New Holland 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System. REPAIR MANUAL

Foreword - How to use this manual ( - A.10.A.40)

The information in this manual is organized using the Integrated Coding Environment (ICE). ICE is a shorthand

system for pointing to Sections, Chapters and sub-Chapters in the manual without using the words. ICE also

identifies the type of information at that location.

A search for information on an engine component will

likely begin at the Table of Contents (TOC) or the Index:

for example, a search for information on the rear seal

of the crankshaft. When you locate “crankshaft - rear

seal” in the TOC with the indicated page number, this

Foreword explains:

•

how to proceed to the correct location in the manual

based on the ICE code,

•

how to identify the type of information you may

expect at that location.

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NOTE: Due to differences in languages and models, the page number indicated in the illustration may not applicable

to your manual. Refer to the table of contents in your repair manual.

Location

The first half of an ICE code describes the location of

the information.

(The ICE code has two parts separated by a hyphen.

The first part describes the location. The periods break

up the ICE code into its parts.)

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The first letter identifies the section.

Sections are arranged alphabetically in a manual. This

engine repair manual is contained within one section -

the Power Production Section - signified by the letter

“B,” and all ICE references in the manual begin with the

letter “B.”

Do NOT confuse a section with a bound book. Because

of its size, a section may require more than one bound

book, sometimes a book for each chapter within a

section.

This repair manual, although contained within one

RCPH05CDC476ABA

section, requires more than one bound book. The book

cover always lists both the section(s) and chapter(s)

contained inside the bound book.

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The second number and letter identify the chapter within

the section.

Chapters are arranged numerically within the section.

The chapters used in this manual are listed below:

ENGINE (B.10.A)

FUEL AND INJECTION SYSTEM (B.20.A)

AIR INTAKE SYSTEM (B.30.A)

EXHAUST SYSTEM (B.40.A)

ENGINE COOLANT SYSTEM (B.50.A)

LUBRICATION SYSTEM (B.60.A)

STARTING SYSTEM (B.70.A)

RCPH05CDC483ABA

The coding indicates that the rear seal is located in

Chapter 10.A (Engine), of Section B (Power Production).

The section and chapter titles (A) are displayed at the

top of each page in the body of the manual.

The ICE code for the section, chapter and page number

(for example, B.10.A/149) (B) are displayed at the bottom

of each page in the body of the manual.

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The last two positions in the location code always form

the title of the document - in this example, crankshaft -

rear seal.

The third number identifies a sub-chapter within the

chapter.

The number “43” represents the crankshaft and indicates

that rear seal information is located under crankshaft in

Chapter 10.A of Section B.

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The fourth number identifies the rear seal itself, a

sub-topic (or sub-sub-chapter) of crankshaft. This is not

any rear seal; this is the rear seal for the crankshaft.

The page numbers for rear seal information within

Chapter 10.A are also given.

RCPH05CDC497ABA

If the same location is viewed as part of a manual outline,

the uniqueness of the location is apparent. Rear seal

information is the only information that will be found at

B.10.A.43.02 within the entire manual.

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When you locate the information at the given page

number, the page heading confirms the location.

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Information type (Infotype)

The information in each chapter, and therefore the table

of contents, is separated into four broad categories:

•

Technical Data

•

Functional Data

•

Service Data

•

Diagnostic Data

NOTE: The information in the Index for a chapter is organized alphabetically. The locations are listed alphabetically,

and then information from the different categories is listed alphabetically for the location.

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This is the order of the information in the chapter and the

table of contents. These are the exact headings used in

the table of contents to separate the information.

There may be information on any component, like the

rear seal of the crankshaft, in any of the four categories.

The location is the same - B.A.10.43.02 for all four

categories. The second part of the code which identifies

the type of information, or infotype, is different.

RCPH05CDC421ABA

In fact, there are only two types of information offered on

the crankshaft rear seal in this manual:

•

technical data which describes a special tool

needed for installation (A),

•

and service data, which describes seal removal,

inspection and installation (B).

