce 7.2H engines
respectively. One insert bushing supports the camshaft for each engine, the other support is assembled in the
engine block. The rear oil seal carrier is part of the ywheel housing. The open oil pan breather assembly uses a
road draft tube to vent oil pan pressure and an oil separator that returns oil to the oil pan.
The crankshaft position sensor - CKP and camshaft position sensor - CMP are used by the ECM to calculate rpm,
fuel timing, fuel quantity and duration of fuel injection.
Manufactured with forged steel and new shape to improve its strength, the pistons are mated with fractured cap
joint connecting rods. Replaceable rolled radius wet cylinder liners are used with the pistons.
The new model of Flywheel viscous damper for the MaxxForce 7.2H engine offers ns to assist in the refrigeration.
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 and ecological lter.
A low-pressure fuel supply pump draws fuel from the fuel tank through a fuel lter assembly that includes a
strainer, lter element, primer pump, drain valves, and water in fuel (WIF) sensor. After ltering, fuel is pumped to
the high pressure fuel pump, then to the fuel rail and nally to the injectors.
The MWM INTERNATIONAL common rail high-pressure injection system includes a cast iron oil manifold, fuel
injectors and a high-pressure pump.
The ECM sends pulse PWM (Pulse Signal Modulation) signal to actuate an EGR valve which pneumatically
controls an EGR ap from EGR cooler assembly to regulate the cooled exhaust gases that recirculate through
the inlet air stream. Cool exhaust gas increases engine tolerance for EGR, while reducing smoke formed by gas
dilution in the mixture.
The new water pump was designed with seven vanes to increase the water ow.
The ECM is responsible for monitoring and controling the electronic engine systems.

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TECHNICAL DATA
The Water In Fuel (WIF) separation occurs when the lter element repels water molecules. The water collects at 1
the bottom of the element cavity in the fuel lter housing.
A Water In Fuel (WIF) sensor in the element cavity of the fuel lter housing detects water. When enough water
accumulates in the element cavity. The WIF sensor sends a signal to the instrument panel. A fuel drain valve 2-5
handle on the housing can be opened to drain water from the fuel lter housing.
ACCESSORIES FEATURES
3
The air compressor is commonly used for air brakes, door controls or air suspensions. A hydraulic power steering
pump is assembled with the air compressor. In the MaxxForce 4.8H and 7.2H engines both components are
located in the hot side next to the powertrain.
4
The alternator is driven by the pulley system and the belt accessories, used to charge the battery and to power a
vehicles electrical system when the engine is running. Its located in the cold side, pulley side of the block (upper
position).
5
The starter motor is an electric motor that initiates rotational motion in an internal combustion engine to iniciate
combustion. On the MaxxForce 4.8H/7.2H engines its located on the cold side, next to the Flywheel.
The high pressure pump from 3rd generation supplies the injectors with high pressure fuel. The maximum pressure
6
rate is 1800 bar. Its located on the cold side next to the powertrain
The Wastegate Turbocharger is an air compressor used for forced-induction of an internal combustion engine. The
purpose of a turbocharger is to increase the air mass entering the engine to create more power. On the MaxxForce
7
4.8H/7.2H engines its located on the hot side, next to the waterpipe and cooled EGR in the upper position.
10
11
12
13
14
15
16
17

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Engine Component Locations
2-6
9
7
1
2
6
5 4
TOP VIEW
1. EGR cooler
2. EGR cooler water pipe
3. EGR air mixer duct
4. Coolant temperature sensor (ECT)
5. ECM cooler inlet pipe
6. Fuel injector electrical connector
7. Main wiring harness
8. Valve cover
9. Thermostat housing

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TECHNICAL DATA
1
2-7
2 3
8 4
3 5
6
7
6
5
9
10
FRONT VIEW 11
1. Water bypass tube assembly thermostat outlet
2. Alternator pulley 12
3. Pulley
13
4. Belt tensioner
5. Vibration damper
14
6. Front cover
7. Fan drive pulley

15
8. Engine oil pressure (EOP)
16
17

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1 2
3
2-8
5
8
6 4
LEFT VIEW (COLD SIDE)
Mechanical Components
1. Turbo control valve
2. EGR control valve
3. Intake air manifold
4. Oil cooler assembly
5. Oil lter
6. Fuel rail
7. Fuel lter
8. Fuel pressure relief valve

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TECHNICAL DATA
2-9
5 4
4
5
7
3
8 7
9
2
1
10
LEFT VIEW (COLD SIDE) 11
Eletrical Components
1. Starter motor 12
2. Fuel pressure regulator valve (M-PROP)

13
3. Camshaft Position Sensor (CMP) mounted close to the high pressure fuel pump
4. Fuel pressure sensor (EFP) - Rail

14
5. Alternator
6. Intake air pressure and temperature sensor (TMAP)

15
7. Crankshaft Position Sensor (CKP)
8. Freeze plug 16
17

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1
12
2-10
2
11
10
9
4
7 6
RIGHT VIEW (HOT SIDE)

1. EGR actuator
2. EGR actuator connector
3. Coolant pipe (air compressor outlet)
4. Air compressor
5. Oil pump
6. Oil dipstick
7. Turbo oil inlet pipe
8. Turbo oil outlet pipe
9. Turbo wastegate
10. Exhaust manifold
11. Coolant pipe
12. Coolant pipe (air compressor inlet)

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TECHNICAL DATA
2 3
2-11
1
4
4 6
8
5
10
REAR VIEW 11
1. EGR and turbo air distributor
2. ECM Cylinder Connector C (16 pins) 12
3. ECM Vehicle Connector A (89 pins)

13
4. ECM Engine Connector B (36 pins)
5. Flywheel
14
15
16
17

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Engine Systems
FOUR VALVES CYLINDER HEAD Elastomer Sealing Lips

2-12
This engine offers an overhead, 4 valves per cylinder Elastomer sealing lips provide the seal for coolant
and crossow cylinder head. and oil. Their material and geometry are specially
adapted to the engine.
A crossow cylinder head is a cylinder head that
features the intake and exhaust ports on opposite Carrier Layer
sides increasing its performance as the gases can Together with the combustion chamber bead, this
ow across the head into and out of the cylinder more layer determines the compressed thickness and the
efciently. gas seal.
The 4 valves are responsible for controling the air/gas Combustion-chamber Base Layer
inlet and outlet. For the 4 valve system, the intake valve
is wider than exhaust valve to allow gas entrance to The combustion-chamber base layer is a design
element that serves to increase the compressive
the cylinders. In such conguration there are 2 valves
strength at the combustion chamber. The bolt forces
for the intake and 2 valves for the exhaust. are thus transferred to the combustion chamber area
in a controlled manner.
CYLINDER HEAD GASKET Full Bead
The cylinder head gasket is made of steel and is This generates a balanced compressive strength
assembled individually. One gasket for each cylinder along the edge of the combustion chamber.
head.
Diaphragm
The ow of coolant can be controlled by guiding the
ow cross-sections over vulcanized diaphragm.
Complex Geometric
The gasket presents complex geometry and radius
along its circumference for this application.
Metal-elastomer cylinder-head gaskets have a

strong and durable sealing system consisting of
metal carriers with vulcanized elastomer proles.
The basics for outstanding performace of the metal-
elastomer cylinder-head gasket is the distribution of
compressive strength in the engine block/cylinder
head region specic compressive strength in the
combustion chamber area and a low compressive
strength in the liquid area.
Elastomer
Sealing Lips Carrier Layer
Combustion
Chamber Full Bead Diaphragm
Base Layer

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TECHNICAL DATA
ENGINE SYSTEM DIAGRAM 1
2-13
The primary engine systems are Air Management and Fuel Management which share some subsystems or have
a subsystem that contributes to their operation.
7
v The Electronic Control system controls the Air Management System and Fuel Management System.
v The Coolant System provides heat transfer for EGR gases and lubrication oil. 8
v The Fuel Supply System pressurizes fuel. Then ows trough the ECM cooler, passes to the transfer pump, fuel
lter, is pressurized by the high pressure fuel pump, sent to the fuel rail and then to the injectors.
9
10
11
12
13
14
15
16
17

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Air Management System
EGR SYSTEM VIEW

2-14
Air Management Components and Air Flow.
Air Management System (AMS).
1. Intake air 8. Wastegate valve
2. Exhaust gas 9. EGR mixer valve
3. EGR cooler 10. TMAP Air pressure and temperature sensor
4. Intercooler 11. Cylinder head with four valves per cylinder
5. Intake air duct 12. Exhaust manifold
6. Crossover 13. Turbocharger
7. Intake manifold 14. Air lter

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TECHNICAL DATA
The air management system includes the following: 1
v Air lter assembly;
v Chassis mounted Intercooler; 2-15
v Intake manifold;
3
v Cooled Exhaust Gas Recirculation (EGR) system;
v Exhaust system;
4
v Intake and EGR mixer duct.
5
AIR FLOW
Air ows through the air lter assembly and enters in the Turbocharger. The compressor increases the pressure,
temperature and density of the intake air before it enters the Charged Air Cooler (CAC). Cooled compressed air
6
ows from the CAC into the EGR mixer duct.
v If the EGR control valve is open, exhaust gas will ow through the exhaust manifold to the EGR cooler and
turbocharger mixing with ltered intake air and ow into the intake manifold. 7
v If the EGR control valve is closed, only ltered air will ow into the intake manifold.
8
After combustion, exhaust gas is forced through the exhaust manifold to the EGR cooler (with opened EGR valve)
and turbocharger.
v Some exhaust gas is cooled in the EGR cooler and ows through the EGR control valve to the EGR mixer 9
duct. When exhaust gas mixes with ltered air, nitrogen oxide (NOx) emissions and noise are reduced.
v The exhaust gas remaining ows to the Turbocharger spins and expands through the turbine wheel, varying
10
boost pressure.
v The Turbocharger compressor wheel compresses the mixture of ltered air.

11
INTERCOOLER
Air from turbocharger passes through a heat exchanger before entering the EGR mixer duct. Outside air owing 12
over the tubes and ns cools the charged air. Charged air is cooler and denser. Cooler and denser air improves
the fuel-to-air ratio during combustion, resulting in improved emission control and power output.
13
14
15
16
17

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Turbocharger System
INTERNAL COMPONENTS
2-16

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TECHNICAL DATA
EXTERNAL COMPONENTS 1
2-17
1 2 3
4
Turbine Compressor
Inlet Outlet
5
7
6
4 3 5 8
Turbo View 10
1. Oil inlet
2. Identication label 11
3. Oil outlet
12
4. Wastegate air actuator
5. Wastegate valve
13
6. Turbo control air nipple
14
15
16
17

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TURBO WASTEGATE
MaxxForce 4.8H/7.2H engines are equipped with a Borg Warner K Series Turbocharger. The K series offers
a housing with single ow and the max ow rate of 0.16 kg/s. The K series is also equipped with an external
2-18 wastegate valve.
The wastegate valve directs exhaust gases away from the turbine wheel, when the valve is activated the exhaust
gases are released to the exhaust manifold. This causes the turbine to loose speed, which in turn reduces the
rotating speed of the compressor. The primary function of wastegate is to stabilize boost pressure in turbocharger
systems, to protect the engine and the turbocharger.
A wastegate is a separate self-contained mechanism typically used with turbochargers. This valve requires a
specially constructed turbo manifold with a dedicated runner going to the wastegate. They are commonly used for
regulating boost levels in high power applications, where high boost levels can be achieved.
Wastegate Control Pneumatic With Electronic Boost Controller
PWM Valve Turbo Control

The wastegate control is a fully integral control system, combining a proportional valve and a pressure sensor in
a closed loop pressure control system in one piece.
This device communicates with the ECM (Engine Control Module) as well as provides diagnostic features to
support OBD (On-Board Diagnostics). It is available with pressure and with PWM (Pulse Width Modulation) control
interface.
Simple modication of exhaust or turbocharger control is possible, along with optimization of engine performance,
efciency and gas recirculation rate.
The Valves is housed in a rated enclosure with a 12 pin connector as the standard interface. Current solutions
are in compliance with Euro IV and V as well as EPA 07 and 10 legislations. High accuracy and control dynamics
are possible through a high sample rate frequency. Variants and customization to application are possible with
software modication.
The wastegate has one port for attaching the boost control line from the charge air supply line coming from boost
control solenoid.
The valve works on both 12V and 24V systems.

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TECHNICAL DATA
Electronic Turbo Boost Control 1

Boost control is the principle of controlling the boost pressure produced in the intake manifold of a turbocharged
engine by adjusting the air pressure delivered to the pneumatic wastegate actuator.
Electronic boost control adds an air control solenoid controlled by the ECM (Electronic Control Module). The same 2-19
general principle of a manual controller is present, which is to control the air pressure presented to the wastegate
actuator. This electronic system has a rening control since it works with intelligent algorithms supplied by the
ECM. 3
At the component level, boost pressure can either be bled out of the control lines or blocked outright. Either can
achieve the goal of reducing pressure pushing against the wastegate. In a bleed-type system air is allowed to pass
out of the control lines, reducing the load on the wastegate actuator. On a blocking conguration, air traveling from 4
the charge air supply to the wastegate actuator is blocked while simultaneously bleeding any pressure that has
previously built up at the wastegate actuator.
The control for the solenoids in the EGR control valve is a closed loop system. Closed loop systems rely on 5
feedback from the intake manifold pressure sensor to meet a predetermined boost pressure.
Solenoids are driven by pulse-width modulation (PWM) as they are binary state devices. By modifying the pulse
width at a sufciently high frequency, average air pressure over time can be controlled. 6
This electronic boost control offers 3-port solenoids and stepper motors in series or parallel controlled by a single
PWM controller.
7
Exhaust Gas Recirculation (EGR) System
10
11
12
13
14
15
16
17

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EGR Control Valve
The EGR system includes the following:

2-20
v EGR control valve;
v EGR cooler;
v Air intake manifold;
v Inlet and EGR mixer duct;
v Exhaust manifold;
v 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 ame temperature and
reducing the amount of excess oxygen. The exhaust gas also increases the specic 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.
EGR FLOW
Some exhaust from the exhaust manifold ows into the EGR cooler. Exhaust from the EGR cooler ows through
the exhaust gas crossover to the EGR valve.
When EGR is actuated, the EGR control valve opens allowing cooled exhaust gases to enter the EGR mixer duct
to be mixed with ltered intake air.

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TECHNICAL DATA
Proportional Valve for Exhaust Gas Recirculation 1

EGR control device provides precise pneumatic proportional control for the hot side EGR control valve. A uni-
directional cylinder which actuates an exhaust ap is controlled by a proportional valve in order to recirculate
exhaust gases for combustion. 2-21
FUNCTIONAL DESCRIPTION OF EGR VALVE CONTROL

3
The function can be divided into three main steps:
v open, lling;
4
v regulating pressure
(pressure at P, the solenoid is on, A and R are alternating open and closed);
5
v off, closed
(pressure at P, no current through solenoid and the valve is closed).
6
10
11
12
13
14
15
16
17

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2-22

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TECHNICAL DATA
EGR CLOSED LOOP OPERATION WITH FAULT MANAGEMENT 1
The EGR is a closed loop system that uses exhaust gas recirculation position to provide feedback to the ECM.
2-23
10
11
12
13
14
15
16
17

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Exhaust System
The exhaust system includes the following:

2-24
v Exhaust valves;
v Exhaust manifold;
v Turbocharger;
v Exhaust piping;
v Mufer.
The exhaust system removes exhaust gases from the engine. Exhaust gases exit from exhaust valves, through
exhaust ports, and ow into the exhaust manifold. Expanding exhaust gases are directed through the exhaust
manifold. The exhaust manifold directs some exhaust gases into the Exhaust Gas Recirculation (EGR) cooler.
Exhaust gases owing into the turbocharger drive the turbine wheel. Exhaust gases exit the turbocharger and ow
into the exhaust piping, through the mufer, and out the exhaust pipe to the atmosphere.

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TECHNICAL DATA
1
Fuel Management System
FUEL MANAGEMENT COMPONENTS

2-25
The fuel management system includes the following:
v Fuel supply system;

3
v Fuel injectors;
v Electronic control system.

4
10
11
12
13
14
15
16
17

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FUEL FLOW SCHEMATIC
2-26
Fuel Flow
The fuel lter housing includes the following components:
v Fuel strainer;
v Fuel ltering element;
v Water separator;
v Water In Fuel (WIF) sensor;
v Water drain valve.

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TECHNICAL DATA
2-27
10
11
12
13
14
15
16
17

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Electronic Control System
ELECTRONIC CONTROL SYSTEM COMPONENTS

2-28
Operation and Function
The Electronic Control Module (ECM) monitors and controls engine performance to ensure maximum performance
and adherence to emissions standards.
The ECM has four primary functions:
v Provides Reference Voltage (VREF);
v Conditions input signals;
v Processes and stores control strategies;
v Controls actuators (output signals).
1. Reference voltage (VREF)

The ECM supplies a 5 volt VREF signal to input sensors in the electronic control system. By comparing the 5 volt
VREF signal sent to the sensors with their respective returned signals, the ECM determines pressures, positions
and other variables important to engine and vehicle functions.
The ECM supplies two independent circuits for VREF:
v VREF A supplies 5 volts to engine sensors;
v VREF B supplies 5 volts to vehicle sensors.
2. Signal conditioner
The signal conditioner in the internal microprocessor converts analog signals to digital signals, squares up sine
wave signals, or amplies low intensity signals to a level that the ECM microprocessor can process.
3. Microprocessor
The ECM microprocessor stores operating instructions (control strategies) and value tables (calibration
parameters). The ECM compares stored instructions and values with conditioned input values to determine the
correct operating strategy for all engine operations.
Continuous calculations in the ECM occur at two different levels or speeds: Foreground and Background.
v Foreground calculations are much faster than background calculations and are normally more critical for en-
gine operation. Engine speed control is an example.
v Background calculations are normally variables that change at lower rates. Engine temperature is an example.
Diagnostic Trouble Codes (DTCs) are generated by the microprocessor, when inputs or conditions do not comply
with expected values.
Diagnostic strategies are also programmed into the ECM. Some strategies monitor inputs continuously and
command the necessary outputs to achieve the correct performance of the engine.

