Challenger Rg900c User manual

Workshop Service Manual

Applicator Chassis

RG900C

RG1100C

RG1300C

North America

4205 River Green Parkway, Duluth GA 30096 USA

Challenger is a registered trademark of Caterpillar

Inc. and is used under license by AGCO.

August 2019

79037219C

English

CALIFORNIA

Proposition 65 Warning

WARNING: Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects, or other reproductive harm.

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds,

chemicals known to the State of California to cause cancer, birth defects, or other reproductive

harm. Wash hands after handling.

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Applicator Chassis

1 General ..................................................................1-1

1.1 Service manual ..................................................... 1-3

1.1.1 Units of measurement ............................................ 1-3

1.1.2 Replacement parts .............................................. 1-3

1.1.3 Identiﬁcation plates .............................................. 1-3

1.1.4 Engine identiﬁcation ............................................. 1-5

1.2 A word to the operator ..............................................1-6

1.2.1 Important safety information ....................................... 1-6

1.2.2 Safety symbol .................................................. 1-7

1.2.3 Safety messages ................................................ 1-8

1.2.4 Information messages ............................................ 1-8

1.2.5 General hazard information ........................................ 1-8

1.2.6 Protective equipment ............................................ 1-10

1.2.7 Prepare for emergencies ......................................... 1-10

1.3 Prepare for operation .............................................. 1-11

1.3.1 Mount and dismount the machine ...................................1-11

1.3.2 Before you start the engine ....................................... 1-11

1.3.3 Start the engine ................................................ 1-12

1.3.4 Before operating the machine ......................................1-12

1.3.5 Operate the machine ............................................ 1-12

1.3.6 Operator station ............................................... 1-13

1.3.7 Park the machine ............................................... 1-13

1.3.8 Safety lamps and marking devices use ............................... 1-14

1.3.9 Roading on public roads .......................................... 1-14

1.3.10 Operate on a slope ............................................. 1-14

1.3.11 Electrical storm injury prevention ................................... 1-14

1.4 Maintenance and service ........................................... 1-15

1.4.1 Practice correct maintenance ...................................... 1-15

1.4.2 Maintenance safety ............................................. 1-16

1.4.3 Wear protective clothing ......................................... 1-20

1.4.4 Fire prevention and ﬁrst aid ....................................... 1-20

1.4.5 Proper disposal of waste ......................................... 1-21

1.4.6 Shield and guards .............................................. 1-21

1.4.7 Support the machine correctly ..................................... 1-22

1.4.8 Asbestos information ............................................ 1-22

1.4.9 Pressurized air ................................................. 1-22

1.4.10 Cut and crush prevention ......................................... 1-22

1.4.11 Boom safety .................................................. 1-23

1.4.12 Fuel safety ................................................... 1-23

1.4.13 Hydraulic safety ................................................ 1-23

1.4.14 High pressure leaks ............................................. 1-24

1.4.15 Chemical safety ................................................ 1-24

1.4.16 Engine safety ................................................. 1-27

1.4.17 Battery safety ................................................. 1-28

1.4.18 Tire safety .................................................... 1-29

1.4.19 Avoid eye contact with radar .......................................1-30

1.4.20 Exhaust fumes ................................................ 1-30

1.4.21 Electrical power lines overhead .....................................1-30

1.4.22 Towing ...................................................... 1-31

1.4.23 Modiﬁcations ................................................. 1-31

1.4.24 Mobile radio installation .......................................... 1-31

1.4.25 Safety signs .................................................. 1-31

Table of contents

Applicator Chassis

79037219C

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1.4.26 Safety and informational signs ..................................... 1-31

