New Holland W270C Tier 4 Wheel Loader Service Repair Manual.pdf

Print No. 84547255C
Wheel Loader
Tier 4
W270C / W300C
SERVICE MANUAL

SERVICE MANUAL
W270C
W300C
84547255C 15/03/2013
EN

Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.202] Air cleaners and lines .............................................................. 10.2
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.3
[10.400] Engine cooling system ............................................................. 10.4
[10.310] Aftercooler.......................................................................... 10.5
Transmission.............................................................................. 21
[21.114] Mechanical transmission ........................................................... 21.1
Four-Wheel Drive (4WD) system .................................................. 23
[23.314] Drive shaft.......................................................................... 23.1
Front axle system ....................................................................... 25
[25.100] Powered front axle ................................................................. 25.1
Rear axle system........................................................................ 27
[27.100] Powered rear axle.................................................................. 27.1
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.525] Auxiliary hydraulic valves and lines ................................................ 35.4
[35.701] Front loader arm hydraulic system ................................................. 35.5
[35.723] Front loader bucket hydraulic system .............................................. 35.6
Frames and ballasting ................................................................. 39
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[39.100] Frame .............................................................................. 39.1
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.216] Cylinders ........................................................................... 41.3
[41.910] Auxiliary steering ................................................................... 41.4
Wheels...................................................................................... 44
[44.511] Front wheels........................................................................ 44.1
Cab climate control ..................................................................... 50
[50.200] Air conditioning..................................................................... 50.1
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.015] Engine control system.............................................................. 55.3
[55.201] Engine starting system ............................................................. 55.4
[55.301] Alternator........................................................................... 55.5
[55.302] Battery.............................................................................. 55.6
[55.202] Cold start aid ....................................................................... 55.7
[55.011] Fuel tank system ................................................................... 55.8
[55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.9
[55.012] Engine cooling system ........................................................... 55.10
[55.024] Transmission control system..................................................... 55.11
[55.519] Cab brake controls ............................................................... 55.12
[55.030] Service brake electrical system .................................................. 55.13
[55.031] Parking brake electrical system .................................................. 55.14
[55.512] Cab controls...................................................................... 55.15
[55.035] Remote control valve electric control ............................................ 55.16
[55.036] Hydraulic system control ......................................................... 55.17
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[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.18
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system............... 55.19
[55.047] Steering control system .......................................................... 55.20
[55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) ................................... 55.21
[55.415] Loader arm and bucket control system .......................................... 55.22
[55.530] Camera........................................................................... 55.23
[55.518] Wiper and washer system........................................................ 55.24
[55.404] External lighting .................................................................. 55.25
[55.405] External lighting switches and relays ............................................ 55.26
[55.514] Cab lighting ...................................................................... 55.27
[55.510] Cab or platform harnesses and connectors...................................... 55.28
[55.408] Warning indicators, alarms, and instruments .................................... 55.29
[55.DTC] FAULT CODES.................................................................. 55.30
Booms, dippers, and buckets ....................................................... 84
[84.100] Bucket.............................................................................. 84.1
Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
[90.151] Cab interior......................................................................... 90.2
[90.114] Operator protections ............................................................... 90.3
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INTRODUCTION
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1

INTRODUCTION
International symbols – Conversion factors
Metric to U.S.
Multiply By To obtain
Sq. meter 10.763 91 Square foot
Area
Hectare 2.471 05 Acre
Newton 3.596 942 Ounce force
Force
Newton 0.224 809 Pound force
Millimeter 0.039 370 Inch
Meter 3.280 840 Foot
Length
Kilometer 0.621 371 Mile
Mass Kilogram 2.204 622 Pound
Mass/Area Kilogram/hectare 0.000 466 Ton/acre
Mass/Energy gr/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume Kg/cubic meter 1.685 555 lb/cubic yd.
Power Kilowatt 1.341 02 Horsepower
Kilopascal 0.145 038 lb/sq. inch
Pressure
Bar 14.50385 lb/sq. inch
Temperature Degree C 1.8 x C +32 Degree F
Newton meter 8.850 748 lb/inch
Torque
Newton meter 0.737 562 lb/foot
Velocity Kilometer/hr. 0.621 371 Miles/hr.