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TECHNICAL DATA
Microprocessor Memory 1
The ECM microprocessor includes Read Only Memory (ROM) and Random Access Memory (RAM).
ROM 2-29
ROM stores permanent information for calibration tables and operating strategies. Permanently stored information
cannot be changed or lost by turning the ignition key OFF or when ECM power is interrupted. ROM includes the
following: 3
v Vehicle conguration, modes of operation and options;
v Engine Family Rating Code (EFRC);
4
v Engine warning and protection modes.
RAM
5
RAM stores temporary information for current engine conditions. Temporary information from RAM is lost when
the ignition key is turned to OFF or when ECM power is interrupted. RAM information includes the following:
v Engine temperature; 6
v Engine rpm;
7
v Accelerator pedal position.
4. Actuator control
8
The ECM controls the actuators by applying a low level signal (low side driver) or a high level signal (high side
driver). When switched on, both drivers complete a ground or power circuit to the actuator.
Actuators are controlled in three ways, determined by the kind of actuator. 9
v A duty cycle (percent time on/off).
v A controlled pulse width. 10
v Switched on or off.
11
ECM control of engine operation
The ECM controls engine operation through the following actuators:
12
v Turbocharger wastegate control module;
v EGR control module and control valve;

13
v Fuel Pressure valve;
v Injectors.
14
15
16
17

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Engine and Vehicle Sensors
2-30
1. Electronic Control Module (ECM) 9. Vehicle Speed Sensor (VSS)
2. Engine Oil Pressure (EOP) 10. Barometric Absolute Pressure (BAP)
3. Engine Coolant Temperature (ECT) 11. Accelerator Position Sensor (APS)
4. Manifold Air Pressure and Temperature (TMAP) 12. Exhaust Gas Recirculation valve Position
(EGRP)
5. Engine Fuel Pressure (EFP)
13. Engine Coolant Level (ECL)
6. Water In Fuel (WIF) sensor
14. Clutch Position Switch (CPS)
7. Crankshaft Position sensor (CKP)
15. Brake Pedal Sensor (BPS)
8. Camshaft Position sensor (CMP)

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TECHNICAL DATA
1
Resistor and Thermistor
v ECT
2-31
v T-MAP (RESISTOR AND THERMISTOR UNIT COMBINED)
v EFP
v BAP 3
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. 4
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.
5
ENGINE COOLANT TEMPERATURE (ECT)

The ECM monitors the ECT signal and uses this information for the instrument panel temperature gauge, coolant
6
compensation, Engine Warning Protection System (EWPS), and intake heater operation. The ECT sensor is
installed in the water pipe, close to the EGR cooler assembly.
7
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.
8
The TMAP sensor is in the top side of the intake manifold.
BAROMETRIC ABSOLUTE PRESSURE (BAP) 9

The ECM monitors the BAP signal to determine altitude, adjust timing and the fuel quantity. The BAP sensor is
installed in the PCB plate from ECM.
10
11
12
13
14
15
16
17

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ENGINE FUEL PRESSURE (EFP)

The ECM monitors the EFP signal to determine correct fuel pressure for efcient engine operation.
The EFP sensor is installed in the fuel rail.
2-32
1. Pressure sensor 4. Microprocessor

2. Electronic Control Module (ECM) 5. Voltage reference (VREF)
3. Ground

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TECHNICAL DATA
1
Capacitor Sensor
s EOP
2-33
EOP consists of a ceramic capacitive sensing element (CSE), a circuit module and a package. The package
includes internal seals against the pressure medium, external environmental seals, an electrical connector and a
port tting.
3
The circuit module consists of a exible circuit with surface mounted components.
The exible circuit consists of copper circuitry sandwiched between two pieces of Kapton lm.
4
When folded into the package, the signal conditioning IC and various discreet components reside on two planes
within the circuit cavity. The circuit module is soldered to the CSE at one end and the base at the other prior to
closing up the package. A tail coming off the end of the exible circuit makes a ground contact to the metal hexport.
5
ENGINE OIL PRESSURE SENSOR (EOP)

The ECM monitors the EOP pressure signal. If a failure is detected, the ECM is able to restrict the power and 6
torque to avoid or reduce engine damages. The EOP sensor is installed in the top right side of timing gear housing.
10
11
12
13
14
15
16
17

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Magnetic Sensors
v CKP
2-34
v CMP
v VSS
A magnetic sensor generates an alternating frequency that indicates speed. Magnetic sensors have a two wire
connection (signal and ground). This sensor has a permanent magnetic core surrounded by a wire coil. The signal
frequency is generated by the rotation of gear teeth that disrupt the magnetic eld.
CRANKSHAFT POSITION (CKP) SENSOR

The CKP sensor provides the ECM with a signal that indicates crankshaft speed and position. As the ywheel
turns the CKP sensor detects several holes made in the outside of the ywheel. All holes are symmetric and
spaced of 58 and 60. By comparing the CKP signal with the CMP signal, the ECM calculates engine rpm and
timing requirements. The CKP is installed in the top left side of the ywheel housing.
CAMSHAFT POSITION (CMP)

The CMP sensor provides the ECM with a signal that indicates camshaft position. As the cam rotates, the sensor
identies the position of the cam by locating a peg on the cam. The CMP is installed in the timing gear housing,
close to the high pressure fuel pump.
VEHICLE SPEED SENSOR (VSS)

The VSS is a Hall sensor installed onto the transmission tail shaft and provides a speed signal to ECM by sensing
rotation from a 8 teeth gear. The detected sine wave signals (AC), received by the ECM, is combined with tire size
and axle ratio to calculate the correct vehicle speed. See vehicle workshop manual for VSS location and further
information.
1. Crankshaft Position signal 6. Camshaft position (CMP) sensor

2. Crankshaft position sensor timing disk 7. Vehicle speed signal
3. Crankshaft Position (CKP) sensor 8. Electronic Control Module (ECM)
4. Camshaft position signal 9. Vehicle Speed Sensor (VSS)
5. Camshaft timing disk

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TECHNICAL DATA
1
Potentiometer
v APS
2-35
A potentiometer is a variable voltage divider that senses the position of a mechanical component.
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 3
to the amount of mechanical movement.
ACCELERATOR POSITION SENSOR (APS) 4
The APS provides the ECM with a feedback signal (linear analog voltage) that indicates the operators demand for
power. The APS is mounted in the accelerator pedal.
5
10
11
1. Ground 12
2. Electronic Control Module (ECM)
3. Microprocessor
4. Voltage reference (VREF) 13
5. Accelerator Position Sensor (APS)
14
15
16
17

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Switches
v CPS (Clutch Pedal Switch)

2-36
v ECL (Engine Low Coolant Level Switch)
v LIS (Low Idle Switch)
v WIF
v BPS (Brake Pedal Switch)
v Parking Brake Switch
Switch sensors indicate position. They operate open or closed, allowing or preventing the ow 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.
ENGINE COOLANT LEVEL (ECL)

ECL is part of the Engine Warning Protection System. The ECL switch is located in the deaeration tank. When a
magnetic switch is open, the tank is full. If engine coolant is low, the lamp on the instrument panel is turned on.
WATER IN FUEL (WIF)

A Water In Fuel (WIF) sensor detects water in the fuel. When enough water accumulates at the bottom of the
housing, the WIF sensor sends a signal to the Electronic Control Module (ECM); the ECM sets a Diagnostic
Trouble Code (DTC) and illuminates the amber WATER IN FUEL lamp on the instrument panel. The WIF sensor
is installed in the base of the fuel lter housing.
LOW IDLE SWITCH (LIS)

The LIS is a redundant switch that provides the ECM with a signal that veries when the APS is in the idle position.

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TECHNICAL DATA
2-37
1. Accelerator pedal 8
2. Low Idle Switch (LIS)
3. Voltage source with current limiting resistor
9
4. Microprocessor
5. ECM
6. Ground
10
11
12
13
14
15
16
17

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NOTES
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1
Operation and Maintenance
2
Engine Operation...................................................................................................................................... 3-2
Cooling Fluid and Coolant ........................................................................................................................ 3-5

3-1
Cooling Fluid Filling Procedure................................................................................................................. 3-6
Maintenance Table.................................................................................................................................... 3-7 4
Conservation for Inative Engines for Long Period .................................................................................... 3-8

5
Starting Engine Preparation ..................................................................................................................... 3-9
Oil Element ............................................................................................................................................. 3-11

6
Mounting Adapter Plate and Engine Lifting ............................................................................................ 3-13
10
11
12
13
14
15
16
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Engine Operation
Start / Stop
v Before operating the MaxxForce 4.8H/7.2H engine check:
3-2 v Coolant level;
v Fuel level;
v Oil leve;
v After the engine is started, run it up at medium speed, without load to warm it up. Monitor oil pressure and
coolant temperature;
v It is recommended that the engine be started without accelerating, keeping it at idle for 30 seconds to pre-
lubricate the turbocharger;
v Before stopping the engine, run it about 30 seconds at idle to allow the turbo to decrease speed.
Cold Start
Starting in very low temperatures can be difcult due to parafn formation (waxing) in the fuel.
The following actions improve cold weather starting:
v Use winter blend fuel, or;
v The use of appropriate fuel heaters.
Turbocharger Cares
v Most turbocharger failures are caused by a lack of oil (lubrication) resulting from delay in lubrication, restriction
or, impurities in the oil, etc. or impurities ingested through the intake.
v To maximize the turbo life follow the following recommendations:
v Do not accelerate the engine immediately after it is started;
v Idle the engine 30 seconds before shutting it down;
v Pre-lubricate the turbocharger after oil change or other service that involves oil drain. Crank the engine a few
times before starting it. Run the engine and allow it to run at idle for a period of time to establish a complete
circulation and oil pressure before running of high speeds and load;
v In low temperatures or when the engine is being put into service after a long period without operation, start
the engine and let it running at idle before running at high speeds;
v Avoid operating the engine at idle speed for long periods of time.

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Running-in 1
All MWM engines are assembled and tested in the factory.
However, engines need to be correctly run-in, the engine performance and durability depend on the care
taken during the initial operation (run-in) phase. 2
They rst 2,000 km for vehicle engines or the rst 50 service hours for stationary, industrial and agriculture
engines is considered or the run-in period.
During this period it is very important to follow the recommendations below: 3-3
v Carefully check engine oil level;

v Carefully check the level of the cooling system; 4
v Avoid operating the engine at high speeds;
v Avoid lugging forcing the engine at low speeds;
5
v Avoid lugging forcing the engine while it has not reached the normal operation temperature yet;
v Avoid operating over 3/4 (75%) of the maximum load of the vehicle or equipment;
v Avoid operating the engine at constant speeds for long periods of time; 6
v Avoid leaving the engine running at idle for a long period of time;
v Follow the maintenance instructions carefully.
7
FUEL SPECIFICATIONS
Brazilian Market 8
Diesel
The diesel fuel used in MWM INTERNATIONAL Engines must meet Brazilian Standard ANP n 32, issued in 9
16.10.2007 DOU 17.10.2007.
Biodiesel 10
The use of B5 (fuel composed by mixing diesel oil and biodiesel* and dened as proportion of no more than 5%
of biodiesel) is allowed in MaxxForce 4.8H/7.2H engines, according to Brazilian Standard ANP N 07 issued in
03.19.2008 DOU in 03.20.2008.
11
! Attention: The use of B5 that does not meet the specications recommended by manufacturer, may
cause serious damage to internal components of the engine, and result in the warranty being 12
void.
* It is understood that biodiesel is a fuel to be used in internal combustion engines with
compression ignition, renewable and biodegradable, derived from vegetable oils and/or 13
animal fats.
Mexican Market
14
The diesel fuel must meet Mexican regulations. See PROY-NOM-086-SEMARNAT-SENER-SCFI from 2005.
LUBRICANT OIL 15
Oil Level Check

v Stop the engine and wait 30 minutes for the oil to ow back to the oil pan. 16
v Make sure that the vehicle is on a level surface.
v Before pulling oil dipstick, clean the surroundings.
17

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v If necessary, top up to the upper mark (MAXIMUM), without exceeding it. Use the same oil mark and type to
complete the level.
v Do not operate the engine with the level below the lower mark (MINIMUM).
v Use only recommended oil.
v Do not mix different oil brands.
v Always use the same type and brand of oil.
3-4
Oil Change
v Ensure the oil is at operating temperature and engine shut-off.
v Drain the oil.
v Install the plug with a new washer and tighten according to the specication.
v Fill with recommended oil to the upper level mark (MAXIMUM) of the dipstick.
Oil Filter Change

v Clean the sealing area of the lter with a clean, lint free cloth.
v Lubricate the lter gasket and install the lter.
v Hand-tighten one (1) turn after the gasket rst contacts the lters head.
v Fill up with new oil. In a levelled vehicle, the oil level must reach the upper mark of the dipstick.
v Run the engine checking the sealing of the lter and drain plug.
v Stop the engine and, after 30 minutes, check oil level again, top-up if necessary.
! Attention: Always use a genuine MWM lter.
The oil is very important for protection of the inner engine components. Oil contaminated with sand, soil, dust,
water or fuel cause damage to the engine.
Check the appearance of the engine lubricant oil. A dark coloration and low viscosity means presence of fuel in
the lubricant oil.The presence of bubbles or a milky coloration indicates presence of water in the oil.
Lubricant Oil Specications

Use only the recommended viscosity of oil that meets SAE 15W40 API CI-4 (or higher) specications.
! Attention: Do not mix different oil brands. Choose one oil type and always use it when lling or topping
up.
Check Lubricant oil Condition

The condition of the oil is very important for protection of the inner components of the engine.

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1
Cooling Fluid and Coolant
! Caution: v Do not open the radiator or deaeration tank cap while the engine is hot.
2
v Check the level when the engine is cold.

3-5
v Check the level of the cooling system daily. If the level is not correct, ll up with the MWM
coolant.
v Carefully open the rst stage of the cap, relieving any vapour pressure. 4
v Check for leaks.
v Check the nominal pressure of the cap.

5
Water Pump Check
Check for leaks through the pump drain hole.
6
10
11
12
13
NOTE: Image shown with high pressure pump removed.
If coolant is coming from this hole, there is a leak from the water pump. 14
15
16
17

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Cooling Fluid Filling Procedure
System Fill
Fill the cooling system with the additive quantity until the MAXIMUM mark.
System total capacity

3-6
To total colling system capacity (Engine + Radiator) see the vehicle manual.
Start the engine and wait until it reaches the normal operating temperature. Fill only MWM INTERNATIONAL
additive. After lled the system, run the engine and inspect for leaks.
MWM INTERNATIONAL Additive
Package
MWMI Number 9.0193.05.6.0802 9.0193.05.6.0801

Name Cooling System Protector Ecological Cooling System Protector Ecological
Proprieties Anti-corrosion / Anti-boiling / Anti-freeze Anti-corrosion / Anti-boiling / Antifreeze
Application Diesel engines / Gasoline / Alcohol / CNG Diesel engines / Gasoline / Alcohol / CNG
Color Red Fluorescent Red Fluorescent
Ratio READY TO USE READY TO USE
Change interval See maintenance table See maintenance table
Anticorrosive ethylene glycol, borates, Anticorrosive ethylene glycol, borates,
Composition
silicates and colouring silicates and colouring
Validity See maintenance table See maintenance table
Volume 1" 5"

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1
Maintenance Table
Initial A B
2
MAINTENANCE PLAN
120.000 Km
10.000 Km
20.000 Km
40.000 Km
80.000 Km
15.000 Km
30.000 Km
60.000 Km
2.500 Km
5.000 Km
Daily
A) Up to 50,000 km/year conditions
B) Over than 50,000 km/year conditions
3-7
DRAIN FUEL FILTER s

CHECK OIL LEVEL s 4
CHECK COOLANT LEVEL s
CHECK FOR ENGINE LEAKS s
CHECK CONNECTIONS s s
5
CHANGE OIL (SAE 15W40 - API CI-4) s s

CHANGE OIL FILTER s s
6
CHANGE FUEL FILTER s s
CHANGE AIR FILTER s s
ADJUST VALVE CLEARANCE s s 7

CHECK DAMPER s s
CHECK BELT(S) s s s
8
REPLACE BELT(S) s s
CHANGE COOLANT s s
CHECK ELECTRICAL CONNECTIONS (Starter Motor and Alternator) s s 9
Remark:
1) This table is only for guidance. The Maintenance Table of the vehicle supercedes over this table. 10
2) For heavy-duty and off-road applications, maintenance intervals should be half of these indicated in the table
above. 11
3) If the engine is out of service for a long time, it should be run weekly to the operation temperature.
4) Engine oil change, should follow the intervals indicated above or every 6 months whichever occurs rst. 12
5) Electronic components (position, speed, air pressure, temperature, oil pressure and water temperature
sensors) are maintenance free and checked by a diagnostic service tool. 13
14
15
16
17

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Conservation for Inactive Engines for Long Period
MWM INTERNATIONAL protected from the factory, at the most, 6 months of under inactivity shelter. When the
engine is out of service for a long period, it is necessary to follow these reccomendations:
1. Clean the outer parts of the engine.
3-8 2. Operate the engine to normal operating temperature.

3. Drain cooling system and oil.
4. Fill the radiator with MWM coolant.
5. Fill up the oil pan with protective oil SAE 20 W 20.
6. Drain fuel system (reservoir, low pressure system).
7. Operate the engine for 15 minutes at 2/3 of the nominal speed, without load, using a mixture of fuel with 15%
of the protective oil SAE 20 W 20.
8. Drain uid from cooling system and oil from the oil pan. The fuel mixture can stay in the system.
9. Remove valve covers from cylinder heads and spray protective oil on the springs and rocker arms. Reinstall
covers.
10. Apply protective grease on linkages.
11. Apply protective oil to machined surfaces.
12. Remove belt(s).
13. Seal all the holes of the engine, to avoid dust and water intrusion.
Remarks:
v Renew the engine preservation procedure after each 8 months of inactivity.
v Items 1, 2 and 3 do not apply to brand new engines.
ENGINE PREPARATION TO RETURN FOR SERVICE

1. Before operating an engine which has been out of service for a long period, follow these procedures:
2. Clean the outer parts of the engine.
3. Fill cooling system with MWM coolant.
4. Change engine oil lter.
5. Fill the oil pan with new lubricant oil according recommendation.
6. Install belt(s) and adjust tension.
7. Remove valve covers and lubricate rocker arms with engine oil. Reinstall covers.
8. Drain the fuel mixture from the reservoir and ll with new fuel.
9. Change fuel lter.

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1
Starting Engine Preparation
CLEAN ENGINE DRAIN ENGINE FLUIDS

2
Draining the Oil
! Warning: To avoid serious personal injury,
possible death, or damage to 1. Place an oil drain pan beneath the oil drain plug to 3-9
the engine or vehicle, read all collect the oil.
safety instructions in the Safety
Information section of this 2. Remove oil pan drain plug (R ) and washer.
Drain engine oil and dispose of used engine oil 4
manual.
according to applicable laws.
! Warning: To avoid serious personal injury, 3. Discard washer, inspect drain plug and replace 5
possible death, or damage to if necessary. Place a new washer onto drain
the engine or vehicle, make plug and install to oil pan. Torque to 55 to
sure the transmission is in 75 N.m.
6
neutral, parking brake is set,
and wheels are blocked before 4 Cylinders Engine
doing diagnostic or service
procedures on engine or vehicle. 7
1. Cap all turbocharger and manifold openings

to prevent water and degreased agents from
internally entering any engine component. 8
2. Cover any exposed electrical connector and ECM

module using plastic and duct tape. 9
3. Use an appropriate detergent mixed in the correct

ratio of water and apply to the engine using warm
water and a moderate pressure washer or similar 10
cleaning equipment.
11
! Attention: Do not use high pressure or 6 Cylinders Engine
excessive hot water temperature
as it may damage the engine
components. 12
! Attention: Do not use solvent, thinner or 13

any product that derivates from
petrol as these products may
damage the wiring harness and
other plastic components. 14
15
16
17

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Priming the Lubrication System

Preferred Method
When the engine has been assembled, lubricate the
engine with oil before starting. This will aid internal
components with the proper lubrication requirements
during the critical initial startup phase. The following
procedure is the preferred method to use when
3-10
priming the lubrication system.
1. If engine was completely disassembled and

rebuilt, remove the plug assembly and pressurize
the lubrication system with sufcient oil to ll the
oil lter and charge the entire lubrication system.
2. Check the oil level before starting engine.
Alternate Method
! Attention: To avoid engine damage, make

sure that all internal moving
components of the engine have
been well oiled during assembly,
if using this procedure.
3. Disconnect CKP and CMP sensor connectors

and crank the engine - but do not start the engine
(ensure CKP and CMP are disconnected) - until
the oil pressure gauge indicates sufcient oil
pressure.
4. After oil pressure is evident in the lubrication

system, reconnect CMP and CKP sensor
connectors and start the engine.

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1
Oil Element
REMOVAL 4. Remove the lter element. Resistance during

element removal is normal due O-Ring pressure 2
1. Remove the drain plug (R ) and discard the in its header housing.
washer. Drain engine oil and dispose of used
engine oil according to applicable laws. 3-11
7
CLEANING AND INSPECTION
2. Using the wrench indicated, unscrew the lter Cleaning the Oil Element Housing From Oil
cover. Module 8
! Attention: To avoid engine damage, the oil 9

cooler must be replaced if there
was a bearing failure. Debris
from a bearing failure cannot be
removed from the oil cooler. 10
See oil cooler removal procedu-

re in this section for further infor-
mation. 11
1. Dry the oil element housing with ltered

compressed air and remove any residue.
12
3. Remove the cover.

13
14
15
16
2. Remove any debris that may block the lter

bypass valve. 17

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INSTALLATION
1. Replace the lter element. Ensure the O-Ring is
installed correctly.
2. Mount the oil element applying pressure until the

O-Ring ts in the head housing.
3-12
6. Install a new washer on the drain plug (R ).

Tighten the drain plug to a torque of 55 to 75
N.m and ll to the maximum mark from dipstick
with new engine oil.
3. Lubricate the cover with new engine oil and place

a new O-ring onto lter cover.
4. Place the cover onto lter head.
5. Using a wrench as shown, tighten the cover to a

torque of 30N.m.

