Challenger TG8400C User manual

Workshop Service Manual
Applicator Chassis
TG8400C
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.
© AGCO 2019
September 2019
79037161C
NA
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 Product identification information ................................... 1-3
1.1.4 Transmission serial number plate .................................... 1-3
1.1.5 Serial number definition ........................................... 1-4
1.1.6 Engine serial number plate ........................................ 1-4
1.2 Important safety information ........................................ 1-5
1.2.1 Prepare for operation ............................................. 1-5
1.2.2 Fire prevention and first aid ........................................ 1-6
1.2.3 Safety symbol .................................................. 1-7
1.2.4 Safety messages ................................................ 1-7
1.2.5 Information messages ............................................ 1-7
1.2.6 General hazard information ........................................ 1-8
1.2.7 Pressurized air .................................................. 1-9
1.2.8 Asbestos information .............................................1-9
1.2.9 Electrical storm injury prevention .................................... 1-9
1.2.10 Mount and dismount the machine ................................... 1-9
1.2.11 Before starting the engine ......................................... 1-9
1.2.12 Start the engine ................................................ 1-10
1.2.13 Before operating the machine ......................................1-10
1.2.14 Operate the machine ............................................ 1-10
1.2.15 Park the machine ............................................... 1-11
1.2.16 Operator station ............................................... 1-12
1.2.17 Cut and crush prevention ......................................... 1-12
1.2.18 Boom safety .................................................. 1-12
1.2.19 Fuel safety ....................................................1-12
1.2.20 Hydraulic safety ................................................ 1-13
1.2.21 Chemical safety ................................................ 1-13
1.2.22 Exit the cab in an emergency ...................................... 1-15
1.2.23 Engine safety ..................................................1-15
1.2.24 Safety lamps and marking devices use ............................... 1-17
1.2.25 Operating on slopes ............................................. 1-17
1.2.26 Roading on public roads .......................................... 1-17
1.2.27 Avoid eye contact with radar .......................................1-18
1.2.28 Exhaust fumes ................................................ 1-18
1.2.29 Electrical power lines overhead .....................................1-18
1.2.30 Shield and guards .............................................. 1-19
1.2.31 Towing ...................................................... 1-19
1.2.32 Modifications ................................................. 1-20
1.2.33 A word to the operator ........................................... 1-20
1.2.34 Work in a clean area .............................................1-21
1.2.35 Support the machine correctly ..................................... 1-21
1.2.36 Maintenance safety ............................................. 1-21
1.2.37 High pressure leaks ............................................. 1-25
1.3 Lubrication and maintenance ....................................... 1-27
1.3.1 Maintenance introduction .........................................1-27
1.3.2 Maintenance symbols ........................................... 1-27
1.3.3 Maintenance chart .............................................. 1-28
1.3.4 Daily maintenance schedule ....................................... 1-29
1.3.5 Maintenance schedule 10 to 1000 hours .............................. 1-29
Table of contents
Applicator Chassis
79037161C
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1.3.6 Maintenance Schedule 2000 to 4000 hours ........................... 1-32
1.3.7 Lubricants and fluids ............................................ 1-32
1.3.8 Lubricant filling reminders ........................................ 1-34
2 Engine, fuel, and exhaust system ..........................................2-1
2.1 Engine system ..................................................... 2-9
2.1.1 Remove the serpentine belt ........................................ 2-9
2.1.2 Install the serpentine belt ......................................... 2-9
2.1.3 Remove the water pump belt ...................................... 2-10
2.1.4 Install the water pump belt ........................................ 2-11
2.1.5 Remove the alternator ........................................... 2-12
2.1.6 Install the alternator ............................................. 2-13
2.1.7 Remove the cooling package ...................................... 2-14
2.1.8 Install the cooling package ........................................ 2-21
2.1.9 Remove the radiator core .........................................2-27