1.5 Tightening speciﬁcations ...........................................1-33

1.5.1 Constant torque hose clamp .......................................1-33

1.5.2 Fastener tightening speciﬁcations ...................................1-33

1.5.3 Metric fasteners ............................................... 1-35

1.5.4 Inch fasteners ................................................. 1-37

1.5.5 Conversion table ............................................... 1-41

2 Engine, fuel, and exhaust system ..........................................2-1

2.1 Introduction ........................................................2-9

2.1.1 Speciﬁcations and standards ....................................... 2-9

2.1.2 Fuel quality requirements ..........................................2-9

2.1.3 Coolant quality requirements ...................................... 2-10

2.1.4 Oil quality .................................................... 2-11

2.1.5 Engine oil type .................................................2-11

2.1.6 Engine speciﬁcation .............................................2-12

2.1.7 Lifting and storage ..............................................2-13

2.2 Engine system .................................................... 2-14

2.2.1 Engine components .............................................2-14

2.2.2 Remove the cooling package ...................................... 2-18

2.2.3 Disassemble the cooling package ...................................2-24

2.2.4 Assemble the cooling package ..................................... 2-29

2.2.5 Install the cooling package ........................................ 2-34

2.2.6 Remove the main serpentine belt ................................... 2-39

2.2.7 Install the main serpentine belt .................................... 2-41

2.2.8 Remove an alternator ........................................... 2-42

2.2.9 Install an alternator ............................................. 2-44

2.2.10 Remove a starter ............................................... 2-44

2.2.11 Install a starter ................................................ 2-45

2.2.12 Remove the fan ................................................2-46

2.2.13 Install the fan ................................................. 2-47

2.2.14 Remove the air ﬁlter assembly ..................................... 2-48

2.2.15 Install the air ﬁlter assembly .......................................2-52

2.2.16 Remove the air ﬁlters ............................................2-56

2.2.17 Install the air ﬁlters ............................................. 2-57

2.2.18 Remov the diesel exhaust ﬂuid .....................................2-58

2.2.19 Install the diesel exhaust ﬂuid ..................................... 2-66

2.2.20 Remove the engine ............................................. 2-75

2.2.21 Install the engine ............................................... 2-86

2.2.22 Remove the engine mounts ....................................... 2-96

2.2.23 Install the engine mounts .........................................2-97

2.2.24 Change the engine oil and ﬁlter .................................... 2-98

2.3 Safety instructions ................................................2-100

2.4 To the user ....................................................... 2-102

2.4.1 Engine type designations ........................................ 2-102

2.4.2 Location of the engine serial number ............................... 2-103

2.4.3 Marking of the electronic control unit ............................... 2-104

2.4.4 Engine lifting ................................................. 2-104

2.5 Engine construction .............................................. 2-106

2.5.1 Technical data ................................................ 2-106

2.5.1.1 Principal dimensions and data ........................... 2-106

2.5.1.2 Fuel system ........................................ 2-106

2.5.1.3 Lubrication system ................................... 2-106

2.5.1.4 Cooling system ......................................2-107

2.5.1.5 SCR system technical data ............................. 2-107

2.5.2 Cylinder block ................................................ 2-107

2.5.3 Flywheel housing ..............................................2-108

Table of contents

Applicator Chassis

79037219C

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2.5.4 Valve mechanism ..............................................2-108