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1
Mounting Adapter Plate and Engine Lifting
ADAPTER PLATE DIESEL ENGINE STAND

2
A good engine stand is one of keys to a stress-free
engine build, eliminating the need to struggle with
rebuilding engines on a bench or on the ground. A
possible death or damage to 3-13
recommended diesel stand must be solid built, stable,
the engine or vehicle use a mi-
offer oil drip pan to keep assembly lube and motor
nimum 3 ton chain hoist, equi-
oil off of the oor. 360 engine rotation and a oor
pped with safety hooks to lift
lock to keep stand from moving during repairs is 4
the engine at designated lifting
recommended for safety.
eyes.
NOTE: The oil drip pan is an important
accessory to the engine stand as it 5
! Warning: To avoid serious personal in-
catches the oil that ALWAYS drips from
jury, possible death, damage to
the engine when working on it, keeping
the engine or vehicle, use only
the oor dry. 6
metric grade 10.9 or SAE grade
8 bolts when mounting adapter
plate to engine as well as the INSTALLING THE ENGINE TO THE STAND
engine stand. 7
Raise the engine with the hoist and using the special
tool No.9.610.0.690.011.6 (adapter plate kit), an
ENGINE HOIST
engine stand and bolts M12X45, visually match up
Keep in mind that safety is the rst concern when adapter plate with bolt holes on right side of engine 8
choosing an engine hoist that is required for safe to determine adapter plate orientation to the engine
lifting of engines and heavy parts. stand.
9
NOTE: Leeve all bolts loose to make it easier
to initally t the adapters onto the
engine and stand plate, then torque the
adapter bolts to the plate and engine. 10
Rear engine side support adapter shown (2 holes

xation).
11
12
13
14
15
16
17

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Front engine side support adapter (use 4 holes for Tighten bolts to the standard torque value (General
6cyl engine or 3 holes for 4 cyl). Torque Guidelines).
Remove safety chain hooks from engine lifting eyes.
6 cyl engine shown
3-14
Install the recommended adapter plate to the engine

stand and secure it by using grade 8 bolts and nuts.
NOTE: Leeve all bolts loose to make it easier

to initially t the adapters onto the
engine and stand plate, then torque the
adapter bolts to the plate and engine.
Using the hoist, align engine stand to match the
adapter plate on the engine, rotating stand and / or
raising engine to match adapter plate. Secure one
bolt and rotate stand if necessary to thread remaining
bolts.
Use metric grade 10.9 bolts M12X45 or longer to
secure engine to adapter plate.

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ENGINE BLOCK
1
Engine Block
2
Disassembly Notes ................................................................................................................................... 4-2
Inspections and Measurements................................................................................................................ 4-3

3
Liners ....................................................................................................................................................... 4-7
4-1
10
11
12
13
14
15
16
17

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Disassembly Notes
To prevent damage, cylinder liner removal must be Remove cylinder liner shim rings.
made with the special tool MWM nr. 9.610.0.690.017.6.
The lower part of the tool must be tted on the lower
edge of the liner.
The liner can be removed threading the nut of the
puller.
4-2
Clean the block surface cylinder head that must be

free of dust or wear.

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ENGINE BLOCK
1
Inspections and Measurements
LINER PROTRUSION
2
4-3
10
Liner over Engine Block Surface 11
Measure mm
Protrusion *0.028 a 0.102 12
*Affect emissions level
13
14
15
16
17

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LINERS
4-4
Liners
Measure mm
Out-of-roundness 0.02
Inner 105.000 - 105.022

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ENGINE BLOCK
ENGINE BLOCK 1
4-5
10
Engine Block
mm
Parallelism 0.05 11
Perpendicularity 0.04
12
Main Bearings (A)
Diameter mm
13
Inner 92.000 - 92.022
14
Tappet Housing (B)
Inner mm
15
standard, nominal 18.000 - 18.018
standard, maximum 18.020
1st repair 18.500 - 18.518 16
17

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Measure main bearing bolt lengths.

Discard bolts longer than 133.5 mm.
4-6
Camshaft Bearing (C) and (E)

inner mm
without bushing
standard nominal 50.000 - 50.025
maximum 50.045
1st repair
without bushing 54.000 - 54.030
with bushing 49.990 - 50.056
Camshaft Bearing (D)

inner mm
without bushing 54.000 - 54.030
with bushing 49.990 - 50.056
*Remark:
Camshaft bearing (D) has a bushing the others do not. When it is necessary the other bearings can receive
bushing as repair.

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ENGINE BLOCK
1
Liners
REMOVAL Remove and install new sealing O-Rings.

2
Using the special tool MWM N 9.610.0.690.017.6,
remove the liners carefully in order to avoid damages
to the block and/or liners.
3
Fit the lower part of the tool to the liner lower border.
The liner must be removed by rotating the nut from
the screw extractor clockwise. 4-7
INSTALLATION
7
Take 4 measurements of 90 degrees from each other
in the rst step of the liner. Use points close to the
cylinder head assembling holes.
8
NOTE:
Remove the stainless steel liner rings. s 4HE DIFFERENCE BETWEEN THE FOUR MEASUREMENTS
9
should not be higher than 0.02 mm;
Clean the block and cylinder head surface until free of
dirt and impurities.
s !LWAYSUSECALIBRATEDINSTRUMENTS
10
11
12
13
14
15
16
17

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To obtain the correct protrusion measurement, use a

shim ring.
Install new stainless steel ring (only one for each
cylinder).
Stainless steel ring thickness available:
9.610.8.340.038.4 = 0.10 mm
9.610.8.340.039.4 = 0.15 mm
9.610.8.340.040.4 = 0.25 mm
4-8 9.612.8.340.013.4 = 0.35 mm
9.610.8.340.041.4 = 0.40 mm
9.612.8.340.014.4 = 0.45 mm
Install special tool MWM INTERNATIONAL No
D7001689C1 using the cylinder head bolt holes at
the indicated places. Apply torque of 40 Nm on bolts
to correctly place the sleeve on its seat and to allow
the correct protrusion measurement.
The cylinder liner has rolled radius to minimize

residual tension load and a specic shape to provide
contact with cylinder gasket.
Using a dial indicator, measure the sleeve height

(protrusion) relative to the top surface of engine block.
The protrusion shall be measured at 4 places equally
distant from each other and it shall be between
Rolled
0.028 mm to 0.102 mm. If not, remove the sleeve

and select a new stainless steel ring until the
45
90
recommended value is reached.
NOTE: If difference between the protrusion

measurements, at the same cylinder, is
larger than 0.02 mm, remove the slee-
ve, clean the surfaces and measure it
again.
Liners Inspection
Measure mm
Out-of_roundness 0.02
Inner 105.000 - 105.022

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ENGINE BLOCK
Lubricate the liners with engine oil, applying oil to the 1

sealing ring contact area.
4-9
5
After selecting the correct stainless steel ring,
carefully remove the sleeve and clean it thoroughly,
removing all impurities and lubricating oil. Then apply 6
Loctite 5900 silicon or equivalent to the sleeves Install manually the liners to the cylinder housing.
rolled radius, as indicated.
10
11
Using the device indicated on picture, spread the ! Attention: The O-ring must be completely
silicon by applying it evenly. Remove eventual clean to avoid possibility of war-
excesses of product. page or damage during assem-
12
bly procedure.
NOTE: The silicon applied shall make an even
contact with the stainless steel ring. Install the special tool MWM INTERNATIONAL n
D7001689C1 and apply torque of 40 Nm on xing 13
bolts in order to seat the sleeve correctly on engine
block.
14
15
16
17

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NOTE: The tool must not be removed before

20 minutes; this is the necessary time
for silicon drying. During this time, the
ywheel shall not be rotated, as the
pistons movement can damage the
correct sealing of the silicon bead.
4-10

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CRANKSHAFT
1
Crankshaft

2
Specications ........................................................................................................................................... 5-3
Inspections and Measurements.............................................................................................................. 5-10 3
Assembly ................................................................................................................................................ 5-14

4
Measurements After Assembly............................................................................................................... 5-16
5-1
10
11
12
13
14
15
16
17

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Disassembly Notes
After removing the oil pan, pistons and connecting

rods, ywheel, pulley and gear housing, position the
engine on the stand in upright position and loosen the
main bearing caps. To remove the bearing caps use
the mounting bolts.
5-2
Remove the axial thrust ring from bearing #1 (ywheel

side).
Carefully remove the crankshaft be careful to not hit

it on any part of the engine block. The storage of the
crankshaft must always be done in upright position in
order to avoid any possibility of warping.

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CRANKSHAFT
1
Specications
CRANKSHAFT
2
5-3
10
11
Gear
12
Diameter mm
Seat 60.020 - 60.039
13
14
15
16
17

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MAIN JOURNALS
5-4
Main Journal
Diameter mm
Standard 85.942 - 85.964
1st repair 85.692 - 85.714
2nd repair 85.442 - 85.464
3rd repair 85.192 - 85.214
4th repair 84.942 - 84.964

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CRANKSHAFT
CRANKPINS 1
5-5
10
Main Journal
11
Diameter mm
Standard 62.951 - 62.970
12
1st repair 62.701 - 62.720
2nd repair 62.451 - 62.470
13
3rd repair 62.201 - 62.220
4th repair 61.951 - 61.970
14
15
16
17

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OUT-OF-ROUNDNESS AND TAPER
5-6
Maximum Out-of-roundness mm
A x C and B x D 0.01
Maximum Taper mm
A x B and C x D 0.01

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CRANKSHAFT
RADIAL 1
5-7
10
Radial Clearance (except central main journal) mm

11
nominal 0.036 - 0.096
maximum 0.245
12
13
14
15
16
17

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FILLETS
5-8
Fillet mm
Nominal 3.8 - 4.0

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CRANKSHAFT
MAIN BEARINGS 1
5-9
10
Engine Block
11
Diameter mm
Without bearing insert 92.000 - 92.022
12
Engine Block
Diameter mm
13
Standard 86.019 - 86.035
1st repair 85.769 - 85.785
14
2nd repair 85.519 - 85.535
3rd repair 85.269 - 85.285
4th repair 85.019 - 85.035 15
Pre-tension 0.05 - 0.15

16
17

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CRANKSHAFT ENGINE BLOCK BEARINGS

Crankshaft and bearings, can be visually checked. Before doing any check on the caps and main
Check for signs of overheating, deep scratches, bearings, make sure that the number engraved on the
cracks or other types of damage. If any damage is engine block corresponds to the bearing cap.
found, it is necessary to check for the possibility of
Install bearing caps and tighten according to the
machining and to use oversized bearing inserts.
specication.
Measure the llets with a calibrated sphere.
1st 45 to 50 N.m
2nd 150 5
Torque Range 170 to 282 N.m
5-10
The measurement of the llets can also be performed

with a radius shim.
Measure bearing journal diameter, out-of-roundness

and taper with bearing inserts removed.

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CRANKSHAFT
Measure bearing with the bore gauge at 30 to the left 1

and 30 to the right from the central position.
30
3
30
5-11
Clean bearing bolt holes. The holes must be
completely free of oil residues and impurities.
6
Depending on the wear pattern in bearing inserts, it is
possible to identify the problem: excessive clearance,
out-of-roundness or taper. Failure or excessive
clearance can be detected by the low oil pressure. 7
The prolonged operation with low oil pressure may
cause noise and vibration in crankshaft and result in
premature failure of the bearing inserts.
8
10
Place the bearing inserts with the aid of the expansion

pin.
11
12
To measure the bearings with the bearing inserts

installed, clean the bearing cap, to prevent distortion 13
due to oil or dirt.
14
15
16
17

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Measure the crankshaft.The measurements must

be taken twice at 90 and in the two edges of
the bearing to check crankpins and main journal
out-off-roundness and taper.
30
30
5-12
Remove one of the bolts bearing and measure bearing
pre-tension.
Pre-tension: 0.05 - 0.15 mm.
Compare the clearances obtained in the crankshaft

through the bore gauge.
Install bearing caps and tighten according to

specication. Measure using same procedure
without bearing inserts to check bearing caps out-off-
roundness.
The 1st measurement is made in the centre of the
bearing 0.036 0.096.

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CRANKSHAFT
Install the crankshaft with only the bearing shells of 1

the rst and last bearings installed and oiled. With a
dial indicator gauge on the central main journal, turn
crankshaft and measure warping.
2
4 cyl. 6 cyl.
Maximum Warping (mm) 0.11 0.15
3
5-13
Check crankshaft thrust rings. Check for damage or

8
excessive wear. During assembly, the side with two
grooves must be toward the shaft.
When needed an over-sized thrust ring, can be used.
9
Its at surface must be adjusted, in order to provide
the correct axial clearance.
10
11
12
13
14
Crankshaft Thrust Ring

Thickness mm 15
Standard 3.42 - 3.47
Over-size 3.67 - 3.72
16
17

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Assembly
Install piston cooling oil injectors. Observe if the two Bolts Tighten Torque Specication
guided pins are correct tted to the block holes.
Step
Torque to 10 1.5 Nm.
1st: 50 - 5 Nm
2nd: 155 5
Lmax 133.50 mm
Install rst bearing lower thrust ring.
5-14
Install and apply oil onto all bearing inserts.
! Attention: Thrust ring grooves must stay

towards the crankshaft (mobile
side).
Install bearing caps with the upper thrust ring.
Install crankshaft.
Thrust Ring
Thickness mm
Standard 3.42 3.47
Oversize 3.67 3.72

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CRANKSHAFT
Tighten bolts in two steps and tighten according to 1

the specication.
The torque must be applied from the center to the
extremities. 2
1st 50-5 N.m

2nd 155 5
3
Torque Range 170 to 282 N.m
5-15
10
11
12
13
14
15
16
17

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Measurements After Assembly
AXIAL CLEARANCE
5-16
Axial clearance (A) mm

Nominal 0.030 - 0.251
Maximum 0.4
Measure the crankshaft axial clearance.

1. Set the dial indicator to zero a .
B
2. Release the cap mounting bolt from one side of
A C the cap b .
3. Using a screwdriver push the crankshaft to the
crankshaft gear side c .
4. Note the value on the dial indicator d.

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CAMSHAFT
1
Camshaft

2
Specications ........................................................................................................................................... 6-3
Inspections and Measurements................................................................................................................ 6-5 3
Assembly .................................................................................................................................................. 6-7

4
6-1
10
11
12
13
14
15
16
17

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Disassembly Notes
REMOVAL
Remove the camshaft to fuel pump gear.
6-2
Remove camshaft lock mounting bolts and its lock
plate.
Remove the spacer and camshaft timing gear.
Rotate the engine assembly, keeping the oil pan side

upwards. Remove camshaft through the front of the
engine. Be careful not to damage the bearings of
the shaft and engine block. If necessary, remove the
camshaft bushing from the engine block.
Remove the gear housing cover, see procedure in the
section 9 in this Service Manual.

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CAMSHAFT
1
Specications
CAMSHAFT
2
6-3
10
11
Gear seat Axial Clearance Limitation Groove

12
Diameter (A) mm Width (B) mm
Nominal 51.971 - 51.990 Nominal 7.100 - 7.190
Maximum 7.275
13
Main journal
Main Journal
Diameter (C) mm 14
Bearing Clearance mm
Standard 49.873 - 49.897
Axial 0.05 - 0.19
Radial 0.093 - 0.183
15
16
17

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TAPPETS AND LOCK PLATE
6-4
Lock Plate Tappets

Thickness mm Diameter (C) mm
Nominal 7.00 - 7.05 Standard
Nominal 17.983 - 17.994
1st repair
Nominal 18.483 - 18.494

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CAMSHAFT
1
Visually check the tappets. Check if there are marks Measure the diameter and out-of-roundness of the
of excessive wear on the contact area with the cams tappet housings. 2
of the camshaft.
6-5
Measure the tappet diameters. 7

NOTE: During its operation the tappets per-
form a rotating movement, resulting in
a uniform distribution of the force, and 8
wear. It must not have wear on only one
area.
Visually check tappet lubrication holes.
9
10
11
Measure the camshaft bearing diameters. 12
13
! Attention: The lubrication holes of the ta- 14

ppets must not be obstructed.
15
16
17

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Comparing the performed measurements, obtain the

clearance between the bearing and the housing.
6-6
Measure the camshaft bearing housing bores.
Measure the camshaft for warping.
4 cyl. 6 cyl.
Maximum warping (mm) 0.04 0.04

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CAMSHAFT
1
Assembly
Clean and lubricate the tappets and the tappets Install it by hand using rotating movements.
housing. 2
NOTE: Be careful not to damage the bushings
in the engine block.
3
After camshaft installation, install the axial lock and
tighten the bolts according to the specication.
Torque: 30 5 N.m
4
6-7
Install them by hand. If it is not necessary to change 7

reinstall them in the original positions.
Measure the camshaft axial clearance. Repeat the

operation to ensure the measurement is correct. 9
10
11
12
Clean and lubricate camshaft bearings.
13
14
15
16
17

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Install the pulse-wheel. Pay careful attention to

the expansion bushing, which guides the correct
positioning.
6-8
Install pulse wheel bolts and tighten according the
specication.
Torque: 8.5 1 N.m
Install camshaft gear.

(6 cylinder camshaft gear shown)

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CAMSHAFT
Pay careful attention to the difference between the pulse wheels of the 4 and 6 cylinders engines. 1
Four Cylinder Six Cylinder 5
See the timing gear installation in the section 9 of this Service Manual.
6-9
10
11
12
13
14
15
16
17

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NOTES
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6-10
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1
Pistons and Connecting Rods

2
Specications ........................................................................................................................................... 7-3
Assembly ................................................................................................................................................ 7-14

4
7-1
10
11
12
13
14
15
16
17

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Disassembly Notes
After the removal of the oil pan and cylinder heads,

position the engine in upright position to remove the
connecting rods.
Remove connecting rod caps. The bolts must be
loosened alternately and in steps. Do not completely
loosen the bolt of one side and then the other.
Remove the piston rings.
7-2
Before removing the piston, clean the inner part of

the liner to remove any residues or impurities. With
the connecting rod caps out, carefully remove the
piston / connecting rod set through the upper side of
the engine.
! Attention: When removing the piston and

connecting rod, observe the
position of the oil injector to
avoid damage.
Remove piston pin snap rings. The piston pins must

move freely.
NOTE: It is not necessary to hit or to heat up

the pins.
To remove connecting rod bushings send the
connecting rods to a specialized authorized service
center.

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1
Specications
The weight of the connecting rod is identied by a sequence of letters and numbers between the stem and the cap.
According to the letter (X, Y and Z) it is possible to identify the weight. 2
Connecting Rod Mark

3
7-3
WEIGHT CLASS
8
Letter Weight Strip Application
X 1855g - 1876g Production
9
Y 1877g - 1898g Spare Part
Z 1899g - 1920g Production
10
The weight difference between all pistons / connecting rods sets, in the same engine, must be of a maximum of
41g. So, as a spare part, only the Y connecting rod is available.
11
CONNECTING ROD MARK

The connecting rod stem / cap pair is made by the alignment of the digits engraved on the connecting rod stem 12
with the rst 4 digits engraved on the connecting rod cap.
13
14
15
16
17

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IDENTIFICATION CODE:
Supplier Control
Ex. 12 01 02 07
Year
Month
Manuft.
Line
Plant
Weight
7-4
Class (*)
Month / Day
( )
* As a spare part only the Y connecting rod is available.
Important: Do not assemble connecting rods of X and Z mass in the same engine, because these connec-
ting rods exceed the maximum limit of mass difference.
PISTON
Observe the two holes for cooling the piston head.

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PISTON GROOVES 1
1st 5
2nd 6
3rd
7-5
10
Remark:
11
The rings are identied by a strip on the outer diameter.
Rings Dimensions and Clearences in the grooves

12
Strip
Groove Dimensions (groove) Dimensions (ring) Clearance
Code
1st Thickness 3.00 (ref) Thickness 3.00 (ref) Width 4.20 to 4.55 0.07 to 0.10 2ED 13
2nd Thickness 2.56 to 2.58 Thickness 2.4 to 2.4 Width 4. to 4.55 0.0 to 0.1 'REEN
Width 3.45 to 3.70
14
(with spring)
3rd Thickness 3.54 to 3.56 Thickness 3.47 to 3.49 0.05 to 0.09 Green
Width 2.45 to 2.85
(Without spring)
15
16
17

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RING ENDS GAPS CONNECTING ROD BEARINGS
7-6
Ends Gap (mm) Connecting Rod Bearing, (bore)

1st groove Diameter (mm)
Nominal 0.30 - 0.5 Standard 62.996 - 63.031
2nd groove Repair 1 62.746 - 62.781
Nominal 0.0 - 0.5 Repair 2 62.496 - 62.531
3rd groove Repair 3 62.246 - 62.281
Nominal 0.25 - 0.55 Repair 4 61.996 - 62.031

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CONNECTING ROD WARPING 1
Maximum Torsion Maximum Warping 6
0.10 0.03
7-7
10
11
12
13
14
15
16
17

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CONNECTING RODS
B
A
7-8
Radial Clearance (mm)
Nominal 0.026 - 0.08
Maximum 0.178
Diameter (mm)
A (With Connecting Rod Bearing) 62.996 - 63.031
B (Without Connecting Rod Bearing) 67.000 - 67.019
Side Clearance (mm)

Nominal 0.30 - 0.50
Maximum 0.90

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PISTON AND PIN 1
7-9
A
Piston Pin 9
Diameter (mm)
Nominal 37.994 to 38.000
10
Maximum 37.900
B 11
Connecting Rod Bushing (assembled)
Diameter (mm)
Nominal 38.037 to 38.095 12
Maximum 38.140
13
C
Connecting Rod Bushing (housing)
Diameter (mm)
14
Nominal 41.455 to 41.480
D 15
Piston Pin to Connecting Rod Bushing Clearance
(mm)
Nominal 0.037 to 0.101 16
Maximum 0.150
17

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Visually check pistons, pins and connecting rods. Measure the clearance of the connecting rod bushing
housing to the piston pin. Inspect the connecting
rod, for damage, marks or wear. Damage on the
connecting rod stem (prole I) could cause cracks
and failure of the connecting rod.
Check piston pin for marks, scratches or excessive

7-10 wear.
Measure the diameter of the pin. Check pin taper and
out-of-roundness.
With the bushing assembled, measure the diameter
of the housing of the piston pin.
Transfer the piston pin measured to the bore gauge.