2.1.10 Install the radiator core .......................................... 2-29
2.1.11 Remove the hydraulic cooler and transmission cooler .................... 2-31
2.1.12 Install the hydraulic cooler and transmission cooler ...................... 2-33
2.1.13 Remove the air intake assembly .................................... 2-35
2.1.14 Install the air intake assembly ......................................2-38
2.1.15 Remove the air cleaner filter .......................................2-41
2.1.16 Install the air cleaner filter ........................................ 2-42
2.1.17 Remove the fan ............................................... 2-42
2.1.18 Install the fan ................................................. 2-46
2.1.19 Remove the air compressor ....................................... 2-49
2.1.20 Install the air compressor .........................................2-53
2.1.21 Remove the starter ............................................. 2-55
2.1.22 Install the starter ............................................... 2-56
2.1.23 Remove the engine ............................................. 2-57
2.1.24 Install the engine ............................................... 2-62
2.2 Safety instructions ................................................ 2-68
2.3 To the user ........................................................ 2-70
2.3.1 Engine type designations ......................................... 2-71
2.3.2 Location of the engine serial number ................................ 2-72
2.3.3 Type plate of the electronic control unit ...............................2-73
2.3.4 Lift the engine .................................................2-73
2.4 Engine construction ............................................... 2-75
2.4.1 Technical data ................................................. 2-75
2.4.1.1 Principal dimensions and data ............................ 2-75
2.4.1.2 Fuel system ......................................... 2-75
2.4.1.3 Lubrication system .................................... 2-75
2.4.1.4 Cooling system ...................................... 2-75
2.4.1.5 Selective Catalyst Reduction (SCR) system technical data ........ 2-76
2.4.2 Cylinder block ................................................. 2-77
2.4.3 Flywheel housing .............................................. 2-77
2.4.4 Valve mechanism .............................................. 2-77
2.4.5 Cylinder head ................................................. 2-78
2.4.6 Crank mechanism .............................................. 2-78
2.4.7 Timing gears .................................................. 2-79
2.4.8 Lubrication system ............................................. 2-80
2.4.8.1 Oil pressure regulating valve ............................. 2-81
2.4.8.2 Oil filter and oil cooler .................................. 2-81
2.4.9 Cooling system ................................................ 2-81
2.4.9.1 Thermostat ......................................... 2-82
2.4.10 Air control system .............................................. 2-83
2.4.10.1 2 stage turbocharging .................................. 2-84
2.4.10.2 Interstage charge air cooling ............................. 2-84
Table of contents
Applicator Chassis
79037161C
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2.4.10.3 Throttle valve ........................................ 2-84
2.4.11 Fuel system .................................................. 2-85
2.4.12 SCR system .................................................. 2-86
2.4.12.1 Selective Catalyst Reduction (SCR) system overview ........... 2-86
2.4.12.2 Selective Catalyst Reduction (SCR) system components and their
functions ........................................... 2-87
2.4.12.3 Supply module connectors and filters ...................... 2-88
2.4.12.4 Dosing module connections ............................. 2-89
2.4.13 Engine control system ........................................... 2-89
2.5 Technical data ..................................................... 2-91
2.5.1 Cylinder block ................................................. 2-91
2.5.2 Cylinder liners ................................................. 2-91
2.5.3 Cylinder head ................................................. 2-92
2.5.4 Valves and rockers ..............................................2-93
2.5.5 Tappets and push rods ........................................... 2-94
2.5.6 Camshaft .................................................... 2-94
2.5.7 Crankshaft ................................................... 2-94
2.5.8 Flywheel ..................................................... 2-96
2.5.9 Timing gears .................................................. 2-96
2.5.10 Connecting rod ................................................ 2-97
2.5.11 Piston, rings and pin ............................................ 2-97
2.5.12 Lubrication system ............................................. 2-98
2.5.13 Oil pump .....................................................2-99
2.5.14 Thermostat ................................................... 2-99
2.5.15 Turbocharger .................................................. 2-99