The first grouping in the illustration is located under the

Technical Data heading in the TOC. The second grouping

is located under the Service Data heading in the TOC.

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The coding for technical information always begins with

the letter “D.” The coding for the service information

always begins with the letter “F.”

The first letter of the infotype code always explains the

category of the information:

D = technical data,

C = functional data,

F = service data,

G = diagnostic data.

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Technical data may be:

•

a specification for the engine, the fuel system, the

air intake system, etc.,

•

a special tool, whether recommended or required,

to perform a service procedure on the component,

•

a torque value for installing a component,

•

a service limit criterion, for determining when

a component must be replaced or the pass/fail

criterion for a test.

RCPH05CDC422ABA

Functional data may be:

•

a dynamic description of how a system or

sub-system works during operation,

•

a static description of a system component,

•

an identification illustration to show the location

of components - sensor locations, fuel system

components, lubrication system components, etc.

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Service data may be:

•

a basic service action like remove, disassemble,

assemble or install,

•

an inspection or testing procedure,

•

an adjusting or measuring procedure.

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Diagnostic data may be:

•

guided troubleshooting to correct a problem,

•

symptom-based troubleshooting to locate the

source of a problem.

RCPH05CDC443ABA

When searching for information in the table of contents

or the index, pay attention to the first letter of the infotype

and its title (special tool, dynamic description, remove,

problem-solving) so you find the type of information you

are seeking.

Applicability - Does the information apply to my model?

If an entry in the table of contents or the index has no

models listed immediately beneath it, the information

applies to all models listed on the repair manual, section

or chapter cover.

The information shown is applicable to all models.

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When an entry in the TOC or index has models listed

below it, the information applies only to those models.

Although the location code, infotype code and title of the

entry are exactly the same, the model names inform you

that the content varies by model.

Go to the page number listed for your model. When you

locate the information in the manual, the same models

are listed below the title to confirm that you are at the

right location.

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Prior Operation and Next Operation

This manual makes extensive use of “Prior operation”

and “Next operation” lists to avoid repetition.

A “Prior operation” list always occurs at the beginning of

document and points to procedures which must precede

the current procedure.

A “Next operation” list always occurs at the end of a

document and points to procedures which must follow

the current procedure in order to restore the engine to

active service.

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Prior and Next operations usually contain an ICE code

reference which follows the same format as previously

explained. For example, installation of the lower main

bearings and bearing caps is the first operation listed

after the crankshaft is installed. The ICE code given is

(B.10.A.43.15 - F.10.A.15) with the title, Crankshaft Main

Bearing - Install.

The location code points to the sub-topic main bearings

(4), in the sub-chapter on the crankshaft (3), in Chapter

10.A (2), of Section B (1).

The infotype code points to a service procedure because

of the initial letter “F” that is located under Service Data

RCPH05CDC473ABA

in the table of contents.

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Safety rules ( - A.50.A.10)

Read and understand all of the safety precautions and warnings before performing any repair. This list contains

the general safety precautions that must be followed for your personal safety. Additional safety precautions are

included in the procedures where they apply.

General safety precautions

•

The work area around the engine must be dry, well lit, ventilated, free from clutter, ignition sources and

hazardous substances.

•

Always wear protective glasses and protective shoes when working.

•

Stay clear of rotating parts which can cut, mutilate or strangle.

•

Do NOT wear loose-fitting or torn clothing. Remove all jewelry when working.

•

Disconnect the battery [negative (-) cable first] and discharge any capacitors before beginning any repair work.

Put a “Do NOT Operate” tag in the cab or on the controls.

•

Only use proper engine barring techniques when rotating the engine manually. Do NOT attempt to rotate the

crankshaft by pulling or prying on the fan. This practice may cause serious personal injury, property damage,

fan damage or premature fan failure.

•

When coolant is hot from engine operation, allow the engine to cool before slowly loosening the pressure cap

to relieve pressure in the cooling system.