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Before performing the measurement of the bearings, 1

check the mark codes on the cap and on the
connecting rod. These codes indicate the parity
between connecting rod and cap, guaranteeing the
perfect seating of the bearing inserts in the assembly. 2
Loosen the bolts of the connecting rod, disassemble
the connecting rod bearing and cap.
3
5
With bearing inserts installed, measure the clearance
with the bore gauge.
6
7-11
Assemble the connecting rod cap tightening according

to the specication (without the bearing inserts) and
8
checking whit 2 points 90 distant each other starting
from 30 of the partition of the connecting rod,
checking out-of-roundness.
9
10
Check connecting rod torsion.

Maximum Torsion = 0.10 mm 11
12
13
Checking crankshaft to connecting rod clearance by

measuring the crankshaft diameter with micrometer 14
and transfer this measure to the bore gauge.
15
16
17

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Check connecting rod warping. Measure the clearance with the bore gauge turned
90 from the partition of the bearing inserts.
Maximum Warping = 0.03 mm
With the bore gauge at 90 from the partition of the

Loosen connecting rod cap, assembly and the bearing
connecting rod, reset the dial indicator gauge, remove
inserts with the aid of the expansion pin, assemble
one of the connecting rod bolts and measure its pre-
the connecting rod cap and tighten according to the
7-12 tension.
specication.
Pre tension: 0.06 - 0.12

Compare the clearances obtained from the crankpins
with the bore gauge.

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CONNECTING ROD BOLT TIGHTENING 1

One void at joint face per side is allowed. The void can not exceed 2 mm x 5 mm on the outer surface of the
connecting rod.
2
Connecting rod to piston assembly mark 5
7-13
Torque-Angle
Step 8
1st.............. 40 5 Nm
2nd ............ 80 2
Lmax = 59.20 mm 9
10
11
12
13
14
15
16
17

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Assembly
The CTOPW, CTOPK and CTOP marks must be

upward.
Check the ring grooves, pin housing and the skirt of

the piston. Check the clearance of the rings in the
piston grooves.
7-14 Assemble the piston rings.
Lubricate the liners and piston rings. When installing

Lubricate the piston pin, assemble the piston in the the piston / connecting rod set in the cylinder, remind
connecting rod, observing the correct positioning the correct assembly position.The arrow on the top of
between them. The arrow on the top of the piston must the piston must point toward the ywheel side.
be toward the side of the 3 holes of the connecting
rod.
Clean the backs of the bearing inserts and assemble
on the stem and on the connecting rod cap.

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Before installing the pistons in the cylinders, place the 1

end of the rings in the direction of the pin, displaced
120 to each other.
2
5
Observe the correct position to the crankshaft.
NOTE: The mark in the piston head must face to

the ynwheel side.
7-15
To assembly the connecting rod with body and cap, it
is necessary to observe the protuberance that shown
the correct position.
8
Install the piston ring compressor.
NOTE: Position the engine ywheel upward to

avoid contracting the oil injectors with the 9
connecting rods.
10
Lubricate the two inner halves of the bearing inserts.
11
12
13
14
Carefully push the piston info the cylinder. Never hit
directly on the top of the piston.
15
Position the connecting rod stem in the crankshaft
crankpin and install the connecting rod cap. Tighten
the bolts according to specication.
16
1st 40 5 N.m
2nd 80 2
17

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Check free side movement of the connecting rod.

Measure the side clearance.
7-16
Ensure the oil injector is aimed to the piston hole

otherwise it may cause excessive piston heat and
damage the engine.

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CYLINDER HEADS
1
Cylinder Heads
Specications ........................................................................................................................................... 8-2

2
General View .......................................................................................................................................... 8-11 3
Removal ................................................................................................................................................. 8-12

4
Disassembly ........................................................................................................................................... 8-15
Assembly ................................................................................................................................................ 8-19 5
Installation .............................................................................................................................................. 8-24

6
8-1
10
11
12
13
14
15
16
17

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Specications
VALVE SEATS
8-2
A
Housing (mm)
Standard
37.600 - 37.625
Intake
33.500 - 33.525
Exhaust
(B)
Outer (mm)
Standard
Intake 37.660 - 37.671
Exhaust 33.580 - 33.596
(C)
Seat Width (mm)
Standard
Intake 2.65 - 2.95
Exhaust 1.8 - 2.0
(D)
Seat Angle (mm)
Intake 60
Exhaust 45

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CYLINDER HEADS
VALVES 1
A
4
6
C B
7
D
8-3
A
9
Stem (mm)
Range 6.956 - 6.970
10
(B)
Head height (mm)
Intake 2.2 11
Exhaust 2.1
(C) 12
Surface width (mm)

Intake 2.65 - 2.95
13
Exhaust 1.8 - 2.0
(D)
14
(mm)
Intake 36.5 - 36.7
Exhaust 32.4 - 32.6 15
16
17

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VALVE GUIDES
8-4
A
After assembly (mm)
Nominal
Repair 7.000 - 7.022
Maximum
(B)
Outer (mm)
Nominal 12.028 - 12.039
(C)
Housing (mm)
Nominal 12.000 - 12.021
(D)
Clearance at the Stem (mm)
Nominal 0.03 - 0.066

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CYLINDER HEADS
GUIDE HEIGHT AND DISTANCE TO CYLINDER HEAD SURFACE 1
6
C
B 7
8-5
Valve Guide Height (A) (mm)

9
Intake and Exhaust 13.85 - 14.15
Distance to cylinder head surface (B) (mm)

10
Nominal
Intake 0.90 - 1.00
Exhaust 1.45 - 1.55
11
Guide height to cylinder head face (C) (mm)

Intake and Exhaust 45.0 12
13
14
15
16
17

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VALVES COURSE AND CLEARANCE
A
A
8-6
(A)
Course (mm)
Intake 10.00
Exhaust 10.00
(B)
Clearance (mm)
Intake
0.20 to 0.40
Exhaust

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CYLINDER HEADS
SPRING VALVES 1
The test is performed placing the springs on a special device and reading the closing force for two different
deections according to the following table.The intake valves springs are single (only one spring) and exhaust
valves springs are double. 2
Without Load C
5
8-7
Intake and exhaust valve spring

10
wire 3.50 mm
Load (kgf) Length (mm)
C 0.0 C 60.6 11
A 350 29 A 40.0
B 520 32 B 30.0
12
Special tool for spring measurement.
13
14
15
16
17

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VALVES DIAGRAM
8-8
Intake
Open 33 DPMS
Close 23 3 DPMI
Exhaust
Open 33 3 APMI
Close 1 3 DPMS

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CYLINDER HEADS
1
Visually check cylinder heads for leaks. Measure the outer diameter of the valve stem at 3
different points: 2
v Upper part;
v Central part; 3
v Lower part.
Check push rods. The push rod ends must not be

loose or cracked. Check for excessive wear. Inspect 7
the push rods for warping.
8-9
Measure the outer diameter of the valve guide.
10
11
12
Cylinder head surfaces must never be machined.
13
NOTE: Do not measure the diameter on the
lower part of the guide.
14
15
16
17

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Measure valve guide housing bore.

After measuring, install valve guides using the special
tool shown.
Check the rocker arm ends for excessive wear or

cracks in the shaft housing or in the contact area with
the valve stem.
Measure the rocker arm shaft out of roundness.
Measure the bore of the assembled valve guide. Check with the micrometer.
Measure the width of the valve contact surface.
8-10
Measure the shaft housing bore.

Measure the valve guide height in relation to the
Check rocker arm end axial clearance in the shafts
cylinder head.
and for deformities like roundness and taper.
Measure the width of the valve seat.

NOTE: Before beginning the assembly of
cylinder head set, all parts must be
cleaned well.

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CYLINDER HEADS
1
General View
8-11
10
11
12
13
14
15
16
17

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Removal
Remove the valve cover. Remove the water pipe mounting bolts.
Remove the O-Ring form the valve cover attaching
bolt and discard.
Remove the coolant outlet pipe.
Remove valve cover seal.

B A
8-12
A. Remove the outlet pipe to line bolt.
B. Remove the exhaust manifold bolts.

Remove the intake manifold.

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CYLINDER HEADS
Remove the nuts and disconnect the electrical wiring 1

from the cylinder head to the injector connectors.
Remove the bolt and disconnect external injector
nozzle connector. 2
8-13
10
11
12
13
14
15
16
17

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PROCEDURE TO REMOVE THE Remove the cylinder head.

INJECTION NOZZLE
1. Remove the clip, bridge and the two bolts.
2. Remove special step bolt.
3. Remove the holder clip bolt.
4. Remove the holder clip.
5. Remove the holder bridge.
6. Remove the high pressure connector.
Remove the push rods.

Remove the gaskets.
8-14
Remove the guide bushings.

Remove the fuel injector from the cylinder head.

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CYLINDER HEADS
1
Disassembly
Remove the M5X10 bolts. Remove the O-Ring.

2
Remove the lubrication pipe lock. To remove the balancer rocker arm shaft, use
the special tools MWM No. D700596C1 and 7
9.407.0.690.040.6.
8-15
10
11
Remove the balancer shaft lubrication pipe lock.

12
Remove the balancer shaft with the O-Ring and
discard the O-Ring.
13
14
15
16
17

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Remove the intake rocker arms. Remove the valve cap.
Remove the balancer shaft with the O-Ring and Install the special tool guide No. D7000598C1, as
discard the O-Ring. shown.
8-16
Remove the exhaust rocker arm. To compress and remove the valve spring locks, use
the special tool No. D7000598C1.
Install the special tool lever to the guide, as shown.

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CYLINDER HEADS
Compress the spring and remove the spring locks, Remove the valve retainers. 1
as shown.
Remove the lower spring discs.

6
Remove the spring upper discs.
8-17
10
Remove the 4 valves.

Remove the spring valves. 11
12
13
14
15
16
17

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Inspect the 9 sealing plugs for leaks, corrosion or

damage. Replace, if necessary.
8-18

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CYLINDER HEADS
1
Assembly
Apply loctite 648 or equivalent to the sealing surface.

2
6
Install the 4 valves.
Install the 9 sealing plugs. See the following illustration

for sealing cover locations. 7
8-19
10
11
Install the lower spring discs.
12
13
14
15
16
17

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Install the special tool No. D7000597C1 to slide the Using the special tool No. D7000597C1 and its spacer,
valve retainer. install the valve retainer in its housing.
To assure the valve retainer is fully tted onto the

stem of cylinder head valve guide, the special tool
spacer must reach the cylinder head surface. Using a
rubber hammer, apply light blows over the special tool
ensuring the spacer reachs its position.
8-20
Put the valve retainers in the shown position.
Install the spring valves.

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CYLINDER HEADS
Install the spring upper discs. Compress the spring and install the spring locks, as 1
shown.
Use the special tool guide No. D7000596C1, as 6

shown. Install the valve cap.
8-21
10
To compress and install the valve spring locks, use Install the exhaust rocker arm. 11
the special tool No. D7000598C1.
Install the special tool lever to the guide, as shown.
12
13
14
15
16
17

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Apply vaseline or clean oil engine to the new O-Ring. Install the intake rocker arms.
Install the O-Ring on its balancer shaft housing.
With the O-Ring previously installed, mount the

balancer shaft with the O-Ring to the outer side.
NOTE: When mounting the balancer shaft,
make sure that the O-Ring ts correctly,
to avoid any damage.
8-22
Install the O-Ring.
Install the balancer shaft with the new O-Ring to the

outer side.

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CYLINDER HEADS
Install the balancer shaft lubrication pipe. Tighten the bolt. 1

Torque: 4 to 6 N.m
Install the lubrication pipe lock.

6
8-23
10
Install the M5X10 bolts.

11
12
13
14
15
16
17

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Installation
Install the guide bushings. a Install the guide pin special tool No.
Two guides for each cylinder at opposite sides, as 9.407.0.690.030.4 to align the cylinder heads
shown. b Install the push rods.
A B
For the cylinder gasket installation, observe the TOP Install the special tool No. D7000595C1 to align the
position mark on the gasket that must be facing up. push rods.
8-24
The gasket must t to the guide bushings. Install the cylinder head.

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CYLINDER HEADS
Install a new O-Ring and sealing washer to the injector PROCEDURE TO INSTALL THE 1
and ensure it is installed in the correct position. INJECTION NOZZLE
1. Manually mount the clip, bridge and the two 2
bolts.
2. Apply a torque of 3 to 5 N.m to the special step

bolt. 3
3. Apply a torque of 1 to 1.5 N.m to the holder clip

bolt.
4
4. Relieve the torque from holder clip bolt to 0 N.m.
5. Apply a torque of 15 to 20 N.m to the high pressure 5

connector.
6. Apply a torque of 3 to 5 N.m to the holder clip bolt

(1St Stage). 6
Install the fuel injector in the cylinder head.
7. Apply a angle torque of 210 (7 to 13 N.m torque

window) to the holder clip bolt (2nd stage). 7
8. Apply a torque of 50 to 55 N.m to the high pressure

connector.
8-25
NOTE: This procedure is necessary to assure
the correct seating and alignment
of the injector and high pressure 9
connector.
10
Install the High pressure connector in its correct 11

position.
12
13
14
15
16
17

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Using a M4 nut, connect the electrical wires from the CYLINDER HEAD ALIGNMENT
cylinder head to the injector connectors. Apply the
torque to the nut. Install the water outlet pipe.
Torque: 1.25 to 1.75 N.m Torque: 10N.m (apply crossed torque from center
to the outside)
With a M6X12 bolt, tighten the external injection
nozzle connector, applying the correct torque.
Torque: 7.5 to 9.5 N.m
7 5 3 1 2 4 6 8
Install the intake manifold.

Torque: 10N.m (apply crossed torque from center to
the outside)
8-26 Install the exhaust manifold.
Torque: Exhaust Manifold - 10N.m (apply crossed
torque from center to the outside)
16 12 8 4 1 5 9 13
5 1 4 8 15 11 7 3 2 6 10 14
6 2 3 7
Apply a torque of 60 to 80 N.m to the exhaust manifold

crossing from center to the external side.
Apply a torque of 21 to 29 N.m to the water outlet pipe
crossing from center to the external side.
Remove the guide pin special tool No.
9.407.8.690.030.4.
Apply a torque of 17 to 23 N.m to the intake crossing
from center to the outside.

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CYLINDER HEADS
12 9 4 1 8 5 16 13
8-27
10 11 2 3 6 7 14 15
9
Tighten the bolts following the sequence above in three steps, for each cylinder, according to the specications
below:
10
Torque conventional and angular:
Pre-Torque - 40 + 5 Nm
Torque - 60 + 3 Nm 11
1st) 60 5
2nd) 60 5
12
3rd) 90 5
Torque Range - 130 to 260 Nm
13
14
15
16
17

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Adjust the valves, see specic procedure in this

section. Clearance
Use a new valve cover gasket, ensure its tted

correctly.
Adjustment Nut
Using a M6x60 bolt, install the valve cover applying

the correct torque.
Torque: 7.5 to 9.5 N.m
8-28
Intake Valve Adjustment
Adjustment clearance for admission and exhaust =

0.20 to 0.40 mm.
ADMISSION AND EXHAUST VALVES

ADJUSTMENT
Follow this procedure to assure the correct valve
clearance adjustment.
With the engine cold, turn the crankshaft until the
cylinder 4 intake and exhaust valves are closed,
ensuring that camshaft is not acting on the rocker arm
that will be adjusted.
Start the adjustment through the intake rocker arm

inserting the feeler gauge between the rocker arm
and valve cap, as shown.
Use the feeler gauge with 0.30 mm.

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Workshop Manual
CYLINDER HEADS
Using a screwdriver and a star key, tighten the Proceed with the same procedure from intake valves 1
adjustment bolt until the clearance between feeler and using the images shown for exhaust valves as
gauge, rocker arm and valve cap is remove. Make reference.
sure it is still possible to remove the feeler gauge.
2
Torque the adjustment bolt.
Torque of adjustment bolt: 20 to 26 N.m
3
NOTES: 1. Once concluded the adjustment nut for

the rst valve, its necessary to check
8-29
the second valve clearance. If the
clearance is correct follow the exhaust
valve adjustment.
9
2. If the second valve clearance found is
higher than the specication, lower the
rst valve in steps of 0.10 mm until the
second valve reachs the specication. 10
Exhaust Valve Adjustment

Adjustment clearance for admission and exhaust = 11
0.20 to 0.40 mm
12
13
14
15
16
17

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NOTES
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GEAR HOUSING
1
Gear Housing
Disassembly Notes .................................................................................................................................. 9-2

2
Specications ........................................................................................................................................... 9-5 3
Assembly .................................................................................................................................................. 9-9

4
9-1
10
11
12
13
14
15
16
17

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Disassembly Notes
1. Use a wrench to loosen the belt tensioner and Before disassembling the pulley, lock the ywheel and
remove the belt. crankshaft assembly with the special tool MWM No.
D7000600C1 to avoid loosening of the timing gear.
2. Remove the fan pulley bolts and then remove the

pulley. Remove the acessory pulley.
Loosen the bolts of crankshaft pulley.
Remove the crankshaft pulley and damper set.
9-2
3. Remove the pulley and tensioner support.
Remove the front seal.

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GEAR HOUSING
Remove the front cover mounting bolts and then 1

remove the cover.
6
Remove and replace the front cover gasket.
9-3
10
11
12
13
14
15
16
17

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Visually check damper and pulley(s).

Visually check gears. Check for signs of wear or
cracks on the base of the teeth.
If any defects are found, the gears must be replaced.
Measure the components of the gear housing
according to the following illustration:
9-4

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GEAR HOUSING
1
Specications

4
Idle gear bearing
Measurements mm
nominal 44.995 - 45.011 5
Gear clearances mm
Radial 0.013 - 0.075
Axial 0.100 - 0.240 6
8
9-3-2
9-5
10
11
12
13
14
15
16
17

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E Thrust ring (for intermediate ring)

E (mm) MWM nr.
3.41 - 3.45 9.610.0.433.004.4
3.46 - 3.50 9.610.0.433.005.4
3.52 - 3.56 9.610.0.433.006.4
Idle gear
hole mm
Without bushing 49.990 - 50.052
With bushing 45.024 - 45.076
Quantity of teeth 61
9-6
Crankshaft front gear
hole 59.994 - 60.019 mm


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GEAR HOUSING
High pressure pump gear

hole 25.000 - 25.033 mm 2
Camshaft front gear

(Camshaft to fuel pump driving gear) 6
hole 50.000 - 50.032 mm

7
9-7
Camshaft back gear 10

(Camshaft timing gear)
hole 52.00 - 52.03 mm
11
12
13
Air compressor gear
hole 30.00 - 30.033 mm
Quantity of teeth 32 14
15
16
17

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GEAR CLEARANCES
ID DENOMINATION
A Crankshaft gear
B Idle gear
C High pressure fuel pump gear
D Camshaft back gear
E Water pump gear
F Air compressor gear
G Oil pump gear
H Balancer unit driving gear (*)
I/J Balancer unit gears (*)
K Camshaft front gear
* For 4.12 engines
E
Z = 18
K
Z = 80
9-8
F
Z = 32
C
Z = 30
D
B Z = 72
Z = 61
A
Z = 36
G
Z = 26
H
Z = 76
I
J
Z = 38
Z = 38
Gears backlash 0.05-0.18 mm

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GEAR HOUSING
1
Assembly
Lock the engine with the special tool No. D7000600C1. Install the gear housing and tightening the xation
With the starter removed install the tool as indicated. bolts crosswise according to the specication. 2
Torque: 15 5 Nm
Install the idle bearing without the disk and the thrust 7
ring to perfectly center of the intermediary piece.
! Attention: The centering of the gear hou-
sing is important to guarantee 8
the specied clearances of the
distribution gears.
9-9
! Attention: When removing/installing the
water pump, lock the cankshaft
and timing gears. 10
Install the water pump, tightening according to the

specication. Be careful not to damage the gasket.
11
Torque: 20 5 Nm
12
Place the gear housing to block gasket.
13
14
15
16
17

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Install the oil pump, tightening according to the

specication. Be careful not to damage the gasket.
Torque: 20 5 Nm
Install lubrication pipes, tightening according to the

specication (electronic engine shown).
Torque: 5 5 Nm
9-10
Install the idle gear.
Install camshaft gear and tighten the bolts according

to the specication.
Torque:
1st: 15 to 25 Nm
2nd: 28 to 32 (torque range from 35 to 65 Nm)

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GEAR HOUSING
To assemble the gears in the correct timing position, AIR COMPRESSOR REPLACEMENT/ 1
use a screwdriver and make short turns. Observe the INSTALLATION
timing gear marks.
Remove the nut and its protector and install the gear
and its nut to the specied torque. 2
Torque: 210 to 250 Nm
6
Install the idle bearing bolts.
7
Install a new O-ring to the air compressor and apply
vaseline to avoid damages during installation.
9-11
10
Torque: 55 to 65 Nm 11
Install the thrust ring of the idle gear.The two grooves

must stay towards the side of the shaft. There are 3
different thickness of thrust rings order to guarantee 12
Install the bolts to the air compressor and tighten to
the axial clearance of the idle gear. the specied torque.
Torque: 40 to 50 Nm
13
14
15
16
17

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Install the bolts to the air compressor bracket.

