Workshop Service Manual

5th Generation 168 AWF Engine

AGCO POWER
Andrii Netliukh
Ivan Franko
44
Derniv
Lviv Oblast
80406
Ukraine

Email address:
[email protected]

Linnavuori
AGCO Power - Linnavuorentie 8-10 - FIN-37240 June 2014
Linnavuori, Nokia, Finland V837091047
© AGCO 2014 English
 Table of contents

5th Generation 168 AWF Engine

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.1Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.2Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.3Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.4Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3 Engine construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.1 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.1 Principal dimensions and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.2 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.3 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.2.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.2.6 SCR system technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.3 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.4 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.5 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.7 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.8 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.3.9 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.3.9.1 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.3.9.2 Oil filter and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.3.10 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.3.10.1 Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.3.10.2 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.3.11 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.3.11.1 2 stage turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.2 Interstage charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.3 Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.4 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.3.12 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.3.13 SCR system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.3.13.1 SCR system components and their functions . . . . . . . . . . . . . . . . . . . . 1-27
1.3.14 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.3.14.1 Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.3.15 Electronic diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.3.15.1 EDT diagnostic terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.3.15.2 Diagnostic terminal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.1 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.2 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.2.1 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1.4 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Liquid quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.1 Oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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2.2.2 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.2.3 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.1 Engine lifting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.2 Timing gear and flywheel housing tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.3 Crank mechanism tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.4 Coolant pump tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.5 Fuel system tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.6 Maintenance and troubleshooting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.1 Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Timing gear assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Fitting the crankshaft hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.2 Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.1 Checking the oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.2 Removing the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3 Fitting the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.4 Fitting the oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.5 Removing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.6 Fitting the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.7 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.8 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.8.1 Installing the closed crankcase ventilation system components . . . . . . . . 3-11
3.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.1 Removing the thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.2 Testing the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.3 Replacing the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.4 Reconditioning the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.5 Installing the cylinder head connection part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Air control system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.1 Checking the air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.2 Checking the inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.3 Removing actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4 Fitting actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.5 Removing the low pressure turbochargers with the mounting bracket . . . . . . . . . 3-17
3.6.6 Fitting the low pressure turbochargers with the mounting bracket . . . . . . . . . . . . 3-18
3.6.7 Removing the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.6.8 Checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.9 Fitting the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.10 Removing the EGR coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.11 Fitting the EGR coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.12 Removing the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.13 Fitting the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.14 EGR link rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.15 Checking the EGR actuator voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.16 Removing the ICACs with the mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.17 Fitting the ICACs with the mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7.1 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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3.7.2 Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.7.3 Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7.3.1 Removing the injectors (CRIN3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7.3.2 Fitting the injectors (CRIN3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.7.4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.7.4.1 Removing the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.7.4.2 Fitting the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.7.5 Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.7.5.1 Removing the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.2 Fitting the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.3 Removing the pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.4 Fitting the pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.5.5 Removing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.5.6 Fitting the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.8 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.8.1 SCR system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.8.2 Mounting of SCR system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.9 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1 Changing the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1.1 Fitting the wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.10 Terminal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

5th Generation 168 AWF Engine

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5th Generation 168 AWF Engine

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 Table of contents

1. Introduction

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.1Engine type designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.2Location of the engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.3Marking of the engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.4Lifting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3 Engine construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.1 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.1 Principal dimensions and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.2 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.3 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.2.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.2.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.2.6 SCR system technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.3 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3.4 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.5 Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.7 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.8 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.3.9 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.3.9.1 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.3.9.2 Oil filter and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.3.10 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.3.10.1 Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.3.10.2 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.3.11 Air control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.3.11.1 2 stage turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.2 Interstage charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.3 Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.3.11.4 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.3.12 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.3.13 SCR system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.3.13.1 SCR system components and their functions . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.3.14 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.3.14.1 Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.3.15 Electronic diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.3.15.1 EDT diagnostic terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.3.15.2 Diagnostic terminal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

5th Generation 168 AWF Engine 1-1

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Table of contents

1-2 5th Generation 168 AWF Engine

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 1. Introduction

1.1 Safety instructions

WARNING:
In the use and service of the engine there is always the possibility of injury. Before
starting the service read and understand the safety instructions and remarks!
• Do not start any repair work that you do not fully understand.
• Make sure that the location and surroundings in which you are carrying out the repair provide a safe
environment in which to work.
• Always ensure the location is clean and free of clutter.
• Do not use faulty or otherwise unsuitable tools.
• Remove all rings, chains and watches before starting work.
• Use up-to-date protection equipment while you work. For example, eye protection, as you will be
working with compressed air for cleaning, grinding, hammering or similar.
• Use a lifting device for lifting and transporting heavy (over 20 kg) pieces. Ensure all lifting hooks and
chains are in good condition. The lifting eyes on the engine must not be subjected to side forces during
lifting.
• Never work under an engine that is hanging from a lifting device or raised up on a jack. Always use
strong supports before starting the work.
• Start the engine only by using the starting switch in the cabin.
• Do not start an engine if the protection covers are removed.
NOTE: The fan is difficult to see when the engine is running! Ensure that loose clothing or long hair
does not get caught in the rotating parts of the engine.
• If you start the engine indoors, ensure that there is proper ventilation.
• Never use an aerosol starting aid! (Risk of explosion, personal injuries and engine damage.)
• When you are operating the engine or working near it, use ear protection to avoid noise injuries.
• Always stop the engine before starting any servicing or repair work.
• Avoid touching the exhaust manifold, turbocharger and any other hot parts of the engine.
• Do not remove the thermal protection of the exhaust manifold.
• Open the radiator cap with care when the engine is hot, as the cooling system is pressurised. The
cooling liquid and lubrication oil of a hot engine will cause injury if they come into contact with skin.
• Do not open high pressure pipe connectors of the fuel system when the engine is running. Wait at least
30 sec. after the stopping of the engine. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
• Never allow a naked flame, smoking or sparks near the fuel system or batteries, especially when
loading batteries, as these are explosive.
• Always disconnect the negative (-) battery cable when servicing or repairing the electric system.
• At temperatures in excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine
(i.e. the undermost cylinder liner O-ring) produce very highly corrosive hydrofluoric acid. Do not touch
with bare hands when viton seals are subjected to abnormally high temperatures. Always use neoprene
rubber or heavy-duty gloves and safety glasses when decontaminating. Wash the seals and the
contaminated area with a 10% calcium hydroxide or other alkali solution. Put all removed material in
sealed plastic bags and deliver them to the relevant disposal point provided by the authorities
concerned.
NOTE: Never destroy viton seals by burning!
• When checking fuel injectors do not allow the jet of high-pressure fuel to come into contact with your
skin. The fuel penetrates the skin causing severe injuries. Get medical help immediately!
• The fuel, lubricating oil and coolant cause long-lasting irritation on contact with skin.
• If you are carrying out welding or similar high current operations for the appliance, we recommend that
you disconnect the electronic control unit (ECU) main connector before starting work.

Important instructions
• Avoid unnecessary idling of the engine.

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1. Introduction

• Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper
disposal point.
• Use only genuine AGCO Parts spare parts.
NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.
• All the engine gaskets are made of non-asbestos material.
• Be careful when washing the engine with high-pressure washing machine equipment. Do not use high
pressure to wash e.g. the electric and fuel equipment or the radiator because they can easily be
damaged. To get humidity removed, it is recommended to run the engine after washing.

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 1. Introduction

1.2 To the user

5th generation engines fulfil the emission requirements set by the authorities (AWF/ATF: EU97/68/EC
Stage IV and EPA 40 CFR 1039 Tier 4 Final). The manufacturer guarantees that all engines of this type are
equivalent to the engine that is officially approved.
Please note that the service schedule should be followed carefully, especially when performing periodical
maintenance. Any adjustment and repair work to the injection system or the electronic control unit should
only be carried out by a representative authorised by AGCO Power Inc. When performing any service or
repair work, only use original AGCO Parts spare parts. Inadequate or delayed service and the use of parts
other than original AGCO Parts spare parts will invalidate the responsibility of AGCO Power Inc. with
respect to the fulfilment of the emission requirements.
This Workshop Manual is intended to assist with workshop operations and repair work.
All measurements are in millimetres and valid when the temperature of the parts is +20°C, unless
otherwise stated.
NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.
Before starting any repair work, please read the safety instructions at the beginning of this book. Make
sure that you have all the necessary tools, parts and accessories to hand. The special tools mentioned in
the work instructions speed up and facilitate the work and contribute to successful execution of the work.
An engine which has undergone repairs must be run in just like a new one.
Should the engine require work not described in this manual, please consult your local agent or the Service
Department of AGCO Power Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts
about the engine before contacting us:
• engine type
• engine number
• model or equipment
• hours operated or kilometres driven
This Workshop Manual does not cover the regular service procedure as this is explained in the 5th
Generation series Operator's Manual.
As AGCO Power Inc. is continuously developing its products, all rights are reserved to alter the
specifications, accessories and the service and repair procedure without separate notice.
NOTE: AGCO Power Inc. takes no responsibility for any damages caused because of possible incorrect
information in this manual. Distribution of this manual in printed or electronic form is not allowed without
our prior agreement.

1.2.1 Engine type designations

(1) Basic type
74 = cylinder displacement, decilitres
A = aftertreatment system
(2) Turbocharged engine
W = wastegate turbo
T = standard turbo
(3) F = Tier 4 Final engine control technology
(4) C = medium duty engine
G = generating set engine
M = marine engine Fig. 1

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1. Introduction

1.2.2 Location of the engine serial number

The engine serial number is always stamped on
the cylinder block.
The serial number is also marked on the type
plate.
Engines have an electronic serial number data,
which is readable with electronic service tool. The
data includes also detailed specification, operation
history and service information.

Fig. 2

1-6 5th Generation 168 AWF Engine

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 1. Introduction

1.2.3 Marking of the engine control unit

The specification of the application is indicated on
the type plate of the engine control unit (ECU).
This specification must always be stated when
ordering a control unit or asking for adjusting
settings.
NOTE: Engine with aftertreatment system meets
EU97/68/EC Stage lV and EPA 40 CFR 1039 Tier 4
final emission requirements.
Do not fit any components on the engine other
than those originally intended for it. The use of
other than original AGCO Parts spare parts
invalidates the responsibility of AGCO Power Inc.
on the meeting of the emission requirements.

Fig. 3

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1. Introduction

1.2.4 Lifting the engine

DANGER:
Safe lifting of the engine is done with
a lifting device where the lifting force
affects the lifting eyes vertically.
A = Engine lifting eyes
Weight of the engine
Approximate dry weight of the engine is 1800 kg.

Fig. 4

1-8 5th Generation 168 AWF Engine

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 1. Introduction

Fig. 5

DANGER:
Safe lifting of the engine is done with a lifting device where the lifting force affects the
lifting eyes vertically.
Use the proper lifting tools when lifting the engine.

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1. Introduction

1.3 Engine construction

1.3.1 Engine overview
The AGCO POWER 168 AWF engine is water-cooled, turbocharged four-stroke diesel engine. The 60° V-
angle engine is equipped with wet cylinder liners, which are supported at the middle. The engine has
double Interstage charge air cooling (ICAC), double 2-stage turbocharging and double Exhaust gas
recirculation (EGR) system.
The general arrangement of the equipment of the engine is shown in the figures.