•

ALWAYS use blocks or the proper engine stand to support the engine before performing any repair work. Do

NOT work on an engine which is only supported by floor jacks or a hoist.

•

Relieve all pressure in the air, oil and cooling systems before any lines, fittings or related items are removed or

disconnected. Be alert for possible pressure when disconnecting any component from a system that uses

pressure. Do NOT check for leaks with your hand. High pressure oil or fuel can cause personal injury.

•

To reduce the possibility of personal injury, use a hoist or an assistant when lifting components that weigh 23

kg (50 lb) or more. Make sure all lifting equipment - such as chains, hooks or slings - is in good condition and

of the correct capacity. Make sure all lift hooks are positioned correctly. ALWAYS use a spreader bar when

necessary; lifting hooks must NOT be side-loaded.

•

Corrosion inhibitor, a component of coolant additives and lubricating oil, contains alkali. Do NOT get the

substance in eyes. Avoid prolonged or repeated contact with skin. Do NOT swallow internally. In case of

contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large

amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF THE

REACH OF CHILDREN.

•

Naptha and Methy Ethyl Ketone (MEK) are flammable materials and MUST be used with caution. Follow the

manufacturer’s instructions when using these materials. KEEP OUT OF THE REACH OF CHILDREN.

•

To prevent burns, be aware of heated parts and hot fuel in lines, tubes and compartments on recently

operated engines.

•

ALWAYS use tools that are in good condition. Understand the correct use of the tool before performing repair

work. Use ONLY genuine CNH replacement parts.

•

ALWAYS use the same fastener part number (or equivalent) when replacing fasteners. Do NOT use a fastener

of lesser quality when replacing components.

•

Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

•

Some government agencies have determined that used engine oil can be carcinogenic and can cause

reproductive toxicity. Avoid inhalation of vapors, ingestion and prolonged contact with used engine oil.

•

Coolant is toxic. If NOT reused, follow local environmental regulations for proper disposal.

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Basic instructions ( - A.90.A.05)

Definition of “clean”

Parts must be free of debris that can contaminate any engine system. This does not mean that cleaned parts

have to appear to be new.

Abrasive pads and abrasive paper

There is no part of an engine designed to withstand abrasion. All engine components are designed to lock together

or slide across each other. Abrasives and dirt particles will degrade both functions.

CNH does NOT recommend the use of emery cloth or sand paper on any part of an ASSEMBLED engine or

component, especially for removing the carbon ridge from cylinder liners or to clean block decks or counterbores.

Use abrasive products with great care when cleaning engine parts, particularly on partially assembled engines.

These cleaning products come in many forms and sizes. All contain aluminum oxide particles, silicon carbide, sand

or some other similar hard material. These materials are harder than most parts of the engine. When pressed

against a softer material, they will either damage the material or become embedded in it.

Once embedded in a part, the abrasive particle will abrade the other part it contacts until contact is no longer

made between the two parts. If the damage sufficiently degrades the oil film, the two parts may fail prematurely

from ineffective lubrication.

In addition, particles fall off of the holding material as the abrasive product is being used.

Gasket surface

The object in cleaning gasket surfaces is to remove gasket material, not to refinish the gasket surface on the part.

CNH does NOT recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used, check

the manufacturer’s directions to make sure the part being cleaned will not be damaged.

Air powered gasket scrapers can save time, but the surface cannot be damaged in the process.

All old gasket material must be removed from the gasket mating surfaces. However, it is not necessary to clean

and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the

gasket sealing surface. Surface finish and flatness tolerances must be maintained to form a quality sealing surface.

Solvents and acid cleaning

Solvents and acid-type cleaner can be used to clean disassembled engine parts (with the exception of pistons). The

best results are obtained with a cleaner that can be heated to 90 - 95 °C (180 - 200 °F). CNH does NOT recommend

any specific brand of cleaner. Always follow the manufacturer’s instructions when using cleaning solutions.

