REPARACION NH TM165

1.SECTION 10 - ENGINE - CHAPTER 1 SECTION 10 - ENGINE Chapter 1 - Engine CONTENT Section 10 000 10 001 10 100 10 200 10 400 Description Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel Test Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Greases and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine stripdown - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine disassembly and overhaul:Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Front cover and timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Oil pan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Connecting rods, bearings pistons and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cylinder block overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Main bearings and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Rear cover plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Oil pump and oil filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Camshaft, tappets and camshaft bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Fuel system components:Fuel pump - Removal, Timing and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Electric lift pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Cooling system components: Radiator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Thermostat removal, testing and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Temperature warning sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Viscous clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Fan blade removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Fan belt and tensioner removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Water pump removal, overhaul and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 84993509-03.2003 2 SECTION 10 - ENGINE - CHAPTER 1 GROUP 10 - GENERAL FEATURES AND SPECIFICATIONS Model (T = Turbocharged) TM115 TM125 (T) TM135 (T) TM150 (T) TM165 (T) No of Cylinders 6 6 6 6 6 ins 4.4 4.4 4.4 4.4 4.4 (mm) 111.8 111.8 111.8 111.8 111.8 ins 5.0 5.0 5.0 5.0 5.0 (mm) 127.0 127.0 127.0 127.0 127.0 cu in 456 456 456 456 456 (cu cm) 7472 7472 7472 7472 7472 17:5-1 17:5-1 17:5-1 17:5-1 17:5-1 375 25.5 375 25.5 375 25.5 375 25.5 375 25.5 Firing Order 153624 153624 153624 153624 153624 Idle Speed R.P.M 750 - 850 750 - 850 750 - 850 750 - 850 750 - 850 Maximum no Load Speed R.P.M 2350 - 2400 2350 - 2400 2350 - 2400 2350 - 2400 2460 - 2510 Rated Engine Speed 2200 2200 2200 2200 2300 Bore Stroke Displacement Compression Ratio Cylinder Bore Compression at cranking speed of 200 R.P.M. lbs in2 bar CYLINDER BLOCK Taper of Cylinder Bore 0.025mm(0.001in ) Repair Limit 0.127mm (0.005in) Wear Limit Cylinder Bore out of Round 0.030mm (0.0015in) Repair Limit 0.127mm (0.0050in) Wear Limit Cylinder Bore Diameters 111.778-111.841mm(4.4007-4.4032in) Rear Oil Seal Bore Diameter 140.77-140.87mm(5.542-5.546in) Block to Head Surface Flatness 0.08mm(0.003in) in any 152mm (6in) 0.03mm(0.001in) in any 25.40mm (1in) CYLINDER HEAD Valve Guide Bore Diameter 9.469-9.495mm(0.3728-0.3738in) Head to Block Surface Flatness 0.03mm(0.001in) in any 25.40mm (1in), or 0.127mm (0.005in) overall limit 84993509-03.2003 SECTION 10 - ENGINE - CHAPTER 1 3. EXHAUST VALVES Face Angle 44°15'-44°30' Relative to the Head of Valve Stem Diameter Std : 9.401-9.421mm (0.3701-0.3709in) 0.076mm(0.003in) Oversize : 9.477-9.497mm(0.3731-0.3739in) 0.38mm(0.015in) Oversize : 9.781-9.802mm(0.3851-0.3859in) 0.76mm(0.030in) Oversize : 10.163-10.183mm(0.4001-0.4009in) Head Diameter 42.88-43.13mm(1.688-1.698in) Stem to Guide Clearance 0.048-0.094mm(0.0019-0.0037in) Lash Clearance (Cold) 0.43-0.53mm(0.017-0.021in) INTAKE VALVES Face Angle 29°15'-29°30' Relative to Head of Valve Stem Diameter Std : 9.426-9.446mm(0.3711-0.3719in) 0.076mm(0.003in) Oversize : 9.502-9.522mm(0.3741-0.3749in) 0.381mm(0.015in) Oversize : 9.807-9.827mm(0.3861-0.3869in) 0.762mm(0.030in) Oversize : 10.188-10.208mm(0.4011-0.4019in) Head Diameter 47.37-47.63mm(1.865-1.875in) Stem to Guide Clearance 0.023-0.069mm(0.0009-0.0027in) Lash Clearance (Cold) 0.36-0.46mm(0.014-0.018in) VALVE SPRINGS Number per Valve 1 Free Length Length,loadedat27.7-31.3kg (61-69lb) Length,loadedat61-69kg(135-153lb) 60.70mm (2.390 in) 48.26mm(1.900in) 35.69mm(1.405in) VALVE TIMING Intake Opening 12° Before Top Dead Centre Intake Closing 38° After Bottom Dead Centre Exhaust Opening 48° Before Bottom Dead Centre Exhaust Closing 12° After Top Dead Centre 84993509-03.2003 4 SECTION 10 - ENGINE - CHAPTER 1 VALVE INSERTS Insert Oversize Exhaust Valve Insert Counterbore Diameter in Cylinder Head Intake Valve Seat Insert Counterbore Diameter in Cylinder Head 0.254mm(0.010in) 44.17-44.20mm (1.739-1.740in) 50.01-50.04mm (1.969-1.970in) 0.508mm(0.020in) 44.42-44.45mm (1.749-1.750in) 50.27-50.29mm (1.979-1.980in) 0.762mm(0.030in) 44.68-44.70mm (1.759-1.760in) 50.52-50.55mm (1.989-1.990in) VALVE SEATS Exhaust Valve Seat Angle 45°00' - 45°30' Intake Valve Seat Angle 30°00' - 30°30' Interference Valve Face Angle to Valve Seat Angle 0°30' - 1°15' Concentricity With Guide Diameter 0.051mm(0.002in) Total Indicator Reading Max Seat Width Exhaust Valve Intake Valve 1.8-2.3mm(0.072-0.092in) 1.9-2.5mm(0.078-0.098in) CAMSHAFT IDLER GEAR Number of teeth 47 End Play 0.051-0.18mm (0.002-0.007 in) Bushing Inside Diameter 50.813-50.838mm(2.005-2.0015in) Adaptor Outside Diameter 50.762-50.775mm(1.9985-1.9990in) Backlash with Crankshaft Gear 0.15-0.45mm (0.006-0.018 in) Backlash with Camshaft Gear 0.15-0.45mm (0.006-0.018 in) Backlash with Fuel Injection Pump 0.10-0.15mm (0.004-0.006in) CAMSHAFT GEAR Number of Teeth 52 Timing Gear Backlash with idler 0.15-0.45mm (0.006-0.018 in) ROCKER ARM SHAFT Shaft Diameter 1.000-1.001in(25.40-25.43mm) Shaft Support Internal Diameter 1.002-1.004in(25.45-25.20mm) ROCKER ARM Inside Diameter 1.003-1.004in(25.48-25.50mm) TAPPETS Clearance to Bore 84993509-03.2003 0.0006-0.0021in(0.015-0.053mm) 0067in) New or unrun engine 0.2003 .0005-0.6258in) Clearance Bushing to Piston Pin 0.) For run engines Grading Diameter (at Right Angles to Piston Pin) 111.0010-0.0127mm(0.719mm(2.17mm(0.0077in) New or unrun engine 0.3895-2. Number and Location Type 1 off.288-41.166-0.9900-0.118-25.0055-0.4998-1.259mm(1.013-0.9889-0. Slotted With Expander 84993509-03. Naturally Aspirated Turbocharged 0.140-0.5000in) 41.012in) PISTON RINGS Compression.025mm(0.64-111. Top Compression Ring 2nd Compression Ring Parallel Sides-Barrelled face Lower side internal chamfer .0130in) Maximum Twist 0.00012-0.18mm(0.023in) 0.10mm(0.166-0.0-0.0020-0.9894in) Tappet Bore Diameter 25.130mm(0.051-0.6255-1.9910in) CAMSHAFT Bearing Journal Diameter 60.tapered face Oil Control.58mm(0.0-0.095-38.30mm(0.15-25.025-0.CHAPTER 1 Tappet Diameter 25.3905in) Bearing Clearance 0.28mm (0.tapered face Turbocharged.6250in) PISTONS Skirt to Cylinder Clearance Naturally Aspirated 0.113-38.00055in) at 21°C (70°F) Piston Crown to Block Face.Barrelled face Lower side internal chamfer .0140mm(0.1st and 2nd from the top of the piston Naturally Aspirated.33mm(0.3951-4.0065-0.5.0050-0. Number and Location 2 off.140-0.-Directly above the Piston Pin.120mm(1.270-41.) For run engines Skirt to Cylinder Clearance Turbocharged 0.011 in.0070in) CONNECTING RODS Small End Bushing (Internal Diameter) Normally Aspirated Turbocharged 38.275mm(1.3991in) in increments of 0.28mm (0.3mm(0.0055-0.0120in) Maximum Bend 0.196mm(0.28-0.076mm(0.171mm(0.0040in) PISTON PIN Outside Diameter Normally Aspirated Engine Turbocharged Engine 38.5005-1.13-0.ENGINE . Top Compression Ring 2nd Compression Ring Keystone Tapered sides .0005in) Piston Pin Clearance 0.693-60.100mm(1.011 in.0030-0.011-0.0010in) Side Float 0.6248-1.5008in) 41.0065-0.74mm(4. SECTION 10 .0030in) End Play 0. 10-1.62-42.008in) 0.10-0.CHAPTER 1 Side Face Clearance To Ring Groove.453-1.40-0.455in) Vertical Assembled Bearing Clearance 0.127mm(0.96-37.72mm(1.0030-0.103-0.035-0.84mm (0.808-4.016-0.23-46.117mm(0.459-1.0016-0.Red 85.055-0. Top Compression Ring .455-1.Turbocharged .N. Top Compression Ring 2nd Compression Ring .41in) 0.0021-0.040-0.Turbocharged .0022-0.11mm(1.751in) Crankshaft Timing Gear Journal Diameter 46.0049in) 0.0002in) Total Indicator Reading Taper Surface Parallel to Centre Line of Main Journal 0.21mm(1.153mm (0.656mm(3.860mm(2.749-2.075-.0037in) .0042in) 0.036in) CRANKSHAFT Main Journal Diameter .20mm(0.45-44.Blue .850-69.28mm(4.090mm (0.12-122.840-69. Oil Control Ring 0.96mm(1.495-1.820-1.750-2.048-3.814in) Crankshaft Pulley Journal Diameter 44.038mm(0.678-1.005mm(0.465in) Main Journal Wear Limits 0.81mm (1.91-39. or intermediate) 36.0002in) Crankshaft Rear Oil Seal Journal Diameter 122.0035in) Gap Width.036in) 0.N.644mm(3.821in) Crankshaft Flange Runout 0.A.016-0.94-28.12-0.Red 69.105mm (0.25mm(1.556mm(0.90mm (0.40-0.97-38.631-85.455-1.005mm(0.38-0.6 SECTION 10 .06-37.0015in) Max CRANKSHAFT DRIVE GEAR Number of teeth 26 MAIN BEARING Liner length (except thrust liner) 27.461in) Intermediate Bearing Journal Length 36.40-0.3718in) 85.7500in) 69.036in) 0.7504in) End Play Crankpin Out of Round 0.125mm (0.055-0.ENGINE .016-0.644-85.094mm(0.19mm(1.465in) Rear Bearing Journal Length 37.0060in) 0.004-0.0041-0.90mm (0.0014-0.3723in) Main Journal Length (except thrust.90mm (0.A.033in) 0.21mm(1.48mm(1.0046in) CRANKPIN BEARINGS Liner Length Vertical Assembled Bearing Clearance 84993509-03.11in) Liner Length (Thrust Liner) 39.682in) Crankpin Diameter .48mm(1. 2nd Compression Ring Oil Control Ring 0. rear.3713-3.005in) Maximum Main and Crankpin Fillet Radius 3.3718-3.015-0.515in) Crankpin Journal Length 42.56-35.14in) Thrust Bearing Journal Length 37.40-1.96-37.2003 35.850mm(2.750-1.Blue . 006-0.76 bar (40 lbf/in2) at normal operating temperature OIL FILTER SUPPORT Relief Valve. Series 3 diesel engine oil with an A.4 20. but the oil and filter interval must be reduced to 150 hours . Operating Pressure Flow Rate Temperature 3.025-0.S Qts Litres 6 CYL 33.1bars(55-60lbf/in2) 68.24 bar (18 lbf/in2) at normal operating temperature Minimum At Engine Rated Speed 2.8-4.001-0.6impgals/min.7 l/min.S Qts Litres 6 CYL 31.0 19.005in) 0.3% use only oils listed above but reduce the oil and filter change period to every 50 hours . (15-16.CHAPTER 1 FLYWHEEL Runout of Clutch Face ( Between Outer Edge of Friction Surface and Mounting Bolt Holes).ENGINE .0035in) 0.025in) OIL PUMP Rotor Clearance Rotor to Pump Housing Clearance Rotor End Play Pump Gear to Camshaft Gear Backlash 0.022in) OIL PRESSURE Minimum At Engine Idle Speed 1. classification of CD may be used instead of CF-4 oil .2003 .56mm(0.I. When using diesel fuel with a sulphur content between 1% and 1.016-0.18-20USgals/min) Oil Viscosity and Type API Classification Engine Oil & Filter Change Period (hours) Below -12°C ( 10°F ) SAE 5W or SAE 5W-30 or SAE 10W-30 CD/SF CD/SF CF-4/SG 150 150 150 -12°C to 4° C (10°F to 40°F) SAE 10W SAE 10W-30 CD/SF CF-4/SG 200 300 0°C to 32°C (32°F to 90°F) SAE 20W SAE 15W-40 CD/SF CF-4/SG 200 300 Above 24°C (75°F) SAE 30W or SAE 15W-40 CF-4/SG 200 300 NOTE: When using diesel fuel with a sulphur content below 1.28mm(0. ENGINE OIL CAPACITIES (LESS OIL FILTER) Model Imp Pints U.7.1-75. SECTION 10 .63mm(0.0%.006in) 0.0 18.P. Ring Gear Runout 0.001-0.15-0.6 19.0 ENGINE OIL CAPACITIES (WITH OIL FILTER) 84993509-03.089mm(0.127mm(0.011in) 0.15mm(0.0 Model Imp Pints U.40-0.025-0. 2003 .S.0bar (14.8 SECTION 10 .ENGINE .Water50%. Galls Litres TM115.7 25. 8 rib FAN BELT Belt Tension Maintained by Automatic Tensioner COOLING SYSTEM CAPACITIES Model Imp Galls U. New Holland Antifreeze 50%. ( New Holland Antifreeze specification: NH900A) 84993509-03. TM125.5 TM150. TM165 5.7 6.6 6.0 COOLING FLUID Content Mixture .9 26. TM135 5.CHAPTER 1 THERMOSTAT Opening Temperature Fully Open 79-83°C (174-181°F) 93-96°C (199-205°F) RADIATOR CAP Opening Pressure 1.5 lbsin2) WATER PUMP Type Drive Centrifugal Poly V Belt. 12Volt / 5 lbf/in2 Fuel Injection Pump Distributor type.9.85mm Injectors: Type BOSCH Multi Hole Quantity.5° All models Pulley timing mark to pointer check (using piston number 2 depth. SECTION 10 . nozzle holes 0.ENGINE . from block face) MODELS PISTON No.5°) 104.2003 .2 DEPTH All Models (No. integral speed governor and advance device BOSCH pump TM115 VE6/12F Type No: 0 460 426 303 TM125 VE6/12F Type No: 0 460 426 307 TM135 VE6/12F Type No: 0 460 426 312 TM150 VE6/12F Type No: 0 460 426 303 TM165 VE6/12F Type No: 0 460 426 313 Pump rotation Clockwise Firing order 1-5-3-6-2-4 Injection pump timing 3. nozzle holes 5 Diameter.254mm All Models Pressure Setting (all) Initial setting 270-278 bar (3915 lbf/in2) Reset if less than 240 bar (3480 lbf/in2) Injector service interval 1800 hours 84993509-03.1 @ 3.CHAPTER 1 FUEL SYSTEM MAIN DATA Turbocharger type: Garrett GT35 Fuel Supply Pump: Electric pump . 