Fig. 6 AGCO POWER 168 AWF engine, right-hand side

(1) High pressure turbocharger (5) Interstage charge air cooler (ICAC)
(2) Low pressure turbocharger (6) Engine type plate
(3) Primary ECU (electronic control unit) (7) EGR valve
(4) Thermostats (8) EGR actuator

1-10 5th Generation 168 AWF Engine

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 1. Introduction

Fig. 7 AGCO POWER 168 AWF engine, left-hand side

(1) Low pressure turbocharger (12) Oil dipstick
(2) Inlet air heater solenoid (13) High pressure pump
(3) Inlet air heater (14) Fuel pre-filter
(4) High pressure turbocharger (15) Belt tightener
(5) Wastegate actuator (16) Fuel filter
(6) Interstage charge air cooler (ICAC) (17) CCV filter
(7) Secondary ECU (electronic control unit) (18) Coolant pump
(8) Hand pump (19) Thermostats
(9) Oil cooler (20) Mass air flow (MAF) sensor
(10) Oil filter (21) Throttle valve
(11) Oil filler plug

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1. Introduction

1.3.2 Technical data

1.3.2.1 Principal dimensions and data

Engine type 168

Number of cylinders 12
Displacement (ltr) 16,80
Cylinder bore (mm) 111
Stroke (mm) 145
Fuel feed Direct injection
Injection advance Automatic adjusted
Valve clearance, intake and exhaust (mm) Hydraulic lift adjusting (HLA)
Direction of rotation from the engine front Clockwise

1.3.2.2 Fuel system

Engine type 168

Fuel injection system Bosch Common Rail
Fuel The fuel must be according to norm EN 590:2009 or
ASTM D975 1-D/2-D , see the information for fuel
quality requirements
Injection order 1-12-2-11-4-9-6-7-5-8-3-10
Maximum injection pressure Max. 2000 bar
Fuel filter: Pre-filter 10 µ
Fuel filter: Main filter 5µ
Maximum continuous fuel inlet temperature 70°C

1.3.2.3 Lubrication system

Lubrication system
Oil pressure in hot engine at running speed 3 - 6 bar
Oil pressure at idle speed, minimum 3 bar
Oil sump capacity 55 - 62 litres

Oil quality requirements

API-grade CJ-4
ACEA-grade E9
Viscosity 10W - 40 or 15W - 40

1-12 5th Generation 168 AWF Engine

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 1. Introduction

1.3.2.4 Cooling system

Engine type 168

Number of thermostats 2
Opening temperature 79 ° C and 82 ° C
Coolant quality requirements See information for coolant quality requirements

1.3.2.5 Electrical system

System Voltage
Electrical system 12 V
SCR system 12 V

1.3.2.6 SCR system technical data

Principal data
SCR system Bosch DENOXTRONIC 2.2+ (12 kg / h)
Minimum operating temperature -40 °C
Maximum DEF temperature 70 °C
Maximum SCR system temperature 80 °C

Dosing system
Reagent fluid type DIN70070/ISO22241 certified DEF (Diesel Exhaust
Fluid), e.g. AdBlue
DEF consumption Approximately 6-8% of fuel consumption[1]
Pre-filters 100 µ
Main filter 10 µ

[1] DEF consumption may be higher, depending on the application and load profile of the engine.

1.3.3 Cylinder block

The cylinder block is the main body of the engine,
to which other engine parts are attached. Wet and
replaceable cylinder liners are supported at the
middle, which reduces vibrations and directs
coolant circulation mainly to the upper part of the
liners.
The seal between the lower part of the cylinder
liner and the cylinder block is achieved by three O-
rings. The O-rings are fitted in grooves in the
cylinder block.The upper part is sealed by the
cylinder head gasket.
The camshafts are located in the cylinder block.
There are separate bearing sleeves in all camshaft Fig. 8
bearing locations and the drilling for the camshaft
rear end is covered with a plug.

5th Generation 168 AWF Engine 1-13

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1. Introduction

There are spaces on both sides of the rear main

bearing for guide bearing shims (the crankshaft
thrust bearings).

1.3.4 Flywheel housing

The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is
placed in a bore in the housing. The starter motor fixing points are fitted in the flywheel housing.
The lower face of the flywheel housing functions as a sealing surface for the oil sump gasket. This means
that the lower face of the cylinder block must be level with the flywheel housing. When fitting the flywheel
housing, its position is determined by tension pins.
The flywheel housing is delivered according to the requirements set by the engine model and different
flywheel housings can be mounted on all engine types.

1.3.5 Valve mechanism

The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is
transferred with the help of tappets and push rods. The camshaft gear wheel is fitted with a nut and
guided with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in
the cylinder block. The valve mechanism has hydraulic lift adjusting.

1.3.6 Cylinder head

The 168 engine has four cylinder heads. All the cylinder heads are for three cylinders. Every cylinder has
four valves and in the middle of the valves there is a place for the injector. The injector is located vertically
in the centre of the cylinder and in the middle of the combustion chamber. This ensures accurate and
homogenous mixing of fuel and air and leads to clean and low emission combustion with good efficiency.
Each cylinder has its own inlet and exhaust ports located on either side of the head. Every inlet valve has
its own inlet port but there is only one exhaust port for every two of the cylinder’s exhaust valves. There
are no water holes on the inlet side of the cylinder head. This eliminates the possibility of water entering
the inlet air.
Cylinder head bolts are high tensile bolts, which are tightened up to yield limit using the angle tightening
method. Due to the large stretch, the tightening forces are kept constant during the whole lifetime and
retightening is unnecessary.
The injector and its side feeding pipe locations are machined directly into the cylinder head. The port for
the side feeding pipe is located between the inlet ports. The inlet and exhaust valve guides are identical
and can be interchanged. Inlet and exhaust valves are fitted with separate valve seat rings.

1.3.7 Crank mechanism

The crankshaft is forged from chrome alloy special
steel and is induction hardened at the bearing and
sealing surfaces. This makes it possible to grind
bearings without a new heat treatment. Gear
wheels are located at the front end of the
crankshaft. They are a press fit, and drive the idler
wheel and oil pump. The belt pulley/vibration
damper is fastened to the crankshaft with a cone
joint. An oil deflector ring is fitted between the hub
and gear wheel.
The crankshaft is supported on the cylinder block
by main bearings, which are placed on both sides
of each cylinder. There is therefore one main
bearing more than there are cylinders. The fourth Fig. 9
main bearing (the main bearing in the middle) is

1-14 5th Generation 168 AWF Engine

V837091047
 1. Introduction

wider than the other main bearings. The crankshaft

thrust washers are placed in both sides of the
rearmost main bearing.
A flywheel, on which there is a press-fit starter ring gear, is fitted at the rear end of the crankshaft. The
forged connecting rod has an I-cross-section. The bearing location at the bottom end of the connecting rod
is fracture-split, and the bearing cup is secured by two special elongated screws. The upper part has a
wedge-shaped bearing location, in which the piston pin bearing bushing is fitted with a press fit.
The piston is made of a eutectic aluminium alloy. In the upper face of the piston there is a combustion
chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The upper ring
location is formed in a cast iron ring, which is cast in the piston. In addition, the piston is graphite-coated to
ensure correct running-in.
The piston has three rings. The upper molybdenum-coated ring has a wedge-shaped cross-section. The
middle ring is tapered and it fits into its groove. The taper takes up the clearance. The oil control ring is
spring-loaded and it has a two-stage, chromed scraping edge.

1.3.8 Timing gears

(1) Crankshaft gear
(2) Idler gear
(3) High-pressure pump gear
(4) Crankshaft gear
(5) PTO gear
The timing gear drives the camshaft, high-pressure
pump and oil pump. The timing gear train consists
of hardened, helically cut gear wheels. The gears
are encased by the timing gear casing, which is
fitted in the front of the engine.
The idler gear is supported with a ball bearing on
the shaft on the front face of the cylinder block.

Fig. 10

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1. Introduction

1.3.9 Lubrication system

11
10

12
8

5 6

Fig. 11
(1) Oil pick-up (7) Main oil gallery (crankshaft)
(2) Oil pump (8) Camshaft + piston cooling oil gallery
(3) Oil pressure regulating valve (9) Valve lifter oil gallery
(4) Oil cooler (10) Oil pipes to turbochargers
(5) Oil filter (11) Oil return from turbochargers
(6) Oil pipe (12) Lubrication to cylinder heads
The engine has a pressure lubrication system with the gear oil pump fitted to the lowest level of the
engine. The oil pump is driven by the gear at the front end of the crankshaft. Nearly all the lubrication
points and auxiliary equipment are connected to the pressurised lubrication system by oil galleries or pipes.
Cylinder block has a main oil gallery in the middle for crankshaft lubrication. Camshafts and piston cooling
nozzles have their common oil galleries on each cylinder bank. Valve mechanism gets the lubrication via
2nd and 4th camshaft bearing. Hydraulic valve lifters have their own oil galleries on each cylinder bank.

1-16 5th Generation 168 AWF Engine

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 1. Introduction

The lubrication of the gears in the gear housing, the upper end of the connecting rods and the pistons is
mainly realized by splash lubrication. The undersides of the pistons are cooled by the oil spray.
The engine is equipped with closed crankcase ventilation (CCV) system. The CCV system is of centrifugal
oil separator type. The CCV system is maintenance free.
NOTE: Always change the oil and oil filter according to the maintenance chart.

1.3.9.1 Oil pump

(1) Nut
(2) Lock plate
The oil pump is driven by the crankshaft gear via
an idler gear attached to the oil pump. The oil
pump is a gear type of pump. The pressure is
produced by two contra-rotating gears.

Fig. 12
(1) Nut
(2) Lock plate
(3) Larger spring
(4) Smaller spring
The oil pressure regulating valve is in the oil pump.
The regulating valve keeps the oil pressure
constant and independent of the engine speed.

Fig. 13

1.3.9.2 Oil filter and oil cooler

(1) Oil cooler
(2) Oil filter
(3) Drain screw
(4) Oil dipstick
(5) Oil filler plug
(6) Coolant drain plug
The engine has an oil filter of main flow type. It
has a replaceable cartridge mounted on the left
side of the engine. To drain the oil filter, there is a
drain screw (3) in the oil filter bracket. By opening
the drain screw the oil drains from the oil filter to
the oil sump.
The engine is equipped with a plate type oil cooler. Fig. 14
The oil cooler is situated next to the oil filter on the
left side of the engine. The oil cooler is cooled by
the engine coolant circulating in the oil cooler. All
oil that circulates through the oil filter goes also

5th Generation 168 AWF Engine 1-17

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1. Introduction

through the oil cooler. The oil cooler is of main

flow type.

1.3.10 Cooling system

Fig. 15
(1) From the radiator (6) Coolant pipe to the oil cooler
(2) Distribution unit (7) Return pipe
(3) Coolant pipe to the EGR cooler (8) From the cylinder head
(4) Return pipe (9) Return pipe
(5) Coolant pipe (10) To the radiator

1-18 5th Generation 168 AWF Engine

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 1. Introduction

Fig. 16
(5) Coolant pipe (15) Coolant pipe to the wastegate actuator
(9) Return pipe (16) Return pipe
(11) Coolant pipe to the ICAC (17) Coolant pipe to the EGR actuator
(12) Return pipe (18) Return pipe
(13) Coolant pipe (19) Return pipe
(14) Return pipe
The coolant pump is attached to the front face of the cylinder block. The thermostat housing is mounted on
the backside of the coolant pump.
The coolant system has an internal liquid circulation. The liquid circulation is regulated by the 2-way
thermostats. This arrangement ensures a steady warming-up of the engine under all conditions.
The coolant circulates from the coolant pump to the distribution unit (2), which is on the cylinder block. The
distribution unit divides the coolant to the cylinder block, to the oil cooler (6) and forward (5) to the next
distribution pipe. The coolant circulates through the cylinder block to the cylinder heads. In the rear end of
the engine the coolant flows from the cylinder heads to the EGR coolers (3). In the front end of the engine
the coolant circulates back to the coolant pump from the cylinder heads.
Above the cylinder block, the coolant pipe (5) leads the coolant to the distribution pipe. The distribution
pipe divides the coolant to the ICACs (Interstage charge air coolers) (11) and through one coolant pipe (13)
to the next distribution pipe. The next distribution pipe divides the coolant to the coolant pipes of the
wastegate actuators (15) and EGR actuator (17).

5th Generation 168 AWF Engine 1-19

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1. Introduction

NOTE: Never use only water as coolant but a mixture of 40 - 60 % of water and antifreeze. See the
information for coolant quality requirements.