2.6 Tightening torques ............................................... 2-100
2.7 Special tools ..................................................... 2-102
2.7.1 Cylinder block tools ............................................ 2-102
2.7.2 Timing gear and flywheel housing tools ..............................2-104
2.7.3 Cylinder head and valve mechanism tools ............................ 2-105
2.7.4 Crank mechanism tools ......................................... 2-108
2.7.5 Coolant pump tools ............................................ 2-109
2.7.6 Air control system tools ......................................... 2-110
2.7.7 Fuel system tools .............................................. 2-111
2.7.8 SCR system tools ............................................. 2-115
2.7.9 Electronic diagnostic tool ........................................ 2-116
2.7.9.1 EDT diagnostic terminal ................................ 2-117
2.7.9.2 Diagnostic terminal components ......................... 2-117
2.8 Liquid quality requirements ....................................... 2-119
2.8.1 Lubricating oil quality requirements ................................. 2-119
2.8.2 Coolant quality requirements ..................................... 2-119
2.8.3 Fuel quality requirements ........................................ 2-120
2.8.3.1 Biodiesel blends ..................................... 2-121
2.8.3.2 Engine output depending on fuel quality ....................2-123
2.9 Terminal diagram ................................................. 2-124
2.10 Cylinder block .................................................... 2-128
2.10.1 Measure the cylinder liner wear ................................... 2-128
2.10.2 Remove the cylinder liner ........................................ 2-128
2.10.3 Do a check for the cylinder block .................................. 2-128
2.10.4 Change the camshaft bushing .................................... 2-129
2.10.5 Fitting plug at camshaft rear end .................................. 2-130
2.10.6 Oversize bushings for camshaft ................................... 2-130
2.10.7 Fitting plug at camshaft rear end (oversize bushings) .................... 2-131
2.10.8 Install the cylinder liner ......................................... 2-131
2.10.9 Remove the block heater ........................................ 2-134
2.10.10 Install the block heater .......................................... 2-134
2.11 Flywheel housing ................................................. 2-135
Table of contents
Applicator Chassis
79037161C
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2.11.1 Remove the flywheel housing .................................... 2-135
2.11.2 Install the flywheel housing ...................................... 2-135
2.11.3 Changing crankshaft rear oil seal .................................. 2-136
2.12 Cylinder head .................................................... 2-137
2.12.1 Removing cylinder head ......................................... 2-137
2.12.2 Removing valves .............................................. 2-137
2.12.3 Do a check for the cylinder head ................................... 2-137
2.12.4 Replace the valve guides ........................................ 2-139
2.12.5 Machine the valve seat ......................................... 2-139
2.12.6 Replace the valve seat rings ...................................... 2-139
2.12.7 Grinding valves ............................................... 2-140
2.12.8 Fitting valves ................................................. 2-141
2.12.9 Install the cylinder head ......................................... 2-141
2.13 Valve mechanism with hydraulic lash adjustment ................... 2-143
2.13.1 Engine with hydraulic lash adjusters ................................ 2-143
2.13.2 How to recognize an engine with hydraulic lash adjusters ................ 2-143
2.13.3 Remove the valve cover ......................................... 2-144
2.13.4 Install the valve cover ...........................................2-144
2.13.5 Pre-adjustment of the hydraulic lash adjusters ......................... 2-144
2.13.6 Recondition the valve mechanism ..................................2-145
2.13.7 Assembling the valve mechanism with the hydraulic lash adjusters ......... 2-146
2.13.8 Pre-adjusting the hydraulic lash adjusters ............................ 2-147
2.13.9 Replace the camshaft or the camshaft gear ...........................2-150
2.14 Crankshaft ....................................................... 2-152
2.14.1 Removing the crankshaft ........................................ 2-152
2.14.2 Checking crankshaft ........................................... 2-152
2.14.3 Replace the crankshaft gears ..................................... 2-153
2.14.4 Installing the crankshaft ......................................... 2-153
2.14.5 Crankshaft hub piece ........................................... 2-154
2.14.6 Viscose type vibration damper .................................... 2-155
2.15 Connecting rods and pistons ...................................... 2-156