0 ± 3.840mm long with 2.ISO 4113 at 44° .3-0.3 ±3.0 ± 1.TM115 7.CHAPTER 1 TEST PLAN .0 cc min. 5 Hydraulic torque control 600 1000 71.0 l/hr 2 Timing piston travel 900 650 - 2.D. 4 Full load fuel a) Rated speed b) Peak torque c) Port to port variation 1100 800 - 1000 1000 1000 65.ENGINE . 90.5 cc 9 Static timing lock plunger lift on port ‘‘B'' - - 1.0 cc 6.06mm 10 Test stand equipment a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure b) High pressure pipes .9 ± 0.8 ± 3.) BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12mm diameter plunger .30 ± 0.00mm O.0 cc 8 Fuel shutoff solenoid 375 1000 1.10 SECTION 10 .0 cc max.0mm diameter and 6.0 cc 77.7mm 0.5 cc 6 Governor breakaway 1150 1000 52.5 litre (456 cu in. 3.46°C outlet temperature 84993509-03.0 cc max.5 ± 1. TYPE NUMBER: 0 460 426 303 Test Description SHEET 1 of 1 Pump rpm Strokes Overcheck 1 Return fuel 1100 - 58.4 bar d) Calibrating fluid .2003 .2mm lift) PUMP NH NUMBER: 87801834 Test No. c) Fuel gallery inlet pressure 0.0 cc 7 Low idle fuel 375 1000 20.1 ± 0.6mm 3 Start fuel 100 350 1000 1000 90.0 ± 10.0 ± 5. 0 cc min.7 ± 0.0mm diameter and 6.4 bar d) Calibrating fluid .0 ± 10. 4 Full load fuel a) Rated speed b) Peak torque c) Port to port variation 1100 700 - 1000 1000 1000 67.0 ± 5.00mm O.11.5cc @400mbar 6 Unboosted fuel 500 1000 66.ISO 4113 at 44° .0 ± 1. 5 Boost control 650 1000 70.46°C outlet temperature 84993509-03.5 cc 10 Static timing lock plunger lift on port ‘‘B'' - - 0.0 cc 77.95 ± 0.06mm 11 Test stand equipment a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure b) High pressure pipes .4 ± 0.0 ± 2.2MM LIFT) PUMP NH NUMBER: 87801835 Test No.0 cc 9 Fuel shutoff solenoid 375 1000 1. c) Fuel gallery inlet pressure 0.0 cc max.7 ± 2.CHAPTER 1 TEST PLAN .5 cc 6. 64.3-0. SECTION 10 .5 ± 1. 3.5 LITRE (456 CU IN.D.TM125 7.7mm 3 Start fuel 100 230 1000 1000 75.840mm long with 2.0 cc max.) BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12MM DIAMETER PLUNGER .0 l/hr 2 Timing piston travel 900 600 - 3.5cc @0mbar 7 Governor breakaway 1170 1000 50.0 cc 8 Low idle fuel 375 1000 15.ENGINE .7mm 1. TYPE NUMBER: 0 460 426 307 Test Description SHEET 1 OF 1 Pump rpm Strokes Overcheck 1 Return fuel 1100 - 56.2003 .8 ± 2.8 ± 3. 0 cc max.0 cc @ 600 mbar 6 Unboosted fuel 500 1000 80.0 ± 5.3-0. 3.5 cc 10 Static timing lock plunger lift n port ‘‘B'' - - 1.0 ± 10.CHAPTER 1 TEST PLAN . TYPE NUMBER: 0 460 426 312 Test Description SHEET 1 of 1 Pump rpm Strokes Overcheck 1 Return fuel 1100 - 57.00 ± 0.46°C outlet temperature 84993509-03.0 ± 4. 90.5 ± 10.4 bar d) Calibrating fluid .2mm lift) PUMP NH NUMBER: 87801836 Test No.0 cc min.ENGINE .TM135 7.6mm 1.ISO 4113 at 44° .5cc @ 0 mbar 7 Governor breakaway 1180 1000 48.0 cc 6.1 ± 0.0 ± 3.2003 .8 ± 3.5 ± 1.7mm 3 Start fuel 100 200 1000 1000 80. 4 Full load fuel a) Rated speed b) Peak torque c) Port to port variation 1100 700 - 1000 1000 1000 75.5 litre (456 cu in. c) Fuel gallery inlet pressure 0.0mm diameter and 6.1 ± 0.5 ± 3. 5 Boost control 650 1000 85.0 cc 9 Fuel shutoff solenoid 375 1000 1.12 SECTION 10 .840mm long with 2.0 cc max.0 cc 9.06mm 11 Test stand equipment a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure b) High pressure pipes .00mm O.0 cc 8 Low idle fuel 375 1000 15.) BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12mm diameter plunger .D.0 l/hr 2 Timing piston travel 1000 700 - 3. ISO 4113 at 44° .0 ± 3.0 l/hr 2 Timing piston travel 900 - 2. 230 1000 90.5cc @ 0 mbar 7 Governor breakaway 1180 1000 49.4 bar d) Calibrating fluid .2 ± 0.840mm long with 2.0mm diameter and 6. c) Fuel gallery inlet pressure 0.46°C outlet temperature 84993509-03. TYPE NUMBER: 0 460 426 303 Test Description SHEET 1 of 1 Pump rpm Strokes Overcheck 1 Return fuel 1100 - 52.CHAPTER 1 TEST PLAN .0 cc @ 500 mbar 6 Unboosted fuel 500 1000 86.ENGINE .7 ± 3.0 ± 4.0 cc - 1000 6.00mm O.0 ± 3.13. Start fuel Full load fuel c) Port to port variation 5 Boost control 650 1000 91.0 cc max.2mm lift) PUMP NH NUMBER: 87801789 Test No.5 litre (456 cu in.0 cc b) Peak torque 700 1000 94.0 ± 5.7mm 3 4 500 - 1.TM150 7.00 ± 0. a) Rated speed 1100 1000 80. SECTION 10 .0 ± 10.5 ± 1.D.0 cc min.) BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12mm diameter plunger . 3.0 cc 8 Low idle fuel 375 1000 15.0 cc max.7 ± 0.6mm 100 1000 130.5 cc 10 Static timing lock plunger lift on port ‘‘B'' - - 1.0 cc 9 Fuel shutoff solenoid 375 1000 1.6mm 700 - 1.06mm 11 Test stand equipment a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure b) High pressure pipes .2003 .3-0.8 ± 0.0 ± 10. TYPE NUMBER: 0 460 426 313 Test Description SHEET 1 of 1 Pump rpm Strokes Overcheck 1 Return fuel 1150 - 57.4 bar d) Calibrating fluid . a) Rated speed 1150 1000 89.ENGINE .1 ± 0.46°C outlet temperature 84993509-03.0 ± 10.0 ± 2.3-0.5 cc - 1000 6.10 ± 0.5 cc 10 Static timing lock plunger lift on port ‘‘B'' - - 1.0 ± 4.0mm diameter and 6.ISO 4113 at 44° .00mm O.) BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12mm diameter plunger .0 ± 10.0 ± 5.5 litre (456 cu in.5 ± 1.TM165 7.0 cc b) Peak torque 700 1000 108.0 l/hr 2 Timing piston travel 950 - 3.0 cc 9 Fuel shutoff solenoid 375 1000 1.2003 .840mm long with 2.0 cc @ 600 mbar 6 Unboosted fuel 500 1000 86.14 SECTION 10 .0 cc @ 0 mbar 7 Governor breakaway 1205 1000 70.2mm lift) PUMP NH NUMBER: 87801837 Test No. Full load fuel c) Port to port variation 5 Boost control 650 1000 97.0 cc max.7mm 3 4 Start fuel 100 1000 85. 3.CHAPTER 1 TEST PLAN .0 cc max. 230 1000 89.5 ± 3.06mm 11 Test stand equipment a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure b) High pressure pipes .0 ± 3.0 cc min. c) Fuel gallery inlet pressure 0.6mm 600 - 1.2 ± 0.D.0 cc 8 Low idle fuel 375 1000 15. Valve Rocker Arm 18 24 Injector Attachment Bolts 17 23 Cover Bolts (Blanks Oil Drilling) 23 31 Oil Pump to Block 17 23 Water Pump-to-Cylinder Block 48 35 Water Pump Cover-to-Pump 20 27 Oil Pan-to-Cylinder Block 33 44 Injector Line Nuts 18 24 Leak-off Tube Banjo Fitting Bolts 4.ENGINE .15.VARIOUS lbf ft Nm 60 + 90° 81 + 90° 110 149 40-70+90° 55-95+90° As above +45° As above +45° Intake Manifold-to-Cylinder Head 26 35 Exhaust Manifold-to-Cylinder Head 45 61 Exhaust Pipe-to-Flange 23 31 Flywheel-to-Crankshaft 145 197 Oil Pan Drain Plug 30 41 Valve Rocker Cover Bolts 18 24 Crankshaft Pulley-to-Crankshaft 210 224 Self-Locking Screw .CHAPTER 1 TORQUE VALUES . SECTION 10 .2003 .4 6 Injection Pump-to-Front Cover 18 24 Camshaft Idler Drive Gear-to-Block 175 237 Front Cover-to-Cylinder Block 18 24 Thermostat Housing Bolts 18 24 Camshaft Gear Bolt 51 69 Camshaft Rear Gear Plate Bolts 35 47 Oil Filter Adaptor Bolts 31 42 Oil Filter Mounting Bolt Insert 25 34 Starting Motor-to-Rear Adaptor Plate 23 31 Injection Pump-to-Gear Nut 68 92 Oil Pressure Switch Assembly 23 31 Turbocharger-to-Exhaust Manifold Nut 33 44 Fan Blade to Viscous Unit 21 27 Viscous Unit to Pulley 40 54 Crankshaft Rear Oil Seal Retainer 15 20 Belt Tensioner Pulley Bolt 40 54 Temperature Senders 15 20 Main Bearing Bolts Connecting Rod Bolts Cylinder Head Bolts (with Engine Cold) Cylinder Head through Rocker Shaft Bolts Tensioner to Water Pump Bolt 40 54 Idler Pulley Bolt 40 54 Pump Connector to Block 18 24 84993509-03. Bolt 3/4x16-UNC x 2 in.394 in.14 NPT SPECIAL TOOLS 1 Fuel Injection Pump Drive Gear Puller (Local manufacture or Special Tool No.CHAPTER 1 TORQUE VALUES The following general nut and bolt installation torque requirements (lubricated) apply to any operation not previously listed.20 1/ 3/ 7/ 9/ 5 4 4 16 16 -18 /6 -18 CYLINDER BLOCK PLUGS 1/ 3/ 4 4 . Three holes 0.295042) 1. INCH SERIES lbf ft Nm 8 11 .28 8 11 5 /16 -18 14 19 5 /16 -24 17 23 .87mm) dia. shown in brackets) 84993509-03.13 65 88 1 /2 .8 3 /4 . where applicable. Bolt 5/16-UNF x 2 in.16 23 31 3 /4 .(51mm) 3.18 NPT 28 38 20 27 1 /4 .375in (9. (10mm) Plate HRLC P&O Steel (Prior Tool Numbers.2003 .16 SECTION 10 . equally spaced material of 0.5mm) dia.18 NPT 22 29.24 33 45 7 /16 -14 48 65 -20 55 75 1 /2 .27 NPT 8 11 1 /4 .2in (56. (51mm) with integral washer (3 bolts required) 2. on 2.ENGINE .20 75 102 90 122 138 187 . 17. SECTION 10 .splitting block 293760 - - Injector .Splitting socket kit 293761 - - Injection pump drive gear puller 295042 - - Adjustable bridge puller - 518 9539 Shaft protector - 625-A 9212 Step plate adaptors - 630-S 9210 Bushing kit - 818 9514 FNH00035 OTC 134-00002 - - - FT.506) N6261-A 1442 292320 MS.6203 1255 (SW.cleaning kit 293671 - - Injector .CHAPTER 1 Description New Holland Tool Number SPX Ltd Tool Number Nuday Tool Number Engine sling hook.hand pump tester 290284 - - Injector . (use with brackets 50075 and 50076) 290740 - - Engine revolving stand 290090 - - Engine overhaul brackets kit 293860 - - Cylinder pressure test kit 291309 - - Lube pressure check kit 292870 - - Piston ring pliers 296028 - - Piston install band 296042 - - Crankshaft rear seal installer 295010 FT.502) 2136 (SW.2700 C - - MS.6212 - Crankshaft front seal installer - NH 10-103 - Valve guide set reamers 295006 FT.ENGINE .502) Valve spring compressor 291050 - - Water pump impeller seal installer 295007 FT.2700 C8 or 297617 - Con rod bush .6202 (SW.remove/install tool Camshaft bearing installer Handle (for camshaft bearing installer) Tractor splitting kit Engine support brackets (for use with tractor splitting kit) GREASE AND SEALANTS Code Number Name A NLG1 Grade 2 Grease B ESF-M1C43-A Grease-Silicone Light Consistency C 82995768 Sealer-Anaerobic Low strength D&J 82995776 Sealer-Silicone E&F 82995774 Sealer-Polyester Urethane G 82995773 Sealer-Anaerobic K 82995772 Thread and Stud Lock L 82995771 Flexible Gasket Sealant 84993509-03.6209 4672 Injector .2003 . and/ormachine the valve guide bores 6.18 SECTION 10 . where fitted 1. Renew bulb 2. Clean and reset 4. Warning light circuit faulty 3. Low cylinder compression 8. Overhaulinjectionpump injectors 84993509-03. Incorrect fuel delivery 7. Oil leak on compressor or turbine side of turbocharger. The following table lists problems and their possible causes with recommended remedial action. Excessive fuel delivery 3. Clean 3. Clean 4. Fuel line obstructed 2.CHAPTER 1 FAULT FINDING IMPORTANT: When effecting a repair the cause of the problem must be investigated and corrected to avoid repeat failures. Check injectors and pump 8. Overhaul turbocharger 2. Check head flatness and fit new gasket 7. 1.2003 and . Warning Light pressure switch faulty 2. Renew pressure switch 3. PROBLEM POSSIBLE CAUSES REMEDY Enginedoesnot developfullpower 1. Air cleaner dirty or restricted 4. Check and renew wiring 1. Renew piston rings or re-bore/resleeve as necessary 1. Burnt. Clogged air cleaner 1. Clean or renew element 2. worn or sticking valves 5. Exhaust leak on exhaust manifold side of turbocharger. where fitted 2. Replace valves with new or oversize.ENGINE . Fit new gasket 3. Blown head gasket 6. Incorrect adjustment Oil pressure warning light fails to operate Excessive exhaust smoke valve clearance 4. Bulb burnt out. Faulty injectors 3. Check and reset 5. Check for source of leakage. Faulty thermostat 6. Radiator fins restricted 5. Coolant aeration 10. check head for damage or distortion 10. Obstruction to radiator air flow 14. Faulty temperature sender 1.CHAPTER 1 PROBLEM Engine overheats POSSIBLE CAUSES 1. Hot spot due to rust and scale or clogged water jackets 13. Faulty water temperature gauge 3. Tighten all connections and check coolant level is correct. Cylinder head gasket improperly installed 12. Reverse flush entire cooling system 12. Check free flow 16. Hose connection collapsed REMEDY leaking or 1.ENGINE . Oil cooler tube blocked 15. Clean with compressed air 6.2003 . Extended engine idling 15. Improperfanbelt adjustment 4. Remove the obstruction 13. Renew cylinder head gasket 11. Clean 16. Renew thermostat 3. Internal engine leakage 7. Radiator cap defective or not sealing 2. renew hose if damaged 2. Repair/renew radiator 4. Re-adjust fan belt 5. Renew thermostat 7. Renew temperature gauge 84993509-03. Renew radiator cap 3. Radiator leakage 3. Overhaul water pump 9. renew gasket or defective parts 8. Radiatorcoretubes blocked Water temperature gauge fails to reach normal operating temperature 1. Water pump faulty 8. Exhaust gas leakage into cooling system 9. Renew cylinder head gasket. Ensure cylinder head gasket has not blown 11. Incorrectorfaulty thermostat 2. SECTION 10 . Tighten hose connection. Renew sender switch 2. Do not allow engine to idle for long periods 14.19. Fit new relief valve 5. Check head for damage or distortion 5. Wrong grade of oil 2. Excessive oil pump rotor and shaft assembly clearance 7. External oil leaks 2. Engine oil level low 1. Repair/renew oil cooler assembly Engine tends to keep firing after fuel is shut off 84993509-03. Renew gasket. as necessary 2.20 PROBLEM Low oil pressure SECTION 10 . Clean pump screen 4. Excessive main or connecting rod bearing clearance Excessiveoil consumption 4. where necessary. Oil leak on compressor side of turbocharger where fitted 2. Overhaul pump 7. Reduce oil level 2.2003 1. Blocked oil