1.3.10.1 Coolant pump

(1) Thermostat 82°C
(2) Thermostat 79°C
(3) From the cylinder head
(4) From the radiator
(5) From the EGR cooler
(6) To the radiator
(7) From the cylinder head
(8) To the cylinder block
The coolant circulates from the coolant pump (8) to
the distribution unit, which is on the cylinder block.
The coolant flows back to the coolant pump from
the EGR coolers (5) and direct to the thermostat
housing from the cylinder head (3). Direct to the
thermostat housing the coolant flows also through Fig. 17
the return pipe (7), which gathers coolant from
cylinder head, oil cooler, ICACs (Interstage charge
air coolers) and EGR and wastegate actuators.

1.3.10.2 Thermostats
(1) Thermostat 82°C
(2) Thermostat 79°C
(A) Cold coolant circuit
(B) Hot coolant circuit
There are two separate thermostats, which differ
in opening temperature. The first thermostat (2)
opens at temperature of 79°C and the second
thermostat (1) opens at temperature of 82°C.
There are no separate winter-type thermostats.

Fig. 18

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(A) Cold coolant circuit

(B) Hot coolant circuit
When the coolant temperature is below the
thermostat opening temperature, the coolant
circulates through the thermostat into the coolant
pump (A). When the thermostat opens, it closes
the coolant circulation into the coolant pump (A)
and directs the coolant into the radiator (B).

Fig. 19

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1. Introduction

1.3.11 Air control system

Fig. 20

The air control system includes pre-filter (or cyclone, if installed), air filter, turbochargers, intercooler,
interstage charge air cooling (ICAC), mass air flow (MAF) sensor, throttle valves, intake manifolds, exhaust
manifolds, EGR valve, EGR cooler and air pipes.
The air comes from the air filter to the low pressure turbochargers (1) and is cooled in ICACs (2). From
ICACs the air flows through high pressure turbochargers (3) to the air to air intercooler (4). After MAF
sensor (5) the air flows through throttle valves (6) to intake manifolds. From intake manifolds (7) the air
flow continues to the combustion chambers. After combustion process exhaust gases are passed through
exhaust manifolds (8) to high pressure turbochargers and low pressure turbochargers (9) and eventually to
DOC and SCR system. Part of the exhaust gases is led from exhaust manifold through exhaust gas
recirculation (EGR) system.
A mechanical or electric sensor can be fitted to indicate the service point of the air filter. It the engine is
operating in very dusty conditions (for example spreading lime) it must be equipped with a special pre-filter
and oil bath air filter.

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1.3.11.1 2 stage turbocharging

The turbocharger is a turbo-compressor driven by exhaust gas. The compact design of the turbocharger is
fast to react even at low engine speeds. The turbocharger is lubricated and cooled by the lubrication
system of the engine. The 168-engine has 2 stage turbocharging. Benefits from 2 stage turbocharging are
increased low speed torque, better specific fuel consumption and decreased exhaust temperature. The 2
stage charging uses two turbochargers: Bigger low pressure turbocharger raises pressure to 1 - 1,5 bar
(relative), Smaller high pressure turbocharger has boost pressure of 2,1 - 3 bar (relative). Boost pressure is
controlled by a wastegate. Traditional wastegate is replaced with a wastegate operated by actuator
controlled by the electronic control unit (ECU). ECU-controlled Wastegate is used to control acceleration
smoke and exhaust temperatures.

1.3.11.2 Interstage charge air cooling

In 2 stage turbocharged engines the charge air is cooled between the turbochargers to increase the
efficiency and reliability. The charge air is cooled by engine coolant in the Interstage charge air cooling
(ICAC). The compressed air from high-pressure turbocharger is cooled on the air-to-air basis. The air
coming from the turbocharger has a temperature of abt. 150°C which is cooled by the cooling air of the
engine. The cooling of the compressed air stabilises the combustion, irrespective of the temperature, and
minimises the thermal and mechanical load of the engine thus lowering nitric oxides (NOx) and particles
(PT).

1.3.11.3 Throttle valve

Intake throttle valve is used to manage
temperatures in exhaust gas aftertreatment
system. The throttle valve controls Air/Fuel -ratio
to speed up engine warming, to increase exhaust
temperatures at low loads and to decrease
exhaust temperatures at high loads. The throttle
valve is controlled by ECU via CAN-bus and it has
an integrated actuator.

Fig. 21

5th Generation 168 AWF Engine 1-23

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1. Introduction

1.3.11.4 Exhaust gas recirculation system

Fig. 22
(1) Exhaust manifold (5) EGR cooler
(2) Intake manifold (6) EGR actuator
(3) Thermostats (7) EGR valve
(4) Coolant pump
The cooled exhaust gas recirculation system (EGR) used on AGCO POWER engines is controlled by
electronic engine control unit (ECU) and EGR actuator. Part of exhaust gases is led from exhaust manifold
through EGR valve to EGR cooler where they are cooled with engine coolant. The cooled exhaust gas is
mixed with fresh intake air in intake manifold before it flows to combustion chamber. The cooled EGR
system decreases the temperature in combustion chamber, which in turn results as lower nitrogen oxide
(NOx) emissions. All EGR engines have air mass flow meter. Its main functions are to measure EGR/fresh
air ratio for EGR control and to enable accurate DEF dosing to the catalyst.

1.3.12 Fuel system

The engine is equipped with common rail system which is controlled by electronic control unit (ECU).

1-24 5th Generation 168 AWF Engine

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 1. Introduction

Fig. 23
(1) High pressure pump (8) Hand pump
(2) Fuel inlet (9) Pressure control valve
(3) Pre filter (10) Injector
(4) Fuel filter (11) Pressure sensor
(5) Fuel temperature sensor (12) Rail
(6) Fuel pressure sensor (13) Overflow pipe
(7) Fuel pressure sensor
Fuel is drawn from the tank via the pre-filter, through the main fuel filter to the high pressure pump. From
the high pressure pump, fuel is pumped up into the rail. This high pressurized fuel is lying in a high
pressure pipe where it is controlled and injected through electronic injectors that are controlled by ECU.
The injection is optimized in terms of emissions, efficiency and operation noise and takes place in four
steps (maximum). Excess fuel returns from the injectors and pressure regulating valves of the high
pressure pump and rail back to the fuel tank. The overflow pipe from the filter helps the bleeding of the
system. The fuel is diesel fuel according to the norm EN 590:2009 or ASTM D975 and it must be clean and
free from water after storage (see the information for fuel quality requirements).

NOTE:
Use of anti-freeze solution is not allowed and not useful at all!

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1. Introduction

WARNING:
Do not make any work at the common rail high pressure fuel system when the engine is
running. Wait at least 30 seconds after stopping the engine .The first high pressure
component has to be loosened slowly, so that the pressure inside the fuel system can
adjust to ambient pressure. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!

1.3.13 SCR system overview

AGCO POWER engines have exhaust gas treatment with SCR technology (Selective Catalytic Reduction).
In SCR technology a liquid called DEF (Diesel Exhaust Fluid) is injected into exhaust gases. DEF liquids are
specified in standards DIN 70070 and ISO 22241. Most commonly known trademarks of DEF are AdBlue,
Air1 and Greenox. The heat of exhaust gases converts DEF to ammonia and carbon dioxide. After this the
ammonia reacts with nitrogen oxides in catalyst reducing them to harmless nitrogen gas and water steam.
The DEF consumption is approximately 6 - 8 % of the fuel consumption. The DEF tank and pipes are
heated so system works also in low temperatures. If DEF freezes, it is automatically defrosted when the
engine is started. The congealing point of DEF with 32,5 % urea concentration is -11 °C.
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. If urea quality sensor detects a problem related to urea quality, it will alert the
engine control system via CAN message thus causing the engine to run under degraded
mode.
See instructions of the machine for details of filling up, location and capacity of the DEF tank.
CAUTION:
The storage of DEF must be done under 30°C, avoiding direct sunlight.

CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. Diluting of DEF or mixing it with other substances is not allowed, it may damage
the catalyst!
CAUTION:
Even small amounts of diesel fuel in DEF tank may damage the gaskets of the SCR
system!
CAUTION:
Be careful when handling DEF. DEF is aggressive to some materials and corrosive to some
metals. DEF becomes crystalline when in contact with air. In case of a spillage rinse with
plenty of water and dry with a clean cloth.
NOTE: Engine with aftertreatment system meets EU97/68/EC Stage lV and EPA 40 CFR 1039 Tier 4 final
emission requirements.
Do not fit any components on the engine other than those originally intended for it. The use of other than
original AGCO Parts spare parts invalidates the responsibility of AGCO Power Inc. on the meeting of the
emission requirements.
NOTE: This manual only provides general information relating to SCR system. All service and repair work
should only be performed by someone with special training and the necessary special tools and gauges. All
servicing and repair work relating to the SCR system requires particular care and cleanliness!

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 1. Introduction

1.3.13.1 SCR system components and their functions

Fig. 24

The exhaust gas aftertreatment system used is Bosch DENOXTRONIC2.2 (DNOX2.2). DNOX2.2 uses SCR
(Selective catalyst reduction) technology in order to reduce the exhaust emissions from the engine.
AGCO POWER SCR system consists of engine control system and DNOX2.2 SCR system. These two
systems are connected together via CAN bus.
See instructions of the appliance for location and instructions for removing and installing the SCR system
components.

Supply module
Supply Module (SM) transfers NOx reductant (DEF) from tank and pressurizes it. It contains also filters for
reductant (prefilter and mainfilter).

Dosing module
Dosing module (DM) is installed in the exhaust pipe between turbocharger and SCR catalyst. DM contains
an electrically operated, ECU controlled solenoid valve, which will inject the required amount of DEF
through the DM nozzle. DEF amount is calculated by EEM4 for optimal reduction of NOx.

Sensors
DNOX2.2 system includes several sensors:
• NOx sensors
• Exhaust temperature sensors
• DEF tank level sensor
• Temperature sensors: DEF tank, Supply Module internal

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1. Introduction

1.3.14 Engine control system

Fig. 25
(1) Primary ECU (12) Throttle valve
(2) Secondary ECU (13) Coolant temperature sensor
(3) Speed sensor (crankshaft) (14) Boost pressure sensor
(4) Oil pressure sensor (15) Inlet air heater solenoid
(5) Fuel pressure sensor (16) Inlet air temperature sensor
(6) Magnetic proportional valve (MPROP) (17) Rail pressure sensor
(7) Fuel pressure sensor (18) Inlet air heater
(8) Fuel pressure sensor (19) Pressure control valve
(9) Fuel temperature sensor (20) Wastegate actuator
(10) Speed sensor (camshaft) (21) EGR actuator
(11) Mass air flow (MAF) sensor
The basic function of the electronic control of the engine is continuous adjustment and measuring of the
load, quantity of the fuel and rotating speed. Other additional functions are for example cold start
automatics, engine protecting automatics and SCR system control.
The engine has two electronic control units (ECU). Both primary ECU and secondary ECU receive
continuous signals from sensors that measure different functions in the engine like rotating speed, oil
pressure, boost pressure, coolant and fuel temperature. The primary ECU receives the relevant information

1-28 5th Generation 168 AWF Engine

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 1. Introduction

about the engine load need from the transmission or cabin through the CAN bus. The primary ECU shares
the information to the secondary ECU. The primary ECU controls the functions (like fuel injection) of the
right side of the engine and the secondary ECU controls the functions of the left side of the engine.
ECU makes it also possible to have a wide diagnostics through error codes.
See the information for the different sensors in the troubleshooting document in the diagnostic tool.

1.3.14.1 Engine wiring

Fig. 26
(1) Wiring for actuators (4) Wiring for machine connector
(2) Wiring for injectors (5) Wiring for intake air heaters
(3) Engine wiring set
The wiring sets are delivered as complete sets; the connectors are not available as separate spare parts.
See the information for fault codes and circuit diagrams in the Troubleshoot documentation in the
diagnostic tool.