2.15.1 Removing pistons together with connecting rods ...................... 2-156
2.15.2 Changing connecting rod bearings ................................. 2-156
2.15.2.1 Piston pin bushing ................................... 2-156
2.15.2.2 Big-end bearing ..................................... 2-157
2.15.3 Do a check for the connecting rod ................................. 2-158
2.15.4 Replace the piston rings ......................................... 2-158
2.15.5 Checking pistons .............................................. 2-159
2.15.6 Install the piston pin ............................................2-160
2.15.7 Install the piston together with the connecting rod ..................... 2-160
2.16 Flywheel ......................................................... 2-161
2.16.1 Changing starter ring gear on flywheel .............................. 2-161
2.16.2 Remove the flywheel ........................................... 2-161
2.16.3 Fitting flywheel ............................................... 2-161
2.17 Timing gear assembly .............................................2-162
2.17.1 Removing timing gear casing ..................................... 2-162
2.17.2 Install the timing gear housing .................................... 2-163
2.17.3 Power take-o ................................................ 2-165
2.17.4 Fan drive device ...............................................2-166
2.18 Lubrication system ............................................... 2-167
2.18.1 Oil pressure regulating valve ......................................2-167
2.18.2 Remove the oil sump ........................................... 2-167
2.18.3 Remove the suction pipe of the oil pump ............................ 2-167
2.18.4 Install the suction pipe of the oil pump .............................. 2-168
2.18.5 Removing and dismantling lubricating oil pump ........................ 2-169
2.18.6 Assembling and fitting lubricating oil pump ........................... 2-169
2.18.7 Install the oil sump gasket ....................................... 2-170
Table of contents
Applicator Chassis
79037161C
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2.18.7.1 Install the oil sump gasket, metal gasket ................... 2-170
2.18.7.2 Install the oil sump gasket, paper gasket ................... 2-170
2.18.7.3 Install the oil sump gasket, cork gasket .................... 2-171
2.18.8 Install the oil sump, self-carrying oil sump and cast oil sump .............. 2-171
2.18.9 Install the oil sump, stamped steel oil sump .......................... 2-173
2.18.10 Piston cooling nozzles .......................................... 2-173
2.18.11 Removing the oil cooler ......................................... 2-174
2.18.12 Fitting the oil cooler ............................................ 2-175
2.18.13 Remove the oil filter adapter ......................................2-175
2.18.14 Install the oil filter adapter ....................................... 2-176
2.18.15 Oil sump capacity ............................................. 2-176
2.18.16 Closed crankcase ventilation ......................................2-176
2.18.16.1 Remove the closed crankcase ventilation system components ... 2-176
2.18.16.2 Installing the closed crankcase ventilation system components ... 2-177
2.19 Cooling system ................................................... 2-178
2.19.1 Remove the distribution pipe of the coolant ...........................2-178
2.19.2 Install the distribution pipe of the coolant ............................ 2-178
2.19.3 Removing the thermostat ........................................2-178
2.19.4 Testing the thermostat .......................................... 2-179
2.19.5 Replace the thermostat ......................................... 2-179
2.19.6 Remove the coolant pump and the thermostat housing .................. 2-179
2.19.7 Install the coolant pump and the thermostat housing .................... 2-179
2.19.8 Reconditioning coolant pump ..................................... 2-180
2.19.8.1 Coolant pumps with standard bearings .................... 2-180
2.19.8.2 Coolant pumps with heavy duty bearings ................... 2-183
2.19.9 Installing the cylinder head connection part ........................... 2-183
2.19.10 Remove the idler pulleys, the belt tightener and the belt pulley .............2-184
2.19.11 Install the idler pulleys, the belt tightener and the belt pulley .............. 2-185
2.20 Air control system maintenance ................................... 2-186
2.20.1 Checking the air cleaner ......................................... 2-186
2.20.2 Do a check for the inlet and exhaust pipes ........................... 2-186
2.20.3 Remove the actuator of the turbocharger ............................ 2-187
2.20.4 Install the actuator of the turbocharger .............................. 2-187
2.20.5 Remove the exhaust manifold and the turbochargers .................... 2-187
2.20.6 Removing the turbocharger ...................................... 2-188
2.20.7 Checking the turbocharger ....................................... 2-189
2.20.8 Install the high-pressure turbocharger ............................... 2-190