pump sump screen 3. Engine oil level too high 1. Renew 3. Oil cooler leak 6. Renew rings and/or rebore/ resleeve block as necessary 6. Cylinder head gasket leaking 4. Drain and refill with correct grade of oil 3. Oil pressure relief valve faulty 5. Aircleanerdirtyor restricted 1.CHAPTER 1 POSSIBLE CAUSES REMEDY 1. Renew oil pump 6. Install new bearings inserts and / or re-grind crankshaft if necessary 1. Renew gaskets and seals. Check mating surfaces for damage or distortion 3. Clean or renew element 2. Overhaul turbocharger . Worn valves. Oil loss past the pistons and rings 5. valve guides or bores 4. Oil pump worn 6.ENGINE . Top up. The exhaust manifold is mounted on the left hand side of the engine. and valves with oversize stems are available in service. Valve guides are integral in the cylinder head. Water outlet connections and thermostat being attached to the front of the cylinder block directly behind the radiator. An external damper is fitted to the crankshaft pulley to ensure smooth running operation. and drives the engine oil lubrication pump mounted forward of the flywheel.CHAPTER 1 21. The intake and exhaust manifolds are bolted to the head. The small end of the connecting rod is fitted with a replaceable bronze bushing. takes place in the specially designed bowl in the crown of the pistons. with the valve rocker arm shaft assembly bolted to the cylinder block through the cylinder head.2003 . CRANKSHAFT ASSEMBLY The crankshaft is supported in the cylinder block by 7 main bearings. DIESEL ENGINE . The connecting rods are of a heavy beam construction and are assembled as a matched set to each engine. The camshaft drive gear is in mesh with and driven by the camshaft idler gear which is driven by the crankshaft timing gear. with oversize valve seats also available in service. attached to the crankshaft. Special replaceable cast alloy valve seats are pressed into each valve port during manufacture. Front and rear crankshaft oil sealing is effected by one piece seals that are designed for long and durable service life. CONNECTING RODS Connecting rods ``Teepee" (wedge) shaped at the small end have been designed to reduce the reciprocating weight at the piston end. They are retained in position by the connecting rod big end cap and secured by two bolts per rod. Cylinder head retaining bolts are evenly spaced with a six point pattern around each cylinder. All valves are fitted with positive valve rotators. and located between the camshaft gear and the front camshaft journal. All engines feature cross flow cylinder heads. CYLINDER HEAD ASSEMBLY The crankshaft is manufactured from steel with machined finished crank webs The cylinder head incorporates valves and springs. the intake manifold is mounted on the right hand side of the engine. mounted in each of the rocker arms.ENGINE . A helical gear is mounted on the rear of the camshaft. with the diesel injectors mounted outside the rocker cover. through which the free floating piston pin is fitted. End thrust is controlled by a thrust bearing incorporated in the centre main bearing of the crankshaft. The fuel and air combustion process. Camshaft end thrust is controlled by a thrust plate bolted to the block. 84993509-03. with the inlet and exhaust manifolds on opposite sides of the cylinder head. CAMSHAFT ASSEMBLY The camshaft runs in 5 replaceable bearings. with both Intake and exhaust valves using umbrella type oil seals. by means of insert-type bearings. The steel pin being held in place within the piston by two snap rings. this ensures an even clamping load across the cylinder head area. Valve clearance is maintained by adjustment of the self locking adjusting screw.SECTION 10 .DESCRIPTION AND OPERATION The engines are 6 cylinder and available in naturally aspirated and turbocharged forms. Also dirt and grit may be drawn through the air cleaner connections if they are not properly secured. The crankshaft gear drives the camshaft idler gear which is attached to the front of the cylinder block. . are on opposite sides of the cylinder head. and is keyed to maintain position of the gear on the camshaft. The cylinder bores are machined integral with the cylinder block.22 SECTION 10 . The configuration of the manifolds also ensures minimum heat transfer to the intake manifold. which are available in service.CHAPTER 1 PISTONS Pistons are constructed of an aluminium silicon alloy with an iron insert for the top ring. TIMING GEARS The intake manifold is connected through tubing to the air cleaner and at the inlet of the manifold a tapped hole is provided for installation of a thermostart or an ether cold starting aid. to a high degree of accuracy during manufacturing. The oil pan which is attached to the bottom of the cylinder block. and cast iron exhaust manifolds.ENGINE . 84993509-03. This enables precise timing being maintained during the life of the engine. Considerable damage to the cylinder bores. The combustion chamber being recessed into the piston crowns. during the manufacturing process. to reduce friction and increase positive sealing.2003 The crankshaft timing gear is heated and press fitted on to the front of the crankshaft. Each piston has two compression rings and one oil control ring. All rings are located above the piston pin. The camshaft gear is bolted to the front of the camshaft. may be incurred by entry of grit or other foreign material if the plug is left loose or missing. This is designed to maintain balanced heat distribution within the cylinder head. A cast iron engine front cover and front plate is attached to the front of the engine and covers all of the timing gear assembly. and water jackets for cooling the cylinders. The idler gear then drives the camshaft and the injection pump via meshing helical gears. They can be bored oversize for the fitment of sleeves. Cylinders are in line and vertical and numbered from 1 to 6 from the front to the rear of the engine. CYLINDER BLOCK ASSEMBLY The cylinder block is an alloy cast iron with deep cylinder skirts. MANIFOLDS The cross flow design aluminium intake. is the reservoir for the engine oil lubrication system. NOTE: On tractors where cold start equipment is not installed ensure the plug in the intake manifold is kept tight at all times. on the left hand side of the engine.2003 . The turbocharger where fitted. is supplied with oil from the oil filter support housing. Engine Lubrication System With Turbocharger Fitted 2 84993509-03. An intermittent flow of oil is directed to the valve rocker arm shaft assembly via a drilled passage in the cylinder block. and the pressure lubricated camshaft drive gear bushing. which runs the length of the cylinder block. The gear has small oil passages machined on both sides allowing excess oil to escape. Figure 1. forward of the flywheel on the left hand side of the engine. are lubricated by oil pressure jets mounted adjacent to each main journal housing.1 camshaft bearing. The main gallery also supplies oil to the crankshaft main bearings and connecting rods both big and small ends. SECTION 10 . Timing gears are lubricated by splashed oil from the cam follower chamber. The camshaft drive gear bushing is pressure lubricated through a drilled passage from the front main bearing. and prevents over pressurisation of the system. The oil pump is driven from the rear of the camshaft and draws oil from the engine oil pan through a tube and screen assembly. The rotation of the camshaft allows a controlled intermediate flow of lubrication. The underside of the pistons and pins.CHAPTER 1 LUBRICATION SYSTEM Lubrication of the engine. Oil flows from the filter to the main oil gallery. mounted on the left hand side of the engine. and aligns to a hole in the cylinder head.23. A spring loaded relief valve is integral with the oil filter body mounted on the left hand side of the engine block.ENGINE . is maintained by a rotor type oil pump mounted in the rear of the engine block. A spin on type oil filter is mounted externally to its support housing. which also intersects the camshaft follower chamber. This is located vertically above No. 24 SECTION 10 - ENGINE - CHAPTER 1 COOLING SYSTEM The function of the water pump mounted at the front of the engine, is to maintain a continuous flow of water around the cooling system. This is essential to ensure correct engine temperature, and performance, during vehicle operation. The pump is driven by a ‘‘Poly V"Belt from the crankshaft pulley, when the engine is running. The fan belt tension is maintained by a spring loaded belt tensioner, bolted to the front cover of the engine. The cooling system for the new generation of engines, is of the recirculating by-pass type with full length water jackets for each cylinder. The coolant is drawn from the bottom tank of the radiator by the water pump, which passes the coolant to the cylinder block. This coolant then flows through cored passages to cool the cylinder walls. Passages in the cylinder head gasket allow coolant to flow from the cylinder block, into the cylinder head. Cored passages also conduct the coolant to the fuel injector nozzle locations, before re-entering the water pump below the thermostat. The thermostat is located in the top of the water pump body, and controls the flow of the water as required by temperature changes. NOTE: A faulty thermostat may cause the engine to operate at too high (hot), or Low (cold) an operating temperature. If not replaced this could result in a damaged engine, or impaired engine performance. When the thermostat is closed a recirculating by-pass is provided to allow the coolant to recirculate from the head to the block to effect a faster warm-up. Once the engine has reached its normal operating temperature, the thermostat will open and allow water to be drawn through the radiator by the pump action. Cooled water then returns to the engine system. 3 Cooling System 1. Cab Heater Core 2. Engine OIl Cooler (Turbo Engines) 3. Engine Block 4. Water Pump 84993509-03.2003 5. Radiator 6. Radiator Blanking Cap 7. Thermostat 8. Header Tank 9. Cylinder Head 10. Water Filter 11. Cab Heater Tap 12. Fan and Viscous Unit 13. System Pressure Cap 14. Cold Coolant Level sender SECTION 10 - ENGINE - CHAPTER 1 25. Cooling occurs as the coolant passes down through the radiator cores, which are exposed to the air as it is drawn through the radiator by the fan. NOTE: Do not operate an engine without a thermostat. It is recommended that a solution of a 50% clean water, and 50% recommended antifreeze, see specifications, is used. The cooling system incorporates a drain plug (1), Figure 3, on the left hand side of the cylinder block. The system pressure cap is located on the header tank. The cap on the radiator is a blanking cap and should not be removed unless refilling the system from empty. Normal topping up should occur at the header tank. 4 The engine cooling fan is mounted on a viscous drive hub (1), Figure 4, which is belt driven from the crankshaft. The viscous drive allows the fan to operate only when required by the cooling system permitting a faster engine warm up, reduced parasitic power loss when the fan is not engaged and reduced noise levels. 5 84993509-03.2003 26 SECTION 10 - ENGINE - CHAPTER 1 Figure 5 - A, Cool air from radiator, fan idling 6 Figure 6 - B, Hot air from radiator, fan driving 7 Air temperature behind the radiator is sensed by a Bimetallic coil (4), Figure 6, located in the centre of the fan hub face. As the temperature increases the coil gradually opens a valve (5), Figure 6, within the hub (3), Figure 5, which allows a modulated flow of viscous fluid (3), Figure 5, to pass from an integral reservoir (2), Figure 5, to the drive area, due to centrifugal force, providing a gradual take up of fan drive. Within the drive area are two sets of interlocking annular fins, one set on the drive member (1), Figure 5, and the other on the free-wheeling hub body (4), Figure 5, to which the fan blade assembly (2), Figure 5, is attached. Viscous liquid passes between the interlocking blades and the resulting drag transmits torque to the fan. The fluid is then recirculated to the reservoir by a pump plate (6), Figure 6, incorporated in the drive member (1), Figure 6. When the air temperature behind the radiator drops sufficiently, the Bi-metallic coil closes the valve preventing fluid from entering the drive area and the fan hub is allowed to idle with respect to the drive member. 