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1. Introduction

1.3.15 Electronic diagnostic tool

NOTE:
See also EDT user manual and instructions of the
appliance.
AGCO's Electronic Diagnostic Tool (EDT) program
offers a common platform diagnostic tool used to
service all AGCO brands. EDT is an in-field
diagnostic program to help the dealer technician
accurately diagnose and solve a technical problem.
The EDT can be used by dealership technicians to
interface with specific machines that have a
Controller Area Network CAN BUS as part of the
electronic system architecture
EDT is a plug and play diagnostic tool kit that
contains a diagnostic terminal, vehicle connection
cables, CAN BUS protocol adapter, carry case, and Fig. 27
other items.
A version of the EDT kit less the diagnostic
terminal and associated parts is available. This kit
will contain the EDT software application, cables,
and 2x4 CAN USB Protocol Adapter.
EDT includes troubleshoot documentation with
ECU fault codes and their explanations.

1.3.15.1 EDT diagnostic terminal

NOTE:
Make sure hands are clean of grease, water or
excessive grime before touching or turning on the
unit.
The EDT diagnostic terminal is a tablet computer.
The terminal has a network connection port and
will function like any other computer.
The EDT diagnostic terminal is semi-ruggedized
which means the terminal will withstand moderate
shock and vibration during use. The screen is fluid
resistant (including oil) with a replaceable
protective cover.
Fig. 28
NOTE:
It is advised to treat the EDT diagnostic terminal as
a service tool and not an additional computer to
include in the dealership LAN network.
The diagnostic terminal needs to be available to
the service technician at all times for use in
repairing customer applications.
The EDT diagnostic terminal has an electronic
keyboard program installed. The keyboard can be
activated by the user from within the EDT
application.

1-30 5th Generation 168 AWF Engine

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 1. Introduction

The on-screen keyboard is touch-screen activated,

fully functional, and is presented in the regional
format based on language requirements.

1.3.15.2 Diagnostic terminal components

(1) Battery LED
(2) Hard drive activity LED
(3) Speaker

Fig. 29 Front terminal view

Fig. 30 Left hand side terminal view

Fig. 31 Top terminal view

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1-32 5th Generation 168 AWF Engine

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 Table of contents

2. Specifications

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.1.1 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.2 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.2.1 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1.4 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Liquid quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.1 Oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.2 Coolant quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.3 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.1 Engine lifting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.2 Timing gear and flywheel housing tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.3 Crank mechanism tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.4 Coolant pump tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.5 Fuel system tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.6 Maintenance and troubleshooting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

5th Generation 168 AWF Engine 2-1

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2-2 5th Generation 168 AWF Engine

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 2. Specifications

2.1 Technical data

2.1.1 Flywheel

Flywheel
Interference fit between ring gear and flywheel 0.425 - 0.600 mm
Before fitting the ring gear, heat up to a 180 - 200 °C
temperature of
Maximum permissible axial wobble of flywheel 0.12: Ø 410
clutch face, measured at inner edge of clutch face
on diameter 410

2.1.2 Lubrication system

Lubrication system
Oil pressure at normal running temperature

• at idling speed (minimum) • 3 bar

• at running speed (warm engine) • 3 - 6 bar

Oil pressure regulating valve

• Free length of oil pressure regulating valve • 70 mm

spring (Ø 29 mm)

• Free length of oil pressure regulating valve • 50 mm

spring (Ø 15 mm)

• Assembly length / load of oil pressure regulating • 37.5 mm / 197.5 Nm

valve spring (Ø 29 mm)

• Assembly length / load of oil pressure regulating • 58.5 mm / 136.85 Nm

valve spring (Ø 15 mm)

Oil filter by-pass valve opens at a pressure 2 ± 0.5 bar

difference of

2.1.2.1 Oil pump

Oil pump
Backlash between gears when crankshaft lies firmly
against the lower side of the main bearings

• crankshaft gear and idle gear • 0.1 - 0.25 mm

• idle gear and oil pump gear • 0.1 - 0.25 mm

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2. Specifications

2.1.3 Thermostat

Type Opening begins at Fully open at Maximum stroke

79°C 79°C ± 2°C 92°C 9,5 mm
82°C 82°C ± 2°C 95°C 9,5 mm

2.1.4 Turbocharger

168 168
High pressure Low pressure
Axial clearance maximum (mm) 0,1 0,1
Radial clearance maximum (mm) 0,5 0,5

2-4 5th Generation 168 AWF Engine

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 2. Specifications

2.2 Liquid quality requirements

2.2.1 Oil quality requirements

Oil quality requirements

API-grade CJ-4
ACEA-grade E9
Viscosity 10W - 40 or 15W - 40

2.2.2 Coolant quality requirements

The coolant used must meet the demands of
standard ASTM D 3306 or BS 6580:1992.
• The cooling mixture must consist 40 - 60 % of
ethylene/propylene-glycol based antifreeze and
water. The best proportion is 50 % of
antifreeze liquid and 50 % of water.
• The water used must be mechanically clean
and not too acid (e.g. swamp water) or too hard
(calciferous well water).
• Check periodically the proportion of antifreeze
(the frost resistance) in the coolant.
• Do not mix ethylene- and propylene-glycol
based antifreeze.
Fig. 1
• Change the coolant every two years.
NOTE: Never use only water as coolant but a
mixture of 40 - 60 % of water and antifreeze. See
the information for coolant quality requirements.
DANGER:
Antifreeze is hazardous to health. Avoid contact with the eyes and skin.

2.2.3 Fuel quality requirements

Requirement Test method
Density, +15°C 0,82 - 0,84 kg/dm3 EN ISO 3675:1998, EN ISO 12185
Viscosity, +40°C 2,0 - 4,5 mm2/s EN ISO 3104
Sulphur content maximum 15 mg/kg EN ISO 14596:2007
Cetane number minimum 51 EN ISO 5165:1998
Water content maximum 200 mg/kg prEN ISO 12937:2000
Lubricity/HFRR maximum 460 µm ISO 12156-1

The fuel must be according to norm EN 590:2009 or ASTM D 975 1-D or 2-D.
CAUTION:
Supplementary admixtures or additives are not allowed.

5th Generation 168 AWF Engine 2-5

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2. Specifications

CAUTION:
Fuels according to EN 590:2009 may contain up to 7% FAME (fatty acid methyl ester) type
biodiesel according to EN 141214:2008. Fuels according to ASTM D975 may contain up to
5% FAAE (fatty acid alkyl ester) type biodiesel according to ASTM D6751-08. Contact
AGCO Power R&D for more information of using different types of biodiesel!

Engine output depending on fuel quality

Different fuel qualities like temperature, density
and viscosity affect the actual output of the
engine. Our outputs are specified by fuel with a
density of 0.84 kg/dm3 and specific heat rate of
42,7 Mj/kg at a fuel temperature of +15°C.
The correction in % caused by the change of fuel
qualities is seen in the attached figures.
FIG. A. Engine output dependence on fuel
temperature. +35°C is the reference temp
(correction 0%). The fuel temperature is not only a
function of ambient conditions but also varies
according to the fuel system of the application
(tank size and location, return flow etc.).
FIG. B. Engine output dependence on fuel density.
Normal value is 0,84 kg/dm3 at +15°C.
FIG. C. Engine output dependence on fuel
viscosity. Normal value is 3 cSt at +20°C.
Note figure B and C only if the fuel quality is
changed.
In fig. A there are all the quality dependencies
caused by the change of the temperature. The fuel
density and viscosity can be seen in the produce
declaration given by the manufacturer.
The output correction is made as follows:
Correction percentages from figures A, B and C
are summed up. The given rated power is then
corrected with the resulting percentage.

Fig. 2

2-6 5th Generation 168 AWF Engine

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 2. Specifications

Alternative fuels
Using diesel fuel according to European norm EN 590:2009 or ASTM D 975 1-D or 2-D, all AGCO POWER
engines have full warranty for the specified warranty period and the engines will work well with good
reliability and long life time.
NOTE: Use of fuel not meeting these requirements may result as reduced performance and shorter engine
life. It also invalidates the engine warranty.

5th Generation 168 AWF Engine 2-7

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2. Specifications

2.3 Tightening torques

Object Nm
Crankshaft screw 1000
Crankshaft pulley screws 80
Flywheel screws 200
Flywheel housing screws
• M14 200
• M12 150
Idler gear screws
• M14 180
• M10 75 + 5
• M8 32
Small idler gear screws (shaft, 2 pcs), M8 45
Small idler gear screws (thrust ring), M8 32
Camshaft gear nut 200
Rocker arm shaft bracket screw and nuts 45
Valve cover and frame screws 30
Oil pump retaining screws 80
Oil sump drain plug M18 80
Oil pump regulating valve nut 210 ± 10
Coolant pump pulley screw M10 50
Belt tightener screw 48
Exhaust manifold screws 50
EGR valve screws (M8) 35
Injector fastening screw 40
Injector Fastening nut 50
Injector wire nuts (M4) 1,5
High pressure pump gear nut 280
High pressure pump fixing screws 37.5 ± 2.5
Low pressure fuel pipes to high-pressure pump 30 ± 3
M16
High pressure fuel pipes to high-presure pump and
rail
• M14 30
• M16 40
Pre-filter water detector 6
Rail pressure sensor 70
Rail pressure control valve Tighten 80 ± 4 Loosen 90° Tighten 85 ± 6
Compressor gear nut (1 and 2 cylinder) 160 (LH thread)

2-8 5th Generation 168 AWF Engine

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 2. Specifications

Object Nm
Mounting bracket of LP turbochargers
• M10 80
• M12 120
Dosing module M6 8
NOx sensor 50
Exhaust gas temperature sensor 40
ECU mounting bracket 30
ECU mounting bracket 10
Oil and fuel pressure sensor M10 25
Coolant and fuel temperature sensor M14 25

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2. Specifications

2.4 Special tools

2.4.1 Engine lifting tools
(1) Lifting tool for engine front end V837081831
(2) Lifting tool for engine rear end V920211590

Fig. 3

2.4.2 Timing gear and flywheel housing tools

(1) Drift for fitting crankshaft rear oil seal
V920215670
(2) Drift for fitting crankshaft front oil seal
V920215660

Fig. 4
(3) Drift for tension pins in timing gear housing
V902598700

Fig. 5

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 2. Specifications

2.4.3 Crank mechanism tools

(1) Opening tool for crankshaft hub nut
V920220290

Fig. 6
(2) Puller for crankshaft hub V910453300

Fig. 7

2.4.4 Coolant pump tools

(1) Drift for fitting coolant pump water seal
V920197880

Fig. 8

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2. Specifications

2.4.5 Fuel system tools

(1) Puller for high-pressure pump gear
V905248900

Fig. 9

2.4.6 Maintenance and troubleshooting tools

(1) Return quantity tester V837079449
(2) SCR tool kit V837091048
SCR tool kit includes:
• Pressure test unit 0-16 bar
• Measuring jug with adapter for dosing module
• Scale with calibration weight
• Adapter tube 9.5x20 transparent (2 pcs.)
• Adapter tube 8.0x20 transparent
• Extension tube 9.5x20 (2 pcs.)
• Extension tube 8.0x20 (2 pcs.)
• Extension cable dosing module (2 pcs.)
• Fill head 8.0x20 Fig. 10
• Fill head 9.5x20
• Rinse adapter 8.0x20
• Rinse adapter 9.5x20
• Rinse hose 9.5x20
• Oil test paper
• Vacuumpump
• Garden hose adapter ½“
• Refractometer
• Pressure test unit -1-1,5 bar

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3. Maintenance

3.1 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.1.1 Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Timing gear assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Fitting the crankshaft hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.2 Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.1 Checking the oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.2 Removing the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3 Fitting the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.4 Fitting the oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.5 Removing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.6 Fitting the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.7 Oil sump capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.8 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.8.1 Installing the closed crankcase ventilation system components . . . . . . . . . . . . . 3-11
3.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.1 Removing the thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.2 Testing the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.3 Replacing the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.4 Reconditioning the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.5 Installing the cylinder head connection part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Air control system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.1 Checking the air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.2 Checking the inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.3 Removing actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4 Fitting actuator of the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.5 Removing the low pressure turbochargers with the mounting bracket . . . . . . . . . . . . . . 3-17
3.6.6 Fitting the low pressure turbochargers with the mounting bracket . . . . . . . . . . . . . . . . . 3-18
3.6.7 Removing the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.6.8 Checking the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.9 Fitting the high pressure turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.10 Removing the EGR coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.11 Fitting the EGR coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.12 Removing the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.13 Fitting the EGR actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.14 EGR link rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.15 Checking the EGR actuator voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.16 Removing the ICACs with the mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.17 Fitting the ICACs with the mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7.1 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7.2 Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7.3 Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7.3.1 Removing the injectors (CRIN3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7.3.2 Fitting the injectors (CRIN3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.7.4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.7.4.1 Removing the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
5th Generation 168 AWF Engine 3-1
V837091047
Table of contents

3.7.4.2
Fitting the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.7.5 Rail . . .
............................................................ 3-29
3.7.5.1
Removing the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.2
Fitting the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.3
Removing the pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.5.4
Fitting the pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.5.5
Removing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.5.6
Fitting the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.8 SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.8.1 SCR system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.8.2 Mounting of SCR system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.9 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1 Changing the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1.1 Fitting the wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.10 Terminal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-2 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

3.1 Flywheel housing

3.1.1 Fitting flywheel housing
The flywheel housing is centred on the cylinder block by two tension pins. Even the flywheel housings
which are delivered as spare parts have ready-made holes for the pins.