2.5.5 Cylinder head ................................................ 2-108

2.5.6 Crank mechanism ............................................. 2-108

2.5.7 Timing gears ................................................. 2-109

2.5.8 Lubrication system ............................................. 2-110

2.5.8.1 Oil pressure regulating valve ............................ 2-111

2.5.8.2 Oil ﬁlter and oil cooler ................................. 2-111

2.5.8.3 Oil ﬁlter and oil cooler ................................. 2-112

2.5.9 Cooling system ............................................... 2-112

2.5.9.1 Thermostat ......................................... 2-113

2.5.10 Air control system ............................................. 2-114

2.5.10.1 Turbocharging ....................................... 2-115

2.5.10.2 2 stage turbocharging ................................. 2-115

2.5.10.3 Cooling of inlet air .................................... 2-115

2.5.10.4 Interstage charge air cooling ............................ 2-115

2.5.10.5 Throttle valve ....................................... 2-115

2.5.11 Fuel system .................................................. 2-116

2.5.12 SCR system ..................................................2-117

2.5.12.1 SCR system overview ................................. 2-117

2.5.12.2 SCR system components and their functions ................ 2-118

2.5.12.3 Supply module connectors and ﬁlters ...................... 2-119

2.5.12.4 Dosing module connections .............................2-119

2.5.13 Engine control system .......................................... 2-120

2.6 Technical data .................................................... 2-121

2.6.1 Cylinder block ................................................ 2-121

2.6.2 Cylinder liners ................................................ 2-121

2.6.3 Cylinder head ................................................ 2-122

2.6.4 Valves and rockers ............................................. 2-123

2.6.5 Tappets and push rods .......................................... 2-124

2.6.6 Camshaft ................................................... 2-124

2.6.7 Crankshaft ...................................................2-125

2.6.8 Flywheel .................................................... 2-128

2.6.9 Timing gears ................................................. 2-128

2.6.10 Connecting rod ............................................... 2-129

2.6.11 Piston, rings and pin ........................................... 2-130

2.6.12 Lubrication system ............................................ 2-132

2.6.13 Oil pump .................................................... 2-132

2.6.14 Thermostat .................................................. 2-133

2.6.15 Turbocharger ................................................. 2-133

2.7 Tightening torques ............................................... 2-134

2.8 Special tools ..................................................... 2-136

2.8.1 Cylinder block tools ............................................ 2-136

2.8.2 Timing gear and ﬂywheel housing tools ..............................2-139

2.8.3 Cylinder head and valve mechanism tools ............................ 2-141

2.8.4 Crank mechanism tools ......................................... 2-143

2.8.5 Coolant pump tools ............................................ 2-145

2.8.6 Fuel system tools ............................................. 2-146

2.8.7 SCR system tools ............................................. 2-151

2.8.8 Electronic diagnostic tool ........................................ 2-152

2.8.8.1 EDT diagnostic terminal ............................... 2-153

2.8.8.2 Diagnostic terminal components ......................... 2-153

2.9 Liquid quality requirements ....................................... 2-155

2.9.1 Lubricating oil quality requirements .................................2-155

2.9.2 Coolant quality requirements ..................................... 2-155

2.9.3 Fuel quality requirements ........................................ 2-156

2.9.3.1 Biodiesel blends ..................................... 2-157

2.9.3.2 Engine output depending on fuel quality ....................2-159

Table of contents

Applicator Chassis

79037219C

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2.10 Terminal diagram ................................................. 2-160