WARNING

When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations

for use. Wear goggles and protective clothing to reduce the possibility of personal injury. M995

Kerosene emulsion based cleaners work the best for cleaning pistons. These cleaners should NOT be heated to

temperatures in excess of 82 °C (180 °F). The cleaners begin to break down at temperatures in excess of 82 °C

(180 °F) and will be less effective.

Do NOT use solutions composed primarily of chlorinated hydrocarbons with cresols, phenols and/or cresylic

components. These solutions often do NOT clean well and are costly to dispose of properly.

Solutions with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. The solutions become highly

alkaline or highly acidic the further they move from the neutral 7.0. Solutions with a pH above approximately 9.5

cause aluminum to turn black; highly alkaline solutions must NOT be used.

A cleaning tank that provides a constant mixing and filtering of the cleaning solution will yield the best results.

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•

Remove all gasket material, O-rings and sludge or carbon deposits with a wire brush or scraper before putting

the parts in the cleaning tank.

•

When possible, use high pressure water or steam clean the parts before submerging them in the tank.

Removing the heaviest dirt before tank cleaning will allow the cleaner to work more effectively.

•

Rinse all parts in hot water after cleaning. Dry completely with clean shop air. Use air to remove the rinse

water from all cap screw holes and the oil drillings.

•

If the parts are NOT to be used immediately after cleaning, dip them in a suitable rust proofing compound.

This compound MUST be removed from the parts before assembly or installation on the engine.

Steam cleaning

Steam cleaning can be used to remove all types of dirt that may contaminate the cleaning tank. Steam cleaning is

an excellent method for cleaning oil drillings and coolant passages.

WARNING

Always wear protective clothing, safety glasses or a face shield when using a steam cleaner or power

washer. Failure to wear protective equipment can cause serious injury. M927

The following components should NEVER be steam cleaned:

- electrical components

- belts and hoses

- wiring harnesses

- bearings (ball or tapper roller)

– injectors

- electronic control module (ECM)

– fuel pump

- ECM connectors

Plastic bead cleaning

CNH recommends using ONLY plastic bead media on any engine part.

CNH does NOT recommend the use of glass bead blast or walnut shell media on ANY engine part. NEVER use

sand as a blast media on any engine part. Glass and walnut shell media can cause excess dust and can embed in

engine parts, which can result in premature component failure from abrasive wear.

Plastic beading can be used on many engine components to remove carbon deposits. The cleaning process is

controlled by the use of plastic beads, the operating pressure and the cleaning time.

CAUTION

Do not use the bead blasting cleaning method on aluminum piston skirts or bore pins in any piston, piston

skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result

in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.

can also be damaged. Follow the cleaning methods specified in the procedure. M1064

CAUTION

Do not contaminate wash tanks and tank type solvent cleaners with foreign material and plastic beads.

Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before

placing them in tanks and cleaners. The foreign material and plastic beads can contaminate the tank and any

other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear. M1065

Plastic bead material (U.S. size 16-20) can be used to clean piston ring grooves. Do NOT use bead blasting

media on piston pin bores or aluminum skirts. Bead blasting is best used on stubborn dirt or carbon build-up that

has NOT been removed by steam or high pressure washing, followed by cleaning in a heated wash tank. This

is particularly true of pistons: steam and soak the pistons first and then use the plastic bead method to safely

remove the carbon remaining in the grooves.

Follow the equipment manufacturer’s cleaning instructions. Adjust the air pressure in the blasting machine to

the manufacturer’s recommendation. Use these guidelines when plastic bead blasting recommendations are

not available:

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•

Use plastic bead size 16-20 (U.S. size) or equivalent.

•

Use an operating pressure of 270 kPa (40 psi) for piston cleaning. Pressure should not cause the beads to

break.

•

Steam clean or wash the parts with solvent to remove all foreign material and plastic beads after cleaning.

Rinse with hot water. Dry with compressed air.