84993509-03.2003 27. SECTION 10 - ENGINE - CHAPTER 1 FUEL SYSTEM 8 Fuel System 1. Injectors 2. Shut-off Solenoid 3. Fuel Injection Pump 4. Fuel Filter 5. Fuel sedimenter The diesel fuel system consists of fuel tank, fuel sedimenter, electric lift pump, fuel filter, BOSCH VE distributor type fuel injection pump, fuel injectors, and interconnecting tubes and lines, Figure 7. The fuel injection pump is pressure fed from an electric lift pump. Fuel flows from the fuel tank to the sediment separator, through the electric lift pump and then through the fuel filter. From the filter the fuel passes to the transfer pump which is an integral part of the fuel injection pump. The transfer pump delivers fuel to the injection pump to supply fuel at high pressure to each injector and also provides extra fuel which lubricates and cools the injection pump. This extra fuel is recirculated, via a fitting on the fuel injection pump governor control housing to the fuel tank, by means of the injector leak off line. 6. Electric Lift Pump 7. Right Hand Fuel Tank 8. Left Hand Fuel Tank 9. Fuel Gauge Sender Unit 10. Thermostart Fuel Shut Off (Injection Pump) All fuel injection pumps are equipped with an electrically operated fuel shut off solenoid. The fuel shut off solenoid is energised by operation of the ignition switch mounted in the instrument panel. With the ignition switched ‘‘OFF" a spring loaded plunger in the solenoid (held in position by the spring tension), prevents fuel flowing into the pump from the main fuel feed port. With the ignition switched ‘‘ON" the magnetised plunger is energised by an internal coil and is drawn up into the body of the solenoid. Fuel is then allowed to flow through the open port into the pump. On all models excess fuel that leaks past the needle valve of the injectors is directed back into the fuel tank, by means of the injection leak off line. 84993509-03.2003 12 84993509-03.CHAPTER 1 Fuel Sedimenter The sedimenter. The fuel enters the sedimenter and flows into the head. The fuel is ignited by the coil producing a flame in the manifold which heats the intake air prior to it entering the combustion chamber. receives the clean fuel from the electric pump. and around the edges of the sediment separator cone. the pump draws fuel from the tank. 10 The filtered fuel then flows up the centre tube of the element to the filter head outlet. by operating the ignition switch. are separated out and sink to the collecting bowl which can be removed and cleaned. The clean fuel is then drawn back through the top of the unit by the electric lift pump and on to the fuel filter. 9 Electric Lift Pump An electric fuel lift pump is fitted to all models.28 SECTION 10 . through the filter paper and into the base chamber. The larger particles of dirt and water (which are heavier than fuel oil). 11 The thermostart is screwed into the inlet of the intake manifold. and the electric lift pump. Figure 11. to be directed down. the heater coil is energised. Figure 11. Figure 8 is positioned between the fuel tank. As the coil heats up a check valve opens which allows fuel to flow over the hot coil. (1) Figure 9. via the sedimenter/filter and passes fuel under pressure to the secondary filter and onto the fuel injection pump. and into the injection pump. A fuel line connects the thermostart to the secondary fuel filter head and the electrical terminal is connected to the ignition switch via the electronic management unit which controls the duration of thermostart operation. Located in the head of the sedimenter. From the filter head the fuel is directed down. close to the sedimenter/primary filter.When When electrical current is applied. Fuel Filter The secondary fuel filter situated to the right hand side of the engine. a thermostart is standard on all models. Thermostart To aid engine starting in cold weather conditions.2003 . on the right hand side of the engine.ENGINE . Operations or repairs that can be performed with the engine still in the tractor. where components are suitable for re-use. and associated components . Operations or repairs that can be performed with the engine separated from the transmission housing. or separated from the transmission housing. Fuel injection pump and related parts. bearing shells. piston removal. 2. or by referring to the following removal procedure. in the main overhaul procedure. Following this section are defined headings which describe detailed repair specifications and procedures.ENGINE . Where new sealant is to be applied refer to ‘‘Engine Specifications". Refer to the specifications section to ensure components are serviceable. Front timing cover/timing gear removal.CHAPTER 1 DIESEL ENGINE STRIPDOWN In the following procedures and illustrations the engine in the main is shown removed from the tractor. Oil pump and drive gear removal. and oil pump suction tubing. 2. or separated at the connection to the front axle support. 1. and the relevant paragraphs. Referring to the specification section as necessary. The engine overhaul procedure initially describes the assembly process for rebuilding an engine using all new components. 7.29. and with oil pan removed 1. and ‘O' rings must be replaced with new upon re-assembly. Crankshaft rear oil seal and carrier removal. crankshaft. (with oil pan removed). Front pulley and damper assembly. Cylinder head and associated inlet and exhaust components. Oil pump relief valve. Dismantle the engine following conventional techniques. 3. 5. NOTE: All gaskets. Water pump. 6. thermostat. 84993509-03. However there are certain operations that can be performed with the engine still in the tractor. Operations or repairs that can be performed with the engine separated from the front axle 1. Oil pan removal for access to oil pan gasket. 4. SECTION 10 . Turbocharger. Where overhaul of components is required without engine being removed from the tractor refer to the following headings. seals.2003 . 30 SECTION 10 .CHAPTER 1 ENGINE REMOVAL . 10 001 10) 13 Right hand View of Tractor 14 Left hand View of Tractor 84993509-03.ENGINE .2003 .INSTALLATION (OP. Figure 13. Position Splitting Tool. Disconnect Front Hitch hydraulic tube.C with engine supports. MS2700. Remove hardware securing the engine to the front support and wheel the front axle and support away from the engine. (3). (2) and 13. MS2700. earth lead first. Figure 15. Disconnect air cleaner inlet tube. Remove front wheel drive propshaft guard and propshaft. Disconnect electrical connection to the steering angle sensor. Drain the cooling system fluid into a clean container and disconnect the radiator hoses. Figure 16. withdraw the condenser from the radiator and remove the receiver dryer.2003 . if fitted. If splitting tool is not available use an overhead crane with suitable straps. 17 18 84993509-03. (4). NOTE: It will be necessary to remove the engine hood. Strap at the front and rear of the front support to maintain balance. 11. 12. again ensuring that the cooler is not allowed to hang on its hoses. Figure 13. Slide out the oil cooler from the radiator and tie up out of the way. 15 5. 3. Disconnect the front differential lock hydraulic tube on FWD models. 6.31. 16 9.C-8 in position. if fitted. 2. Disconnection of the radiator lower hose provides a suitable drain point. if fitted and drain oil into a clean container. Figures 12. SECTION 10 . Disconnect power steering hoses from cylinder. If air conditioning is fitted. Remove the radiator fan shroud hardware. 4. 7. Figure 16. Support the engine at the front of the transmission and position wedges between axle and support to prevent articulation. Carefully move both items away from the front of the tractor and secure to the side of the engine ensuring that they are not allowed to hang on their tubes. Disconnect battery. leaving shroud in position. (2) 10.ENGINE . 8. Place a large clean tray under the vehicle to capture the fluid for future use.CHAPTER 1 Separating Front Axle from Engine (with reference to Figures and ) 1. near bellhousing. 6. Figure 13 (5). Start and run the engine until correct operating temperature is achieved to purge air from cooling system. Disconnect steering tubes. 11. Figure 13. near bellhousing. Disconnect starter motor wiring and retaining bolts and remove starter motor. 19 5. Figure 13 (6). Figure 14 (1). Figure 21. 8. Remove the exhaust muffler. Carefully prise the engine from the transmission. 1. • Ensure after installation that all fluid levels are correct prior to start up.ENGINE . if fitted. Figure 13 (4). Disconnect the main harness to engine harness connector. Remove the buckle up bolts between the engine and transmission. Figure 19 and remove the engine hood assembly. Figure 13 (7). 3.290740 with brackets 50075 and 50076.32 SECTION 10 . (8). Disconnect water pipe to heater shut off tap located at rear of cylinder head. rectify as required and recheck fluid levels. • After connection of the battery it will be necessary to reset the radio / clock. check for leaks. 2. noting the following points: • Ensure all attaching hardware is tightened to the correct torque value as detailed in the specifications. tool No. ensuring that all wires and tubes are disconnected. Disconnect front hitch supply tube. Disconnect hood harness connector. Place the engine onto a suitable stand for repair. Disconnect the fuel lines to the fuel sedimenter and the overflow return to tank.CHAPTER 1 Separating Engine From Transmission (with reference to Figures and ) With engine previously separated from front axle. Engine Installation 21 Installation of the engine is the reversal of the removal procedure. Disconnect brake tubes to master cylinder. Figure 20. Support the engine using a suitable hoist.2003 22 . 9. 12. 20 10 Disconnect the left hand water hose to the cab. 4. 84993509-03. 7. Figure 13 (3). Stop engine. Disconnect air conditioning at quick release connectors. the vacuum tube to boost control unit. if necessary.ENGINE . Figure 24. Valves. rocker cover bolts (2). SECTION 10 .CHAPTER 1 ENGINE DISASSEMBLY Cylinder Head. • Disconnect and remove the rocker cover ventilation tube. • Remove the turbocharger assembly. check for concentricity and place in a numbered rack for reassembly. 84993509-03. Remove or disconnect the following components to allow removal of the cylinder head:• Remove the engine hood. • Remove the inlet manifold. • Remove remaining cylinder head bolts working inwards from the end of the cylinder head. • Remove the engine breather tube(3). injector to injection pump high pressure tubes and. Figure 23. • Remove the fan drive belt (1) and the water pump (2). • 23 24 25 Carefully lift the cylinder head assembly away from the engine block. rocker cover(1) and gasket. • Drain the engine coolant. • Disconnect the low pressure fuel lines to the filters. the injector leak off tube. 10 101) Cylinder head removal NOTE: The cylinder head can be removed with the engine installed in the tractor. (1).33. where fitted.14 off. into a clean receptacle. thermostart feed tube. Using the Drain plug on the block. (cap all exposed openings). Remove the push rods. • Remove the cylinder head bolts which pass through the rocker shaft supports and the rocker shaft assembly together as an assembly.2003 . • Disconnect air cleaner tubes. Disconnect and remove the engine hood frame with the air cleaner and water expansion bottle. And Related Parts (Op. water hoses to the expansion bottle and water filter and air cleaner to exhaust tube. if fitted. ensuring all openings are capped to prevent dirt ingress. • Remove the exhaust manifold if necessary. Figure 25. alternately to the centre of the cylinder head. CHAPTER 1 CYLINDER HEAD DISASSEMBLY 1. Inspection and Repair. see ‘‘SPECIFICATIONS". also cleaning valve guide bores.ENGINE . Disconnect leak off tubes and remove injectors from the cylinder head Figure 26. 28 29 84993509-03. to the new plug mating faces. NOTE: Ensure injector washers have been removed prior to cleaning. Clean the area surrounding the fuel injectors. Figure 28. Figure 29.34 SECTION 10 . springs(1). 5 off.291050. Clean the cylinder head. Using a valve spring compressor. and place in a numbered rack. in the intake face. 1. or leaking require changing. in the rear of the cylinder head. Scrape all gasket surfaces clean and wash cylinder head in a suitable solvent.(1) remove the retainer locks(2). 27 Core plugs required in the Cylinder Head.2003 . 6 off. 3. Apply sealant G. seals. Cylinder head core plugs if discoloured (rusty). In the top. 2. and drive the new plugs into location. and 1 off. Cylinder Head 1. tool No. Before fitting new plugs remove all old sealer from the cylinder head. Rocker Shaft Disassembly NOTE: Leave bolts in the rocker shaft supports during removal as they retain the support on the shaft(5). Remove the cylinder head bolts (3) and withdraw the supports(2). and remove carbon deposits from around the valve heads. rotators. springs(3). 26 Valve and Spring Assembly Removal 1. rockers(4) and spacers(6). By placing the cylinder head less gasket. 84993509-03. 5. or 0.127mm). 0. Therefore the cylinder block thread must be increased using a 9/16-13UNC-2A Thread tap. determine all head bolt faces will seat. If the cylinder head has been resurfaced.4mm).SECTION 10 . Ensure rocker shaft supports are fitted with long bolts. 4. overall limit Figure 30. 