2.20.9 Install the exhaust manifold and the turbochargers ..................... 2-190
2.20.10 Remove the ICAC ............................................. 2-191
2.20.11 Install the ICAC ............................................... 2-192
2.20.12 Remove the intake manifold ...................................... 2-192
2.20.13 Install the intake manifold ........................................2-193
2.21 Fuel system ...................................................... 2-194
2.21.1 Bleed the fuel system .......................................... 2-194
2.21.2 Measuring fuel feed pressure ..................................... 2-195
2.21.3 Remove the fuel filters .......................................... 2-195
2.21.4 Install the fuel filters ........................................... 2-196
2.21.5 Remove the injector overflow pipe ................................. 2-196
2.21.6 Install the injector overflow pipe ................................... 2-196
2.21.7 Inspecting injectors ............................................ 2-197
2.21.7.1 Remove the injectors (CRIN3) ........................... 2-197
2.21.7.2 Install the injectors (CRIN3) ............................. 2-199
2.21.8 High-pressure pump ........................................... 2-201
2.21.8.1 Remove the high-pressure pump ......................... 2-201
2.21.8.2 Install the high-pressure pump .......................... 2-202
2.21.9 Rail ........................................................ 2-202
2.21.9.1 Removing the rail .................................... 2-203
2.21.9.2 Install the rail ....................................... 2-204
Table of contents
Applicator Chassis
79037161C
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2.21.9.3 Removing the pressure control valve ...................... 2-204
2.21.9.4 Fitting the pressure control valve ......................... 2-205
2.21.9.5 Removing the pressure sensor .......................... 2-205
2.21.9.6 Fitting the pressure sensor ............................. 2-205
2.21.10 Troubleshooting of the Common rail fuel system ....................... 2-205
2.21.10.1 Testing the suction pressure between the fuel tank and the fuel pre-
filter .............................................. 2-205
2.21.10.2 Testing the suction pressure between the fuel pre-filter and the feed
pump ............................................. 2-207
2.21.10.3 Testing the feed pressure between the feed pump and the fuel main
filter .............................................. 2-209
2.21.10.4 Testing the feed pressure between the main fuel filter and the high-
pressure pump ...................................... 2-210
2.21.10.5 Testing the total return quantity from the injectors ............ 2-211
2.21.10.6 Testing the return quantity from the injectors ................ 2-213
2.21.10.7 Testing the pressure control valve leakage .................. 2-218
2.21.10.8 Testing the pressure release valve leakage .................. 2-220
2.21.10.9 Testing the return line pressure .......................... 2-223
2.22 SCR system ...................................................... 2-224
2.22.1 Selective Catalyst Reduction (SCR) system maintenance ................. 2-224
2.22.2 Mounting of SCR system components .............................. 2-225
2.22.3 Removing the supply module ..................................... 2-226
2.22.4 Installing the supply module ...................................... 2-226
2.22.5 Removing the hydraulic connectors ................................ 2-226
2.22.6 Installing the hydraulic connectors ................................. 2-226
2.22.7 Replace the main filter and the inlet filter of the supply module ............ 2-227
2.22.8 SPN 521008 FMI 1 ............................................ 2-228
2.22.8.1 Solve the DEF pressure build-up failure .................... 2-229
2.22.8.2 Supply module lifting capacity test ........................2-231
2.22.8.3 Solve the failure when the SM lifting capacity test is not OK ..... 2-232
2.22.8.4 Solving the failure when the SM lifting capacity test is OK ...... 2-234
2.22.9 SPN 521025 FMI 31, SPN 521026 FMI 31 ............................ 2-235
2.22.9.1 Cleanup of the SCR catalyst ............................ 2-237
2.22.9.2 Make the dosing rate test .............................. 2-238
2.22.9.3 Checking the quality of DEF ............................ 2-242
2.23 Engine control system ............................................ 2-244
2.23.1 Remove the bracket of the electronic control unit ...................... 2-244
2.23.2 Install the bracket of the electronic control unit ........................ 2-244
2.23.3 Remove the electronic control unit ................................. 2-244
2.23.4 Install the electronic control unit ................................... 2-244
2.23.5 Replace the electronic control unit ................................. 2-245
2.23.6 Replace an empty electronic control unit (ECU) ........................ 2-246
2.23.7 Wiring sets .................................................. 2-247
2.23.7.1 Injector wiring sets ................................... 2-247