Cubic centimeter 0.061 024 Cubic inch
Cubic meter 35.314 66 Cubic foot
Cubic meter 1.307 950 Cubic yd.
Milliliter 0.033 814 Ounce (US fluid)
Litre 1.056 814 Quart (US liquid)
Litre 0.879 877 Quart (Imperial)
Litre 0.264 172 Gallon (US liquid)
Volume
Litre 0.219 969 Gallon (Imperial)
Litre/min. 0.264 172 Gallon/min. (US liquid)
Volume/time
Litre/min. 0.219 969 Gallon/min. (Imperial)
U.S. to Metric
Square foot 0.092 903 Square meter
Are
Acre 0.404 686 Hectare
Ounce force 0.278 014 Newton
Force
Pound force 4.448 222 Newton
Inch 25.4 * Millimeter
Foot 0.304 8 * Meter
Length
Mile 1.609 344 * Kilometer
Pound 0.453 592 Kilogram
Mass
Ounce 28.35 Gram
Mass/Area Ton/acre 2241 702 Kilogram/hectare
Mass/Energy lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume lb/cubic yd. 0.593 276 kg/cubic meter
Powe Horsepower 0.745 700 Kilowatt
lbs/sq. in. 6.894 757 Kilopascal
lbs/sq. in. 0.069 Bar
Pressure
lbs/sq. in. 0.070 303 Kg/sq. cm
Temperature Degree F 1.8 F - 32 Degree C
Pound/inch 0.112 985 Newton meter
Torque
Pound/foot 1.355 818 Newton meter
Velocity Miles/hr. 1.609 344 * Kilometer/hr.
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INTRODUCTION
Cubic inch 16.387 06 Cubic centimeter
Cubic foot 0.028 317 Cubic meter
Cubic yard 0.764.555 Cubic meter
Ounce (US fluid) 29.573 53 Milliliter
Quart (US liquid) 0.946 353 Litre
Quart (Imperial) 1.136 523 Litre
Gallon (US) 3.785 412 Litre
Volume
Gallons (Imperial) 4.546 092 Litre
Volume/time: Gallon/min. 3.785 412 Litre/min.
* = exact
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INTRODUCTION
Torque
Decimal hardware
Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and
UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities,
Molydisulfide greases, or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts and Studs
1/4 in 12 - 15 N·m (106 - 133 lb in)
5/16 in 23 - 28 N·m (204 - 248 lb in)
3/8 in 48 - 57 N·m (425 - 504 lb in)
7/16 in 73 - 87 N·m (54 - 64 lb ft)
1/2 in 109 - 130 N·m (80 - 96 lb ft)
9/16 in 149 - 179 N·m (110 - 132 lb ft)
5/8 in 203 - 244 N·m (150 - 180 lb ft)
3/4 in 366 - 439 N·m (270 - 324 lb ft)
7/8 in 542 - 651 N·m (400 - 480 lb ft)
1.0 in 787 - 944 N·m (580 - 696 lb ft)
1-1/8 in 1085 - 1193 N·m (800 - 880 lb ft)
1-1/4 in 1519 - 1681 N·m (1120 - 1240 lb ft)
1-3/8 in 1980 - 2278 N·m (1460 - 1680 lb ft)
1-1/2 in 2631 - 2983 N·m (1941 - 2200 lb ft)
Grade 8 Bolts, Nuts and Studs
1/4 in 16 - 20 N·m (142 - 177 lb in)
5/16 in 33 - 39 N·m (292 - 345 lb in)
3/8 in 61 - 73 N·m (540 - 646 lb in)
7/16 in 95 - 114 N·m (70 - 84 lb ft)
1/2 in 149 - 179 N·m (110 - 132 lb ft)
9/16 in 217 - 260 N·m (160 - 192 lb ft)
5/8 in 298 - 358 N·m (220 - 264 lb ft)
3/4 in 515 - 618 N·m (380 - 456 lb ft)
7/8 in 814 - 976 N·m (600 - 720 lb ft)
1.0 in 1220 - 1465 N·m (900 - 1081 lb ft)
1-1/8 in 1736 - 1953 N·m (1280 - 1440 lb ft)
1-1/4 in 2468 - 2712 N·m (1820 - 2000 lb ft)
1-3/8 in 3227 - 3688 N·m (2380 - 2720 lb ft)
1-1/2 in 4285 - 4827 N·m (3160 - 3560 lb ft)
NOTE: Use thick nuts with Grade 8 bolts.