6. check the flatness of the cylinder head in all directions does not exceed. 30 7. 8.CHAPTER 1 35.001in(0. Using a straight edge and feeler gauges.2003 . Using a feeler gauge. Identify the bolt heads and ensure they are reinstalled in the bolt holes they were checked in. Remove using a suitable abrasive and ensure faces are clean after repair.03mm) in any 1in(25. check clearance between underside of bolt heads and cylinder head or rocker shaft support. on the cylinder block and installing bolts hand tight.25mm) feeler gauge can be inserted under the bolt head the bolt has bottomed.005in(0.010in(0. If a 0.ENGINE . Inspect cylinder head for nicks and burrs on mating face. 30° 2.2-1. Intake =30. Valve seat angle.750in(44.20mm) 1.010in (0.034-0.9-2.002in(0. as described in the above chart.55mm) NOTE: Refacing the valve seat should always be coordinated with refacing of the valve to ensure a compression tight fit.27-50.970in(50.098in (1.8-2. on the exhaust manifold side in line with the valve seat concerned.065in (1.5mm) oversize on diameter are sometimes installed during manufacture. Check the width of the valve seat inserts.45mm) 1.760in(44. 1.0°-45. Intake =0.740in(44.CHAPTER 1 Valve Inserts Counter Bore in Cylinder Head Insert Oversize Exhaust valve insert Intake valve insert 0.4mm) Exhaust =0. the cylinder head must be counter bored.739-1.092in (1. Examine the valve seat inserts and reface if pitted.980in(50.052in (0.010in(0.17-44. Total Indicator Reading should not exceed 0.52-50. Measure the concentricity of valve seats. using a dial indicator and measure concentricity of seat to the valve guide bore.6mm) 31 NOTE: Valve inserts of 0.25mm) 1. Figure 31.989-1. Figure 32.051mm).0°-30.30° Exhaust =45. renew if loose or damaged. Valve Head Face to Cylinder Head Face Depth. 4.030in (0.42-44. Valve seat width.749-1. Intake =0.58mm) 1.29mm) 0.072-0.32mm) Exhaust =0.70mm) 1. The new insert must be chilled in dry ice prior to installation.68-44.759-1.990in(50. 2.25mm) and 0.86-1.979-1. To install a new valve insert.04mm) 0.969-1. Cylinder Heads with oversize inserts are stamped so10/os.ENGINE .01-50.020in (0.078-0. 3.36 SECTION 10 .76mm) 1. and as required reface by grinding to dimensions detailed above. 84993509-03.2003 32 . so20/os.3mm) 3.020in(0.047-0. Valve Seat Specifications. 1. Rotate a new or refaced valve in the seat using engineering blue.076mm) oversize reamer.2003 . 0. Use a seat cutter to correct any seat eccentricity. 0.048-0. and standard diameter pilot. Intake valves. 33 Raise.38mm).0027in(0. by removing material from the top of seat using a. item 2 Figure 33. Such cylinder heads have 15 or VO15OS stamped on the cylinder head exhaust manifold side adjacent to the valve concerned. in the following manner. 30° grinding wheel for. 60° grinding wheel for.0019-0. reamer. and 84993509-03.ENGINE . Exhaust valves and a 15° grinding wheel for.015in(0. always use reamers in sequence. 0. If any blue remains below or around the seat raise or lower the seat accordingly. ream out the valve stem guide.0037in(0. Lower.003in(0. Exhaust valves and a 45° grinding wheel for.76mm) oversize 0. 34 NOTE: Production cylinder heads may have one or more machined.023-0. ensure all the blue is transferred to the valve head protrusion. and ensure it does not exceed.37. item 1 Figure 33. 6. measure the valve guide bore clearance. Ensure after any rework that seat width is within specified limits.CHAPTER 1 5. the valve seats. with three reamer and pilot combinations as follows:3.38mm) oversize pilot. Using a telescopic gauge.003in(0. Critical valve points. the valve seats. When going from a standard valve stem to an oversize. 0. and micrometer. 35 0. Figure 34: Valve land edgeValve head Valve face angleValve face Valve stem Valve tip Valve Guides 1. or valves installed. 2. Intake valves. or clean up of pits and grooves. ontheexhaustvalvestem.076mm) oversize pilot. reamer. SECTION 10 .094mm). ontheintakevalvestem. Figure 33.38mm) oversize 0.030in(0.069mm). and 0.0009-0. oversize valve guide bores. 295006.015in(0.015in(0. by removing material from the bottom of seat using a. Using reamer set. Figure 35. Assemble rocker shaft support with long head bolts. replace with new. and push rod ends of the rocker arm. If not to specification or push rods were found not to be straight during dismantling install new rods.ENGINE . and loaded length.69mm) using a weight of 135153lb(61-69kg) Ensure the valve spring retainer locks are in good condition.9in(48. Rocker Shaft inspection and Reassembly 1. If re-used.95in(47-49. Inspect rocker arm adjusting screws. Free length = 2.39in(60. 5. If any of these characteristics are not to specification replace with new parts. including the ball end of the screws for nicks. should not exceed 0. or excessive wear.6mm) Loadedlength=1. 37 NOTE: Do not attempt to straighten bent push rods. between the square. 2.7mm) Installedlength=1. Figure 37. Check the ends of the push rods for damage or wear.CHAPTER 1 Valve Springs 1. damage. 3. If not to specification replace with new. and spring at the top edge. 38 84993509-03.38 SECTION 10 . Figure 36. 3.060in (1.26mm) using a weight of 61.2003 .52mm). Length of valve springs should be checked on both free length. Figure 37.4in(35. forwards and upwards. Checked on a flat surface squareness. and replace if worn or damaged. Position the shaft identification groove.96lb(28-31kg) 36 Loadedlength=1. Also inspect the inside diameter of the rocker arm for damage or wear. on internal and external diameters respectively.86-1. 4. Check the rocker shaft for signs of wear or damage. before reassembly clean thoroughly in solvent making sure all oil passages are clear. This ensures oil grooves and holes face downwards. ensuring springs and spacers are re-assembled as in. only when the engine is cold.39.021in). 217Nm(160lbfft) NOTE: Bolts to be lubricated prior to assembly. SECTION 10 . Install new cylinder head.018in). 156Nm (115lbfft) Stage2. Figure 37. Insert the valves into the guide bores from which they were removed and lap with a suitable paste. NOTE: Valve clearance is to be set. Lubricate all components with clean engine oil on reassembly. Figure 39: A=Exhaust B=Inlet 2. 1.53mm(0. rotators.2003 .36-0. and rockers free to move. and collets.ENGINE . Coat all components with clean engine oil prior to assembly. Figure 40. 41 Intake Valve clearance. 3. Exhaust Valve clearance. observing the following.46mm(0. and should be tightened to torque specification.43-0. NOTE: Ensure exhaust manifold gasket is fitted correctly to suit profile of exhaust ports. 40 Stage1. Use a spring compressor to reassemble the valves. Figure 42. 2.017-0. ensure all traces of paste are removed after lapping. Figure 41. 39 CYLINDER HEAD INSTALLATION Installation of the cylinder head assembly and components is the reverse of the removal procedure. 3.CHAPTER 1 CYLINDER HEAD RE-ASSEMBLY 1. and install new umbrella seals. Tighten the cylinder head bolts in sequence progressively in three stages. intake and exhaust manifold gaskets. with the engine cold. 42 84993509-03. Adjust valve clearance setting with each piston in turn at Top Dead Centre. retainers. 0. 0. 190Nm(140lbfft) Stage3. valve springs. and insert each push rod into its original position.014-0. ensuring each ball end is seated in its cam follower. ENGINE . 7. ENGINE FRONT COVER AND TIMING GEAR REMOVAL (Op. 3. 10 102 & 10 106) NOTE: Timing cover and gears can only be serviced after removing the radiator.40 SECTION 10 . Figure 44. 45 84993509-03. during torque up. 38Nm (28lbfft). Withdraw the bolts retaining the front cover plate. Figure . and remove the front plate(1). Using puller. 44 2. Remove the fan belt. and tensioner.518 or FT.4lbfft) NOTE: Hold the leak off plastic tubing when tightening to prevent the pipes pivoting. 5. Exhaust manifold bolts are to be refitted and tightened to a torque of. Install the injectors with new seat washers. cork seals.9539. and withdraw the bolt and washer. Install the leak off line with new washers.CHAPTER 1 4. No. 38Nm (28lbfft). spacer and O-ring from the shaft. 6Nm (4.2003 . from the crankshaft pulley. Intake manifold bolts are to be refitted and tightened to a torque of.ft). and shaft protector No 625-A or 9212. Install the injector lines and torque to 24Nm (18lbf. 1. and torque to 23Nm (17lbfft) Figure 43. and torque the leak off banjo bolts to. remove pulley. 43 6. and adaptor from the block.002-0.15mm(0. item 1. 48 3. The gear is heat shrunk on to the crankshaft and aligned to the crankshaft No1 pin. Manufacture a suitable gear puller (1) Figure . then remove the camshaft gear bolt and disassemble.006-0. 0. Using a dial indicator or feeler gauge. should not be removed. fit a new camshaft thrust plate. If required the timing gear rear cover may now be removed. and washer from the fuel pump and remove the gear from the shaft.10mm (0.15-0.004in). Pry the camshaft gear using a lever. SECTION 10 . check the clearance. 49 84993509-03. Figure 46.46mm(0. Remove retaining nut. 4. gear.007in) limit. Figure 48. Figure 47. Renew if the backlash exceeds the following:Backlash to crankshaft gear.2003 . 0.ENGINE . 2.018in) Backlashtofuelinjectionpumpgear.006-0.004-0.15-0. 46 5.CHAPTER 1 NOTE: The crankshaft timing gear (1). Remove the camshaft idler gear retaining bolt. if outside of 0. to measure the backlash between each set of gears.295042 .018in) Backlash to camshaft gear. as shown in Special Tools listing or use Tool No.006in) 47 CAMSHAFT and FUEL INJECTION PUMP DRIVE GEARS REMOVAL 1. If the gear is damaged a new crankshaft is required. Before removing the timing gears use a dial indicator or feeler gauge. away from thrust plate.0760. to within 0.10-0. Remove the six retaining bolts and carefully pry the cover from the engine block.46mm(0. Figure 46.41. 0.35mm(0. 4. Rotate the gears and check the backlash at four equal points on the gears. Position piston no. and tighten to 69Nm(51lbfft) Figure 50.). using a suitable solvent cleaner and carefully apply a thin bead. Ensure the camshaft idler gear adaptor is free from obstruction and bushing is not damaged. burrs.2003 . rotate the eccentric until the backlash is correct and tighten the idler gear retaining bolt to a torque value of 242Nm (180lbf.015mm (0. (28lbf. Holding the idler gear.ENGINE . approximately 2mm. to the cover. 4. install the spacer.CHAPTER 1 Inspection and repair of gears 1. relative to the oil pan face of the block. If the backlash is outside the specification of 0. or scratches. With piston No1 at Top Dead Centre.42 SECTION 10 . aligning the mark on pump flange to the timing mark on the front cover. 3. Assemble the washer and nut to the shaft.ft. If the rear cover was removed thoroughly clean the mating surfaces between the cover and engine block. Minor marks can be removed using a fine abrasive. and camshaft gear. thoroughly clean before re-assembly. check the backlash between the pump and idler gear with a feeler gauge or dial indicator. of the recommended flexible gasket sealant. PROCEED TO REASSEMBLE THE FRONT COVER.ft) 50 2. leaving loose at this stage to allow the gear to rotate freely on the pump shaft. key.Clock position. and examine gear teeth for wear. Install the camshaft idler gear to the block. Wash the gears using a suitable solvent.006in).ft. Type ‘L'. Camshaft key and key-way should be checked for damage and repaired as required. 53 84993509-03. aligning the timing marks to the crankshaft and camshaft gears. assemble the ‘LOCKED' pre-timed fuel injection pump with a new ‘O' ring. 2. Assemble the cover to the engine and tighten the two lower retaining bolts to a torque of 37Nm. Torque pump retaining boltsto 24Nm(18lbfft) Install the pump gear over the pump shaft. Install the eccentric adjuster into the idler gear and initially position the larger of the two holes of the eccentric in the 6-9 O.010-0.004-0.) and the remaining four bolts to a torque of 24Nm (18lbf. 51 52 NOTE: DO NOT TIGHTEN THE INJECTION PUMP SHAFT NUT AT THIS STAGE.1 at Top Dead Centre. Installation 1. fitting a new ‘O' ring(1) first. stopping with the cover pointer aligned with either the 6° or 6. Tighten the retaining bolts to 37Nm (28lbf. Type ‘L'.37mm 160PS (6. 28lbf. (68lbf.ft. Thoroughly clean the mating surfaces between the cover and plate using a suitable solvent cleaner and carefully apply a thin bead. (15lbf. and drive the seal into position from the front of the plate. Drive out the old seal using a punch taking care not to damage the front plate. SECTION 10 . to the front plate. Coat a new seal in a suitable lubricant. 9. depending on engine type. and drive the seal into the rear of the front plate using. 55 10. Tool No 630-16 as in. Install the access cover for the injection pump gear nut.) NOTE: Fuel pump (injection) timing is set at 6° Before Top Dead Centre (BTDC) for 100.). Clean surfaces and apply a 2mm bead of flexible gasket sealant. to verify pulley to pointer timing marks. 