2.11 Cylinder block .................................................... 2-164

2.11.1 Measure the cylinder liner wear ................................... 2-164

2.11.2 Remove the cylinder liner ........................................ 2-164

2.11.3 Do a check for the cylinder block .................................. 2-164

2.11.4 Changing camshaft bushing ...................................... 2-165

2.11.5 Fitting plug at camshaft rear end .................................. 2-166

2.11.6 Oversize bushings for camshaft ................................... 2-166

2.11.7 Fitting plug at camshaft rear end (oversize bushings) .................... 2-166

2.11.8 Install the cylinder liner ......................................... 2-167

2.11.9 Remove the block heater ........................................ 2-169

2.11.10 Install the block heater .......................................... 2-169

2.12 Flywheel housing ................................................. 2-170

2.12.1 Remove the ﬂywheel housing .................................... 2-170

2.12.2 Install the ﬂywheel housing ...................................... 2-170

2.12.3 Changing crankshaft rear oil seal ...................................2-171

2.13 Cylinder head .................................................... 2-172

2.13.1 Removing cylinder head ......................................... 2-172

2.13.2 Removing valves .............................................. 2-172

2.13.3 Do a check for the cylinder head ................................... 2-172

2.13.4 Replace the valve guides ........................................ 2-174

2.13.5 Machine the valve seat ..........................................2-174

2.13.6 Replace the valve seat rings ...................................... 2-174

2.13.7 Grinding valves ............................................... 2-175

2.13.8 Fitting valves ................................................. 2-176

2.13.9 Install the cylinder head ......................................... 2-176

2.14 Valve mechanism with hydraulic lash adjustment ................... 2-178

2.14.1 How to recognize an engine with hydraulic lash adjusters .................2-178

2.14.2 Remove the valve cover ......................................... 2-179

2.14.3 Install the valve cover ........................................... 2-179

2.14.4 Pre-adjustment of the hydraulic lash adjusters ......................... 2-179

2.14.5 Reconditioning the valve mechanism ............................... 2-179

2.14.6 Compressing the oil out from the hydraulic lash adjusters ................ 2-180

2.14.7 Assembling the valve mechanism with the hydraulic lash adjusters ......... 2-181

2.14.8 Pre-adjusting the hydraulic lash adjusters ............................ 2-182

2.14.9 Changing camshaft or camshaft gear ............................... 2-184

2.15 Crankshaft ....................................................... 2-185

2.15.1 Removing the crankshaft ........................................ 2-185

2.15.2 Checking crankshaft ........................................... 2-185

2.15.3 Replace the crankshaft gears ..................................... 2-186

2.15.4 Installing the crankshaft ......................................... 2-186

2.15.5 Crankshaft hub piece ........................................... 2-187

2.15.6 Viscose type vibration damper .................................... 2-188

2.16 Connecting rods and pistons ...................................... 2-189

2.16.1 Removing pistons together with connecting rods ...................... 2-189

2.16.2 Changing connecting rod bearings ................................. 2-189

2.16.2.1 Piston pin bushing ................................... 2-189

2.16.2.2 Big-end bearing ..................................... 2-190

2.16.3 Checking connecting rod ........................................ 2-191

2.16.4 Replace the piston rings ......................................... 2-191

2.16.5 Checking pistons .............................................. 2-192

2.16.6 Install the piston pin ............................................2-193

2.16.7 Install the piston together with the connecting rod ..................... 2-193

2.17 Flywheel ......................................................... 2-195

2.17.1 Changing starter ring gear on ﬂywheel .............................. 2-195

2.17.2 Remove the ﬂywheel ........................................... 2-195

2.17.3 Fitting ﬂywheel ............................................... 2-195

Table of contents

Applicator Chassis

79037219C

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2.18 Timing gear assembly .............................................2-196