2.23.7.2 Sensor and actuator wiring sets ..........................2-248
2.23.7.3 Wiring set for intake air heater ...........................2-248
2.23.7.4 Sensors of the engine control system ..................... 2-249
2.23.8 Remove the wiring harnesses .................................... 2-252
2.23.9 Install the wiring harnesses ...................................... 2-253
2.24 Prepare the long block replacement ................................ 2-254
2.25 Parts for the long block replacement ............................... 2-255
2.25.1 Delivery content of the long block engine ............................ 2-255
2.25.2 The parts that must be removed from the old engine ....................2-255
2.25.3 Other parts of the long block replacement ........................... 2-256
2.26 Remove the engine .............................................. 2-257
2.27 Lift the engine ....................................................2-258
2.27.1 Lift the engine ................................................ 2-258
Table of contents
Applicator Chassis
79037161C
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2.28 Disassemble the engine ........................................... 2-260
2.28.1 Remove the wiring harnesses .................................... 2-260
2.28.2 Remove the electronic control unit ................................. 2-260
2.28.3 Remove the bracket of the electronic control unit ...................... 2-261
2.28.4 Remove the exhaust manifold and the turbochargers ....................2-261
2.28.5 Removing the EGR system ...................................... 2-262
2.28.6 Change oil filter ............................................... 2-262
2.28.7 Removing the oil cooler ......................................... 2-262
2.28.8 Remove the oil filter adapter ..................................... 2-263
2.28.9 Remove the ICAC ............................................. 2-263
2.28.10 Remove the distribution pipe of the coolant .......................... 2-264
2.28.11 Remove the fuel filters ..........................................2-265
2.28.12 Remove the closed crankcase ventilation system components ............. 2-265
2.28.13 Removing the rail ............................................. 2-265
2.28.14 Remove the high-pressure pump .................................. 2-266
2.28.15 Remove the block heater ........................................ 2-266
2.28.16 Remove the intake manifold ...................................... 2-266
2.28.17 Remove the coolant pump and the thermostat housing .................. 2-267
2.28.18 Remove the idler pulleys, the belt tightener and the belt pulley ............ 2-267
2.28.19 Remove the valve cover ......................................... 2-268
2.28.20 Remove the injectors (CRIN3) .................................... 2-268
2.28.20.1 Remove the injector overflow pipe ........................2-270
2.28.21 Remove the flywheel ........................................... 2-270
2.28.22 Remove the oil sump ........................................... 2-270
2.28.23 Remove the suction pipe of the oil pump ............................ 2-271
2.28.24 Remove the flywheel housing .................................... 2-271
2.29 Assemble the engine ............................................. 2-272
2.29.1 Prepare the new long block ...................................... 2-272
2.29.2 Install the flywheel housing ...................................... 2-272
2.29.3 Changing crankshaft rear oil seal .................................. 2-273
2.29.4 Install the suction pipe of the oil pump .............................. 2-274
2.29.5 Install the oil sump gasket ....................................... 2-275
2.29.5.1 Install the oil sump gasket, metal gasket ................... 2-275
2.29.5.2 Install the oil sump gasket, paper gasket ................... 2-275
2.29.5.3 Install the oil sump gasket, cork gasket .................... 2-275
2.29.6 Install the oil sump, self-carrying oil sump and cast oil sump .............. 2-276
2.29.7 Install the oil sump, stamped steel oil sump .......................... 2-277
2.29.8 Fitting flywheel ............................................... 2-278
2.29.9 Install the high-pressure pump .................................... 2-278
2.29.10 Install the rail .................................................2-279
2.29.11 Installing the closed crankcase ventilation system components ............ 2-279
2.29.12 Install the fuel filters ........................................... 2-280
2.29.12.1 Install the injector overflow pipe ......................... 2-280
2.29.13 Install the injectors (CRIN3) ...................................... 2-281
2.29.14 Install the valve cover ...........................................2-282
2.29.15 Install the idler pulleys, the belt tightener and the belt pulley .............. 2-282
2.29.16 Install the intake manifold ....................................... 2-282
2.29.17 Install the coolant pump and the thermostat housing .................... 2-283
2.29.18 Install the block heater .......................................... 2-283
2.29.19 Install the distribution pipe of the coolant ............................ 2-284