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INTRODUCTION
Metric hardware
Use the following torques when specifications are not given.
These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated
with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Grade 8.8 Bolts, Nuts and Studs
M4 3 - 4 N·m (27 - 35 lb in)
M5 7 - 8 N·m (62 - 71 lb in)
M6 11 - 12 N·m (97 - 106 lb in)
M8 26 - 31 N·m (230 - 274 lb in)
M10 52 - 61 N·m (460 - 540 lb in)
M12 90 - 107 N·m (66 - 79 lb ft)
M14 144 - 172 N·m (106 - 127 lb ft)
M16 217 - 271 N·m (160 - 200 lb ft)
M20 434 - 515 N·m (320 - 380 lb ft)
M24 675 - 815 N·m (498 - 601 lb ft)
M30 1250 - 1500 N·m (922 - 1106 lb ft)
M36 2175 - 2600 N·m (1604 - 1918 lb ft)
Grade 10.9 Bolts, Nuts, and Studs
M4 4 - 5 N·m (35 - 44 lb in)
M5 9 - 11 N·m (80 - 97 lb in)
M6 15 - 18 N·m (133 - 159 lb in)
M8 37 - 43 N·m (327 - 381 lb in)
M10 73 - 87 N·m (54 - 64 lb ft)
M12 125 - 150 N·m (92 - 111 lb ft)
M14 200 - 245 N·m (148 - 181 lb ft)
M16 310 - 380 N·m (229 - 280 lb ft)
M20 610 - 730 N·m (450 - 538 lb ft)
M24 1050 - 1275 N·m (774 - 940 lb ft)
M30 2000 - 2400 N·m (1475 - 1770 lb ft)
M36 3500 - 4200 N·m (2581 - 3098 lb ft)
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INTRODUCTION
Grade 12.9 Bolts, Nuts and Studs
Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.
Steel hydraulic fittings
37°flare fitting
Tube OD hose ID Thread size Torque
6.4 mm (0.25 in) 7/16-20 8 - 16 N·m (71 - 142 lb in)
7.9 mm (0.31 in) 1/2-20 11 - 22 N·m (97 - 195 lb in)
9.5 mm (0.37 in) 9/16-18 14 - 34 N·m (124 - 300 lb in)
12.7 mm (0.50 in) 3/4-16 20 - 57 N·m (177 - 504 lb in)
15.9 mm (0.63 in) 7/8-14 34 - 79 N·m (301 - 699 lb in)
19.0 mm (0.75 in) 1-1/16-12 54 - 108 N·m (40 - 80 lb ft)
22.2 mm (0.87 in) 1-3/16-12 81 - 135 N·m (60 - 100 lb ft)
25.4 mm (1.00 in) 1-5/16-12 102 - 158 N·m (75 - 117 lb ft)
31.8 mm (1.25 in) 1-5/8-12 169 - 223 N·m (125 - 164 lb ft)
38.1 mm (1.50 in) 1-7/8-12 285 - 338 N·m (210 - 249 lb ft)
Split flange mounting bolts
Size Torque
5/16-18 20 - 27 N·m (177 - 239 lb in)
3/8-16 27 - 34 N·m (239 - 301 lb in)
7/16-14 47 - 61 N·m (416 - 540 lb in)
1/2-13 74 - 88 N·m (55 - 65 lb ft)
5/8-11 190 - 203 N·m (140 - 150 lb ft)
Straight threads with O-ring
Tube OD hose ID Thread size Torque
6.4 mm (0.25 in) 7/16-20 16 - 26 N·m (142 - 230 lb in)
7.9 mm (0.31 in) 1/2-20 22 - 34 N·m (195 - 301 lb in)
9.5 mm (0.37 in) 9/16-18 34 - 54 N·m (301 - 478 lb in)
12.7 mm (0.50 in) 3/4-16 57 - 91 N·m (504 - 805 lb in)
15.9 mm (0.63 in) 7/8-14 79 - 124 N·m (699 - 1097 lb in)
19.0 mm (0.75 in) 1-1/16-12 108 - 174 N·m (80 - 128 lb ft)
22.2 mm (0.87 in) 1-3/16-12 136 - 216 N·m (100 - 159 lb ft)
25.4 mm (1.00 in) 1-5/16-12 159 - 253 N·m (117 - 187 lb ft)
31.8 mm (1.25 in) 1-5/8-12 224 - 357 N·m (165 - 263 lb ft)
38.1 mm (1.50 in) 1-7/8-12 339 - 542 N·m (250 - 400 lb ft)
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7

INTRODUCTION
Steel hydraulic fittings