2.18.1 Removing timing gear casing ..................................... 2-196

2.18.2 Install the timing gear housing .................................... 2-197

2.18.3 Remove the hub nut of the crankshaft and the crankshaft hub ............. 2-199

2.18.4 Install the crankshaft hub and the hub nut of the crankshaft ............... 2-200

2.18.5 Power take-o ................................................ 2-201

2.18.6 Fan drive device ...............................................2-201

2.19 Lubrication system ............................................... 2-202

2.19.1 Oil pressure regulating valve ..................................... 2-202

2.19.2 Remove the oil sump ........................................... 2-202

2.19.3 Remove the suction pipe of the oil pump ............................ 2-202

2.19.4 Install the suction pipe of the oil pump ..............................2-203

2.19.5 Removing and dismantling lubricating oil pump ........................ 2-204

2.19.6 Assembling and ﬁtting lubricating oil pump ........................... 2-204

2.19.7 Install the oil sump gasket ....................................... 2-205

2.19.7.1 Install the oil sump gasket, metal gasket ................... 2-205

2.19.7.2 Install the oil sump gasket, paper gasket ................... 2-205

2.19.7.3 Install the oil sump gasket, cork gasket .................... 2-206

2.19.8 Install the oil sump, self-carrying oil sump and cast oil sump .............. 2-206

2.19.9 Install the oil sump, stamped steel oil sump .......................... 2-208

2.19.10 Piston cooling nozzles .......................................... 2-208

2.19.11 Lubricating oil cooler ........................................... 2-209

2.19.12 Removing the oil cooler ......................................... 2-210

2.19.13 Fitting the oil cooler ............................................ 2-210

2.19.14 Remove the oil ﬁlter adapter ...................................... 2-211

2.19.15 Install the oil ﬁlter adapter ....................................... 2-212

2.19.16 Oil sump capacity ............................................. 2-212

2.19.17 Closed crankcase ventilation ..................................... 2-212

2.19.17.1 Remove the closed crankcase ventilation system components ... 2-213

2.19.17.2 Installing the closed crankcase ventilation system components ... 2-213

2.19.17.3 Installing the closed crankcase ventilation system components ... 2-213

2.20 Cooling system ................................................... 2-215

2.20.1 Remove the distribution pipe of the coolant ...........................2-215

2.20.2 Install the distribution pipe of the coolant ............................ 2-215

2.20.3 Removing the thermostat ........................................2-216

2.20.4 Testing the thermostat .......................................... 2-216

2.20.5 Replace the thermostat ......................................... 2-216

2.20.6 Remove the coolant pump and the thermostat housing .................. 2-216

2.20.7 Install the coolant pump and the thermostat housing .................... 2-217

2.20.8 Reconditioning coolant pump ..................................... 2-217

2.20.8.1 Coolant pumps with standard bearings .....................2-217

2.20.8.2 Coolant pumps with heavy duty bearings ................... 2-220

2.20.9 Installing the cylinder head connection part ........................... 2-220

2.20.10 Remove the idler pulleys, the belt tightener and the belt pulley ............ 2-221

2.20.11 Install the idler pulleys, the belt tightener and the belt pulley .............. 2-222

2.21 Air control system maintenance ................................... 2-223

2.21.1 Checking the air cleaner .........................................2-223

2.21.2 Do a check for the inlet and exhaust pipes ........................... 2-223

2.21.3 Remove the actuator of the turbocharger ............................ 2-224

2.21.4 Install the actuator of the turbocharger .............................. 2-224

2.21.5 Remove the exhaust manifold and the turbochargers ....................2-225

2.21.6 Removing the turbocharger ...................................... 2-226

2.21.7 Checking the turbocharger ....................................... 2-226

2.21.8 Install the high-pressure turbocharger ............................... 2-227

2.21.9 Install the exhaust manifold and the turbochargers ..................... 2-227

2.21.10 Remove the ICAC ............................................. 2-229

2.21.11 Install the ICAC ............................................... 2-229

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Applicator Chassis

79037219C

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2.21.12 Remove the intake manifold ...................................... 2-230