Procedure
1. Clean the sealing surfaces between the
cylinder block and the flywheel housing.
2. Apply silicone sealant V836662741 as shown
in the figure.
3. Lift the flywheel housing into place and fit all
the bolts.
4. Fit the tension pins with drift V902598700.
5. Apply thread sealant Loctite 572 to the fixing
bolts reaching oil or water spaces.
6. Tighten the fixing bolts to the correct torque
value.

Fig. 1

3.1.2 Changing crankshaft rear oil seal

Procedure
1. Lift out the engine.
2. Remove the clutch assembly (and if
applicable the turbine clutch).
3. Remove the flywheel.
4. Remove the oil seal.
Do not damage the crankshaft.
5. Clean the seal location and grind off any
burrs.
NOTE: If the crankshaft is worn at the
sealing location, a 2 mm spacer ring, can be
fitted in front of the crankshaft rear oil seal.
Fig. 2

(1) Spacer ring

6. Fit the seal.
a) Fit the seal dry, not oiled.
b) Put the sleeve (A) against the crankshaft
rear end so that the sleeve is on the shaft
bevelling.
c) Push the seal (B) over the sleeve on the
shaft and further against the flywheel
housing.
d) Remove the sleeve and hit the seal into
position with the fitting tool.

Fig. 3

5th Generation 168 AWF Engine 3-3

V837091047
3. Maintenance

Fig. 4

(1) Fitting tool V920215670

3-4 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

3.2 Flywheel
3.2.1 Fitting flywheel

Procedure
1. Clean the contact surfaces on the crankshaft
rear flange and on the flywheel.
2. Fasten the flywheel to the crankshaft rear
end.
Suitable studs (2 pcs) can be used as guide
pins and screwed into the flywheel fixing bolt
holes.
3. Tighten the flywheel retaining screws evenly
to the correct torque value.

5th Generation 168 AWF Engine 3-5

V837091047
3. Maintenance

3.3 Timing gear assembly

3.3.1 Fitting the crankshaft hub
When installing the hub must the conical surfaces be absolutely clean.

Procedure
1. Check and clean carefully the conical
surfaces on the crankshaft and the hub.

Fig. 5

(1) Crankshaft hub

(2) Crankshaft hub nut
(3) Vibration damper
(4) Belt pulley
(5) Belt pulley
2. Install the hub in its place towards the
crankshaft gear.
3. Lubricate the hub screw thread, rear surface
and outer surface (the surfaces affecting nut
friction) with Vaseline.
NOTE: Do not use oil, it may run into the
conical surfaces.
4. Install the hub screw onto the crankshaft
thread and tighten it to the correct torque
value.

3-6 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

3.3.2 Power take-off

The engines use a transmission that can be
equipped with a PTO run from the camshaft gear.
The PTO can run e.g. a hydraulic pump.
NOTE: Use molybdenite-sulphide (MoS2) ball
bearing grease (NLGI 2) for the grooves of the
hydraulic pump shaft and the coupling sleeve.

Fig. 6

5th Generation 168 AWF Engine 3-7

V837091047
3. Maintenance

3.4 Lubrication system

3.4.1 Checking the oil pressure regulating valve
If the pressure of the engine lubricating oil is insufficient or varies, the oil level must be checked. If needed,
check the oil pressure regulating valve after checking the oil level.

Procedure
1. Drain the engine oil.
2. Remove the oil sump.
3. Remove the nut (1) and the lock plate (2).
4. Remove the larger spring (3) and the smaller
spring (4).
5. Clean the parts.
6. Check that the sealing surfaces are
undamaged.
Damaged parts must be changed.
7. Fit the springs.
8. Fit the lock plate and nut.
NOTE: Make sure that the lock plate goes
under the nut.
Fig. 7
9. Fit the oil sump.
10. Fill in the lubrication oil. (1) Nut
(2) Lock plate
(3) Larger spring
(4) Smaller spring

3.4.2 Removing the oil pump

Procedure

1. Drain the engine oil.

2. Remove the oil sump.
3. Remove the oil pump suction and pressure pipe.
4. Remove the oil pump together with any shims between the oil pump and the cylinder block.

3.4.3 Fitting the oil pump

Procedure
1. Fit the oil pump.

3-8 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

2. Check the tooth backlash.

a) Check the backlash between the
crankshaft gear and idle gear.
b) Check the backlash between the idle gear
and the oil pump gear.
NOTE: When measuring the tooth backlash,
the engine should be the correct way up as
the crankshaft bearing clearance affects the
tooth backlash.
The clearance is adjusted with shims
between the pump body and the cylinder
block. One shim increases/decreases the
backlash by about 0.07 mm. Fig. 8

3. Connect the oil pump suction and pressure

pipes using new seals.
4. Apply thread sealer Loctite 242 to oil sump
bolts (engines with steel sump).
5. Fit the oil sump.
6. Fill in the lubrication oil.

Fig. 9

3.4.4 Fitting the oil sump gasket

Procedure
1. Fit the oil sump gasket against the cylinder
block.
2. Make sure that the oil sump gasket is fitted
in correct position.
There is a cut for the oil pressure pipe flange
on the left side of the oil sump gasket. The
oil sump gasket must not remain under the
oil pressure pipe flange. If the oil sump
gasket remains under the oil pressure pipe
flange, it can result in oil leak.

Fig. 10

3.4.5 Removing the oil cooler

5th Generation 168 AWF Engine 3-9

V837091047
3. Maintenance

Procedure
1. Open the coolant drain plug under the oil
cooler and drain the coolant into a suitable
container.
2. Remove the turbo oil pipes and the oil
pressure pipe.
3. Remove the CCV pressure oil pipe.
4. Remove the oil filter.
5. Drain the oil into a container.
6. Remove the oil cooler from the engine and
simultaneously remove the coolant pipes
from the oil cooler.
7. Unscrew the cell screws and remove the cell
Fig. 11
from the mounting bracket.
8. Clean all the parts. (1) Oil cooler
(2) Oil filter
(3) Drain screw
(4) Oil dipstick
(5) Oil filler plug
(6) Coolant drain plug

3.4.6 Fitting the oil cooler

NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.

Procedure
1. Fit the cell to the mounting bracket.
° After fitting the cell to the mounting
bracket, the oil side can be pressure
tested. Test pressure is 4 bar.
° After fitting the cell to the mounting
bracket, the water side can be pressure
tested. Test pressure is 4 bar.
2. Fit the oil cooler to the engine and
simultaneously fit the coolant pipes to the oil
cooler.
3. Fit the oil pipes.
4. Replace the oil filter.
5. Fill the coolant system. Fig. 12
6. Start the engine and check for leakages.

3-10 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

3.4.7 Oil sump capacity

Oil sump capacity
• minimum: 55 litres
• maximum: 62 litres

Fig. 13

3.4.8 Closed crankcase ventilation

All 5th Generation engines have closed crankcase ventilation (CCV) with filtering of ventilation gases. This
is to prevent oil and soot getting into engine air intake with ventilation gases. The CCV system is
maintenance-free.
The CCV system has a centrifugal-type filtering, which is driven by the engine oil pressure.

3.4.8.1 Installing the closed crankcase ventilation system components

The CCV filter is mounted on the front end of the cylinder block with a mounting bracket. Centrifugal filter
is connected to engine oil circulation with a pipe. The ventilation gases are circulated from valve cover to
inlet piping with rubber hoses.

Procedure
1. Replace the mounting bracket O-ring and
shaped gasket, if the CCV filter has been
removed
2. Fit the CCV system hoses.
Make sure that there are no unnecessary
bends or creases on the CCV system hoses.
The hose line must be straightforwardly
ascending as shown in the figure.
3. Make sure that the monitoring hole for
ambient pressure is not blocked.

Fig. 14

5th Generation 168 AWF Engine 3-11

V837091047
3. Maintenance

3.5 Cooling system

3.5.1 Removing the thermostats

Procedure
1. If the ECUs are cooled by fuel, disconnect
the fuel pipe connectors carefully from the
primary ECU.
2. Remove the primary ECU.
3. Remove the mounting brackets of the
primary ECU.
4. Open the clamps of the coolant pipes
connected to the thermostat housing.
5. Open the thermostat housing cover screws.
6. Disconnect the wiring from the coolant
temperature sensor.
NOTE: Beware of the thermostats.
If more space is needed for disconnecting
the wiring from the coolant temperature,
slide the thermostat housing cover. Slide
carefully the thermostat housing cover
parallel with the thermostat housing away
from the engine until there is enough space
to disconnect the wiring of the coolant
temperature sensor.
7. Remove the silicone hoses of the coolant
pipes.
8. Remove the thermostat housing cover.
9. Remove the thermostats.
Fig. 15
10. Clean the sealing surfaces.
(1) Fuel pipe connector
(2) Primary ECU (electronic control unit)
(3) Mounting bracket
(4) Mounting bracket
(5) Clamp
(6) Coolant temperature sensor

3.5.2 Testing the thermostat

Procedure

1. Lower the thermostat into a vessel of boiling water so that it does not touch the sides or bottom.
2. Opening of the thermostat must begin after less than 20 seconds.
3. The thermostat must be fully open in less than 50 seconds. See the technical data of the thermostat.

3-12 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

3.5.3 Replacing the thermostat

Procedure
1. Lubricate the sealing rings with liquid soap
and place the thermostats in the thermostat
housing.
2. Fit the thermostat housing cover. Do not
tighten the thermostat housing cover
screws.
3. Fit the silicone hoses of the coolant pipes.
4. Connect the wiring to the coolant
temperature sensor.
If more space is needed for connecting the
wiring to the coolant temperature, slide the
thermostat housing cover.
Fig. 16
a) Slide carefully the thermostat housing
cover parallel with the thermostat housing (1) Thermostat 82°C
away from the engine until there is (2) Thermostat 79°C
enough space to connect the wiring of (A) Cold coolant circuit
the coolant temperature sensor. (B) Hot coolant circuit
NOTE: Beware of the thermostats.
b) Connect the wiring of the coolant
temperature sensor.
c) Slide carefully the thermostat housing
cover parallel with the thermostat housing
back to its position.
5. Tighten the thermostat housing cover
screws.
6. Tighten the clamps of the coolant pipes.
7. Fit the mounting brackets of the primary
ECU.
8. Fit the primary ECU.
See the instructions for fitting the ECU.
9. If the ECUs are cooled by fuel, connect the
fuel pipe connectors carefully to the primary
ECU.

3.5.4 Reconditioning the coolant pump

NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.

5th Generation 168 AWF Engine 3-13

V837091047
3. Maintenance

Procedure
1. Drain the coolant.
2. Remove the coolant pump cover.
3. Remove the belt pulley by opening the belt
pulley fixing screw.
4. Remove the impeller.
5. Tap out the water seal and the shaft.
6. Remove the bearings and the intermediate
sleeve from the shaft.
7. Clean the parts and inspect the condition of
the parts.
8. Replace faulty or worn parts with new ones.