O-ring face seal end O-ring boss end fitting or lock nut
Nom. SAE dash
size
Tube OD Thread size Torque Thread size Torque
–4 6.4 mm (0.25 in) 9/16-18
14 - 16 N·m (124
- 142 lb in)
7/16-20
23 - 27 N·m (204
- 239 lb in)
–6 9.5 mm (0.37 in) 11/16-16
24 - 27 N·m (212
- 239 lb in)
9/16-18
34 - 41 N·m (301
- 363 lb in)
–8 12.7 mm (0.50 in) 13/16-16
43 - 54 N·m (381
- 478 lb in)
3/4-16
61 - 68 N·m (540
- 602 lb in)
–10 15.9 mm (0.63 in) 1-14
62 - 76 N·m (549
- 673 lb in)
7/8-14
81 - 88 N·m (60 -
65 lb ft)
–12 19 mm (0.75 in) 1-3/16-12
90 - 110 N·m (66
- 81 lb ft)
1-1/16-12
115 - 122 N·m (85
- 90 lb ft)
–14 22.2 mm (0.87 in) 1-3/16-12
90 - 110 N·m (66
- 81 lb ft)
1-3/16-12
129 - 135 N·m (95
- 100 lb ft)
–16 25.4 mm (1.00 in) 1-7/16-12
125 - 140 N·m (92
- 103 lb ft)
1-5/16-12
156 - 169 N·m
(115 - 125 lb ft)
–20 31.8 mm (1.25 in) 1-11/16-12
170 - 190 N·m
(125 - 140 lb ft)
1-5/8-12
203 - 217 N·m
(150 - 160 lb ft)
–24 38.1 mm (1.50 in) 2-12
200 - 254 N·m
(148 - 187 lb ft)
1-7/8-12
258 - 271 N·m
(190 - 200 lb ft)
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8

INTRODUCTION
Basic instructions
Coolant solution
Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high
boiling point with no additives to prevent leakage. Do not use non-approved anti-rust additives. Anti-rust additives
and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the
cooling system, and causing damage to the cooling system and radiator. Contact your Dealer who can supply you
with the suitable coolant solution.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the
ambient temperature is over -36 °C (-32.8 °F) use a blend of 50% ethylene-glycol based anti-freeze.
For areas where the temperature is below -36 °C (-32.8 °F) - it is advisable to use a blend of 40% water and 60%
anti-freeze.
Fuel
Use diesel fuel suitable for the ambient temperature conditions ( ASTM D975).
Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard (North America). In Europa,
fuel must comply with specification standard EN 590 or ITS EQUIVALENT.
Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high
fuel consumption.
In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier
for appropriate fuel supply.
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power
loss or will prevent the engine from starting.
In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.
Engine oil
NEW HOLLAND AMBRA UNITEK CJ-4 ENGINE OIL SAE
15W-40 is recommended for your engine. This oil insures
correct lubrication of your engine in all working conditions.
See General specification () to choose the correct oil for
climate/temperatures.
If NEW HOLLAND AMBRA UNITEK CJ-4 ENGINE OIL SAE
15W-40 cannot be obtained, use only oil of the API CI4
category.
NOTE: Do not put any performance additive or other ad-
ditive in the sump. Oil change intervals shown in this
manual are based on tests carried out utilizing NEW HOL-
LAND CONSTRUCTION lubricants.