54 8. 7. Initially tighten the injection pump gear nut to a torque of 20Nm. can be equated to a piston depth. Lubricate the crankshaft. Figure 56. Figure 54. Do not overheat as the damper assembly will be damaged.2003 . The pump gear retaining nut can now be fully tightened to a torque value of 92Nm. Assemble the plate to the cover and tighten the retaining bolts to a torque of 37Nm. Alternatively use.5° marking on the front pulley. (A) 100-115PS (6°) 106.ft). Rotate the crankshaft two revolutions. using number 2 cylinder. NOTE: Gentle and careful heating of the centre of the pulley will assist fitment. 6.43. The front oil seal should be replaced. Pulley Timing Mark to Pointer Check.56mm 57 84993509-03. approximately 2mm. onto the crankshaft and push fully home. 115 and 135PS models and 6. type ‘L'.81mm 135PS (6°) 107.CHAPTER 1 5. slide the pulley spacer(2) over the key(4). every time the front plate is removed. ‘UNLOCK' the pump by releasing the locking bolt and installing the spacer between the pump body and bolt head. 12. of the recommended flexible gasket sealant. Tool No T87T-6019-A.5° BTDC on the 160PS model. while holding the gear in a counter clockwise position to remove backlash from gears. Figure The degrees BTDC timing.ft. 56 11. 284Nm (210lbfft). Place pulley(3).5°) 108.ENGINE .ft. tightening the securing bolt to. The Number 2 cylinder dimensions are: Models Piston depth. Install the radiator and refill with the specified quantity and type of coolant fluid. clean sump in a suitable solvent. 1. and remove the bearing liner from the connecting rod. CONNECTING RODS. with a ridge remover to enable removal of the pistons. 1.(1). NOTE: Before installing the oil pan ensure that the rear oil seal carrier (2). 2. Installation 1. is correctly aligned with the block. and torque to 44Nm (33lbf. and liner. With cylinder head removed clean off any ridge from the top of the cylinder bores. less than 0. ie. this is essential if old pistons are to be re-used as failure to do so could result in ring land damage.CHAPTER 1 OIL PAN REMOVAL (OP. 2. Install a new gasket to the oil pan. AND RINGS. Installation is the reverse of removal but with the following requirements.33mm recessed. 10 102) WARNING Due to the weight of the oil pan it is recommended that a hydraulic jack is used to support and lower the oil pan to the ground. With the piston at the bottom of the stroke remove the end cap bolts.15mm protrusion or 0. 58 Inspection and repair 1. REMOVAL. 10 105) NOTE: The connecting rods and pistons can be removed with the engine installed after removal of the cylinder head and oil pan sump . Clean gasket material from sump face. inspect sump for cracks damaged threads or damaged sump face. . 59 NOTE: Bearing caps and liners must be kept with their respective connecting rods. PISTONS. 2. NOTE: It is necessary to move the front support forward a couple of inches to allow removal of the oil pan.2003 . Using the handle end of a hammer push the piston assembly out through the top of the block. Ensure block face is clean and free of gasket material. cap. BEARINGS. (OP.44 SECTION 10 .ft). Position the oil pan and install a bolt at each corner finger tight to hold in position. install remaining bolts.ENGINE . 60 84993509-03. Drain engine oil through oil pan plug and remove oil level indicator. Refer to engine removal at begining of chapter. 3. Remove oil pan bolts including those through the transmission and lower to ground. 41. Using an expander.45.6248-1.004in). 4. 41. 38.ENGINE . and inside diameter of the connecting rod bushing. Maximum Twist 0.CHAPTER 1 3.30mm(0. and place in an alignment fixture to check for distortion. Inspection and Repair 1. Measure the outside diameter of the piston pin.4998-1.625in).2003 . and ensure that any distortion. Ensure each piston and rod assembly.10mm (0. Check piston pin bushing for damage or wear in the following manner. Maximum Bend 0.113-38.288-41.100mm(1.6258in) 64 84993509-03.270-41. Check connecting rod components for damage.295mm(1.012in). 63 Connecting Rod Bush internal Diameter Naturally Aspirated. remove the piston rings. to the following:- Piston Pin Outside Diameter Naturally Aspirated. 5. Turbocharged.095-38.6255-1. and connecting rod assembly. 2. remains matched together for re-assembly into the cylinder block. skirts. SECTION 10 .5008in). Turbocharged.275mm(1. in a suitable solvent and inspect for damage to ring lands. or pin bosses. is within specification as follows. Remove piston pin snap rings from each side of piston and remove pin. Tool No. Turn the crankshaft again and repeat the process for the remaining pistons. 38.120mm(1. 61 Clean the piston.500in). 62 3.296028.5005-1. 46 SECTION 10 . Use a guide as described. Press fit a new bush through the fixture using the installation detail. and loose chippings are cleaned from the connecting rod before re-assembly into the engine. Use an expanding reamer to obtain correct bushing to piston pin clearance referring to specification section. 10. and press out the old bush using the removal fixture as shown in. by using a suitable piece of bar stock. Drill through the existing oil hole. Location Plate 4. After fitting a new bush ensure all sharp edges and burrs are removed. and gently drive the bush from its position. 1. A new bush can then be fitted in a similar manner.187in) bit. . and gently drive in the new bush into the connecting rod. and chippings. After installation grind the side faces of the new bush to match the side faces of the connecting rod. 3. Remover Insert 2 11.6mm(0. 7. 2. Removal Washer Collar Installation Insert 1 Bush Installation Insert 2 Pins Fixture Connecting Rod Bush Installation B. a standard bush can be fitted in the following manner. and into the connecting rod as shown in. Figure . with an end face machined flat to suit the standard parallel bush. Connecting Rod Location 13. 9. Ensure all sharp edges are removed. Remover Insert 1 10. 8. NOTE: Ensure the split in the small end bush is at right angles to centre line of connecting rod. to suit the connecting rod bush side face. With a new bush fitted drill a hole through the top of the connecting rod using a 4. It is recommended a guide is manufactured to assist alignment of the bar stock during this operation. 4. 5. Remove burrs. 84993509-03. Remover Insert 3 12. Position the tool on the bush. before refitting. Where special tooling is not available for the removal or fitment of the connecting rod bush. Figure . 5. If not to specification use tool No FNH 00053. Figure . 6. 6. Figure .CHAPTER 1 CONNECTING ROD BUSH 65 A. a press tool with the end face ground at an angle. Washer 14. Place the connecting rod securely in a bench press.2003 7. Installation 8. Connecting Rod Facing up 9.ENGINE . Manufacture from suitable bar stock. CHAPTER 1 Cylinder Block Core Plug and Sensor Ports. Pipe plug (2) torque to 24-34Nm(18-25lbfft). refer to ‘‘Specifications". Plug (3) drive into block. E. Plug (4) torque to 54-81Nm(40-60lbfft). Front and Left Hand Side 47. 67 Pipe Plug(3) torque to 24-34Nm(18-25lbfft) Use sealant. CYLINDER BORE 84993509-03. Clean the old sealant off the block. should be coated in sealant. Figure 72. Plug(2)torque 27-47Nm(20-35lbfft) Use sealant. apply engine oil only on re-assembly ‘‘Do not use sealant". Use sealant. 66 A Cylinder Block Core Plug and Sensor Ports.ft) Use sealant. Plug (1) torque to 8-14Nm(6-10lbf.SECTION 10 . E. Oil Jets (5) replace with new if damaged.ENGINE . NOTE: New part mating faces. and threads. E. Plug (4) drive in to block. refers to the front and left hand side of the cylinder block. Use sealant. and fit new plugs with sealer. require changing if leaking or rusty. Use sealant. 2. E. G. E. and must be replaced. and senders.2003 . Figure 71. Use sealant. 10 105) 1. Assemble in the following manner. Cylinder block plugs. E. Pipe plug (1) torque to8-14Nm(6-10lbfft). (Op. refers to the rear and right hand side of the block. Rear and Right Hand Side CYLINDER BLOCK OVERHAUL. Use sealant G. -Cylinder bore is damaged beyond re-boring limits. 84993509-03.ENGINE .4032in).0. i. use a telescopic gauge.127mm(0. does not exceed 0.127mm(0.0015in) wear limit. and C. to B. 2 Sleeving of the cylinder bores becomes expedient when. Where only minor imperfections exist and bores are to specification. 111.005in) Cylinder bore out of round. installed in service. C.2003 69 .0.4007-4. or taper. and compare dimensions. A.778-111. Measure lengthwise. Figure 73. Variances will indicate an out-of-round condition.48 SECTION 10 .011in). and compare dimensions lengthwise. Measure crosswise. to D. to D. A. 1.001in) wear limit. wear. Provided piston to bore clearance. Check the cylinder bore for scuffing or rings around the ring travel area.250mm (0.025mm(0. -Replacing sleeves.0. Variances between the readings will indicate ‘‘taper".e. Taper of cylinder bore. To check out-ofroundness.03mm(0.CHAPTER 1 1. Specifications 68 NOTE: Repair Limit' refers to the tolerance allowed after a repair has been performed. hone the bores prior to installing new piston rings.841mm (4. to B. the repair must be within the repair limit. Irregularities can be felt by running a finger over the surface. repair limit . The ‘Wear Limit' is the tolerance prior to repair.005in) Cylinder bore diameter. -Oil consumption is high. repair limit.0. Leave a step at the bottom of the bore a minimum of 9.BORING AND HONING 1. Measure the outside diameter (1) of the sleeve in several places.76mm(4.16mm (0.005-0. Figure 75. 5.111. to achieve the specified flatness of.4007-4.ENGINE . 2.7mm (8. Grease the sleeve with a general purpose grease and press the sleeve home to the lip in the bore. Bore through diameter.03mm(0. Bore the sleeve to. MaximumOvality.001in) through to bottom of the bore.025-0.00-111. 70 4. allowing for run out of chamfers.4015-4.454-4. to the diameter of. Interference of sleeve to the cylinder bore to be 0. from the block face.127-1.001-0.4015in.025mm(0.0mm(4.076mm (0.06in). surface finish of the bore is not to exceed (80 microns).2003 .0015in) 84993509-03. 6. Counter bore to a depth of 204. to prevent piston damage on re-assembly.038mm(0. 0. 0. and average the dimension. Hone the cylinder bore to. A chamfer in the internal diameter at the top of the sleeve to 45° x0.001in)inany25.4023in. 7. Counter bore the cylinder block (see step 2) using the average dimension to obtain a press fit. and top of sleeves. GradeA.400in). Skim the block face.80 (4.5mm (0. 0.4mm(1in). The top of the sleeve should protrude through the top of the block.3116. Break the sharp edge at the bottom of the sleeve prior to honing. 8. 110. Clean the cylinder bores and thoroughly dry. 9.003in).003in)inany152mm(6in) 0.78-111.) NOTE: Surface finish to be an average of 20 to 30 Microns.020in) should be maintained.0mm(0.400in).SECTION 10 . MaximumTaper. 3.08mm(0.040in).38-0. 0. between bore and sleeve. 114.CHAPTER 1 49. SLEEVING .) GradeB.80-111.3985-4.456in).111.82 (4.60-10. cross hatched at 35°-55°. Install the piston pin and retainers.011in.58mm(0. 4. NOTE: Pistons are only available as standard. (0. and piston. D. Figure 76. Naturally Aspirated. 0. in a vertical position at the top. middle. Figure 79.ENGINE .25 in. Measure the diameter of the piston at point B. using a feeler gauge. C. with the letter or grade mark on the piston. B.6mm (3.165-0. 25.) normally aspirated engine from the bottom of the piston.CHAPTER 1 Re-Assembly NOTE: Pistons that are replaced must be of the same type that were removed and have the same identification letters. A. 82.0mm (0. and numbers. Subtract piston diameter from the bore diameter and the resultant figure for a new.2003 . If clearance is ‘‘greater" try a similar new piston. 72 After an engine has run and settled down the maximum bore to piston clearance allowed is 0.0077in(0.98in) Turbocharged engine. Check the piston ring gap width.140mm(0.012in) 71 2. unrun engine should be. and bottom of the bore.0067-0. as embossed on the piston crown 1. Figure 78. E.3mm (1.) from the top of the block. 74 84993509-03.28-0.00-0.023in) Turbocharged.3mm(00.0065-0. Check the piston to bore clearance in the following manner.250mm).50 SECTION 10 .171-0. Lubricate all of the components with engine oil and assemble the connecting rod.0055in) Naturally Aspirated 0. New pistons should always be fitted if the clearance exceeds specification. 28. 0-0. If the clearance is ‘‘less" hone bore to obtain desired clearance.196mm Turbocharged engines. ensure the piston to block height is correct using a dial indicator to. aligned to the pip (1).11in. Upon re-assembly with the piston at Top Dead Centre.011-0. on the connecting rod. 0. if limit is still exceeded it will be necessary to rebore and resleeve. 73 3. Measure the cylinder bore diameter at point A. 0030-0. 81.055-0. ring . is towards the front of the engine. 