Fig. 17
9. Fit the bearings and the intermediate sleeve
onto the shaft.
10. Grease the bearings with heat-resistant ball
bearing grease (NLGI 2).
11. Fit the shaft and the bearings into the coolant
pump.
Ensure the ball bearings do not transmit the
pressure.

Fig. 18

(1) Belt pulley fixing screw

(2) Washer
(3) Belt pulley
(4) Lock spring
(5) Bearing
(6) Intermediate sleeve
(7) Shaft
(8) Coolant pump cover
(9) Water seal
(10) Impeller
12. Fit the water seal with drift.
Use coolant as a lubricating liquid between
the shaft and the seal.

Fig. 19

(1) Drift V920197880

3-14 5th Generation 168 AWF Engine

V837091047
 3. Maintenance

Fig. 20

(A) Mounting dimension for the water seal, A =

11.94 ± 0.18 mm
13. Press the impeller into position.
At the same time, support the shaft at the
other end.
The mounting depth for the impeller is B =
3.8 mm ± 0.1 mm.
Ensure the shaft can rotate freely.
14. Fit the belt pulley by fixing the belt pulley
fixing screw.
15. Fit the coolant pump cover.

Fig. 21

(B) Mounting dimension for the impeller, B = 3.8

mm ± 0.1 mm

3.5.5 Installing the cylinder head connection part

NOTE: When installing cylinder head connection
part and side covers, the gaskets (1 and 2) must
be installed with protruded side towards the
cylinder heads for better sealing. Tightening torque
for connection part bolts is 50 Nm. Tighten the
screws in crosswise sequence.

Fig. 22

5th Generation 168 AWF Engine 3-15

V837091047
3. Maintenance

3.6 Air control system maintenance

3.6.1 Checking the air cleaner
The engine performance and length of service life depend to a great extent on the state of the air cleaner.
A defective air cleaner allows impurities to pass through, which in time damages the turbocharger and the
engine. A blocked air cleaner reduces the engine output and also causes oil leakage through the sealing
ring on the turbocharger shaft.
See the instructions of the machine manufacturer for checking or cleaning the air cleaner.

3.6.2 Checking the inlet and exhaust pipes

NOTE: Leaks in the inlet or exhaust system
drastically reduce the effect of the turbocharger.
Because of the pressure, even small leaks in the
manifold or the turbine inlet contact flange quickly
increase in size. For this reason, all leaks must be
dealt immediately.
Inlet air

Exhaust gases

Lubrication oil
Fig. 23

Procedure

1. Inspect the pipes and sealing surfaces between the air cleaner and the turbocharger, as well as
between the turbocharger and the intake manifold.
If the intake manifold is dusty inside, there is a leak in either the air cleaner or the inlet pipes. Fix the
leak.
2. Clean the intake manifold sealing surface.
a) Check that the sealing surface is flat using a straight ruler.
b) Machine or renew the intake manifold, if the sealing surface is not flat or the sealing surface has
scratches on it.
3. Ensure that the cylinder heads are parallel.
4. Fit a new gasket and fasten the intake manifold.
Tighten the intake manifold fixing screws to 30 Nm.
5. Fasten the air pipes carefully.
6. Check that the exhaust manifold is airtight.
a) Tighten the exhaust manifold nuts to 50 Nm.
b) Inspect for any damage (cracks, deformation, corrosion etc.)
c) Check the connection between the turbocharger and the exhaust manifold.
7. Remove the exhaust manifold if necessary.
a) Clean the sealing surfaces and remove any carbon deposits.
b) Check that the sealing surfaces are flat.
c) Machine the fastening flanges or renew the exhaust manifold, if the fastening flanges are twisted
or there are scratches on the sealing surfaces.
8. Ensure that no loose objects or impurities have entered the exhaust pipe or the silencer.

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Any loose objects or impurities can increase the back pressure for the exhaust gases from the
turbine wheel.

3.6.3 Removing actuator of the high pressure turbocharger

Procedure

1. Remove cooling pipe and cooling pipe support of the actuator.

2. Remove the actuator from the turbocharger without removing the mounting bracket of the actuator
from the turbocharger.
NOTE: Do not remove the link rod of the actuator.

3.6.4 Fitting actuator of the high pressure turbocharger

Procedure

1. Fit the actuator to the turbocharger.

2. Fit the cooling pipe and the cooling pipe support.
3. Finally, remove the air from the cooling system by using the highest bleeding plug of the engine.

3.6.5 Removing the low pressure turbochargers with the mounting bracket

Before starting the procedure

CAUTION:
Heavy parts. Careless work may cause an injury or damage the machine. Use proper
lifting devices.
NOTE: Write labels for pipes when removing the pipes. Labels make it easier to install the pipes back to
the engine.

Procedure
1. Disconnect the wiring for wastegate actuators.
2. Disconnect the wiring for EGR actuator.
3. Remove the coolant pipes for wastegate actuators.
4. Remove the coolant pipes for EGR actuator.
5. Remove the coolant pipes between the coolant distributors.
6. Remove the coolant distributor in rear end of the engine.
7. Remove the bleeding pipes for the EGR coolers.
8. Remove the bleeding pipes for the ICACs (interstage charge air coolers).
9. Remove the oil pipes for the low pressure turbochargers.
10. Open the clamps of the boost hoses between the low pressure turbochargers and high pressure
turbochargers.
11. Remove the boost hoses between the low pressure turbochargers and high pressure turbochargers.
12. Open the clamps of the boost hoses between the low pressure turbochargers and ICACs.
13. Remove the boost hoses between the low pressure turbochargers and ICACs.

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14. Open the upper head screws of the vertical

supports for the low pressure turbochargers.
15. Open the screws holding the mounting
bracket for the low pressure turbochargers.
16. Remove the low pressure turbochargers with
the mounting bracket.
The vertical supports remain to the mounting
bracket of the ICACs.

Fig. 24

(1) Vertical support

(2) Mounting bracket

3.6.6 Fitting the low pressure turbochargers with the mounting bracket
CAUTION:
Heavy parts. Careless work may cause an injury or damage the machine. Use proper
lifting devices.
CAUTION:
Risk of engine damage. Gap between the cast iron part and the contact surface can cause
stress to the parts and result in engine damage. When fitting heavy cast iron parts, make
sure that the parts are parallel with the contact surface.

Procedure

1. Fit the low pressure turbochargers with the mounting bracket.

2. Tighten the screws holding the mounting bracket for the low pressure turbochargers.
3. Tighten the upper head screws of the vertical supports for the low pressure turbochargers.
4. Fit the boost hoses between the low pressure turbochargers and ICACs (interstage charge air cooler).
5. Tighten the clamps of the boost hoses between the low pressure turbochargers and ICACs.
6. Fit the boost hoses between the low pressure turbochargers and high pressure turbochargers.
7. Tighten the clamps of the boost hoses between the low pressure turbochargers and high pressure
turbochargers.
8. Fit the oil pipes for the low pressure turbochargers.
9. Fit the bleeding pipes for the ICACs.
10. Fit the coolant distributor in rear end of the engine.
11. Fit the bleeding pipes for the EGR coolers.
12. Fit the coolant pipes between the coolant distributors.
13. Fit the coolant pipes for EGR actuator.
14. Fit the coolant pipes for wastegate actuators.
15. Connect the wiring for EGR actuator.
16. Connect the wiring for wastegate actuators.

3.6.7 Removing the high pressure turbocharger

Procedure

1. Remove the inlet and exhaust pipes and pressure and return oil pipes from the turbocharger.

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2. Untighten the clamp between the HP turbocharger and the intermediate piece of the turbochargers.
3. Remove the cooling pipes of the actuator and the actuator wire.
4. Remove the fixing nuts and remove the turbocharger.

3.6.8 Checking the turbocharger

If a fault is suspected in the turbocharger, it can be located in the following way:

Procedure
1. Visually inspect the turbine and compressor wheels. The vanes must not show any signs of damage,
deformation or wear caused by foreign objects.
2. Investigate any oil leaks through the sealing
rings on the shaft in the turbine and
compressor housing.
NOTE: At low idling speed there is always a
certain amount of oil leakage on the
compressor side. However, this should not
cause too much concern unless the oil
consumption is too great.

Fig. 25

3. Check the turbine shaft running clearance.

Place the stylus of a dial gauge against the
shaft and move the shaft sideways. Refer to
the clearance given in the specifications. See
Technical data, Turbocharger.
4. Check the shaft end float. Place the stylus of
the dial gauge against the end of the shaft
and move the shaft axially. Refer to the
clearance given in the specifications. See
Technical data, Turbocharger.

Fig. 26

Result of the procedure

If any defects or wear are detected, the turbocharger should be replaced.
If the engine does not work correctly and the turbocharger is not defective or too worn, the fault could be
traced to one of the following items:
• Blocked air filter.
• Leakage in the inlet or exhaust systems. Leaking flange seal.
• Defective high-pressure pump or engine control unit.
• Defective or wrongly adjusted injectors.
• Low fuel pressure (e.g. blocked fuel filter).
• Low compression, wrong valve clearance.

3.6.9 Fitting the high pressure turbocharger

Locate the cause of the defects on the turbocharger. Remedy the fault before fitting the new turbocharger.

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3. Maintenance

In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition.
Likewise, the oil should be to the correct quality specification. The air filter and oil filter should be serviced
according to the Instruction Manual specification.
The adjusting of the engine control system affects definitely to the function of the turbocharger. The
adjusting have to be made according to the manufacturer's instructions.
Tightening torque for the clamp of the inlet and exhaust pipes of the turbocharger is 12 Nm.

Procedure
1. Check the tightness of the intake and exhaust manifolds, and that they are securely fastened. Ensure
that there are no loose carbon or rust particles, or other foreign objects in the manifolds.
2. Connect the turbocharger to the exhaust manifold and tighten down using new gasket.
3. Fit the clamp between the high pressure turbocharger and the connecting part of the turbochargers.
4. Connect the inlet pipe and the exhaust pipe to the turbo.
5. Connect the actuator cooling pipe and actuator wire.
6. Pour about 0.1 litres of pure engine oil into
the bearing housing before attaching the
pressure oil pipe. This is very important in
order to ensure that the turbocharger is
lubricated when starting.
7. Connect the pressure and return oil pipes.
Use a new seal. Check that there is no
tension in the pipes when tightening.
8. Remove the air from the cooling system by
using the highest bleeding plug of the
engine.
9. Start the engine and check that there are no
leaks.
Fig. 27

3.6.10 Removing the EGR coolers

Procedure

1. Remove the low pressure turbochargers with the mounting bracket.

2. Remove the EGR actuator.
3. Remove the EGR actuator mounting bracket.
4. Open the clamps of the EGR cooler coolant pipes.
5. Remove the support plate of the EGR coolers.
6. Open the screws of the EGR coolers
7. Remove the thermal protection for the EGR actuator.
8. Remove the EGR coolers.

3.6.11 Fitting the EGR coolers

Procedure

1. Fit the EGR coolers.

2. Fit the support plate of the EGR coolers.
3. Fit the thermal protection for the EGR actuator.
4. Tighten the screws of the EGR coolers.
5. Tighten the clamps of the EGR cooler coolant pipes.
6. Fit the EGR actuator mounting bracket.

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7. Fit the EGR actuator.

8. Fit the low pressure turbochargers with the mounting bracket.

3.6.12 Removing the EGR actuator

Procedure

1. Remove the EGR actuator cooling pipes.

2. Disconnect the EGR actuator wire.
3. Disconnect the actuator from the EGR link rod by opening the bolt in the head of the link rod.
NOTE: Do not change the length of the EGR link rod.
4. Open the fixing nuts of the EGR actuator.
5. Remove the EGR actuator from its mounting bracket.

3.6.13 Fitting the EGR actuator

Procedure

1. Fit the EGR actuator into its mounting bracket and fasten the fixing nuts.
2. Fit the EGR link rod to the actuator.
NOTE: See the information for the correct position of the levers and the correct length of the EGR
link rod.
3. Connect the EGR actuator cooling pipes and the EGR actuator wire.
4. Finally, remove the air from the cooling system.