Torque: 14 to 26 Nm A B
Tighten all mounting bolts of timing gears to the

specied torques. See special torques table in
Appendix A.
Install high pressure pump to the gear housing.
Measure the clearance between high pressure pump

timing gear and camshaft gear.
9-12
Tighten the mouting bolts.

Torque: 45 to 55 Nm
HIGH PRESSURE FUEL PUMP

PRE ASSEMBLY
a Check and replace the O-ring from fuel pump
ensuring that its in the correct position to avoid
damage during ange adapter assembly.
b Install the ange adapter to the fuel pump housing.

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GEAR HOUSING
Install the fuel pump gear and nut to the specied 1

torque.
Torque: 100 to 110 Nm
2
5
Clearance: 0.05 to 0.25 Nm
View of assembled gears set.

7
9-13
10
Place a new gasket on the front cover gear housing.
11
! Attention: v During engine operation there

12
should not be any gear noise.
v A noisy operation indicates
too much clearance between
gears or excessive wear on the 13
gear teeth.
Measure the clearance between both timing gears. 14

Clearance: 0.05 to 0.25 Nm
15
16
17

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Center the front cover with the special tool MWM nr. Place the new front seal and the special tool hub and
tighten as indicated placing the seal to its housing.
9.610.0.690.019.6.
Install the Oil Pressure Sensor.

Loosely install the bolts to allow the cover to be
adjusted. Install bafe plate and the front pulley with the damper.
Tighten the bolts crosswise to the specied torque.
Tighten the front cover bolts.
Torque: 1st: 100 10 Nm
Torque: 22 to 28 Nm
2nd: 275 15 Nm
9-14
Install the special tool MWM nr. 9.610.0.690.019.6.

Tighten the 2 bolts indicated to t the tool onto the
gear.

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GEAR HOUSING
Install the adapter, then the camshaft sensor and Install the acessory belt by loosing the tensioner with 1
apply the specied torque. a wrench.
Torque: 7.5 to 9.5 Nm
2
Install the pulley and tensioner support.

Torque: 17 to 23 Nm 7
9-15
10
11
Install the fan pulley. 12

Torque: 34 to 46 Nm
13
14
15
16
17

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NOTES
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9-16
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FLYWHEEL AND FLYWHEEL HOUSING
1
Flywheel and Flywheel Housing
Disassembly Notes ................................................................................................................................. 10-2

2
Assembly ................................................................................................................................................ 10-3
10-1
11
12
13
14
15
16
17

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Disassembly Notes
Before removing the ywheel, lock the engine PRE-ASSEMBLY INSPECTIONS

crankshaft with the special tool MWM nr.
9.610.0.690.026.4. Visually inspect the ywheel housing for cracks or
damage.
With the starter removed install the tool as indicated.
Visually inspect the ywheel and gear ring. Failures in

To remove the gear ring (1) from the ywheel (2), the starter motor gearing may be caused by broken
heat the gear at 180 C and hit it. gear ring or damage teeth.
Ensure if the sensor holes are clean and in good
condition.
10-2 2

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FLYWHEEL AND FLYWHEEL HOUSING
1
Assembly
To install the ring gear on the ywheel, rst heat it

up to a temperature around 250C and assembly it 2
paying attention that the teeth with the V shape face
to the starter starter gear side.
3
6
Install the rear seal with the special tool MWM No.
9.610.0.690.020.6.
Clean the housing and the engine block. Apply Loctite

515 on the contact surface between the engine block
8
and the housing, surrounding the bolt holes, as
illustrated.
10-3
11
With the engine locked, assembly the ywheel.Tighten
the crankshaft bolts according to the specication.
12
Torque: 1st: 90 to 110 Nm
2nd: 260 to 290 Nm
13
Install the housing on the engine block and tighten the
bolts according to the specication.
Torque: 85 to 115 N.m 14
15
16
17

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Check the side oscillation of the ywheel. Assembly the speed sensor and install to the specied
torque.
Maximum side oscillation = 0.30 mm
Torque: 7.5 to 9.5 Nm
Check the parallelism from ywheel to the housing.

Maximum parallelism = 0.20 mm
10-4
Check the concentricity of ywheel to the housing.

Maximum concentricity = 0.20 mm

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BALANCER UNIT
1
Balancer Unit
Remark ................................................................................................................................................... 11-2

2
Assembly ................................................................................................................................................ 11-4 3
10
11-1
12
13
14
15
16
17

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Remark
The balancer unit is an exclusive item of the 4

cylinders engines, especially for vehicle applications.
Its removal is not recommended and may cause
excessive vibration to the chassis, cab, accessories,
etc.
11-2

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BALANCER UNIT
1
Disassembly Notes
After removing the oil pan, carefully remove the oil

suction pipe. Be careful not to let the sealing ring fall 2
inside the suction gallery.
NOTE: Inspect and replace the O-ring, if 3

necessary.
6
Remove the dipstick mounting bolt.
8
Remove the deector of the balancer unit. Loosen the
four balancer mouting bolts and carefully remove it.
Keep the guided-pins on their positions.
9
10
11-3
Using a screwdriver detach the balancer from engine
housing and remove it.
12
13
Remove the four balancer to block mounting bolts.

14
15
16
17

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Assembly
Loosen the two bolts of the bearing caps corresponding Keeping bearing caps loosen, reinstall the mass
to the balancer unit and, with a rubber hammer. balancer. Observe the marks oo and 0 on the
balancer and crankshaft gears to ensure the proper
assembly timing.
Observe the marks 00 and 0 on the balancer gear

and on the crankshaft gear ring to ensure the timing
of assembly is correct. Place a 0.25 mm feeler gauge over the two shims/
axles from mass balancer (see the position indicated).
With it the bearing cap position determined, tighten
the two loose bearing cap mounting bolts.
Remove the balancer unit applying the specied
torque to the bearing cap which the adjustment was
done.
Torque: 1st: 50 5 Nm
2nd: 155 5
Torque range: 170 to 282 Nm
11-4
AXIAL CLEARANCE PROCEDURE

Loosen the bolts of the bearing caps correspondent
to the balancer unit and, with a rubber hammer.

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BALANCER UNIT
Reinstall the balancer unit without the feeler gauge. 1

Tighten to the specied torque.
6
Install a dial indicator and adaptors, as shown, to
measure the axial clearance in the balancer unit
shafts.
7
Mount the balancer unit with the shim observing

the timing gears. Perform the measurements and 10
changing the shim as necessary until the correct axial
clearance is obtained.
11-5
Clearance specication: 0.10 to 0.30 mm

If necessary, change the shim to adjust the clearance. 12
There are three thicknesses of shims available:
9.208.0.433.002.4 - 3.35 to 3.40 mm (3.4)
13
9.226.0.433.001.4 - 3.45 to 3.50 mm (3.5)
6.208.0.433.003.4 - 3.55 to 3.60 mm (3.6)
14
15
16
17

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Radial Clearance Procedure

Install a dial indicator and adaptors, as shown.
Measure the backlash between the balancer and
crankshaft gears.
Clearance specication: 0.05 to 0.18 mm

Determine the necessary amont of shims needed
between the balancer and bearing caps considering
the shims are available with thickness of 0.1mm.
Use the same amount of shims on the two bearings to
keep the balancer alignment.
Remove the balancer and, with the chosen bearing
thrust rings, install the correct shims on the bearing
cap guide-pins.
11-6

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LUBRICATION SYSTEM
1
Lubrication System
Lubrication System ................................................................................................................................. 12-2

2
Oil System Module (Ecological Filter)..................................................................................................... 12-4
Disassembly Notes ................................................................................................................................. 12-5 3
Removal ................................................................................................................................................. 12-6

4
Installation .............................................................................................................................................. 12-8
Assembly .............................................................................................................................................. 12-10

6
10
11
12-1
13
14
15
16
17

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Lubrication System
OIL LUBRICATION CIRCUIT
12-2

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LUBRICATION SYSTEM
10
11
12-3
13
14
15
16
17

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Oil System Module (Ecological Filter)
Oil system module (Ecological lter module)

12-4 1. Oil pressure regulator valve
2. Oil cooler gasket
3. Oil cooler
6. Filter element
7. Cover
8. Mounting bolt
9. Mounting bolt

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LUBRICATION SYSTEM
1
Disassembly Notes
Remove oil cooler by removing only the hexagonal

bolts. 2
During the removal of oil cooler, do not remove the

Torx bolts, to avoid the mixture of oil into the cooling
system. 3
The Torx bolts require a special driver for removal

and, if necessary, can only be removed when the oil
cooler is removed from the engine block. 4
1 8 6
4 6
7
3 7 2
5 9 8
10
11
12-5
13
14
15
16
17

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Removal
OIL SYSTEM MODULE 4. Remove all oil cooler to block mounting bolts.

possible death, or damage to
the engine or vehicle, read all
safety instructions in the Safety 1 8 6
Information section of this 4
manual.
! Warning: To avoid serious personal injury, 3 7 2

the engine or vehicle, make
sure the transmission is in 5 9
and wheels are blocked before
doing diagnostic or service 5. Remove the oil module and gasket. Discard the
procedures on the engine or gasket.
vehicle.
! Warning: To avoid serious personal injury

or possibly death, do not remove
the oil system module from a hot
engine. Wait until engine cools
down before removing.
1. Remove the drain plug, and drain the oil engine.

Discard the washer.
2. Remove the oil lter element and cover. See

specic procedure in engine preparation section.
3. Using the tool indicated, remove the clamp and

the hose.
12-6

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LUBRICATION SYSTEM
SEPARATING THE OIL COOLER FROM 1

OIL COOLER HOUSING ! Attention: To avoid engine damage, do not
attempt to clean the assembled
1. Remove the four allen mounting bolts. oil system module in solvent.
2
Solvent will be trapped in
the oil cooler, regulator valve
assembly, and oil thermal valve
assembly. Failure to follow this 3
caution could result in engine
damage.
The following items should be removed: 4
v Oil cooler
5
The following items should NOT be removed:
v Oil pressure regulator valve assembly;
v Remaining oil housing plugs. 6
The oil system module housing can be cleaned in

solvent and blown dry with clean ltered compressed
! Attention: To avoid engine damage, air. 7
when removing the oil cooler

from its base housing, do not 1. Remove any gaskets remaining on the oil housing,
use excessive force against cooler and engine block to cooler housing. 8
the aluminum cooler plate to
separate from base. Do not 2. Immerse the disassembled oil cooler housing into
apply any force to the oil cooler a suitable solvent.
9
ns.
3. Flush and drain the oil cooler housing to remove
2. Using a small rubber hammer, apply just enough any residue. Dry all components with ltered
force to break the coolant and oil gasket bonds. compressed air. 10
3. Separate the oil cooler from the oil cooler housing.

Remove and discard the two gaskets.
11
Removing the Oil Pressure Regulator Valve
(Only remove in case of failure)
12-7
1. Using a wrench, remove the oil pressure valve
from the oil system module.
Replace the regulator valve assembly. 13
CLEANING AND INSPECTION 14
Cleaning the Oil System Module

4. Check the oil cooler housing for blocked orices
15
and damaged threads. Replace oil cooler housing
! Attention: To avoid engine damage, the oil if necessary.
cooler must be replaced if there
was a bearing failure. Debris 5. Remove any debris that may be blocking the lter 16
from a bearing failure cannot be bypass valve.
removed from the oil cooler.
17

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Installation
OIL SYSTEM MODULE AND OIL COOLER

1. Place two new gaskets onto the oil cooler. Install the four allen mounting bolts and tighten to the torque of
25 to 30 N.m.
2. Place a new oil module gasket and mount the oil module onto the engine block.
3. Install the oil cooler to block bolts torque to 22 to 28 N.m.
4. Install the clamp and the hose to the oil module.
5. Install the oil element and cover. See specic procedure in Engine Preparation section.
12-8

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LUBRICATION SYSTEM
1
Clean and check the oil suction pipe for cracks or Visually check the drive gear of the oil pump, the
inner part of the housing and the rotor, for damage or 2
blockages.
excessive wear.
6
1026
Change the sealing ring of the oil suction pipe. 7
10
11
Remove the oil pump. 12-9
13
14
15
16
17

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Assembly
Carefully install the oil suction pipe being carefully not Clean the sealing surfaces and carefully assembly,
to let the sealing ring fall inside the suction gallery. and reinstall the oil cooler.Tighten the hexagonal
bolts crosswise to the specied torque.
Install a new oil pan gasket. The gasket must be
installed without glues or adhesives. Torque: 22 to 28 Nm
1 8 6
4
3 7 2
5 9
Then tighten again using the same torque

(22 to 28 Nm) and the sequence shown.
4 3 2
1
5 9 8
6 7
Assembly the oil pan tightening the bolts from the
edges, crosswise to the specied torque.
12-10
Torque: 25 5 Nm (for bolts and nuts) NOTE: This procedure is important to avoid oil
10 2 Nm (for studs) leaks from oil module to block surface.

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ENGINE ELECTRICAL
1
Engine Electrical
Sensor Identication ............................................................................................................................... 13-2

2
10
11
12
13-1
14
15
16
17

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Sensor Identication
! Warning: To avoid serious personal injury, possible death, or damage to the engine or vehicle, read
all safety instructions in the Safety Information section of this manual.
! Warning: To avoid serious personal injury, possible death, or damage to the engine or vehicle, make
sure the transmission is in neutral, parking brake is set, and wheels are blocked before
doing diagnostic or service procedures on the engine or vehicle.
NOTE: For information regarding the removal or installation of adjacent components, refer to the following
service procedures located in other sections of this manual:
This section should be used for sensor identication and location. For a more detailed description of electrical
sensors, see Engine and Vehicle Sensors in the Introduction in this manual, or the diagnostic manual.
ENGINE SENSORS
Camshaft Position (CMP) Sensor
The camshaft position sensor is a magnetic type sensor used to sense camshaft position. It responds to a rotating
plate actuator mounted onto the back of the camshaft gear. The CMP sensor is installed in the front cover, close
to the high pressure fuel pump.
When ordering this sensor for replacement, make sure that the sensor you receive is the same one pictured.
Crankshaft Position Sensor (CKP)
13-2
The CKP sensor is a magnetic pickup sensor used to sense crankshaft position. The CKP sensor is installed on
the top left of the ywheel housing.

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ENGINE ELECTRICAL
Engine Oil Pressure (EOP) Sensor 1
7
The EOP consists of a Ceramic Capacitive Sensing Element (CSE), custom ASIC signal conditioning and a
standard housing with integral connector. The sensor provides a ratiometric analog voltage output proportional to
the applied pressure and supply voltage.
8
This sensor measures the absolute pressure.
The EOP sensor is installed in the top right of the housing gear, close to the air compressor.
Installation: Place the EOP sensor with a new washer. Using a 12mm wrench apply the torque of 25 to 29N.m. 9
Test of component:
- Voltage signal from pin 2 to ground 10
NOTE: Tests below must be done with U supply of 5 Volts.
Engine Coolant Temperature (ECT) Sensor 11
12
13-3
14
15
16
The ECT sensor is a thermistor type sensor.

The ECT sensor is installed in the EGR cooler inlet pipe located on the right rear side of the engine. 17

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Manifold Air Pressure and Temperature (TMAP) Sensor
The TMAP sensor measures the absolute air pressure and temperature.
This sensor consists of a piezo-resistive pressure sensor element and the temperature sensor element is an NTC-
resistor in a suitable circuitry for signal amplication and temperature compensation integrated on a silicon chip.
This component is marked as EGR that means it is specially developed to operate under air stream after inlet of
13-4 exhaust gas recirculation.
The TMAP sensor is installed onto the air intake manifold, located in the left engine side.
Installation: The O-ring will seal the sensor from atmosphere only a thin lm of light engine oil (5W20) is needed
as lubricant. Dont use silicone based lubricants.

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ENGINE ELECTRICAL
Fuel Pressure (EFP) Sensor - Rail 1
The EFP sensor is a variable capacitance sensor. The EFP sensor is installed in the fuel rail.
9
Barometric Absolute Pressure (BAP) Sensor
10
11
12
13-5
14
The BAP sensor is a variable capacitance sensor. The BAP sensor is located in the ECM.
15
16
17

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Turbo Control PWM Valve
The Turbo control receives PWM pulses from ECM and actuates a wastegate valve to control turbo pressure via
a pneumatic system.
EGR Control Valve
The EGR valve receives PWM pulses from ECM and actuates a uni-directional cylinder via a pneumatic system
which actuates an exhaust ap to control the recirculation exhaust gases.
Proportional Valve for Exhaust Gas Recirculation
13-6
A uni-directional cylinder which actuates an exhaust ap is activated by the proportional valve in order to recirculate
exhaust gases for combustion.

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ENGINE ELECTRICAL
Rail Pressure Valve 1
The Fuel pressure valve actuator is mounted in the High Pressure Fuel Pump.
The Rail Pressure limiter valve is installed in the Fuel Rail. 7
Electronic Control Module (ECM)

8
10
11
12
13-7
14
15
16
17

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Fuel Injectors
VEHICLE SENSORS
Throttle Position Sensor (TPS)
Vehicle Speed Sensor (VSS)
13-8
The VSS sensor is designed to measure the vehicle speed. It is located in the vehicle, see vehicle workshop
manual for further information.

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ENGINE ELECTRICAL
Water In Fuel (WIF) Sensor 1
The Water in Fuel sensor detects water in the fuel.

The WIF sensor is installed at the base of the fuel lter housing. 6
Engine Coolant Level (ECL) Sensor

7
10
11
The ECL sensor is a variable capacitance sensor.
The ECL sensor is located in the vehicle. See vehicle workshop manual for further information.
12
Clutch Pedal Sensor (CPS)
13-9
14
15
16
The CPS sensor is a normally open type switch. The CPS sensor is located in the clutch pedal assembly. See
vehicle workshop manual for further information. 17

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Brake Pedal Sensor (BPS)
Engine Brake Solenoid
13-10

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COOLING SYSTEM
1
Cooling System
Cooling System ...................................................................................................................................... 14-2

2
Inspections ............................................................................................................................................. 14-4 3
Thermostat Test Procedure .................................................................................................................... 14-5

4
Assembly ................................................................................................................................................ 14-6
Water Pipe .............................................................................................................................................. 14-7 5
Installation .............................................................................................................................................. 14-8

6
10
11
12
13
14-1
15
16
17

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Cooling System
COOLING CIRCUIT
14-2
Thermostat opened valve

Thermostat closed valve

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COOLING SYSTEM
1
Disassembly Notes
WATER PUMP
2
! Caution: Never perform a service on

any component of the cooling 3
system while the engine is
running.
4
! Caution: Avoid touching the components
of the cooling system soon after
the operation of the engine, this
can cause burns. 5
! Caution: The cooling uid can spill and

cause burns if the radiator cap
6
is removed while the system is Reinstall the mounting bolts in the other holes, as
still hot, let the system to cool indicated, and then tighten the bolts to remove the
down. Remove the radiator cap, water pump from its housing.
turn the cap to the rst stage 7
and ensure all the pressure is
relieved.
To access the water pump, remove the front cover 8

and camshaft gear, see gear housing removal in the
section 9.
9
10
11
12
13
Remove the water pump mounting bolts.