LELI12WL30004AA 1
Fuel storage
Prolonged storage of fue l can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
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9

INTRODUCTION
Hydraulic fluid
NEW HOLLAND AMBRA HYDROSYSTEM 46 HV is specifically designed for high pressure applications and for NEW
HOLLAND CONSTRUCTION hydraulic systems. Your NEW HOLLAND CONSTRUCTION Dealer can provide hy-
draulic fluid to fulfill different climate/temperature conditions. Refer to the General specification ().
Transmission component oil
Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for
your climate/temperature conditions such as NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL.
See General specification ().
Grease
The type of grease to use depends on ambient temperature such as: NEW HOLLAND AMBRA GR 75 MD.
Environment
Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not
drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center
or your Dealer for correct disposal information.
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10

SERVICE MANUAL
Engine
W270C
W300C
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10

Engine - Engine and crankcase
Engine - General specification
Engine W/4 speed trans.
A. Idle RPM 870 - 930 RPM
Alternate low idle 570 - 630 RPM
Alternate accelerated idle 1170 - 1230 RPM
B. Maximum no load 2162 - 2212 RPM
C. Converter stall 1st gear 1970 RPM - 2nd/4th gear 2075 RPM
D. Hydraulic stall 1885 - 2195 RPM
E. Converter & hydraulic stall 1665 RPM
NOTE: Hydraulic stall and converter & hydraulic stall RPM values are read while the lift arms are rising with the bucket
held rolled back and the engine at WOT in max power mode.
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Engine - Overview – Stall tests
Instrument cluster displays
1. With the engine running, press the up or down key
and scroll through the information screens and trip
screens. The following sequence is using the down
key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen.
2. From the driving screen push the down arrow, as
shown.
LEPH12WL30050AA 1
3. “Info 1” is the first information screen using the down
arrow from the driving screen. It displays engine
RPM’s, speed, fuel level, and the Urea level.
LELI12WL30051AA 2
4. “Info 2” will be displayed next. The “Info 2” screen will
display coolant temperature, turbocharger air temper-
ature, engine oil temperature in either Fahrenheit or
Celsius, and the Urea level.
LELI12WL30052AA 3
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5. Push the down button again and the “Info 3” screen.
This screen displays the temperature in Fahrenheit or
Celsius of the transmission oil, hydraulic oil, sump oil,
and the Urea level.
LELI12WL30053AA 4
6. Push the down key again to display the “info 4” screen.
This screen display the voltage level, turbocharger air
temperature, Urea temperature and Urea level.
LELI12WL30054AA 5
7. Press the down button again and the “Trip 1” screen
will display. The LCD provides two trip computers.
These will display since last reset the total time in
hours, the total fuel, and the average fuel consump-
tion per hour.
LELI12WL30055AA 6
8. By continuing to scroll down, the fifth screen will dis-
play the “Trip 2” screen. “Trip 1” and “Trip 2” screens
can be reset independently. The previous screen can
be accessed by using the up arrow key.
LELI12WL30056AA 7
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Engine - Remove – Engine
NOTE: Put caps on the fittings and plugs in the hoses to
prevent foreign material from entering the system when dis-
connecting fuel lines or hydraulic hoses.
1. Park the machine on a level surface and lower the
bucket to the ground. Put the articulation lock (1) in
the LOCKED position.
2. Key in the RUN position, engine Off, place the pilot
control switch in the normal OPERATION position.
3. Move the loader hydraulic control handle to the raise
and lower position in order to release any hydraulic
pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure
in the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve.
6. Depress the brake pedal several times to discharge
brake accumulators.
7. Slowly loosen the filler cap on the hydraulic oil tank
to release air pressure.
LELI12WL30005AB 1
8. Put the master disconnect switch (1) in the “OFF”
position.
9. Drain the engine radiator coolant.
10. Drain the engine oil.
LELI12WL30006AB 2
11. Loosen the hose clamp (1) on the air box snorkel
under the air inlet hood.
LELI12WL30007AB 3
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12. Remove the mounting bolts on the exhaust stack
hood. Attach lifting equipment to the exhaust stack.
Remove the exhaust stack hood (1).
LELI12WL30008AB 4
13. Remove the SCR line support bracket (1).
LELI12WL30009AB 5
14. Disconnect the deaeration tank overflow hose (2).
Remove the P-clamps (1) that secure the overflow hose
to the wall and brackets. Position the overflow hose away
from the engine and engine wall.