2.21.13 Install the intake manifold ....................................... 2-230

2.22 Fuel system ...................................................... 2-231

2.22.1 Bleed the fuel system .......................................... 2-231

2.22.2 Measuring fuel feed pressure ..................................... 2-231

2.22.3 Remove the fuel ﬁlters ..........................................2-232

2.22.4 Install the fuel ﬁlters ........................................... 2-232

2.22.5 Remove the injector overﬂow pipe ................................. 2-233

2.22.6 Install the injector overﬂow pipe ................................... 2-233

2.22.7 Inspecting injectors ............................................ 2-233

2.22.7.1 Remove the injectors (CRIN3) ........................... 2-234

2.22.7.2 Install the injectors (CRIN3) ............................. 2-235

2.22.8 High-pressure pump ........................................... 2-237

2.22.8.1 Remove the high-pressure pump ......................... 2-237

2.22.8.2 Install the high-pressure pump .......................... 2-237

2.22.9 Rail ........................................................ 2-238

2.22.9.1 Removing the rail .................................... 2-239

2.22.9.2 Install the rail ....................................... 2-240

2.22.9.3 Removing the pressure control valve ...................... 2-240

2.22.9.4 Fitting the pressure control valve ......................... 2-241

2.22.9.5 Removing the pressure sensor .......................... 2-241

2.22.9.6 Fitting the pressure sensor ............................. 2-241

2.22.10 Troubleshooting of the Common rail fuel system ....................... 2-241

2.22.10.1 Testing the suction pressure between the fuel tank and the fuel pre-

ﬁlter .............................................. 2-241

2.22.10.2 Testing the suction pressure between the fuel pre-ﬁlter and the feed

pump ............................................. 2-243

2.22.10.3 Testing the feed pressure between the feed pump and the fuel main

ﬁlter .............................................. 2-245

2.22.10.4 Testing the feed pressure between the main fuel ﬁlter and the high-

pressure pump ...................................... 2-246

2.22.10.5 Testing the total return quantity from the injectors ............ 2-247

2.22.10.6 Testing the return quantity from the injectors ................ 2-249

2.22.10.7 Testing the pressure control valve leakage .................. 2-254

2.22.10.8 Testing the pressure release valve leakage .................. 2-256

2.22.10.9 Testing the return line pressure .......................... 2-259

2.23 SCR system ...................................................... 2-260

2.23.1 SCR system maintenance ....................................... 2-260

2.23.2 Mounting of SCR system components .............................. 2-260

2.23.3 Removing the supply module ..................................... 2-261

2.23.4 Installing the supply module ...................................... 2-261

2.23.5 Removing the hydraulic connectors ................................ 2-262

2.23.6 Installing the hydraulic connectors ................................. 2-262

2.23.7 Replace the main ﬁlter and the inlet ﬁlter of the supply module ............ 2-262

2.23.8 SPN 521008 FMI 1 ............................................ 2-263

2.23.8.1 Solve the DEF pressure build-up failure .................... 2-264

2.23.8.2 Supply module lifting capacity test ........................2-266

2.23.8.3 Solve the failure when the SM lifting capacity test is not OK ..... 2-267

2.23.8.4 Solving the failure when the SM lifting capacity test is OK ...... 2-269

2.23.9 SPN 521025 FMI 31, SPN 521026 FMI 31 ............................ 2-270

2.23.9.1 Cleanup of the SCR catalyst ............................ 2-272

2.23.9.2 Make the dosing rate test .............................. 2-273

2.23.9.3 Checking the quality of DEF ............................ 2-277

2.24 Engine control system ............................................ 2-279

2.24.1 Remove the bracket of the electronic control unit ...................... 2-279

2.24.2 Install the bracket of the electronic control unit ........................ 2-279

2.24.3 Remove the electronic control unit ................................. 2-279

2.24.4 Install the electronic control unit ................................... 2-279

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2.24.5 Replace the electronic control unit ................................. 2-280

2.24.6 Replace an empty electronic control unit (ECU) ........................ 2-281

2.24.7 Wiring sets .................................................. 2-281

2.24.7.1 Injector wiring sets ................................... 2-282

2.24.7.2 Sensor and actuator wiring sets ..........................2-283

2.24.7.3 Wiring set for intake air heater ...........................2-283

2.24.7.4 Sensors of the engine control system ..................... 2-283

2.24.8 Remove the wiring harnesses .................................... 2-286

2.24.9 Install the wiring harnesses ...................................... 2-287

2.25 Prepare the long block replacement ................................ 2-289

2.26 Parts for the long block replacement ............................... 2-290

2.26.1 Delivery content of the long block engine ............................ 2-290

2.26.2 The parts that must be removed from the old engine ....................2-290

2.26.3 Other parts of the long block replacement ........................... 2-291

2.27 Remove the engine .............................................. 2-292

2.28 Engine lifting ..................................................... 2-293

2.28.1 Lift the engine ................................................ 2-293

2.29 Disassemble the engine ........................................... 2-295

2.29.1 Remove the wiring harnesses .................................... 2-295

2.29.2 Remove the electronic control unit ................................. 2-295

2.29.3 Remove the bracket of the electronic control unit ...................... 2-296

2.29.4 Remove the exhaust manifold and the turbochargers ....................2-296

2.29.5 Removing the EGR system ...................................... 2-297

2.29.6 Change oil ﬁlter ............................................... 2-297

2.29.7 Removing the oil cooler ......................................... 2-297

2.29.8 Remove the oil ﬁlter adapter ..................................... 2-298

2.29.9 Remove the ICAC ............................................. 2-298

2.29.10 Remove the distribution pipe of the coolant .......................... 2-299

2.29.11 Remove the fuel ﬁlters ..........................................2-300

2.29.12 Remove the closed crankcase ventilation system components .............2-300

2.29.13 Removing the rail ............................................. 2-300

2.29.14 Remove the high-pressure pump .................................. 2-301

2.29.15 Remove the block heater ........................................ 2-301

2.29.16 Remove the intake manifold ...................................... 2-301

2.29.17 Remove the coolant pump and the thermostat housing .................. 2-302

2.29.18 Remove the idler pulleys, the belt tightener and the belt pulley ............ 2-302

2.29.19 Remove the valve cover ......................................... 2-302

2.29.20 Remove the injectors (CRIN3) .................................... 2-303

2.29.20.1 Remove the injector overﬂow pipe ........................2-304

2.29.21 Remove the ﬂywheel ........................................... 2-305

2.29.22 Remove the oil sump ........................................... 2-305

2.29.23 Remove the suction pipe of the oil pump ............................ 2-305

2.29.24 Remove the ﬂywheel housing .................................... 2-305

2.30 Assemble the engine ............................................. 2-306

2.30.1 Prepare the new long block ...................................... 2-306

2.30.2 Install the ﬂywheel housing ...................................... 2-306

2.30.3 Changing crankshaft rear oil seal .................................. 2-307

2.30.4 Install the suction pipe of the oil pump ..............................2-308

2.30.5 Install the oil sump gasket ....................................... 2-309

2.30.5.1 Install the oil sump gasket, metal gasket ................... 2-309

2.30.5.2 Install the oil sump gasket, paper gasket ................... 2-309

2.30.5.3 Install the oil sump gasket, cork gasket .................... 2-309

2.30.6 Install the oil sump, self-carrying oil sump and cast oil sump .............. 2-310

2.30.7 Install the oil sump, stamped steel oil sump .......................... 2-311

2.30.8 Fitting ﬂywheel ............................................... 2-312

2.30.9 Install the high-pressure pump .................................... 2-312

2.30.10 Install the rail ................................................. 2-313

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2.30.11 Installing the closed crankcase ventilation system components ............ 2-313