3.6.14 EGR link rod

The length of the EGR link rod must be adjusted
very carefully. It is measured (1) from the ball joint
centre of the EGR actuator lever to the ball joint
centre of the EGR valve lever. The correct length
of the link rod in static state is 203 mm.
Assembling is done having the EGR valve in its off
position. It is important that the EGR valve lever
(A) and the EGR actuator lever (B) have an angle of
34°.
The EGR actuator will be calibrated automatically
by the ECU every time, when the ignition power is
turned on.
Fig. 28

3.6.15 Checking the EGR actuator voltages

The EGR actuator calibrates itself automatically
(minimum position) before every start of the
engine.
When the engine is running, the EGR actuator
operates the EGR valve according to engine speed
and load% (stepless control). When the engine is
idling, the EGR valve remains closed. At engine
speeds over 1500 rpm and when the load is heavy
enough, the EGR actuator starts to adjust the EGR Fig. 29
valve.

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3. Maintenance

The EGR actuator is controlled via can-bus and

operated with 12V supply voltage.
In case of actuator malfunction the electronic
control unit (ECU) activates an error code, which
reduces engine power and running speed. Power
is limited to ~75% of the maximum and the speed
is limited to 1800 rpm.
Check the supply voltage to the EGR actuator and
the can-bus voltages carefully.

Pin Number Assignment

1 Vbat
2 GND
3 CAN low
4 CAN high

Procedure

1. Switch on the primary ECU.

2. Measure the voltage between wire 3 from the ECU and ground 2. The voltage should be
approximately 2V.
3. Measure the voltage between wire 4 from the ECU and ground 2. The voltage should be
approximately 3V.
4. Measure the voltage between wire 1 from the ECU and ground 2. The voltage should be
approximately 12V.

3.6.16 Removing the ICACs with the mounting bracket

Before starting the procedure

CAUTION:
Heavy parts. Careless work may cause an injury or damage the machine. Use proper
lifting devices.
NOTE: Write labels for pipes when removing the pipes. Labels make it easier to install the pipes back to
the engine.

Procedure
1. Remove the low pressure turbochargers with
the mounting bracket.
2. Remove the ECUs.
3. Remove the fuel filters with the mounting
bracket.
4. Remove the mounting brackets of the ECUs.
5. Remove the EGR actuator.
6. Remove the EGR actuator mounting bracket.
7. Remove the thermal protection for the EGR
actuator.
8. Remove the EGR coolers.
9. Remove the ICAC cooling pipes. Fig. 30
10. Open the ICAC mounting bracket screws.
11. Remove the ICACs with the mounting
bracket.
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3.6.17 Fitting the ICACs with the mounting bracket

Before starting the procedure

CAUTION:
Heavy parts. Careless work may cause an injury or damage the machine. Use proper
lifting devices.
CAUTION:
Risk of engine damage. Gap between the cast iron part and the contact surface can cause
stress to the parts and result in engine damage. When fitting heavy cast iron parts, make
sure that the parts are parallel with the contact surface.

Procedure
1. Fit the ICACs with the mounting bracket.
2. Tighten the ICAC mounting bracket screws.
3. Fit the ICAC cooling pipes.
4. Fit the EGR coolers.
5. Fit the thermal protection for the EGR
actuator.
6. Fit the EGR actuator mounting bracket.
7. Fit the EGR actuator.
8. Fit the mounting brackets of the ECUs.
9. Fit the fuel filters with the mounting bracket.
10. Fit the ECUs.
11. Fit the low pressure turbochargers with the Fig. 31
mounting bracket.

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3. Maintenance

3.7 Fuel system

3.7.1 Bleeding the fuel system
WARNING:
Do not make any work at the common rail high pressure fuel system when the engine is
running. Wait at least 30 seconds after stopping the engine .The first high pressure
component has to be loosened slowly, so that the pressure inside the fuel system can
adjust to ambient pressure. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!

Procedure
1. Open the bleeding plug on the pre-filter
bracket.
2. Put a transparent hose in the plug hole and
lead it into a suitable container.
3. Pump fuel with the hand pump on top of the
pre-filter.
4. Pump with the hand pump until there are no
air bubbles in the fuel stream.
5. Remove the hose and turn in the bleeding
plug.
6. Clean the engine of eventual overspill fuel.

Fig. 32
7. Start the engine. The fuel system removes automatically the air left in the system.
NOTE: Do not use the hand pump when the engine is running. Do not use any tools or excessive
force on the pre-filter hand pump.
NOTE: The fuel system is equipped with a pressure sensor that alarms before interference has
developed. Reasons can be for instance:
• Empty fuel tank.
• Clogged fuel filters.
• Suction piping clogged or leaking air.
• Unsuitable fuel (e.g. summer fuel in the winter).
NOTE: Use of spirits as antifreeze is not useful or recommended at all. It makes the fuel solidify and
weakens the lubricating qualities of the fuel and increases the possibility of corrosion.

3.7.2 Measuring fuel feed pressure

Procedure
1. Clean the pre-filter, the fuel filter and the related fuel pipes from the outside.

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 3. Maintenance

2. Disconnect the fuel pressure sensor (1) from

the fuel filter and connect the pressure
gauge instead (the thread is M10x1).
3. Run the engine at low idling speed for a
while and compare the gauge reading with
the prescribed value (3,5 - 13 bar).

Fig. 33

(1) Fuel pressure sensor

(2) Fuel temperature sensor
(3) Fuel pressure sensor

Result of the procedure

If the pressure is below the prescribed value, this may be caused by:
• Clogged fuel filters.
• Suction piping clogged or leaking air.
• Empty fuel tank or unsuitable fuel (e.g. summer fuel in the winter).

3.7.3 Inspecting injectors

WARNING:
Do not make any work at the
common rail high pressure fuel
system when the engine is running.
Wait at least 30 seconds after
stopping the engine .The first high
pressure component has to be
loosened slowly, so that the pressure
inside the fuel system can adjust to
ambient pressure. If the jet of high
pressure fuel contacts your skin, fuel
penetrates the skin causing severe
injuries. Get medical help
immediately! Fig. 34

The function of the injectors can be tested using

service tool (so-called “Run-up test”). For more
detail, please see the service tool manual.
NOTE: The nozzle on the injector cannot be
changed. Instead a spare injector is available.

3.7.3.1 Removing the injectors (CRIN3)

Procedure

1. Clean high-pressure pipes and surroundings.

2. Remove the valve cover.
3. Detach the high-pressure pipe and injector wires.

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3. Maintenance

NOTE: Prevent fuel circulation to the engine via the overflow pipe located in the cylinder head (if the
fuel tank is above the engine).
4. Loosen the fastening screw holding the injector in place and the fastening nut holding the feeding
pipe in place. Unscrew and remove them. Plug plastic covers into all the connection points.
NOTE: The injector and feeding pipe are calibrated as couple. Do not mix them up.
5. Also remove the injector seal ring from the cylinder head if it has not been removed with the injector.
Blow the injector and feeding pipe locations dry.

3.7.3.2 Fitting the injectors (CRIN3)

Before starting the procedure

NOTE: See the information for the correct tightening torques.

Procedure
1. Ensure the injector seat on the cylinder head
is clean.
2. Replace the old seal ring and the O-rings
with new ones.
3. Lubricate the O-rings.
4. Install the injector and feeding pipe on the
cylinder head.
Pay attention to the position of the feeding
pipe. Adjust the feeding pipe’s control balls
(shown with an arrow on the figure) so that
they line up with the grooves in the cylinder
head.
5. Tighten the fastening screw and nut
progressively.
a) Pre-tighten the fastening screw (2) to 15
Nm
b) Undo the fastening screw
c) Pre-tighten the fastening nut (6) to 15 Nm
d) Tighten the fastening screw (2) to 40 Nm
e) Tighten the fastening nut (6) to 50 Nm

Fig. 35

(1) Injector wiring

(2) Fastening screw
(3) Washer
(4) Fastener
(5) Feeding pipe
(6) Fastening nut
(7) Seal ring
6. Install the high-pressure pipe.
7. Tighten the high-pressure pipe to correct torque value.
8. Install the injector wire.
9. Tighten the injector wire to correct torque value (nut M4).
10. Replace the valve cover seals.
11. Fit the valve cover.

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12. Tighten the valve cover to correct torque value.

3.7.4 High-pressure pump

The function of the high-pressure pump can be
tested using the service tool (so-called “High-
pressure test”). For more detailed information,
please see the service tool manual.

Fig. 36

3.7.4.1 Removing the high-pressure pump

Before starting the procedure

WARNING:
Do not make any work at the common rail high pressure fuel system when the engine is
running. Wait at least 30 seconds after stopping the engine .The first high pressure
component has to be loosened slowly, so that the pressure inside the fuel system can
adjust to ambient pressure. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
NOTE: Write labels for pipes when removing the pipes. Labels make it easier to install the pipes back to
the engine.

Procedure
1. Disconnect the electric main switch.
2. Clean the high-pressure pump and
surroundings.
3. Disconnect the MPROP wire.
4. Remove the fuel pipes connected to the
high-pressure pump.
5. Insert protective plugs on the fuel pipe
connections.

Fig. 37

(1) Magnetic proportional valve (MPROP)

(2) Fuel pipe from fuel pre-filter
(3) Fuel pipe from fuel filter
(4) Fuel pipe to rail
(5) Return pipe from rail
(6) Bleeding pipe from fuel filter
(7) Fuel pipe to main filter

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3. Maintenance

6. Remove the cover.

7. Open the high-pressure pump gear nut.
8. Remove the high-pressure pump gear from
the high-pressure pump.
Use a puller to remove the high-pressure
pump gear.
Removing the gear housing cover is not
necessary. The high-pressure pump gear
remains inside the timing gear housing.
9. Open the high-pressure pump fixing screws.
10. Remove the high-pressure pump.
Fig. 38

(1) Key
(2) High-pressure pump gear
(3) High-pressure pump gear nut
(4) Seal
(5) Cover

Result of the procedure

The high-pressure pump can be taken to Bosch Diesel agent or to the AGCO Power Inc. to be
reconditioned.

3.7.4.2 Fitting the high-pressure pump

Before starting the procedure

NOTE: See the information for the correct tightening torques.

Procedure
1. Lubricate all o-rings.
2. Fit the high-pressure pump.
3. Tighten the high-pressure pump fixing
screws.
4. Tighten the high-pressure pump gear nut.
5. Fit the cover.

Fig. 39

(1) Key
(2) High-pressure pump gear
(3) High-pressure pump gear nut
(4) Seal
(5) Cover

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6. Fit the fuel pipes to the high-pressure pump.

7. Connect the MPROP wire.

Fig. 40

(1) Magnetic proportional valve (MPROP)

(2) Fuel pipe from fuel pre-filter
(3) Fuel pipe from fuel filter
(4) Fuel pipe to rail
(5) Return pipe from rail
(6) Bleeding pipe from fuel filter
(7) Fuel pipe to main filter

3.7.5 Rail
WARNING:
Do not make any work at the common rail high pressure fuel system when the engine is
running. Wait at least 30 seconds after stopping the engine .The first high pressure
component has to be loosened slowly, so that the pressure inside the fuel system can
adjust to ambient pressure. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
NOTE:
It is recommended that high-pressure pipes are replaced every time they are removed.
The 168 engine has two rails. Both rails have pressure sensors. The rail on the left-hand side has pressure
control valve (PCV).
The rail is attached to the intake manifold.

(1) Pressure sensor

(2) Pressure control valve (PCV)

Fig. 41

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3.7.5.1 Removing the rail

WARNING:
Do not make any work at the common rail high pressure fuel system when the engine is
running. Wait at least 30 seconds after stopping the engine .The first high pressure
component has to be loosened slowly, so that the pressure inside the fuel system can
adjust to ambient pressure. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
DANGER:
Risk of fire! Leaking fuel can result in fire in a hot engine. Prevent fuel from leaking. Insert
plugs where fuel connectors have been removed.
CAUTION:
Cleanliness needed. Any impurities can cause system malfunction. Clean carefully
surroundings and maintenance related parts before maintenance work.