14-3
15
16
17

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Inspections
Inspect the water pump housing and rotor.
! Attention: When removing/installing the

water pump, lock the cankshaft
and timing gears.
Install the water pump, tightening according to the

specication. Be careful not to damage the sealing
ring.
Torque: 20 5 Nm
14-4 Check the inspection hole located on the left side of

the engine block (seen by the ywheel side). Signs
of water or oil leakage, are indication that there are
leaks at the water pump or through the sealing rings.
Inspect and replace, if necessary.

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COOLING SYSTEM
1
Thermostat Test Procedure
Test the thermostat and check its operation according to the procedure below:
2
v Place the thermostat in a recipient and ll in with water until the valve is totally immersed;
v Position a dial indicator gauge on the stem of the thermostat and adjust a pre-load of 1 mm;
3
v Install a thermometer with a scale of 0-100C immersed into the water;
v Gradually heat the water up;

4
v Take note of the temperatures at the beginning and nal opening of the thermostat (beginning and end of the
dial indicator gauge movement), and the nal total movement of the dial indicator gauge (fully open);
v Compare the values found with the table. Change the thermostat if the temperature of the beginning of opening 5
is out of the specied values and / or the total operational movement is below specied.
10
11
12
13
14-5
15
16
17

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Assembly
THERMOSTAT
The thermostat valve is part of valve housing and can

not be removed from its assembly.
When needed, replace the thermostat and housing
assembly.
! Attention: Never operate the engine

without the thermostat, because
the engine will not reach the
correct operating temperature.
Always install new sealing rings

on the replaced component.
14-6

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COOLING SYSTEM
1
Water Pipe
REMOVAL
2
1. Remove EGR cooler assembly. See specic
procedure in this service manual for further
information. 3
B A
4
2. Coolant pipe removal: 8

a Remove the coolant tube to air compressor
outlet pipe hollow bolt.
b Remove the mounting bolts. 9
3. Remove the coolant pipe and discard the

O-Rings.
10
CLEANING
1. Clean the mating surfaces between the coolant 11
pipe and cylinder heads.
2. Inspect coolant pipe for damage, cracks, and
wear. Replace the pipe as necessary. 12
3. Clean coolant pipe thoroughly with a suitable
non-caustic solvent.
4. After cleaning, blow dry using ltered compressed 13
air.
14-7
15
16
17

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Installation
! Attention: To avoid engine damage, do not attempt to grind or machine the coolant pipe to compensate
for a warped condition.
1. Install new O-Rings onto the coolant pipe.
7 5 3 1 2 4 6 8
2. Install coolant pipe and its bolts. Bolts to the torque and sequence shown.
Torque: 25 4 Nm
3. Thread the coolant tube to air compressor outlet pipe hollow bolt to the torque of 20 6 Nm.
4. Install EGR cooler assembly. See specic procedure in this service manual for further information.
! Attention: For the best performance of the cooling system, ensure that all the water passages inside
the engine are properly lled up. The aeration of the cooling system can cause high
temperature spots on the cylinder heads and engine block surfaces, and result in cracks in
those components and burns on cylinder head gaskets.
14-8

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FUEL INJECTION SYSTEM
1
Fuel Injection System
Common Rail Modulated Pressure Fuel Injection System ..................................................................... 15-3

2
Common Rail Harness ........................................................................................................................... 15-4
CP 3.3 Pump Rear Part View .............................................................................................................. 15-5 3
Removal ................................................................................................................................................. 15-7

4
Installation .............................................................................................................................................. 15-9
Fuel High-Pressure Pump .................................................................................................................... 15-11 5
Electronic Control Module (ECM) ......................................................................................................... 15-13

6
Installation ............................................................................................................................................ 15-15
Deaeration of Low Pressure System .................................................................................................... 15-16

7
10
11
12
13
14
15-1
16
17

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! Caution: v Never perform service on any component of the system while the engine is running.
v Do not smoke while is servicing the fuel system or any other system of the engine.
v Avoid contact with electrical components.
v Always check tanks, piping, hoses and other components of the fuel system for leaks.
v When the engine is in operation, do not touch the injector connectors. The high voltage
can cause serious injuries.
v Do not bleed the fuel injection system with the engine in operation. The high pressure in
the system can cause serious injuries.
v Under no circumstances can the ECM be disassembled for service. Only the Bosch
authorized service center can check or repair this component. Unauthorized repair will
result in component and engine warranty being voided.
v The solenoids installed on the Rail can only be disassembled if operational problems
show up on the scanner. Otherwise it must not be disassembled under any circumstances.
v Before connecting the harness to the ECM, make sure that the battery cables are
disconnected.
v Repair to the injection system only can be performed after waiting 30 seconds after engine
is stopped, this waiting time assures the bleed down of the pressure in the Rail.
15-2

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1
Common Rail Modulated Pressure Fuel Injection System
10
11
12
13
14
15-3
16
17

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Common Rail Harness
15-4

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1
CP 3.3 Pump Rear Part View
2
B
E
D 3
A
F 4
C
5
10
A Camshaft position sensor (CMP)
B Rail pressure control valve (M-PROMPT)

11
C Fuel inlet from the tank to gear lift pump
D Fuel outlet from gear lift pump to lter 12
E Fuel outlet to the rail (High Pressure)
F Fuel inlet (from lter) 13
14
15-5
16
17

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BCP 3.3 IDENTIFICATION PLATE 1. Drain the fuel lter assembly of all water and
fuel into a suitable container before removing
The identication plate of the high-pressure fuel assembly.
pump is important in the tracking of the component
and indication of the manufacturing plant.
Pump Nr.
Manufacturing Engine Pump

Date Model Model
FUEL RAIL

Information section of this
manual.

sure the transmission is in
procedures on engine or vehicle.

the engine or vehicle, comply
15-6
with the following when draining
fuel:
s $ONOTSMOKE
s +EEPAWAYFROMOPENmAMES
and sparks.

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1
Removal
1. Disconnect wire bracket from front side engine. 4. Disconnect all fuel injector connectors.
2
2. Detach the EGR control valve connector. 5. Lift and remove the wiring from the engine.
7
6. Air distributor pipe removal:
a To release the pipe, use a screwdriver to push
the metallic ring as shown in the gure;
8
b while press the ring, pull the pipe out;
c Release the two pipes from air distributor.
9
10
B
11
3. Detach the connector from wastegate control

valve. 12
A
13
14
15-7
16
17

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7. For pipe to PWM valve removal, unscrew the nut 11. Using the tool shown, remove the clamp from the
(shown in a ) and release the two pipe connectors fuel return hose.
(shown in b ).
B A
12. Fuel pipe connectors and bracket removal:
8. Unscrew and remove the two mounting bolts.
a. unscrew all fuel rail to injector connectors;
9. Remove the PWM valve assembly.
b. unscrew the high pressure pump to fuel rail
pipe connectors from both sides.
c. unscrew and remove the fuel rail bracket
mounting bolts;
! Attention: Discard all fuel pipes after

removal.
13. Remove the fuel rail assembly using the sequence

A, B and C shown.
A C
10. Remove the pipe bracket mounting bolt.
15-8

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1
Installation
6. Install the PWM valve assembly. Mount the two

! Warning: Always use new fuel rail pipes. bolts and the torque to 17 to 23 Nm. 2
To avoid serious personal injury,
the fuel system or engine do not 3
re-use the fuel rail pipes.
1. Install the fuel rail bracket onto the engine block.

4
2. Using new fuel pipes. Install the fuel rail to injector
pipes and torque to 27 to 33 N.m a .
3. Using new fuel pipe. Install the high pressure 5
pump to fuel rail pipe and torque to 30 to
33 N.m b .
6
A B
7. Install the pipe to PWM valve connector by 7

pushing the connector until a Click is heard.
8. Air distributor pipe mounting:
8
A. To install the pipe, push the metallic ring as
shown in the gure;
B. While pressing the ring, push the pipe in until
9
the pipe bottoms end;
C. Mount the two pipes from air distributor.
10
4. Install the clamp from fuel return hose.
5. Thread the pipe bracket mounting bolt. Torque to 11

23 to 27 N.m.
B
12
13
A
14
15-9
16
17

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Observe the pipe connections.
9. Mount the wiring harness and connectors:

Connect all fuel injector connectors.
Attach the connector from wastegate control
valve.
Attach the connector from EGR control valve.
15-10 Connect the wire bracket from the front side
engine. Torque to 7 to 9 N.m.

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1
Fuel High-Pressure Pump
REMOVAL The removal must be done with caution. The friction

between the o-ring and the housing of the pump can 2
After loosening and removing the pipes, loosen the make it difcult to remove. After removal, put it in a
high pressure pump bolts on the intermediary piece. safe place to prevent demage.
3
! Attention: v Any disassembly of the high
pressure pump will void the
warranty. 4
v If it is necessary to repair the

pump, it must to be sent to
on authorized Bosch service 5
center.
INSTALLATION 6
Install a new o-ring on the high pressure pump. Clean
the area and put a layer of vaseline on the contact
area of the o-ring.
7
Loosen and remove the nut of the high pressure
pump gear by the side of the gearing cover. Remove
the gear. 8
10
11
Install high pressure pump. Tighten carefully ensuring

the o-ring doesnt slip or get damaged. Position the 12
pump with the bolts until it touches the mounting face
of the intermediary piece then tighten to the specied
After removing the gear, loosen the bolts and remove torque.
the high pressure pump. 13
Ensure if there is a good seat of the pump on the
intermediary piece.
Torque to 40 6 Nm. 14
15-11
16
17

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! Attention: v The cone of the high pressure

pump shaft and the gear must
be clean and free of oil and
grease before the installation.
Cleaning can be done using:
test benzene, ethyl using,
glycol or isopropanol.
v The high-pressure pump,

is lubricated by the fuel.
Before the rst start, ll
approximately 60 ml of fuel
to lubricate the inner parts.
For the rst lling, a electric
fuel pump can be used with
After installing the pump, position the gear on the
minimum pressure of 2 bar
shaft and assembly. Note there is not timing on this
and 4 bar maximum.
gear to the pump shaft and does not need cotter for
positioning.
Position gear washer and xation nut and apply the
specied torque.
The protective caps must be removed only
immediately before the piping is installed in order to
avoid contamination.
15-12

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1
Electronic Control Module (ECM)
REMOVAL
2
Place an oil drip pan to collect any fuel that comes out
of the ECM cooler during removal procedure.
Remove the two ECM electrical connectors: 3
v pull out the connector lift lock;
v remove the connector.
4
6
Remove the ECM to engine support mounting nuts
and then remove the ECM assembly.
Drain the fuel from ECM cooler and remove the wiring
bracket: 9
v loosen the ECM to cooler mounting bolts to drain

the remaining fuel;
10
v remove the wiring bracket mounting bolts and
then remove the bracket.
11
With the ECM assembly removed, loosen the ECM to
cooler mounting bolts.
12
13
14
15-13
Remove the fuel inlet and outlet pipe connectors.
v push the connector lock;
16
v pull off the connector.
17

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Detach the ECM module and cooler. Discard and

replace the O-Ring.
INSPECTION
Check visually the connectors pins and wiring for
corrosion, dirt, damaged pins and water ingress.
Clean or replace the components, as necessary.
! Attention: Opening the ECM may cause

damage to its internal components.
15-14

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1
Installation
Replace the O-Ring and install the ECM module and

cooler. 2
Tighten the bolts to a torque of 7 to 9 N.m.
6
Install the wiring bracket mounting bolts.
Torque the bracket bolts to 25 to 35 N.m.
7
Install the 2 ECM electrical connectors:
Install the ECM to engine support mounting nuts.
v Relieve the connector lock, as shown in A. Then
Torque: 22 to 28 N.m install the male to the female connector;
8
v Lock the connector, as shown in B.
A B 9
10
11
12
Install the fuel inlet and outlet pipe connectors.

13
v push the connector lock;
v push in the connector.
14
15-15
16
17

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Deaeration of Low Pressure System
After perfoming maintenance of the injection system or in the event the engine runs out of fuel, bleed the air from
the low pressure system with the manual pump and start the engine.
If the engine quits, repeat the procedure and start the engine again.
After the engine is started, leave it running for a few minutes, at idle.
! Attention: This procedure must be used on:

v Engine run out of fuel;
v Maintenance (ex: replacement of lters / pipes).
15-16

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INTAKE, EXHAUST AND TURBOCHARGER SYSTEM
1
Intake, Exhaust and Turbocharger System
Air Intake Manifold .................................................................................................................................. 16-2

2
Removal ................................................................................................................................................. 16-3
Installation .............................................................................................................................................. 16-4 3
Turbocharger .......................................................................................................................................... 16-5

4
Exhaust Manifold .................................................................................................................................... 16-7
EGR Cooler ............................................................................................................................................ 16-9 5
10
11
12
13
14
15
16-1
17

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Air Intake Manifold
! Warning: To avoid serious personal injury, possible death, or damage to the engine or vehicle, read all
safety instructions in the Safety Information section of this manual.
! Warning: To avoid serious personal injury, possible death, or damage to the engine or vehicle, make
sure the transmission is in neutral, parking brake is set, and wheels are blocked before doing
diagnostic or service procedures on engine or vehicle.
! Warning: To avoid serious personal injury, possible death, or damage to the engine or vehicle, comply
with the following when draining fuel:
s $ONOTSMOKE
s +EEPAWAYFROMOPENmAMESANDSPARKS
16-2

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1
Removal
1. Remove the fuel rail. See specic procedure in

this service manual for further information. 2
2. Remove the EGR and wastegate air pipe bracket 7

mounting bolt.
3. Remove the air mixer mounting bolts.

8
16 12 8 4 1 5 9 13
10
15 11 7 3 2 6 10 14
11
12
4. Remove the manifold mounting bolts.

13
5. Lay down the intake manifold and then remove it,
as shown.
14
$ISCARDMANIFOLDGASKETSANDREMOVEALLGASKETS
remaining over the cylinder heads and intake
manifolds holes.
15
16-3
17

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Installation
EXHAUST MANIFOLD, EGR COOLER,

! Attention: To avoid engine damage, do not TURBOCHARGER AND WATER PIPE
attempt to grind or machine the
intake manifold to compensate
for a warped condition. ! Warning: To avoid serious personal injury,
1. Clean manifold inlet thoroughly with a suitable the engine or vehicle, read all
non-caustic solvent. safety instructions in the Safety
2. After cleaning, blow dry using ltered compressed manual.
air.
3. Check manifold for cracks and damage. Replace ! Warning: To avoid serious personal injury,
intake manifold as necessary.
sure the transmission is in
ALIGNING INTAKE GASKETS TO
neutral, parking brake is set, and
MANIFOLD wheels are blocked before doing
diagnostic or service procedures
1. Insert an intake manifold bolt into each end of the
on engine or vehicle.
intake manifold (both top holes).
NOTE: For information regarding the removal
2. Place intake manifold gasket over these two bolts or installation of adjacent components,
to ensure proper alignment between the manifold refer to the following service procedures
and gasket. located in other sections of this
manual:
3. Place all manifold bolts into bolt hole mounting
nger tight, in their correct positions. v Turbo Wastegate;
v Intake Air Elbow;
v EGR Valve and Sensor;
v EGR Cooler;
v Air Compressor;
16 12 8 4 1 5 9 13
v Hidraulic Pump;
v Coolant Pipe;
15 11 7 3 2 6 10 14 v Exhaust Manifold.
4. Torque intake manifold bolts to the specied value

and according to the sequence.
Torque through 20 3 Nm.
5. Assembly the remaining components using the

16-4 reversal order of removal procedure.

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1
Turbocharger
REMOVAL 3. Remove the elbow and discard its O-Ring after

removal. 2

possible death, or damage to 3
manual. 4
! Warning: To avoid serious personal injury, 5

the engine or vehicle, make sure
that the engine has cooled down
sufciently before attempting to 6
remove turbocharger assembly.
! 4. Remove the hollow bolt from oil inlet tube. 7

Warning: To avoid serious personal injury,
sure to disconnect the battery 8
cables from the battery.
Failure to remove the battery
ground cable could cause an 9
electrical arc while removing the
turbocharger.
1. Oil inlet tube and elbow removal: 10

a Remove the oil inlet tube hollow bolt and its
TWOWASHERS$ISCARDTHEWASHERS
11
b Remove the elbow to turbocharger clamp.
A 5. Using the tool illustrated, remove the clamp from 12

outlet pipe.
13
14
B
15
2. Remove the elbow support bracket bolt. 16-5
17

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6. Release the clamp and remove the wastegate 4. Clean off any remaining gasket material from the
actuator hose. turbine housing and exhaust manifold mounting
surfaces.
INSTALLATION
7. Remove the turbocharger mounting nuts (four

nuts).
1. Place a new outlet pipe mounting gasket onto

turbocharger.
2. Place four new mounting nuts to the turbocharger,

new O-Ring onto elbow each end of the turbo oil
drain tube and lubricate with clean engine oil.
3. Mount turbocharger assembly onto exhaust

manifold and thread four new mounting nuts onto
the top studs and leave loose.
4. Install the hose and its clamp to the wastegate

actuator.
5. Before installing the oil inlet tube, lubricate the

8. Remove the turbocharger assembly.
turbocharger axle by applying new oil engine
$ISCARD TURBO MOUNTING GASKET WASHERS AND through the oil inlet hole.
mounting nuts.
NOTE: After removal, cover the turbocharger

! Attention: This procedure is important
holes to avoid contamination which to avoid damages by lack of
could damage its internal components. turbo lubrication during the rst
engine start.
CLEANING 6. Install oil inlet tube into turbocharger upper side

placing the four new washers. Torque the hollow
Turbocharger and Related Parts bolt to 20 to 30 N.m.
1. Use soap and water to clean piping between 7. Install outlet pipe to the lower turbocharger side.
turbocharger and air cleaner assembly. Use Torque to 10 to 14 N.m.
ltered compressed air to dry all piping.
8. Torque all four turbocharger mounting nut. Torque
2. Use ltered compressed air to clean the air inlet to 60 to 80 N.m.
piping and connecting hoses.
16-6 9. Place a new O-Ring on the elbow and mount it
3. Use a suitable solvent and a nylon brush to clean onto the turbocharger using the clamp.
the oil inlet tube and oil drain tube. Use ltered
compressed air to dry the tubes. Replace any 10. Install the elbow bracket. Torque to 20 to 30 N.m.
damaged tubes.

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1
Exhaust Manifold
REMOVAL
2
1. Remove the turbocharger assembly. See removal
procedure in this section.
3
C
6
4. Remove the exhaust manifold mounting nuts and
discard them.
B
7
CLEANING AND INSPECTION
2. Exhaust and manifold pipe bracket bolt removal:
a. Remove the lower EGR to manifold pipe 1. Remove the gaskets remaining on the manifold
holes and clean exhaust manifold thoroughly with 8
nuts.
a suitable non-caustic solvent. Scrape off excess
b. Remove the turbo pipe actuator bracket bolt. scale and rust from manifold surfaces.
c. Remove the upper EGR to turbo pipe 9
mounting bolts. 2. After cleaning, blow dry using ltered compressed
air.
3. Check manifold for cracks and damage. Replace 10

the manifold as necessary.
4. Check for warpage of the manifold and engine: 11

Install the exhaust manifold without the gasket to
a cleaned cylinder head mating surface, applie
a low level torque to the bolts enough to provide 12
contact between the two surfaces, and measure
the gap between the mating surfaces using a
0.25mm feeler gauge. If necessary, recheck the
cylinder head alignment. If gap remains replace 13
the exhaust manifold.
14
3. Remove the pipe and both metallic gaskets.
15
16-7
17

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INSTALLATION 3. Torque all exhaust manifold bolts in the sequence

above and using the three torque steps below.
Torque: 4 to 6 Nm (stud)
! Attention: To avoid manifold or cylinder
head damage, make sure the 60 to 80 Nm (Nut)
cylinder heads are aligned
before proceed the exhaust 4. Follow the remaining installation procedures
manifold installation. using the inverse sequence of removal procedure
and applying the torque indicated.
Upper EGR to turbo pipe torque bolts: 25 to 35 Nm
! Attention: To avoid engine damage, make
sure the manifold gasket and Turbo pipe actuator bracket bolt: 17 to 23 Nm
exhaust manifold are aligned Lower EGR to manifold pipe nuts: 25 to 35 Nm
before tightening bolts to the
specied torque value. 5. Install the turbocharger assembly. See installation
procedure in this section.
1. After cleaning and inspecting the manifold, install
new exhaust manifold gaskets.
2. Align and hold the gaskets while placing the

manifold. Install the new mounting nuts to the
turbocharger.
5 1 4 8
6 2 3 7
16-8
NOTE: 4 cylinder shown. When considering 6
cylinder versions, use the same order,
as indicated above.