CAUTION

Bead blasting must not disturb the metal surface of the component. If the metal surface is disturbed,

the engine can be damaged due to increased parts clearance or inadequate surface finish on parts that

move against other parts. M1066

•

When cleaning pistons, it is NOT necessary to remove all the dark stain from the piston. Removing the carbon

on the rim and from the ring grooves IS necessary. Direct the blast across the part rather than straight at the

part. If machining marks are disturbed by the blasting process, the pressure is too high or the blast is being

held on one spot too long. The blast operation must not disturb the metal surface.

•

Always direct the bead blast nozzle across rather than at the part. This allows the beading to get under the

unwanted material. Keep the nozzle moving, rather than held in one spot, to prevent surface damage.

•

Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the

nozzle across the seat surface and radius rather then straight at them.

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Torque ( - A.90.A.10)

IMPORTANT: When replacing cap screws, always use a cap screw of the same measurement and strength as

the cap screw being replaced.

Metric cap screws and nuts are identified by the grade number stamped on the head of the cap screw or on the

surface of the nuts. U.S. customary cap screws are identified by radial lines stamped on the head of the cap screw.

Cap screw marking and torque value - Metric

Commercial steel class

8.8

10.9

12.9

Cap screw head marking

rh04h178

rh04h179

rh04h180

Dia.

Cast iron

Aluminum

Cast iron

Aluminum

Cast iron

Aluminum

ft lb

115

125

180

133

195

145

195

140

100

280

200

140

100

290

210

140

100

280

200

180

135

390

285

180

135

400

290

180

135

400

290

550

400

NOTES

Always use the torque values listed in the above table when specific torque values are not supplied in a

procedure.

Do NOT use these torque values in place of specified torque values in a procedure.

The values in the table are based on lubricated threads.

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Cap screw marking and torque value - U.S. Customary

Cap screw head marking

SAE Grade 5

SAE Grade 8

rh04h175

rh04h176

Cast iron

Aluminum

Cast iron

Aluminum

Body size

ft lb

1/4 - 20

1/4 - 28

5/16 - 18

5/16 - 24

3/8 - 16

3/8 - 24

7/16 - 14

7/16 - 20

1/2 - 13

130

1/2 - 20

100

150

110

9/16 - 12

135

100

110

190

140

110

9/16 - 18

150

110

115

210

155

115

5/8 - 11

180

135

150

110

255

190

150

110

5/8 - 18

210

155

160

120

290

215

160

120

3/4 - 10

325

240

255

190

460

340

255

190

3/4 - 16

365

270

285

210

515

380

285

210

7/8 - 9

490

360

380

280

745

550

380

280

7/8 - 14

530

390

420

310

825

610

420

310

1-8

720

530

570

420

1100

820

570

420

1 - 14

800

590

650

480

1200

890

650

480

NOTES

Always use the torque values listed in the above table when specific torque values are not supplied in a

procedure.

Do NOT use these torque values in place of specified torque values in a procedure.

The values in the table are based on lubricated threads.

When a ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb wrench.

Pipe plug torque values

Size

Torque

Thread

Actual thread OD

In aluminum housing

In cast iron or steel housing

ft-lb

1/16

0.32

45 lb in

1/8

0.41

1/4

0.54

3/8

0.68

1/2

0.85

3/4

1.05

1.32

1-1/4

1.66

115

1-1/2

1.90

135

100

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Newton-meter to pound-foot conversion

N•m

lb-in/lb-ft

N•m

lb-ft

N•m

lb-ft

9 lb in

155

114

44 lb in

160

118

53 lb in

165

122

62 lb in

170

125

71 lb in

175

129

80 lb in

180

133

89 lb in

185

136

97 lb in

190

140

106 lb in

195

144

124 lb in

100

200

148

133 lb in

105

205

151

142 lb in

110

210

155

159 lb in

115

215

159

15 lb ft

120

220

162

18 lb ft

125

225

165

22 lb ft

130

230

170

26 lb ft

135

100

235

173

30 lb ft

140

103

240

177

33 lb ft

145

107

245

180

37 lb ft

150

111

250

184

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Conversion factors ( - A.92.A.21)

Weights and measures