LELI12WL30010AB 6
15. Remove the left bracket (1) and right bracket (2).
LELI12WL30011AB 7
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16. Remove the hydraulic oil lines (1).
LELI12WL30012AB 8
17. Remove the after air cooler tube (1).
Remove the bulkheads (2).
LELI12WL30013AB 9
18. Remove the oil dipstick P-clamp (3). Pull the oil dip-
stick tube (1) through the wall.
Label and disconnect the hood lift strut electrical connector
(2).
LELI12WL30014AB 10
19. Remove the before air coller tube (1).
Remove the upper radiator tube (2).
LELI12WL30015AB 11
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20. Label and disconnect the humidity sensor electrical
connector (1). Remove the turbo inlet tube (2).
Label and disconnect the air filter restriction sensor electri-
cal connector (3).
LELI12WL30016AB 12
21. Remove the wire harness P-clamp (1).
Loosen the hose clamp on the air box snorkel (2).
Disconnect the air box snorkel (3).
LELI12WL30017AB 13
22. Remove the lower, right panel (1) on the engine wall.
LELI12WL30018AB 14
23. Remove the air box assembly.
LELI12WL30019AA 15
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24. Remove the lower radiator tube (1).
LELI12WL30020AB 16
25. Attach lifting equipment to the engine wall. Remove
the engine wall’s hold-down bolts. Lift and remove
the engine wall.
LELI12WL30021AA 17
26. Remove the turbo exhaust tube (1).
LELI12WL30022AB 18
27. Disconnect the SCR coolant solenoid heater hose
(1).
LELI12WL30023AB 19
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28. Remove two bolts (2), washers (3), and nuts (4).
Remove the air box snorkel (1).
LELI12WL30024AB 20
29. Disconnect the inlet and outlet heater core heater
hoses (1).
LELI12WL30025AB 21
30. Disconnect the starter battery cables (1) and starter
switch wire (2).
LELI12WL30026AB 22
31. Disconnect the following from the crank case venti-
lation/fuel filter bracket assembly:
• Fuel pump electrical connector
• Water sensor electrical connector
• Ground wire
• Wire harness P-clamp
• Crank case filter inlet hose
• Crank case filter outlet hose
• Crank case filter oil return hose
• Fuel pump inlet tube
• Fuel pump outlet tube
LELI12WL30027AA 23
32. Remove the crank case ventilation/fuel filter bracket
assembly.
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33. Label and disconnect the engine control module
electrical connector (1).
LELI12WL30028AB 24
34. Disconnect the fuel return line (1). Disconnect the
battery positive wire (2) on the air grid heater.
LELI12WL30029AB 25
35. Disconnect the engine ground wires (1).
Remove the wire harness P-clamp (2).
LELI12WL30030AB 26
36. Remove the engine serpentine belt (1).
LELI12WL30031AC 27
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37. Label and disconnect the A/C compressor electrical
connector (1).
Label and disconnect the A/C pressure switch electrical
connector (4).
Remove the alternator power wire (3). Label and discon-
nect the bulk electrical connector (5).
Remove the A/C compressor (2). Position the A/C com-
pressor (2) away from the engine.
LELI12WL30032AB 28
38. Remove the wire harness P-clamps (1).
LELI12WL30033AB 29
39. Remove the engine oil drain tube (1).
LELI12WL30034AB 30
40. Attach lifting equipment to the engine. Support the
engine.
LELI12WL30035AA 31
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41. Remove the hydraulic oil return tube P-clamp (1).
Position the hydraulic oil return tube away from the con-
verter housing cover plate.
LELI12WL30036AB 32
42. Remove the converter housing cover plate (1).
LELI12WL30037AB 33
43. Remove the flex plate bolts (1).
LELI12WL30038AB 34
44. Remove the harmonic balancer (1).
LELI12WL30039AB 35
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45. Remove the front engine mounts (1) and engine
mount plate (2).