2nd compression ring.2003 . Install top and second compression rings with the word top towards the top of the piston. Figure 80.0022-0.90mm (0.CHAPTER 1 51. Naturally Aspirated 0.0049in).90mm (0.015-0.016-0. Oil control ring.105mm (0. 5. is used to remove or install rings. 7. 2.036in).040-0. check with a feeler gauge.036in). 0.0042in). INTO BLOCK 1.0041-0. Oil control ring.B = Naturally Aspirated 77 PISTON ASSEMBLY INSTALLATION.A = Turbocharged . 2nd compression 0. and with no gap on the thrust side of the piston.SECTION 10 .Turbocharged. slide pistons into bores. and lubricate all parts with new engine oil. 78 84993509-03. Tool No.075-0.40-0. Top compression ring.90mm (0.125mm (0. and a soft drive.0016-0.296028. the gap between the ring and groove. Using a new piston ring. Turn the crankshaft to position No 1 crankpin at the bottom of the stroke.033in). 6. Figure 83.090mm (0. Ring Gap Specifications: 0.016-0.84mm(0.036in). ensuring grade letter on pistons. 8.103-0.38-0. Figure 76 . Tool No. Install the piston rings.0060in). Top compression ring Turbocharged 0.0035in). Select the correct bearing liners as in the following crankshaft section. but note the following: 76 NOTE: Before installing new pistons and rings into a used cylinder bore. and install in the rod and cap.016-0.296042. ensure the liner tang locates in the slots of the rod and cap. 0.Naturally Aspirated 2nd compression 75 0. 0. ring .ENGINE . Top compression ring. Using ring compressor. Ensure the ring gaps are staggered a minimum of 120° from each other on the diameter.40-0. remove the high polish from the cylinder walls by honing as previously described.153mm (0. Ensure the correct expander.40-0. 80 MAIN BEARING REMOVAL 1. Leave the remainder securely in place. AND CRANKSHAFT. 10 103) NOTE: Replaceable bearings are installed in production. in the crankshaft journal oil passage.and oil pan as previously described. The crankshaft can only be serviced after removal from the engine. 110lbfft) 4. 0. Inspection and Repair 1. Fit new bolts lubricated with oil. or damage replace as required. 79 MAIN BEARINGS. Remove the oil pan. the engine requires to be split from the transmission housing. Figure 84. 5. flatten and bend the head to conform to angle of oil passage in the crankshaft. refill engine oil and coolant. and tighten to a torque value of 149 Nm (15Kgf m. Figure . Using feeler gauges. Remove the main bearing cap from the journal to be repaired. check the side clearance of each connecting rod to crankshaft. 2. Ensure the connecting rod bearing liner.013in) and continue for remaining assemblies. to ensure correct crankshaft journal to bearing clearance is maintained in service. NOTE: A bearing removal tool can be fabricated from a 1in (25mm)x1/8in split pin. NOTE: It is recommended that all the main bearings should be replaced if it is found necessary to replace any one set of main bearings. and caps.13-0. Refit the oil pump tube/screen. to the connecting rod as a matched assembly. seats on the crankpin with the bearing cap fitted. Turn the crankshaft counter clockwise until the tool forces the bearing out of the cylinder block. Install the bearing removal tool. and inspect for wear.2003 81 .33mm(0. and run the engine checking for leaks.CHAPTER 1 3.ENGINE . to gain access to the crankshaft. (OP. The main bearings can be overhauled with the engine in the tractor. 84993509-03. FLYWHEEL. or removed from the tractor totally. journals. Thoroughly clean bearings. and install only one set at a time.52 SECTION 10 . scores.005-0. To remove the flywheel. CHAPTER 1 Installation 1. To gain access to the flywheel separate the engine to transmission. 2. If a new thrust bearing liner is installed the bearing must be aligned as described in the following crankshaft section. 197Nm (145lbfft).63mm(0.5in) below the root of the teeth. rotate the flywheel. The main bearing caps are tightened in two stages: Stage 1. 2.2 maximum. 4. SECTION 10 .53. 2. and measure to specification 0. If not to specification check crankshaft to flywheel seating. Installation 83 1. and direct the flame against the internal face of the gear.ENGINE . FLYWHEEL REMOVAL 1. 84993509-03. Clean the crankshaft rear flange and mating surface of the flywheel. Inspection and Repair 1. using a torque angle gauge tighten all bolts a further 90° in a single stroke. with flat face against the shoulder on the flywheel.127mm (0. The gear to flywheel runout should be checked using a dial indicator and should not exceed a Total Indicator Reading of 0. and mark with a 212°C ( 450°) crayon at a point just below root of the teeth. Inspect the flywheel ring gear. Figure . Use temperature indicating crayons to mark the side face of the ring gear in six equal places. tighten all bolts to a torque of 81Nm (60lbf.ft) Stage 2. and if damaged renew in the following manner. 82 Clean the mating surfaces of the new ring gear. and flywheel. 3.025in). Prior to removal and using a dial indicator. Use an oxy-acetylene torch with a tip size of No. and install the flywheel. Cut old ring gear free from the flywheel. mark with a 204°C (400°F) crayon at a point 13mm(0. Coat all parts lightly with new engine oil prior to assembly.2003 .005in) Total Indicator Reading. torque the bolts to. Quickly place the hot gear on the flywheel. and position the rear seal over the end of the crankshaft. and journal. on the end of the crankshaft using the three attaching bolts. Tighten evenly. Secure centre stock of tool to crankshaft flange with two screws. seal. Apply a liberal coating of clean engine oil to the rear seal retainer. to the crankshaft end and install the new seal squarely. and check for damage or distortion around the sealing faces. Split tractor as described in Section 10 001. With rear of engine exposed loosen and remove the 12 attaching bolts. Apply a liberal coating of new engine oil on a new oil seal. (1). Locate tool. 2. No FNH 01301. and the rear cover.52mm(0. To gain access to the engine oil pump.060in) further in.2003 . (1). Figure 91. in the following manner. until the seal is fully seated. Clean off all sealer. camshaft gear. Remove the tool after assembly and check the crankshaft seal run out as shown in. Tighten the nut until outer diameter of tool abuts retainer. 85 2. (1). or end of crankshaft remove the oil pan as previously described. Assemble cylinder end plate to centre stock and secure with nut and washer as in. 3. A new seal should be mounted on the crankshaft.CHAPTER 1 REAR COVER PLATE REMOVAL (OP. NOTE: The first seal replacement should be pushed into retainer with plain end of tool and subsequent seals with stepped end of tool which will reposition seal 1. remove crankshaft oil seal. and gently pry off cover plate. then bolt tool 295010. 10 102) 1. Figure 92. Figure 93. Figure . Figure 92. Tool must not be over tightened as stress and distortion could be imposed on the retainer.54 SECTION 10 . As an alternative the rear crankshaft oil seal can be installed using the following installation tool. 84 Installation 1. 3.ENGINE . 87 84993509-03. 86 4. and squarely. place a dial indicator. If not within this specification orientate the carrier around the slotted bolt.022in). 89 OIL PUMP REMOVAL NOTE: The oil pump can only be removed with the engine split from the transmission.22mm recessed. Install the carrier and loosely install the bolts. engine oil pan. 6. and the flywheel. Hand tighten this bolt followed by the remaining bolts and ensure the carrier is still correctly aligned. to 16-23Nm (12-17lbfft).56mm(0. 90 2. 1. Fully tighten the twelve bolts.400. detach the 3 pump mounting bolts. 91 84993509-03. 88 7.55. SECTION 10 .CHAPTER 1 5. protruding or 0. With new crankshaft seal installed. Figure ).016-0. NOTE: It is not necessary to apply any additional sealant to the carrier or block face.15mm. Prior to pump removal check pump gear to camshaft gear backlash does not exceed. (11.020in) Total Indicator Reading. Ensure the rear of the block face is clean. Figure 96. Loosen and remove the camshaft gear. back plate. Figure . and oil pump tube removed.ENGINE .51mm (0. in sequence. and withdraw the pump from the block.2003 .0. Ensure the edge of the carrier is aligned to the block to within 0. Place a straight edge along the rear of the engine block above the seal carrier. on the end of the crankshaft and ensure seal runout is within 0. Figure 95. Install a new gasket to the carrier and apply grease to retain in position. to expose the oil pump. Placing a ruler across top of both. by inserting a feeler gauge between the rotor and body. and place outer rotor over inner rotor.022in). slide a feeler gauge. Wash all parts in a suitable solvent and inspect inside of pump plate.0035in). Check to a maximum of 0. If exceeded a new pump is required. as reduced pump pressure through wear could result in reduced engine life. Place outer rotor in pump body and check clearance.ENGINE .CHAPTER 1 Disassembly 1. 92 Inspection and Repair 1. If visually okay check in the following manner. between ruler and inner rotor. Invert pump plate/rotor assembly. 93 3. to 0. Figure 98.55mm (0.001-0. Loosen and remove the pump face plate to body bolts. 4 off. Figure 99.2003 .56 SECTION 10 . Disassemble the pump and discard the O-rings. 94 84993509-03. 2. NOTE: If not to specification replace the oil pump. Figure 100.089 mm (0.025-0. for excessive wear or damage. and body. OIL FILTER SUPPORT ASSEMBLY Removal 1. at least 5 revolutions. and should not be removed during the life of the engine. in Figure 103. Fit a new O-Ring. and torque the attaching bolts(3). item 1. into the suction port. 23. 5. Clean and coat parts in new engine oil. Place outer rotor in pump body. 98 84993509-03. Assemble the front plate to the body andtorquethe retaining bolts to. 2. Fitting a new gasket (4).ENGINE . turbocharged. item 2 Figure 101.0-28. Figure . 27-34Nm(20-25lbfft). Figure 103. Lubricate and insert tube/screen assembly(2) into pump(1) through bottom of engine. to the output tube. and pump plate assembly.28.2003 .0 . 95 3. loosen the 4 attaching bolts and oil connections. lubricate and insert the pump into the block tightening the bolts. Unscrew and discard the old filter. Installation 1. Clean the filter support in a suitable solvent. is factory installed to facilitate machining. normally aspirated. Fit a new O-Ring.4 Nm (17-21lbfft). 96 Refit gears as previously described along with the rear plate. if not ‘‘disassemble" and repeat the exercise.4Nm (17-21lbf. and flywheel. 23. 4.SECTION 10 . and remove filter support assembly from the block. into the body and ensure that shaft is fully seated into bushing. Discarding the three O-Rings. Figure 104. to. NOTE: After tightening ensure the drive gear rotates freely by hand.CHAPTER 1 57. Figure 101. and ensure free rotation. NOTE: Plug item 5. to.ft). 97 2. Insert inner rotor. 2.8mm(2. Figure 106. rear cover plate. and spring. 102 84993509-03. Lubricate the pressure relief valve(1) and spring(2) and insert into housing.ENGINE . main bearing caps and liners. Remove pressure relief valve plug. Failure to do so could result in premature wear to the engine. Fit a new O-Ring to plug (3) Figure . 3.6kgs (34. CRANKSHAFT REMOVAL (OP. Compressedlength = 37. Fit tube to connector and torque to 27Nm (20lbfft). Remove the connecting rod caps. NOTE: If crankshaft is removed with cylinder head in position ensure all timing marks are realigned prior to reassembly. 99 Installation 1. due to oil bypassing the filter and returning back to the system. check spring length. Remove the engine from the tractor and place on an engine stand.3lbs). 4. and replace as necessary. This action will prevent possible interference between valves and pistons during reassembly. Remove the oil pan and oil pump tube as previously described. crankshaft pulley and engine front cover as previously described.58 SECTION 10 .46in) using a weight of 15. Clean assembly in a suitable solvent and ensure all ports are free of dirt. 10 103) 100 1. and identify to facilitate re-assembly. Remove the flywheel. 55Nm (42lbfft). Carefully remove crankshaft from cylinder block. ensuring free movement. wear.2003 . and torque to.CHAPTER 1 3.0mm(1. 101 4. 5. 5.08in). Check the parts for damage. removing valve. To ensure correct operation of the pressure relief valve. Freelength = 52. Dress minor imperfections using an oil stone but for severely marked journals machine to the next undersize bearing size. 2. SECTION 10 . Measuring. in four places to determine out-of-round.ENGINE . taper. approximately 6. A. compared with C and D. Examine the rear oil seal journal for score marks. Measuring.59. letters being stamped on one of the crankshaft counter balance weights. or wear. C. 103 3.25mm) undersize. If crankshaft timing gear teeth are worn or damaged it will be necessary to replace the complete crankshaft assembly. A and B. 4. Measuring. remove minor imperfections with fine emery cloth. indicates journal out-of-round. Position a piece of correct size plastigauge across the full width of the bearing cap. compared with D. Measure diameter of each journal. 