2.29.20 Install the ICAC ............................................... 2-284
2.29.21 Install the oil filter adapter ....................................... 2-285
2.29.22 Fitting the oil cooler ............................................ 2-285
2.29.23 Change oil filter ............................................... 2-285
2.29.24 Fitting the EGR system ......................................... 2-286
2.29.25 Install the exhaust manifold and the turbochargers ..................... 2-286
2.29.26 Install the electronic control unit ................................... 2-288
2.29.27 Install the bracket of the electronic control unit ........................ 2-288
Table of contents
Applicator Chassis
79037161C
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2.29.28 Install the wiring harnesses ...................................... 2-288
2.30 Lift the engine ....................................................2-290
2.30.1 Lift the engine ................................................ 2-290
2.31 Install the engine ................................................ 2-292
2.32 After the long block change ....................................... 2-293
2.32.1 Starting the engine after major maintenance .......................... 2-293
2.32.2 Update the engine software ...................................... 2-293
2.32.3 Break in the engine ............................................ 2-293
2.33 Fuel system ...................................................... 2-295
2.33.1 Fuel tank .................................................... 2-295
2.33.1.1 Fuel tank description .................................. 2-295
2.33.1.2 Remove the fuel tanks ................................ 2-295
2.33.1.3 Disassemble the left-hand fuel tank ....................... 2-297
2.33.1.4 Disassemble the right-hand fuel tank ...................... 2-298
2.33.1.5 Assemble the left-hand fuel tank ......................... 2-299
2.33.1.6 Assemble the right-hand fuel tank ........................ 2-300
2.33.1.7 Install the fuel tanks .................................. 2-300
2.33.2 DEF tank .................................................... 2-303
2.33.2.1 Remove the DEF tank ................................. 2-303
2.33.2.2 Disassemble the DEF tank ............................. 2-304
2.33.2.3 Assemble the DEF tank ............................... 2-305
2.33.2.4 Install the DEF tank ...................................2-305
2.33.3 Remove the fuel lines .......................................... 2-306
2.33.4 Install the fuel lines ............................................ 2-310
2.33.5 Replace the inline fuel strainer .................................... 2-313
2.33.6 Remove the primary fuel filter/water separator ........................ 2-313
2.33.7 Install the primary fuel filter/water separator .......................... 2-315
2.33.8 Remove the secondary fuel filter .................................. 2-315
2.33.9 Install the secondary fuel filter .................................... 2-316
2.33.10 Prime the fuel system .......................................... 2-316
2.34 Exhaust system .................................................. 2-318
2.34.1 Remove the exhaust system ..................................... 2-318
2.34.2 Install the exhaust system ....................................... 2-323
3 Axles .................................................................... 3-1
3.1 Front axle .......................................................... 3-5
3.1.1 Front axle introduction ............................................ 3-5
3.1.1.1 Front axle description ................................... 3-7
3.1.1.2 Front non-drive steering axle identification .................... 3-7
3.1.2 Remove the front axle ............................................ 3-9
3.1.3 Install the front axle ............................................. 3-14
3.1.4 Remove the front end components ................................. 3-19
3.1.4.1 Remove the wheel ends ................................ 3-19
3.1.4.2 Remove the drag link .................................. 3-20
3.1.4.3 Remove the steering arm ............................... 3-21
3.1.4.4 Remove the tie rod end components ....................... 3-21
3.1.4.5 Remove the king pins and steering knuckle .................. 3-23
3.1.4.6 Remove the threaded draw keys .......................... 3-23
3.1.4.7 Remove the king pin bushings from the knuckle ...............3-24
3.1.5 Inspect the front axle ............................................3-25
3.1.5.1 Check the draw key nuts ................................3-26
3.1.5.2 Check the steering knuckle vertical end play ................. 3-26
3.1.5.3 Check the upper and lower king pin bushings for wear .......... 3-27
3.1.5.4 Inspect the tie rod ends ................................ 3-29
3.1.5.5 Inspect the front axle wheel bearings ...................... 3-29
3.1.5.6 Do a check of the front axle brake hardware ..................3-31
3.1.6 Prepare parts for installation ....................................... 3-34
Table of contents
Applicator Chassis
79037161C
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