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1
EGR Cooler
GENERAL VIEW 1. Remove the water temperature connector, hose

and duct: 2
a. Remove the water temperature sensor

A B
connector.
3
b. Release the water hose clamps from both
F G sides. Lift the water pipe and remove it.
c. Remove the upper air mixer duct mounting 4
bolts.
A 5
D C E B 6
A. EGR valve
7
B. EGR cooler
C. EGR position sensor
$ EGR actuator 8
E. PWM to EGR valves control pipe B C
F. EGR air mixer duct

9
2. Remove the EGR valve position connector.
G. Water duct
REMOVAL 10

possible death, or damage to 11
Information section of this 12
manual.
! Warning: To avoid serious personal injury, 13

sure the transmission is in 14
procedures on engine or vehicle. 15
16-9
17

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3. Cooler water hose and EGR valve control pipe

removal:
A. Cut the retaining clamp and detach the PWM
valve pipe from hose.
B. Release the water hose clamp and remove it.
6. Remove the pin lock-ring to cooler support. Then

remove the pin.
4. Water and EGR valve control pipe removal:
A. Remove the valve control pipe mounting bolt.
B. Remove the water pipe bolts and metallic

GASKET$ISCARDTHEGASKET
B
7. Cooler support removal:
A. Remove the EGR sensor assembly mounting
bolt.
B. Using an Allen wrench, remove the support
mounting bolt.
8. Pull the cooler support, EGR valve and sensor
assembly away.
A
$ISCARDANDREPLACETHEGASKETS
5. Loosen the cooler to support bolt.
16-10

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CLEANING 1
1. Clean off any gasket material and carbon deposits between the EGR cooler, EGR valve and air mixer duct
mating surfaces.
2
2. Clean mating surfaces between air mixer duct and EGR valve.
4. Clean mating surfaces between EGR valve and intake mixer duct.
3
INSTALLATION
1. Place new metallic gaskets, mounting nuts, clamps and lock-ring for the installation procedure.
4
2. Mount the EGR cooler assembly and support. Make sure the support fully engages the EGR cooler assembly.
Torque to 17 to 23 Nm.
3. Mount the pin and place the new lock-ring. 5
4. Install the cooler to support mounting bolt. Torque to 17 to 23 Nm.
5. Install the coolant and EGR valve control pipe. Torque to 17 to 23 Nm.
6
6. Install a new EGR valve control hose and clamp.
7. Install the EGR valve position connector.
8. Install the temperature sensor connector. 7
9. Place the upper air mixer duct retaining bolts.

10. Install the duct with new water hoses and clamps. 8
INSPECTION
9
1. Visually inspect for any damages or cracks.
2. Equipment to perform pressure tests on the removed EGR cooler are expensive. For this reason the functionality
must be veried with assembled components.
10
A defective EGR cooler may result in:
Lack of power;
Excessive smoke; 11
n $AMAGEINTHEINTERNALENGINECOMPONENTSDUECOOLANTMIXINGWITHTHEAIRMIXERDUCTANDmOWINGTOTHE
air intake duct.
12
13
14
15
16-11
17

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NOTES
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16-12
____________________________________________________________________
____________________________________________________________________

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TROUBLESHOOTING
1
Troubleshooting
Introduction ............................................................................................................................................. 17-2

2
Symptom Table ....................................................................................................................................... 17-3
10
11
12
13
14
15
16
17-1

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Introduction
! Attention : v Fully understand the problem before trying any repair.

v Check the simplest and obvious rst.
v Find the rout cause and correct the problem.
17-2

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TROUBLESHOOTING
1
Symptoms Table
SYMPTOM PROBABLE CAUSES 2
Low crank speed 01-02-03

3
05-06-07-08-09-10-14-15-16-17-22
Engine does not start
23-25-26-27-29-40-53
4
01-02-03-05-07-08-09-10-14-15-16
Difcult / hard start
17-18-22-25-26-27-29-40-53-68
07-08-09-10-14-15-16-17-18-19-20 5
Low Power / Performance
21-22-23-25-26-27-29-44-53-54-56-57-68
07-08-09-10-14-15-16-17-19-20-21
Engine misring 6
22-23-24-26-29-44-53
09-14-15-17-18-21-22-23-25-26-27
Excessive fuel consumption
29-57-60-68
7
09-14-15-17-18-21-22-23-25-26-27
Black smoke
29-53-54-57-60-68
8
04-14-15-17-19-21-22-23-25-26-27
White-bluish smoke
28-29-39-40-44
Low oil pressure 04-29-30-31-32-33-34-36-37-38-52 9
14-17-22-23-25-26-28-29-30-33-36
Internal engine noise
39-40-53 10
Excessive vibration 10-15-17-29-41-42-43-61-62

11
High oil pressure 04-32-35
09-14-18-19-39-44-45-46-47-48-51
Overheating 12
58-63-64-65
Excessive pressure in the crankcase with possible oil leaks 19-25-27-28-39-49-67

13
Low compression 09-14-19-22-23-25-26-27-28-40-53
Engine starts and stops 08-09-10-17-29 14
15
16
17-3

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SYMPTOMS TABLE (CONTINUATION)
SYMPTOM PROBABLE CAUSES
High oil consumption 04-12-13-15-25-27-28-39-49-54-55
Coolant in oil 10-19-50
Coolant mixed to lubricating oil 50
Irregular idle speed 07-08-09-10-16-17-29-59
Engine stops during vehicle stop 06-07-08-10-17-29
Engine misring 10-17-29
Coolant leak from cylinder head 63
17-4

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TROUBLESHOOTING
SYMPTOMS TABLE (CONTINUATION) 1
Nr. Probable Cause What to do

2
01 Low battery charge Charge or change battery
3
02 Bad contact on the electrical connections Clean and retighten the connections
03 Defective starter motor Repair / replace the starter motor

4
04 Inadequate oil viscosity Use oil of correct viscosity
5
05 Low starter voltage Check connections, battery and starter motor
06 Fuel tank empty Fill with fuel

6
07 Low pressure fuel pipe obstructed Clear the system
7
08 Fuel lters obstructed Clear fuel lters or change elements
Clear obstruction in the intake system or clean

09 Restriction in the air intake system 8
air lter element (dry type)
10 Air in fuel system Bleed the system

9
11 Leaks through cylinder liners sealing rings Replace cylinder liners sealing rings
12 Rings not seating correctly Replace 10
13 High oil level in the oil pan Adjust oil level

11
14 Incorrect camshaft gear timing Adjust to the correct timing
15 Low compression Measure compression isolate failure and repair 12
16 Fuel tank breather obstructed Clear obstruction from breather

13
17 Fuel not to specication Use recommended fuel
18 Obstructed exhaust Clear obstruction in pipes, silencers, etc. 14
Replace gasket and check the potential

19 Leak through cylinder head gasket
causes of the failure 15
16
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20 Overheating Check cooling system
21 Engine excessively cold Test thermostat
22 Incorrect valve clearance Adjust valve clearance
23 Griped valves Correct the operation of the valves
24 Incorrect high pressure pipes Repair
25 Cylinder wear Repair
26 Valves and seats burnt Recondition or replace
27 Broken, worn or griped rings Replace
28 Valve stems and guides worn Replace
Perform Diagnosis on the system according to

29 Failure in electronic fuel injection system
the Diagnostic Manual of the engine
30 Damaged or worn bearings Replace
31 Low oil level in the oil pan Top up level
32 Oil pressure semper faulty Replace
33 Oil pump with has excessive inner wear Replace
34 Oil pump pressure relief valve locked open Repair or replace
35 Oil pump pressure relief valve locked closed Repair or replace
36 Pressure relief valve spring broken Replace
37 Defective oil pump suction pipe Repair or replace
38 Oil lter blocked Replace element
39 Piston griped Repair cylinders
17-6

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TROUBLESHOOTING
SYMPTOMS TABLE (CONTINUATION) 1

2
Incorrect piston height in relation to the engine block
40 Use correct pistons
surface
3
41 Damaged fan Replace
42 Defective engine mounts Replace

4
43 Flywheel or ywheel housing misaligned Align
5
44 Defective thermostat Replace
45 Restriction in coolant passages Clean the system

6
46 Fan belt(s) loosen Tighten
7
47 Radiator blocked outside or inside Clean
48 Defective water pump Replace

8
49 Crankcase breather blocked Clean

9
50 Oil cooler leakage Repair / Replace
51 Lack of coolant in the cooling system Top up level 10
52 Oil pump suction pipe blocked Clean

11
53 Valve spring broken Replace
54 Turbocharger damaged or dirty Repair or clean 12
56 Turbocharger oil seal leaks Replace seals

13
57 Leaks at exhaust manifold to turbocharger Replace gaskets
58 Low intake air pressure Check turbocharger. Repair leaks 14
59 Exterior leaks (gaskets, seals, etc.) Repair

15
60 Inadequate engine inclination angle Repair
16
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60 Engine overloaded Operate the engine inside the load limit
61 Balancer out of position (4 cylinder engines) Repair
62 Defective damper Replace
Liner protrusion below specication (leaks through liner

63 Repair
collar)
64 Thermostat not seating Repair
Lack or incorrect coolant mixture ratio in the cooling

65 Repair
system
66 Leaks through valve guide seals Replace
67 Defective PCV Replace
Wrong connection between EGR actuator air pipe and Correct the air pipe connectors from EGR and
68
wastegate actuator air pipe wastegate actuator.
17-8

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APPENDIX A
A-1
Appendix A
ENGINE BLOCK (MaxxForce 4.8H / 7.2H)

B
Qtd. Description Size Application Torque (Nm)
1st. 2nd. Torq. Range
2 Bolt M14 x 132 Bearing Cap to Block
50 - 5 155 5 170 to 282
OTHER RELATED ENGINE PARTS (MaxxForce 4.8H / 7.2H)

Qtd. Description Size Application Torque (Nm) Required Sealing
Cylinder Head
2 Engine Lifting Hook M14 80 10 **
Mouting Bolt
Water Drain Plug to

1 Plug 3/8" 10 + 5 Loctite 638
Block
1 Hollow Bolt M8 x 1 Oil Ejector to Block 10 1.5 **
1 Plug M10 x 1 Oil Galery Plug to Block 10 + 5 Loctite 638
CONNECTING ROD (MaxxForce 4.8H)

Connecting Rod to 1st. 2nd. Torq. Range

2 Bolt MJ12 x 58
Crankshaft 40 5 80 2 114 to 144
CONNECTING ROD (MaxxForce 7.2H)

Connecting Rod to 1st. 2nd. Torq. Range

2 Bolt MJ12 x 58.5
Crankshaft 40 5 80 5 114 to 144
CAMSHAFT (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt 1st. 2nd. Torq. Range

4 M8 x 30 Gear to Camshaft
with ange 15 1 45 2 38 to 68
Hexagonal Bolt
2 M8 x 16 Camshaft Lock to Block 30 5
with ange
Hexagonal Bolt Pulse Wheel to

4 M6 x 12 8.5 1
with ange Camshaft Gear

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A-2 GEAR HOUSING (MaxxForce 4.8H)

Hexagonal Bolt
10 M8 x 20 Gear Housing to Block 25 5 **
with ange
Hexagonal Bolt
with ange
Lubrication pipe to Gear

1 Hollow Bolt M8 x 1 5+5 **
Housing
Lubrication Pipe to
Block
Hexagonal Bolt Intermediated Bearing

3 M10 x 70 60 5 **
with ange with Gear to Block
Gear Housing
2 Plug M10 x 1 10 5 **
(Rear Half)
Pressure and Oil
2 Cylindrical Bolt M6 x 20 Temperature Sensor to 8.5 1 **
Gear Housing
Phase Sending Unit to
1 Cylindrical Bolt M6 x 20 8.5 1 **
Gear Housing
GEAR HOUSING (MaxxForce 7.2H)

Hexagonal Bolt with
ange
Hexagonal Bolt with

ange
Lubrication pipe to
Gear Housing
Lubrication Pipe
to Block
Hexagonal Bolt with Intermediated Bearing

3 M10 x 70 60 5 **
ange with Gear to Block
Gear Housing
2 Plug M10 x 1 10 5 **
(Rear Half)
Pressure and Oil
2 Cylindrical Bolt M6 x 20 Temperature Sensor 8.5 1 **
to Gear Housing
Phase Sending Unit
1 Cylindrical Bolt M6 x 20 8.5 1 **
to Gear Housing

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APPENDIX A
IDLE GEAR (INTERMEDIATE GEAR) (MaxxForce 4.8H / 7.2H) A-3

Intermediate Gear to B
3 Bolt M10 x 70 60 5 **
*ear +ousing
BALANCER UNIT (MaxxForce 4.8H / 7.2H)

4 Bolt M1 0x 100 Balancer Unit to Bearing 60 5 **
Balancer Unit Deector

3 Bolt M8 x 10 20 3 **
to Balancer Unit
OIL PUMP (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt
2 M8 x 20 Oil Pump to Block 20 5 **
with ange
WATER PUMP (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt
2 M8 x 20 Water Pump to Block 20 5 **
with ange
VALVE LUBRICATION PIPES (MaxxForce 4.8H)

Valve Lubrication 3ipe
4 Hollow Bolt M10 x 1 10 5 **
to Cylinder Head
Valve Lubrication 3ipe

1 Hollow Bolt M10 x 1 10 5 **
to Oil Cooler
VALVE LUBRICATION PIPES (MaxxForce 7.2H)

Valve Lubrication 3ipe to
6 Hollow Bolt M10 x 1 10 + 5 **
Cylinder Head
Valve Lubrication 3ipes

1 Hollow Bolt M12 x 1.5 20 + 6 **
to &onnection
Valve Lubrication 3ipe to

1 Hollow Bolt M10 x 1 10 + 5 **
Oil Cooler

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A-4 FRONT COVER (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt with Front Cover to Gear
14 M8 x 16 25 3 **
ange Housing
Hexagonal Bolt with Front Cover to Gear

9 M8 x 55 25 3 **
ange Housing To Block
WATER OUTLET PIPE (MaxxForce 4.8H)

Hexagonal Bolt with Water Outlet Pipe to
8 M8 x 55 25 4 **
ange Cylinder Head
WATER OUTLET PIPE (MaxxForce 7.2H)

Hexagonal Bolt Water Outlet Pipe to
12 M8 x 55 25 4 **
with ange Cylinder Head
STARTER ENGINE (MaxxForce 4.8H)

Hexagonal Bolt Starter Engine to
3 M10 x 30 56 8 **
with ange Flywheel Housing
STARTER ENGINE (MaxxForce 7.2H)

Hexagonal Bolt Starter Engine to
3 M10 x 25 56 8 **
with ange Flywheel Housing

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APPENDIX A
ELECTRONIC CONTROL UNIT (MaxxForce 4.8H) A-5

Hexagonal Bolt with B
3 M10 x 20 Block to ECU Bracket 40 6 **
ange
4 Cushion M8 x 16 ECU Bracket to Cushion 10 1.5 **
4 Hexagonal Nut M8 ECU Cooler to Cushion 15 2 **
Hexagonal Bolt
5 M6 x 30 ECU Cooler to ECU 81 **
with ange
ECU Bracket to
3 Stud M6 x 30 62 **
ECM Cooler
ECU Bracket to
3 Hexagonal Nut M6 8.5 1 **
ECM Cooler
ELECTRONIC CONTROL UNIT (MaxxForce 7.2H)

Hexagonal Bolt with
3 M10 x 20 Block to ECU Bracket 35 4 **
ange
4 Cushion M8 x 16 ECU Bracket to Cushion 30 5 **
4 Hexagonal Nut M8 ECU Cooler to Cushion 25 3 **
Hexagonal Bolt
8 M6 x 30 ECU Cooler to ECU 81 **
with ange
HARNESS (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt Harness Bracket to
2 M6 x 12 81 **
with ange Gear Housing

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A-6 TURBOCHARGING (MaxxForce 4.8H)

Turbocharger Spacer to
4 Stud M8 x 20 62 **
Turbocharger
Turbocharger Spacer to
4 Stover Nut M8 70 10 **
Turbocharger
Turbocharger to Exhaust
4 Stud M8 x 25 62 **
Manifold
Turbocharger Stud to
Exhaust Manifold
Turbochager Inlet
1 Hollow Bolt M12 x 1.5 Lubrication Pipe to 30 5 **
Turbocharger
Turbochager Inlet
1 Hollow Bolt M14 x 1.5 Lubrication Pipe to 20 6 **
Block
Turbocharger
2 Cylinder Bolt M6 x 16 Lubrication Return Pipe 12 2 **
to Turbocharger
TURBOCHARGING (MaxxForce 7.2H)

Turbochager Inlet
1 Hollow Bolt M14 x 1.5 Lubrication Pipe to 20 + 6 **
Turbocharger
Turbochager Inlet
1 Hollow Bolt M14 x 1.5 Lubrication Pipe to 20 + 6 **
Block
Turbocharger
Hexagonal Bolt
2 M8 x 20 Lubrication Return Pipe 20 3 **
with ange
to Turbocharger
Manifold
4 Stud M10 x 20 10 2 **
Manifold
ALTERNATOR BRACKET (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt with Alternator Bracket to
4 M10 x 35 40 6 **
ange Gear Housing

1 M10 x 110 40 6 **
ange Alternator to Bush

2 M8 x 20 20 3 **
ange Gear Housing

1 M12 x 40 25 5 **
ange Alternator
Hexagonal Bolt with Pulley to Alternator

1 M10 x 50 40 6 **
ange Bracket

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APPENDIX A
HIGH PRESSURE PUMP (MaxxForce 4.8H) A-7

High Pressure Pump Wo B
3 Cylindrical Bolt (Allen) M10 x 40 High Pressure Pump 40 6 **
Flange
High Pressure Pump
3 Cylindrical Bolt (Allen) M10 x 30 40 6 LOCTITE 242
Flange to Gear Housing
Gear to High Pressure

1 Nut M18 x 1.5 105 5 **
Pump
HIGH PRESSURE PUMP (MaxxForce 7.2H)

High Pressure Pump yo
3 Cylindrical Bolt (Allen) M10 x 40 High Pressure Pump 50 5 **
Flange
High Pressure Pump
3 Cylindrical Bolt (Allen) M10 x 40 50 5 **
Flange to Gear Housing
Gear to High Pressure

1 Nut M18 x 1.5 105 5 **
Pump
FUEL FILTER (MaxxForce 4.8H)

Hexagonal Bolt
2 M10 x 25 Fuel Filter to Block 35 4 **
with ange
Fuel Inlet - Outlet to

2 Connection M14 x 1.5 23 3 **
Filter Head
Pipe - Fuel Filter to High

1 Nut M16 x 1.5 30 2 **
Pressure Pump
Pipe - High Pressure
1 Nut M16 x 1.5 Pump Outlet to Fuel 30 2 **
Filter
FUEL FILTER (MaxxForce 7.2H)

Hexagonal Bolt with
2 M10 x 25 Fuel Filter to Block 35 4 **
ange
Fuel Inlet - Outlet to

2 Connection M14 x 1.5 20 + 6 **
Filter Head
Pipe - Fuel Filter to High

1 Nut M16 x 1.5 30 2 **
Pressure Pump
Pipe - High Pressure
1 Nut M16 x 1.5 Pump Outlet to Fuel 30 2 **
Filter

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A-8 EGR CONTROL VALVE (MaxxForce 4.8H / 7.2H)

EGR Control Valve to
2 Bolt M8 x 90 EGR Control Valve 20 3 **
Bracket
EGR Control Valve to
2 Bolt M8 x 50 EGR Control Valve 20 3 **
Bracket
EGR Control Valve
2 Bolt M8 x 35 20 3 **
Bracket to Engine Block
Air Distributor to Intake

2 Bolt M8 x 25 20 3 **
Manifold
EGR Control Valve Tube

1 Bolt M8 x 16 20 3 **
to ExKaust Manifold
EGR Control Valve Tube

2 Bolt M8 x 20 20 3 **
to Intake Manifold
HIGH PRESSURE PIPE (MaxxForce 4.8H)

High Pressure Pipe
5 Nut M18 x 45 30 + 3 **
to Rail
High Pressure Pipe
4 Nut M14 x 1.5 to High Pressure Fuel 30 + 3 **
Connector
High Pressure Pipe to
1 Nut M14 x 1.5 30 + 3 **
High Pressure Pump
Hexagonal Bolt
3 M8 x 30 Rail to Intake Manifold 15 + 5 **
with ange
HIGH PRESSURE PIPE (MaxxForce 7.2H)