2.30.12 Install the fuel ﬁlters ........................................... 2-314

2.30.12.1 Install the injector overﬂow pipe ......................... 2-314

2.30.13 Install the injectors (CRIN3) ...................................... 2-315

2.30.14 Install the valve cover ........................................... 2-316

2.30.15 Install the idler pulleys, the belt tightener and the belt pulley .............. 2-316

2.30.16 Install the intake manifold ........................................2-316

2.30.17 Install the coolant pump and the thermostat housing .................... 2-317

2.30.18 Install the block heater .......................................... 2-317

2.30.19 Install the distribution pipe of the coolant ............................ 2-318

2.30.20 Install the ICAC ............................................... 2-318

2.30.21 Install the oil ﬁlter adapter ....................................... 2-319

2.30.22 Fitting the oil cooler ............................................ 2-319

2.30.23 Change oil ﬁlter ............................................... 2-319

2.30.24 Fitting the EGR system ......................................... 2-320

2.30.25 Install the exhaust manifold and the turbochargers ..................... 2-320

2.30.26 Install the electronic control unit ................................... 2-322

2.30.27 Install the bracket of the electronic control unit ........................ 2-322

2.30.28 Install the wiring harnesses ...................................... 2-322

2.31 Engine lifting ..................................................... 2-324

2.31.1 Lift the engine ................................................ 2-324

2.32 Install the engine ................................................ 2-326

2.33 After the long block change ....................................... 2-327

2.33.1 Starting the engine after major maintenance .......................... 2-327

2.33.2 Update the engine software ...................................... 2-327

2.33.3 Break in the engine ............................................ 2-327

2.34 Fuel system ...................................................... 2-329

2.34.1 Backﬂush fuel ﬁlter water separator ................................ 2-329

2.34.2 Operate the fuel priming pump ....................................2-331

2.34.3 Remove the right fuel tank ....................................... 2-333

2.34.4 Remove the left fuel tank ........................................ 2-336

2.34.5 Disassemble the fuel tanks ...................................... 2-340

2.34.6 Assemble the fuel tanks ........................................ 2-341

2.34.7 Install the right fuel tank .........................................2-342

2.34.8 Install the left fuel tank ......................................... 2-345

2.34.9 Remove the tank for the diesel exhaust ﬂuid .......................... 2-349

2.34.10 Disassemble the diesel exhaust ﬂuid tank ............................ 2-351

2.34.11 Assemble the diesel exhaust ﬂuid tank .............................. 2-352

2.34.12 Install the tank for the diesel exhaust ﬂuid ............................2-353

2.34.13 Replace the sensor for the fuel tank ................................ 2-355

2.34.14 Remove the primary fuel ﬁlter .................................... 2-365

2.34.15 Install the primary fuel ﬁlter ...................................... 2-366

2.34.16 Remove the secondary fuel ﬁlter .................................. 2-367

2.34.17 Install the secondary fuel ﬁlter .................................... 2-368

2.34.18 Remove the fuel ﬁlter water separator .............................. 2-369

2.34.19 Install the fuel ﬁlter water separator ................................ 2-371

2.34.20 Check and tighten the fuel tank bolts ............................... 2-372

2.35 Exhaust system .................................................. 2-373

2.35.1 Removing the exhaust system without diesel exhaust ﬂuid ............... 2-373

2.35.2 Install the exhaust system without diesel exhaust ﬂuid .................. 2-375

2.35.3 Remove the exhaust system with diesel exhaust ﬂuid ................... 2-378

2.35.4 Install the exhaust system with diesel exhaust ﬂuid .....................2-383

2.35.5 Remove the supply module ...................................... 2-388

2.35.6 Install the supply module ........................................ 2-389

2.35.7 Remove the DEF ﬁlter .......................................... 2-390

2.35.8 Install the DEF ﬁlter ............................................ 2-391

2.35.9 Remove the dosing module ...................................... 2-392

Table of contents

Applicator Chassis

79037219C

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Table of contents

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