Procedure

1. Remove the ICACs (interstage charge air cooler) with the mounting bracket.
2. Clean the rail and the surroundings.
3. Disconnect the wire connector from the pressure control valve (PCV).
4. Disconnect the wire connector from the pressure sensor.
5. Disconnect the fuel pipes from the rail.
a) Prevent fuel from leaking to the ground.
b) Insert plugs where fuel connectors have been removed.
6. Open the rail fixing screws.
7. Remove the rail.

3.7.5.2 Fitting the rail

CAUTION:
Cleanliness needed. Any impurities can cause system malfunction. Clean carefully
surroundings and maintenance related parts before maintenance work.
NOTE: See the information for the correct tightening torques.

Procedure

1. Fit the rail.

2. Tighten the rail fixing screws.
3. Connect the fuel pipes to the rail.
4. Connect the wire connector to the pressure control valve (PCV).
5. Connect the wire connector to the pressure sensor.
6. Fit the ICACs with the mounting bracket.

3.7.5.3 Removing the pressure control valve

The pressure control valve (PCV) will be delivered as a spare part for the rail. The rail needs to be removed
before changing the PCV. Alternatively, the complete rail can be replaced.
NOTE: PCV must not be reused!

Procedure
1. Remove the rail.

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2. Mark the position of the PCV.

The PCV needs to be fitted in the same position.
3. Clean interface area of the PCV using proper degrease materials and compressed air for drying.
NOTE: Cleaning material must not penetrate the electric contacts.
4. Remove the PCV.
a) Loosen the PCV using an open ended
insert tool 30.
b) Grasp the PCV by hand.
c) Pull the PCV out simultaneously turning it
counter-clockwise.
5. Clean the thread and the sealing surface of
the rail.
6. Close the orifice using a plastic cap after
removing the PCV.
7. Inspect the sealing surface of the rail.
Only concentric grooves are allowed. No cuts
in radial direction are tolerable. Fig. 42

3.7.5.4 Fitting the pressure control valve

The pressure control valve (PCV) will be delivered as a spare part for the rail. The rail needs to be removed
before changing the PCV. Alternatively, the complete rail can be replaced.
NOTE: PCV must not be reused!

Procedure

1. Lubricate the sealing rings with fuel.

2. Insert the PCV manually and position the electric connection orientation.
3. Screw in the flange screw manually maintaining the orientation of the connector.
4. Tighten the PCV using the open ended insert tool 30 counteracting with a wrench 45 at the hexagon
of the housing.
a) Tighten the PCV first to torque of 80 Nm ± 4 Nm.
b) Loosen the PCV 90°.
c) Tighten the PCV to final torque value of 85 Nm ± 5 Nm.
NOTE: The electric cable must not be under tension.

3.7.5.5 Removing the pressure sensor

Procedure

1. Disconnect the electrical connector.

2. Remove the pressure sensor.
3. Check the condition of the end sealing surface of the pressure sensor.
Radial scratch is not permissible.

3.7.5.6 Fitting the pressure sensor

NOTE: See the information for the correct tightening torques.
The pressure sensor will be delivered as a spare part for the rail. The pressure sensor can be changed
while the rail is in position. Alternatively, the complete rail can be replaced.
The ICACs need to be removed with the mounting bracket before rails and pressure sensors can be
reached.
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3. Maintenance

Procedure

1. Clean the sealing surface and thread of the rail.

2. Lightly lubricate the pressure sensor thread and sealing surface.
3. Tighten the sensor in place to correct torque value.
4. Connect the electrical connector.

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3.8 SCR system

3.8.1 SCR system maintenance
AGCO POWER SCR system is durable and almost maintenance free. Only main filter change for supply
module is required in normal use. AGCO POWER SCR is equipped with on-board diagnostic, which will
warn the operator or limit the usage of the machine if any problems (e.g. leakages or blocking of lines)
occur in the system.
NOTE: Engine with aftertreatment system meets EU97/68/EC Stage lV and EPA 40 CFR 1039 Tier 4 final
emission requirements.
Do not fit any components on the engine other than those originally intended for it. The use of other than
original AGCO Parts spare parts invalidates the responsibility of AGCO Power Inc. on the meeting of the
emission requirements.
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. Diluting of DEF or mixing it with other substances is not allowed, it may damage
the catalyst!
CAUTION:
Make sure that genuine DEF (DIN 70070 or ISO 22241 certified) is used as a reducing
agent. If urea quality sensor detects a problem related to urea quality, it will alert the
engine control system via CAN message thus causing the engine to run under degraded
mode.
CAUTION:
Even small amounts of diesel fuel in DEF tank may damage the gaskets of the SCR
system!
CAUTION:
The storage of DEF must be done under 30°C, avoiding direct sunlight.

3.8.2 Mounting of SCR system components

Dosing module (DM)

Dosing module is mounted with three M6x20
screws. Tightening is done in two stages:
1 Tighten the screws in sequence shown in
picture until the gasket is pressed evenly to
its mounting surface on the exhaust.
2 Tighten the screws to 8 Nm torque in
sequence shown in picture.
NOTE: Always change the gasket when opening
the dosing module joint.

Fig. 43

5th Generation 168 AWF Engine 3-33

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3. Maintenance

NOx sensor
NOx sensor includes a control unit and a separate
sensor head.
Mounting: 2 sensors on the exhaust line, before
DOC catalytic converter and after the SCR catalytic
converter.
• Sensor head thread: M20x1,5
• Sensor head torque: 50 Nm
• Voltage 12 V or 24 V

Fig. 44

Exhaust gas temperature sensor

Mounting: 3 sensors on the exhaust line, before
the DOC catalytic converter, before and after the
SCR catalytic converter.
• Thread: M14x1,5
• Torque: 40 Nm

Fig. 45

3-34 5th Generation 168 AWF Engine

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 3. Maintenance

3.9 Engine control system

3.9.1 Changing the electronic control unit
NOTE:
The electronic control unit (ECU), formatted with
AGCO POWER software, will be delivered with
the specified software version already loaded. The
engine serial number or F.I.E. number (Fuel
Injection Equipment) must be provided when
ordering the ECU.
The primary ECU is on the right-hand side of the
engine and the secondary ECU is on the left-hand
side of the engine. The engine serial number is
indicated on the type plate of the ECU.
NOTE: See the information for the correct
tightening torques.
Fig. 46

Fig. 47

Procedure
1. Turn the main switch to the OFF position or disconnect the battery connectors.
2. If the ECU is cooled by fuel, disconnect the fuel pipe connectors carefully from the ECU.
3. Remove the plastic cover and disconnect the
multipole connectors.
Do not touch the connector poles.
Note the position of the earth wire.
4. Remove the control unit from the bracket.
5. Check that the bracket rubber dampers work.
Change the bracket rubber dampers if
necessary.

Fig. 48

5th Generation 168 AWF Engine 3-35

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3. Maintenance

6. Attach the new control unit.

a) Tighten the screws to the correct torque
value in the order shown in the figure.
b) Note the position of the earth wire.
7. Connect the multipole connectors.
8. Attach the plastic cover.
9. If the ECU is cooled by fuel, connect the fuel
pipe connectors carefully to the ECU.
10. Turn the main switch to the ON position.

Fig. 49

3.9.1.1 Fitting the wiring

Procedure

1. Attach the wiring sets to the brackets with bands.

2. Avoid too sharp turns or damaging the wiring sets on sharp parts.

3-36 5th Generation 168 AWF Engine

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 3. Maintenance

3.10 Terminal diagram

Fig. 50

5th Generation 168 AWF Engine 3-37

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3. Maintenance

Fig. 51

3-38 5th Generation 168 AWF Engine

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 3. Maintenance

Fig. 52

5th Generation 168 AWF Engine 3-39

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3. Maintenance

Fig. 53

3-40 5th Generation 168 AWF Engine

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 3. Maintenance

Fig. 54

5th Generation 168 AWF Engine 3-41

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3. Maintenance

Fig. 55

3-42 5th Generation 168 AWF Engine

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 Index

Index
A I
air control ............................................................... 1-22 injector .......................................................... 3-25, 3-26
air control system .......................................................... inlet pipe ................................................................ 3-16
egr .................................................................. 1-24 interstage charge air cooler ...........................................
icac ................................................................. 3-22
interstage charge air cooling .........................................
C
icac ................................................................. 1-23
closed crankcase ventilation ..........................................
ccv .................................................................. 3-11 L
coolant pump ................................................ 1-20, 3-13
cooling system ...................................................... 1-18 lifting the engine ...................................................... 1-8
crank mechanism ......................................... 1-14, 2-11 link rod ................................................................... 3-21
crankshaft ...................................................................... lubrication system .......................................... 1-16, 2-3
oil seal .............................................................. 3-3
crankshaft hub ......................................................... 3-6
O
cylinder block ......................................................... 1-13
cylinder head ................................................................. oil cooler ................................................ 1-17, 3-9, 3-10
connection part .............................................. 3-15 oil filter ................................................................... 1-17
oil pressure regulating valve .................................... 3-8
D oil pump .........................................................................
oil pressure regulating valve ........................... 1-17
diesel exhaust fluid ........................................................ oil quality ................................................................. 2-5
def .................................................................. 1-26 oil sump capacity ................................................... 3-11
dosing module ....................................................... 1-27 oil sump gasket ....................................................... 3-9

E P
ecu ......................................................................... 3-35 power take-off ......................................................... 3-7
egr ................................................................................. pressure control valve ...................................................
actuator .......................................................... 3-21 pcv ..................................................................
cooler ............................................................. 3-20 pressure control valve ............. 3-30, 3-31
electronic control unit .................................................... pressure sensor ..................................................... 3-31
ecu ................................................................. 1-28
electronic diagnostic tool ...............................................
R
components ................................................... 1-31
edt ......................................................... 1-30, 1-31 rail ................................................................. 3-29, 3-30
engine control system ........................................... 1-28
engine overview .................................................... 1-10
engine serial number ............................................... 1-6
S
engine type .............................................................. 1-5 scr ..................................................................................
exhaust pipe .......................................................... 3-16 maintenance ................................................... 3-33
special tool ....................................................................
F coolant pump ................................................. 2-11
special tools ...................................................................
flywheel ............................................................ 2-3, 3-5 engine lifting ................................................... 2-10
flywheel housing ................................................... 1-14 flywheel housing ............................................ 2-10
fuel ................................................................................ fuel system .................................................... 2-12
quality requirements ........................................ 2-5 return quantity tester ..................................... 2-12
fuel feed pressure ................................................. 3-24 scr tool kit ....................................................... 2-12
fuel system ............................................................ 1-24 timing gear ..................................................... 2-10
supply module ....................................................... 1-27
H
T
high-pressure pump ..................................... 3-27, 3-28
technical data ................................................................
cooling system ............................................... 1-13
dimensions ..................................................... 1-12

5th Generation 168 AWF Engine Index-1

V837091047
Index

fuel system .................................................... 1-12

lubrication system .......................................... 1-12
turbocharger ..................................................... 2-4
terminal diagram .................................................... 3-37
testing ................................................................... 3-12
thermostat .....................................................................
removing ........................................................ 3-12
replacing ......................................................... 3-13
throttle valve .......................................................... 1-23
tightening torques ................................................... 2-8
timing gears ........................................................... 1-15
turbocharger ..................................................................
actuator .......................................................... 3-17
high pressure ......................................... 3-17–3-19
hp .......................................................... 3-17–3-19
low pressure .................................................. 3-17
turbocharging ........................................................ 1-23

V
valve mechanism ................................................... 1-14

W
wiring ............................................................ 1-29, 3-36
work instructions ...........................................................
air cleaner ....................................................... 3-16
flywheel housing .............................................. 3-3
injector ........................................................... 3-25

Index-2 5th Generation 168 AWF Engine

V837091047
© AGCO Corporation, 2014. All rights reserved.
V837091047 (English)
June 2014