7 Nut M18 x 1.5 30 3 **
Rail
High Pressure Pipe
6 Nut M14 x 1.5 to High Pressure Fuel 30 + 3 **
Connector
1 Nut M14 x 1.5 30 + 3 **
High Pressure Pump

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APPENDIX A
LOW PRESSURE PIPE (MaxxForce 4.8H) A-9

High Pressure Pump to B
1 Nut M16 x 1.5 30 2 **
Fuel Return Pipe
ECU Cooler Pipe to

1 Nut M16 x 1.5 30 2 **
High Pressure Pump
Inlet and Return Fuel
Pipes to Inlet and
2 Nut M16 30 2 **
Return Fuel Pipes
Bracket
Inlet and Return
Hexagonal Bolt with
2 M8 x 16 Fuel Pipes Bracket to 20 3 **
ange
Flywheel Housing
LOW PRESSURE PIPE (MaxxForce 7.2H)

Fuel Return Pipe to
6 Connection M8 x 1 81 **
Cylinder Head
High Pressure Pump to

1 Nut M16 x 1.5 25 2 **
Fuel Return Pipe
ECU Cooler Pipe to

1 Nut M16 x 1.5 25 2 **
High Pressure Pump
Hexagonal Bolt
2 M16 Pipes Bracket to 20 3 **
with ange
Flywheel Housing
Pipes to Inlet and
2 Nut M8x16 25 2 **
Return Fuel Pipes
Bracket

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A-10 EGR (MaxxForce 4.8H)

EGR Valve Tube to
Exhaust Manifold
EGR Valve Tube to
2 Stud M8 x 25 62 **
Exhaust Manifold
EGR Valve Tube to
EGR Valve
EGR Valve Tube to
2 Stud M8 x 25 62 **
EGR Valve
EGR Valve to EGR
CoRler
EGR Valve to EGR
4 Stud M8 x 25 62 **
CoRler
Hexagonal Bolt EGR Cooler to OXtlet
2 M8 x 65 27 4 **
with ange ExKaust Gases Flange
EGR Cooler to OXtlet
Hexagonal Bolt
2 M8 x 25 ExKaust Gases Flange 27 4 **
with ange
to Inlet Gases Tube
Outlet ExKaust Gases
Hexagonal Bolt
2 M8 x 25 Flange to Inlet Gases 20 3 **
with ange
Tube
Hexagonal Bolt Inlet Gases Tube to
2 M8 x 25 20 3 **
with ange Intake Air Elbow
1 Hollow Bolt M12 x 1.5 EGR Cooler 20 5 **
1 Allen Bolt M8 x 60 EGR CoRler Clamp 82 **
1 Allen Bolt M6 x 60 EGR Valve 81 **
EGR (MaxxForce 7.2H)

Hexagonal Bolt EGR Valve Tube to
2 M8 x 25 22 2 **
with ange Exhaust Manifold
Hexagonal Bolt EGR Valve Tube to
2 M8 x 25 22 2 **
with ange EGR Valve
EGR Valve Tube to
EGR CoROer
EGR Valve Tube to
4 Stud M8 x 25 62 **
EGR CoRler
2 M8 x 65 27 4 **
2 M8 x 25 27 4 **
Outlet ExKaust Gases
Hexagonal Bolt
2 M8 x 25 Flange to Inlet Gases 20 3 **
with ange
Tube
Hexagonal Bolt Inlet Gases Tube to
2 M8 x 25 20 3 **
with ange Intake Air Elbow
1 Hollow Bolt M12 x 1.5 EGR Cooler 20 5 **
1 Allen Bolt M8 x 60 EGR CoRler Clamp 20 2 **
1 Allen Bolt M6 x 60 EGR Valve 81 **

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APPENDIX A
INTAKE MANIFOLD (MaxxForce 4.8H) A-11

Hexagonal Bolt Intake Manifold to B
8 M8 x 35 25 5 **
Hexagonal Bolt Intake Manifold to

8 M8 x 80 25 5 **
Air Pressure and
1 Cylindrical Bolt M6 x 12 Temperature Sensor to 3 0.5 **
Intake Manifold
INTAKE MANIFOLD (MaxxForce 7.2H)

12 M8 x 35 20 3 **

12 M8 x 80 20 3 **
Air Pressure and
1 Cylindrical Bolt M6 x 16 Temperature Sensor to 3 0.5 **
Intake Manifold
INTAKE ELBOW (MaxxForce 4.8H)

Hexagonal Bolt Intake Elbow to Intake
1 M8 x 70 20 3 **
with ange Manifold
Hexagonal Bolt Intake Elbow to Intake

3 M8 x 45 20 3 **
with ange Manifold
Hexagonal Bolt Bracket to

1 M8 x 16 25 + 5 **
with ange Turbocharging Elbow
Hexagonal Bolt Bracket to Exhaust

1 M8 x 16 25 + 5 **
with ange Manifold
INTAKE ELBOW (MaxxForce 7.2H)

Hexagonal Bolt Intake Elbow to
2 M8 x 70 20 3 **
with ange Intake Manifold
Hexagonal Bolt Intake Elbow to

2 M8 x 120 20 3 **
with ange Intake Manifold
Hexagonal Bolt Bracket to

2 M8 x 16 25 + 5 **
with ange Turbocharging Elbow

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A-12 EXHAUST MANIFOLD (MaxxForce 4.8H)

Exhaust Manifold to
8 Stud M10 x 45 62 **
Cylinder Head
Exhaust Manifold to
Stud to Cylinder Head
EXHAUST MANIFOLD (MaxxForce 7.2H)

Exhaust Manifold to
12 Stud M10x45 62 **
Cylinder Head
Exhaust Manifold to
12 Stover Nut M10 70 10 **
Stud to Cylinder Head
EXHAUST ELBOW (MaxxForce 4.8H)

ExKaust Elbow to
4 Stud M8 x 30 62 **
Turbocharger
ExKaust Elbow to Stud

4 Stover Nut M8 x 30 70 10 **
to Turbocharger
EXHAUST ELBOW (MaxxForce 7.2H)

ExKaust Elbow to
4 Stud M10 62 **
Turbocharger
ExKaust Elbow to Stud

to Turbocharger

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
APPENDIX A
ENGINE BREATHER (MaxxForce 4.8H) A-13

Hexagonal Bolt Breather to Cooler to B
2 M8 x 35 25 5 **
with ange Block
Hexagonal Bolt Clamp to Engine
1 M8 x 16 25 5 **
with ange Breather Tube Bracket
Engine Breather Tube
Hexagonal Bolt
1 M8 x 25 Bracket to Oil Pan to 25 5 **
with ange
Block
ENGINE BREATHER (MaxxForce 7.2H)

Hexagonal Bolt Breather to Cooler
2 M8 x 35 25 3 **
with ange to Block
Hexagonal Bolt Clamp to Engine
1 M8 x 25 25 5 **
with ange Breather Tube Bracket
Engine Breather Tube
Hexagonal Bolt
1 M8 x 16 Bracket to Oil Pan to 10 2 **
with ange
Block
COMPRESSOR LK39 (MaxxForce 4.8H)

Air Compressor to
3 Cylindrical Bolt M10 x 40 45 5 **
Gear Housing
Air Compressor Inlet
1 Hollow Bolt M14 x 1,5 Water Hose Connector 20 + 6 **
to Block
Air Compressor Outlet
1 Hollow Bolt M14 x 1,5 Water Hose Connector 20 + 6 **
to Water Outlet Pipe
1 Nut M20 Gear to Air Compressor 230 20 **
Hexagonal Bolt Air Compressor Bracket
2 M8 x 20 20 3 **
with ange to Air Compressor
Hexagonal Bolt Air Compressor
2 M8 x 20 20 3 ****
with ange Bracket to Block
COMPRESSOR LK39 (MaxxForce 7.2H)

Air Compressor to Gear
3 Cylindrical Bolt M10x40 45 5 **
Housing
Air Compressor Inlet
1 Hollow Bolt M14x1,5 Water Hose Connector 20 + 6 **
to Block
Air Compressor Outlet
1 Hollow Bolt M14x1,5 Water Hose Connector 20 + 6 **
to Water Outlet Pipe
1 Nut M20 Gear to Air Compressor 230 20 **
Hexagonal Bolt with Air Compressor Bracket
2 M8x20 20 6 **
ange to Air Compressor
Hexagonal Bolt with Air Compressor Bracket
2 M8x20 20 6 **
ange to Block

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
A-14 HYDRAULIC PUMP (MaxxForce 4.8H)

Hexagonal Bolt Hydraulic Pump to
2 M10 x 25 35 5 **
with ange Air Compressor
HYDRAULIC PUMP (MaxxForce 7.2H)

Hexagonal Bolt Hydraulic Pump to Air
2 M10x25 45 5 **
with ange Compressor
OIL PAN (MaxxForce 4.8H)

Oil Pan to Gear Housing
Hexagonal Bolt
22 M8 x 16 to Flywheel Housing to 25 + 5 **
with ange
Engine Block
4 Stud M8 x 25 Oil Pan to Block 10 2 **
4 Nut M8 Stud to Oil Pan to Block 25 + 5 **
1 Plug R Oil Pan 65 10 **
OIL PAN (MaxxForce 7.2H)

Oil Pan to Gear Housing
Hexagonal Bolt
28 M8 x 16 to Flywheel Housing to 25 + 5 **
with ange
Engine Block
2 Stud M8 x 25 Oil Pan to Gear Housing 10 2 **
2 Nut M8 Oil Pan to Gear Housing 25 + 5 **
4 Stud M8 x 25 Oil Pan to Engine Block 10 2 **
4 Nut M8 Oil Pan to Engine Block 25 + 5 **
1 Plug R Oil Pan 65 10 **
1 Plug M14 x 1.5 Oil Pan 20 + 6 **
FLYWHEEL (MaxxForce 4.8H)

1st. 2nd. 3rd.
6 Cylindrical Bolt M16 x 40 Flywheel to Crankshaft
100 10 275 15
FLYWHEEL (MaxxForce 7.2H)

1st. 2nd. 3rd.
8 Cylindrical Bolt M16x40 Flywheel to Crankshaft
100 10 275 15

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
APPENDIX A
CRANKSHAFT PULLEY (MaxxForce 4.8H) A-15
Crankshaft Pulley 1st. 2nd. 3rd. B

4 Cylindrical Bolt M16 x 65
to Crankshaft 100 10 275 15
Hexagonal Bolt Dumper to Crankshaft
6
with ange
M10 x 20
Pulley
70 5
CRANKSHAFT PULLEY (MaxxForce 7.2H)

Crankshaft Pulley to 1st. 2nd. 3rd.

4 Cylindrical Bolt M16 x 65
Crankshaft 100 10 275 15
Hexagonal Bolt Dumper to Crankshaft 1st. 2nd. Torque Range
9 M8 x 30
with ange Pulley 25 3 55 5 31 a 71 Nm
ENGINE BRACKET (MaxxForce 4.8H)

Hexagonal Bolt LS Front Bracket
3 M12 x 70 100 15 **
with ange to block
Hexagonal Bolt RS Front Bracket

3 M12 x 70 100 15 **
with ange to Block
Hexagonal Bolt Central Front Bracket

4 M16 x 85 250 + 20 **
with ange to Front Brackets
ENGINE BRACKET (MaxxForce 7.2H)

Hexagonal Bolt LS Front Bracket
4 M12 x 70 100 15 **
with ange to block
Hexagonal Bolt RS Front Bracket

4 M12 x 70 100 15 **
with ange to Block
FAN BRACKET AND TIGHTENER (MaxxForce 4.8H / 7.2H)

Hexagonal Bolt
1 M10 x 25 Fun Hub to Washer 40 6 **
with ange
Hexagonal Bolt Fun Bracket to Gear

3 M8 x 110 20 3 **
with ange Housing to Block
Hexagonal Bolt Fun Bracket to

1 M10 x 70 40 6 **
with ange Front Cover
Hexagonal Bolt Belt Tightener to

1 M10 x 85 50 5 **
with ange Fun Bracket
Hexagonal Bolt
4 M10 x 16 Fun Pulley to Fun Hub 40 6 **
with ange

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
A-16 FLYWHEEL HOUSING (MaxxForce 4.8H)

Hexagonal Bolt Flywheel Housing
13 M12 x 30 100 5 **
with ange to Block
Rotation Sending Unit to

1 Cylindrical Bolt M6 x 16 13 1.5 **
Flywheel Housing
FLYWHEEL HOUSING (MaxxForce 7.2H)

Hexagonal Bolt with Flywheel Housing
13 M12 x 30 100 5 **
ange to Block
Flywheel Housing
1 Liquid gasket ** ** Loctite 515-67
to Block
Rotation Sending Unit to

1 Cylindrical Bolt M6 x 16 13 1,5 **
Flywheel Housing
OIL SUCTION PIPE (MaxxForce 4.8H)

Hexagonal Bolt Oil Suction Pipe
2 M8 x 20 25 4 **
with ange to Block
OIL SUCTION PIPE (MaxxForce 7.2H)

Hexagonal Bolt Oil Suction Pipe
3 M8 x 20 25 4 **
with ange to Block
Hexagonal Bolt
1 M6 x 16 Clamp to Block 20 3 **
with ange
WATER FILLER (MaxxForce 4.8 H / 7.2H)

Hexagonal Bolt Water Inlet Connection
3 M8 x 20 20 3 **
with ange to Block

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
APPENDIX A
LUBRICATING OIL FILTER HEAD AND OIL COOLER (MaxxForce 4.8 H / 7.2H) A-17

Oil Filter Head to Oil B
2 Allen Bolt M8x25 25 + 5 **
Cooler
Hexagonal Bolt with Lubricating Oil Cooler

6 M8x30 25 3 **
ange to Block
Hexagonal Bolt with Lubricating Oil Cooler

2 M8x45 25 3 **
ange to Block
2 Screw Plug M20x1,5 Oil Filter Head 45 + 5 **
1 Screw Plug M30x1,5 Oil Filter Head 90 + 5 **
1 Cover ** Cover to Oil Filter Head 30 + 5 **
Oil Filter Head to Oil
1 Allen Bolt M8x45 25 + 5 **
Cooler
Oil Filter Head to Oil
1 Allen Bolt M8x60 25 + 5 **
Cooler
Valve Lubricating Oil

1 Screw Plug M22x1 25 + 5 **
Pressure Control
LUBRICATING OIL FILTER HEAD AND OIL COOLER (MaxxForce 4.8 H / 7.2H)
Pre- Torque Torque Torque Torque
Qtd. Description Size Application Torque
Torque 1 () 2 () 3 () Range
Cylinder Head 120 to
4 Bolt M14 x 152 40 + 5 60 + 10 60 3 60 3 90 3
to Block 260
COMPONENTS OF THE CYLINDER HEAD (MaxxForce 4.8H / 7.2H)

See Tightening
Sequence in
Fuel Injector the Cylinder
1 Cilindrical Bolt M6 x 30 **
Fixing Bridge Head
Assembly
Section
See Tightening
Sequence in
the Cylinder
1 Special Step Bolt ** Fuel Injector Fixing Clip **
Head
Assembly
Section
See Tightening
Sequence in
Fit of High Pressure the Cylinder
1 Nut M22 **
Connection to the Head Head
Assembly
Section
Lubrication Pipe to the
2 Cilindrical Bolt M5 x 10 51 **
Cylinder Head

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
A-18 INJECTION NOZZLE WIRING HARNESS AND VALVE COVER ( ONE CYLINDER HEAD) -
(MaxxForce 4.8H / 7.2H)
Fuel Injector Nozzle
2 Nut, Lock M4 1.5 + 0.25 **
Terminal
External Injection
1 Bolt M6 x12 8.5 1 **
Nozzle Wiring Harness
2 Bolt M6 x 60 Valve Cover 8.5 1 **
STANDARD TORQUE TABLE FOR NORMAL STEEL BOLTS

(ACCORDING TO DIN 2230)
Bolt Class (Nm)
Nominal Size
8.8 10.9 12.9
M5 61 91 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 table is only applied when the Torque isnt reffered in the Service Manual. For all other
condditions use the special torques provided by the related procedures.

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
APPENDIX B
A
Special Tools
MWM CODE TOOL TYPE COMPONENT IMAGE

B-1
9.610.0.690.011.6 Adapter Engine Support
Dial Indicator Measure Cylinder Head

9.610.0.690.025.4
Device Cylinder Liner
9.610.0.690.024.6 Installer Cylinder Liner
9.610.0.690.020.6 Installer Rear seal
9.610.0.690.017.6 Extractor Cylinder Liner
Not available at
Installer/Removal device Connecting rod bushing
publication date
Not available at
Installer Front seal
publication date

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
MWM CODE TOOL TYPE COMPONENT IMAGE
B-2
9.610.0.690.062.4 Dial indicator adapter Piston height measure
9.407.8.690.030.4 Guided-pins Cylinder Head
Impact hammer 0,5Kg

Fuel injector
9.407.0.690.040.6 and adapter
with adapter

D7000600C1 Locking device Flywheel
Cylinder compression and

9.612.0.690.003.4 Fuel injector
timing test adapter
9.407.0.690.065.4 Socket SW27 fuel pressor sensor (rail)
Extractor/ Spring
D7000598C1 Spring valve
compressor

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
APPENDIX B
MWM CODE TOOL TYPE COMPONENT IMAGE A
B-3
Aligner for cylinder head
D7000595C1 Cylinder head
installation
9.407.0.690.043.6 Installer Valve retainer
Adapter for use

D7000597C1 with installer Valve retainer
9.407.0.690.043.6
Extractor for use with tool

D7000596C1 rocker arm guided-shaft
9.407.0.690.040.6
REMARK: The illustrations may be different from the real tools.

Publication P/N: 9.612.0.006.716.4 08/11
Workshop Manual
NOTES
____________________________________________________________________
B-4
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Publication P/N: 9.612.0.006.716.4 08/11
Produced by:
ASC Comunicao Tcnica
www.asccomunicacao.com.br

9 612 0 006 716 4

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WORKSHOP MANUAL

MaxxForce 4.8H / 7.2H

MWM INTERNATIONAL Motores

web site: www.mwm-international.com.br

OPERATION AND MAINTENANCE

PISTONS AND CONNECTING RODS

FLY WHEEL AND FLY WHEEL HOUSING 10

MWM INTERNATIONAL Motores

How to Use this Workshop Manual ........................................................................................................... 1-2

General Instructions ................................................................................................................................. 1-4 4

Cleaning General Instructions .................................................................................................................. 1-5

Cylinder Numbering .................................................................................................................................. 1-7

Engine Identication ................................................................................................................................. 1-8

MWM INTERNATIONAL Motores

How to Use this Manual

v Component disassembly, cleaning, inspection and dimentional specications.

Information on Metric System

MWM INTERNATIONAL Motores

v Do not work with materials that are lifted by jacks or cranes. 10

MWM INTERNATIONAL Motores

! Attention: v Use good quality fuel, free of water and impurities.

v Use only recommended oil.

MWM INTERNATIONAL Motores

CLEANING WITH ACIDS AND SOLVENTS

4. High pressure pump; 7

5. Belts, pipes and hoses;

MWM INTERNATIONAL Motores

1. Identication plate on the water pipe.

MWM INTERNATIONAL Motores

MWM INTERNATIONAL Motores

ENGINE SERIAL NUMBER

v Power steering pump;

v High Pressure Fuel Pump.

MWM INTERNATIONAL Motores

High Pressure Pump

MWM INTERNATIONAL Motores

ECM Electronic Control Module

MWM INTERNATIONAL Motores

Fuel System ............................................................................................................................................. 2-2

Cooling System ........................................................................................................................................ 2-3 4

Thermostat ............................................................................................................................................... 2-3

Engine Component Locations .................................................................................................................. 2-6

Engine Systems ..................................................................................................................................... 2-12

Turbocharger System ............................................................................................................................. 2-16

Exhaust System ..................................................................................................................................... 2-24 9

Fuel Management System ..................................................................................................................... 2-25

Engine and Vehicle Sensors .................................................................................................................. 2-30

Resistor and Thermistor......................................................................................................................... 2-31

Magnetic Sensors .................................................................................................................................. 2-34

Switches ................................................................................................................................................ 2-36 14

MWM INTERNATIONAL Motores

2-2 Engine Data 4.8 7.2

Description 4 Cylinders 6 Cylinders

MWM INTERNATIONAL Motores

Description 4.8 7.2 2-3

Description 4.8 7.2

Opening Total Maximum opening

MWM INTERNATIONAL Motores

Cold side (left engine side)

Hot side (right engine side)

MWM INTERNATIONAL Motores

MWM INTERNATIONAL Motores

Engine Component Locations