LELI12WL30040AB 36
46. Remove the bell housing bolts (1).
LELI12WL30041AD 37
47. Remove the engine.
LELI12WL30035AA 38
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Engine - Install
1. Carefully lower the engine into the chassis.
LELI12WL30035AA 1
2. Install the bell housing bolts (1). Tighten the bell
housing bolts (1) to a torque of 54 - 60 N·m (40 -
44 lb ft).
LELI12WL30041AB 2
3. Install the engine mount plate (5) and the engine
mount brackets (1), but do not tighten the bolts to
a torque value.
Tighten the engine bracket upper bolts (2) to a torque of
171 - 231 N·m (126 - 170 lb ft). Tighten the engine bracket
lower bolts (3) to a torque of 69 - 80 N·m (51 - 59 lb ft).
Tighten the engine mount plate bolts (4) to a torque of 386
- 434 N·m (285 - 320 lb ft). Tighten the engine bracket-to-
engine mount plate bolts (6) to a torque of 397 - 447 N·m
(293 - 330 lb ft).
LELI12WL30042AB 3
4. Install the harmonic balancer (1). Tighten the har-
monic balancer bolts (2) to a torque of 115 N·m (85
lb ft).
LELI12WL30043AB 4
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5. Install the flex plate bolts (1). Tighten the flex plate
bolts (1) to a torque of 33 - 41 N·m (24 - 30 lb ft).
LELI12WL30044AB 5
6. Apply DOW 732 RTV SILICONE CLEAR to the con-
verter housing cover plate (1).
Install the converter housing cover plate (1).
LELI12WL30037AB 6
7. Connect the inlet and outlet heater core heater hoses
(1).
LELI12WL30025AB 7
8. Reposition the hydraulic oil return tube. Install the
hydraulic oil return tube P-clamp (1).
LELI12WL30036AB 8
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9. Install the air box snorkel (1). Install two bolts (2),
washers (3), and nuts (4).
LELI12WL30024AB 9
10. Connect the SCR coolant solenoid heater hose (1).
LELI12WL30023AB 10
11. Install the turbo exhaust tube (1).
LELI12WL30022AB 11
12. Remove lifting equipment from the engine.
LELI12WL30035AA 12
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13. Install the engine wall.
LELI12WL30021AA 13
14. Install the lower radiator tube (1).
LELI12WL30020AB 14
15. Install the air box.
LELI12WL30019AA 15
16. Install the wire harness P-clamp (1). Connect the air
box snorkel (3). Tighten the hose clamp on the air
box snorkel (2).
LELI12WL30017AB 16
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17. Install the lower, right panel (1) on the engine wall.
LELI12WL30018AB 17
18. Install the turbo inlet tube (2).
Connect the humidity sensor electrical connector (1).
Connect the air filter restriction sensor electrical connector
(3).
LELI12WL30016AB 18
19. Install the upper radiator tube (2).
Install the before air cooler tube (1).
LELI12WL30015AB 19
20. Install the engine oil drain tube (1).
LELI12WL30034AB 20
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21. Install the wire harness P-clamps (1).
LELI12WL30033AB 21
22. Install the engine serpentine belt (1).
LELI12WL30031AB 22
23. Install the A/C compressor (2).
Connect the A/C compressor electrical connector (1).
Connect the A/C pressure switch electrical connector (4).
Connect the alternator power wire (3). Connect the bulk
electrical connector (5).
LELI12WL30032AB 23
24. Connect the engine ground wires (1).
Install the wire harness P-clamp (2).
LELI12WL30030AB 24
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25. Connect the fuel return line (1).
Connect the battery positive wire (2) on the air grid heater.
LELI12WL30029AB 25
26. Connect the engine control module electrical con-
nector (1).
LELI12WL30028AB 26
27. Install the crank case ventilation/fuel filter bracket as-
sembly.
28. Connect the following on the crank case ventilation/
fuel filter bracket assembly:
• Fuel pump electrical connector
• Water sensor electrical connector
• Ground wire
• Wire harness P-clamp
• Crankcase filter inlet hose
• Crankcase filter outlet hose
• Crankcase filter oil return hose
• Fuel pump inlet tube
• Fuel pump outlet tube
LELI12WL30027AA 27
29. Connect the starter battery cables (1) and starter
switch wire (2).
LELI12WL30026AB 28
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