1. indicates horizontal taper. Figure 111.010in(0. and if severely damaged renew the crankshaft.25in) off centre. compared with B.2003 . 104 5.CHAPTER 1 Inspection and repair NOTE: Current production engines may have a crankshaft with main or crankpin journals ground 0. Wash the crankshaft and drilled passages in a suitable solvent. These are identified with the letters 010 MUS and/or 010 PUS respectively. 105 84993509-03. If the journal exceeds specified limits refer to ‘‘specifications" chapter 3 and refinish journal to the next undersize bearing.35mm (0. CRANKSHAFT RE-ASSEMBLY 1. Check the crankshaft bearing clearance using a plastigauge as follows. Figure . indicates vertical taper. 2. but bearings of the same material must be used on the same journal. If these combinations of bearings do not produce specified clearance. Narrowest point. of gauge establishes maximum clearance. The difference between the two readings is the taper. 107 8. refinish crankshaft and fit appropriate size service bearings. ensure liner suits maximum diameter of journal. IMPORTANT: Engines may be assembled with bearings of different material.60 SECTION 10 . 7. Figure 111. Remove the cap and use the scale to check the width of the flattened plastigauge. 4.ENGINE . but if a bearing which is to specification is fitted to an out-of round journal. 5. Widest point. Install the cap and tighten bolts to 149Nm (110lbf ft).CHAPTER 1 3. fit appropriate size service bearings. 106 NOTE: Normally main bearing journals wear evenly and will not be out-of-round.2003 . 6. 108 84993509-03. Ensure the bearing surfaces are clean and bearing tangs. 9. Position the bearings and caps in the block and coat with oil. If the crankshaft has been refinished. of gauge establishes the minimum clearance. align with slots in the block and cap. 004-0. 11. remove the camshaft oil pump drive gear.2003 . NOTE: The front timing gear may be left on and the camshaft removed from the front if required.ft).CHAPTER 1 10. leave finger tight) to a torque of 197Nm (145 lbt ft). Tighten all bearing caps (except thrust bearing cap. with that of the camshaft idler gear and install the crankshaft. 111 84993509-03. Pry crankshaft towards rear of engine and note reading on dial if end play exceeds 0. and cylinder head. To ensure seal concentricity.. hold crankshaft forward and pry bearing cap rearwards taking care not to pry against flange of the bearing. or dirt. 15. Install rear crankshaft oil seal as previously described in back plate removal. Check the camshaft end play. 2. scratches. After removal of the flywheel.61. Figure 118. Invert the engine on the stand. 1. 4. see timing gears section. NOTE: Do not pre-install seal into retainer. installing remaining bearing caps to their original location. 14. SECTION 10 . pry crankshaft towards front of engine and set dial indicator to zero. Carefully withdraw the camshaft from the rear of engine.ENGINE . 10 106) NOTE: The camshaft bearings and tappets can only be serviced with engine removed from the tractor.20mm (0. Align the timing mark on the crankshaft gear. Remove the engine front cover. and remove gear. This will align thrust surfaces of both halves of bearing. 12. 5. install a new thrust plate prior to re-assembly if required. it must be assembled with rear plate and installation tool when fitted to crankshaft.008in) fit a new thrust bearing. and remove the oil pan. 109 13. and rear cover. Check crankshaft end play with a dial indicator gauge. hold forward pressure on crankshaft and tighten bearing cap bolts to a torque of 197Nm (145 lbt.10-0. if camshaft bearings are to be replaced. Figure . Install a thrust bearing cap with flange type bearing first. 110 CAMSHAFT REMOVAL (OP. If the end play is less than specification check thrust bearing for burrs. 3. Pry the crankshaft forward against thrust surface of bearing. and re-align thrust bearing as in operation 12. To remove. Figure 119. If any of these conditions exist install a new camshaft. 2.17mm (0. Measure the clearance between the internal diameter of bearing and outside diameter of respective journal. pitting. 3. NOTE: A positive alignment check can only be made with crankshaft removed when a 4.390in).076mm (0. 4.001-0.9900-0.15-25. and drive bearing into bore using tools as described. 112 3.693-60. 2. and place in a numbered rack for reassembly. if not to specification renew.CHAPTER 1 6. Bearing is correctly positioned when end of rod passes through oil hole in the bearing. Tool No N 6261-A or 1442. Remover/Replacer Tool No FT 6203. Position tool against bearing to be removed and attach handle. Inspect the camshaft journals.ENGINE . Inspect the camshaft bearings for wear or damage. 0. lobes. for damage. driving bearing from bore.719mm (2.62 SECTION 10 . CAMSHAFT BEARINGS 1. Inspection and repair 1. if exceeded fit a new camshaft. 4.003in).9910in).018in) rod can be passed down the oil passage from the crankshaft main bearing.025-0.389-2. Figure 120. Inspect the oil pump drive gear on camshaft for broken or worn teeth. If any wear or damage is apparent fit new gears. 60.6mm (0. Lift out the tappets. or 1255 and handle. To install. align oil holes of new bearing with holes in block. Measure the diameter and out-of-round condition of bearing journals.2003 113 . or heat discolouration. 84993509-03. If specification is exceeded install new bearings using. and mating gear on oil pump. Check each tappet for wear or damage and check diameters. 25. 2003 . 7. Install camshaft gear. Clean the injector bore and crank the engine to blow out any loose carbon particles. if the pressure fails to climb steadily and remains the same during the first two successive strokes. and coat tappet body with oil. steps 5-7 for each cylinder.7bar) of each other. 84993509-03. Crank the engine to distribute the oil and repeat the compression test. 5. Install an engine compression test gauge. A reading of more than the 25lbfin2 (1. 2. and install camshaft into engine. Connect the gauge and hose to the adapter. Apply petroleum jelly to each tappet foot. using a new seat washer and the injector mounting bolts. TEST READINGS 2. but the valves are leaking. or fails to climb during the entire test. Install new spacer and keyway on end of camshaft.ENGINE .7bar) below the other cylinders indicates leakage at the cylinder head gasket. A low even compression in two adjacent cylinders indicates a cylinder head gasket leak. 5. During a compression test. into the injector bore. All cylinder compressions should be uniformly within 25lbfin2 (1. Check this item before condemning the rings or valves. 10 001) TEST PROCEDURE 1. From kit No.291309 with fault injector 295039. If approximately the same reading is obtained. and repeat the compression test. Apply sealant ESE-M2G-114A to the sealing flange of the front cover plate on re-assembly. but climbs higher on the succeeding strokes. and recheck end play.63. SECTION 10 . Observe the gauge reading. 4. 3. 2. The oil will temporarily seal any leakage past the rings. 1. 4. A reading of more than 25lbfin2 (1. Crank the engine at 200 rev/min with the electric fuel shut off wire disconnected to prevent engine start up. the rings are satisfactory.CHAPTER 1 Installation 8. squirt the equivalent of a tablespoon of heavy oil into the combustion chamber. and align the camshaft gear timing mark. Warm up the engine by operating for a minimum of half an hour at 1200 rev / min 3. 3. Be sure battery performance meets specifications. there is leakage past the rings. TEST CONCLUSION To determine whether the rings or the valves are at fault. Oil camshaft journals and apply petroleum jelly to the cam lobes. piston rings or valves. If compression has increased over the original reading.7bar) above the other cylinders indicates excessive carbon deposits on the piston and cylinder head. 1. 4. Install tappets in bores from which they were removed. ENGINE COMPRESSION TEST ( Op. 6. suspect a sticking valve. Stop the engine and remove the injector and seat washer from no1 cylinder. Using a suitable manufavtured puller. the pump can be locked into position by removing the spacer plate and tightening the screw. 116 84993509-03. If the pump operation is suspect it should be taken to an approved BOSCH agent for testing and repair. clockwise(when viewed from the front).1 cylinder on the compression stroke. Remove the pump gear nut. 5.CHAPTER 1 FUEL SYSTEM Bosch VE Type Fuel Injection Pump-Removal (Op.Arrows denote items to be disconnected for removal. Withdraw the pump mounting bolts and remove the pump from the front cover. 1. NOTE: If the pump is only being removed to replace the sealing ‘O' ring or for another reason which does not involve rotating the pump shaft or the engine. Cap all openings to prevent dirt ingress. 2. Disconnect and remove all fuel lines from the injection pump. 160PS model) mark on the front pulley. so that the engine cover pointer aligns with the 6° BTDC (6. 4.64 SECTION 10 . 115 6.2003 . ot Tool No. To aid reassembly turn the engine over. remove the gear. Disconnect the throttle cable and fuel shut-off solenoid wire. as detailed under ‘Special Tools'. Remove the fan drive belt and then remove the injection pump gear access plate and belt tensioner assembly from the front cover plate. 114 3. injectors and front cover access plate are clean. with No.295042.ENGINE . 7. Figure .5° BTDC. This can be verified by removing the valve rocker cover and ensuring that valves 1 and 2 are both closed.The pump can then be replaced without having to use the special timing tool. NOTE: Ensure that the areas around the injection pump. Figure 116. 10 2) Figure 114 . Inspection The pump should not be tampered with in any way. 5. aligning the mark on pump flange to the timing mark on the front cover.ft). Figure 125. Rotate the pump so that the shaft keyway groove aligns with the injector outlet. of the recommended flexible gasket sealant. for No. Remove the D. Remove the centre bolt from the rear of the pump and install special tool No.5° BTDC and assemble the ‘LOCKED' pre-timed fuel injection pump with a new ‘O' ring. 4. Pre-load the gauge approximately 2mm.NH.ENGINE . see specifications. Mount the pump into a vice and ensure the pump is in the unlocked condition. Torque pump retaining boltsto 24Nm (18lbfft). Set the dial gauge to zero. to the access plate.10-100. Ensure the engine is set to 3. approximately 2mm.). 2.65. 291754.1 firing position.I. 117 3. gauge and special tool and install and tighten the rear centre bolt and washer. and a dial test indicator. The remainder of installation is the reverse of removal. The pump gear retaining nut can now be fully tightened to a torque value of 92Nm. marked ‘B'. i. Remove the spacer from the screw head located on the pump body and tighten the screw.2003 . the spacer.T.ft). 119 8. ‘UNLOCK' the pump by releasing the locking bolt and installing the spacer between the pump body and bolt head. SECTION 10 . Rotate the pump clockwise (when viewed from the shaft end) until the dial gauge indicates the plunger has moved the amount specified for the particular pump.Position the pump gear retaining nut onto the pump shaft and initially tighten to a torque of 20Nm (15lbf. is between the screw head and the pump body. This positions the pump into the No. 120 84993509-03.ft.e. 118 6. see specifications. Thoroughly clean the mating surfaces between the cover and plate using a suitable solvent cleaner and carefully apply a thin bead. while holding the gear counter clockwise to remove gear backlash. to lock the pump in position.1 cylinder.CHAPTER 1 Fuel Injection Pump Timing and Installation The pump timing should be checked prior to installing the pump to the engine using the following procedure: 1. Assemble the plate to the cover and tighten the retaining bolts to a torque of 24Nm (18lbf. (68lbf. (1).(1). 7. with the aid of an assistant. carefully pull the leak off tubes from the injectors. 121 Injector Removal 1. bleed the system using the following procedure: 1. remove the two retaining bolts of each injector and withdraw the injectors from the cylinder head. New seals should always be installed on reassembly.2003 122 . ‘Crack' open the nuts of the high pressure lines to each of the injectors. Crank the engine on the starter motor to expel the air. If the engine fails to start after several turns. i.CHAPTER 1 Injection System Bleeding It may be necessary after injection pump removal.e. to purge the system of air to allow the engine to start. NOTE: Each injector should have a cork seal under the retaining flange. after one of the above situations has occurred. WARNING Wear suitable eye and skin protective clothing. tighten the injector nuts as the engine begins to fire. 2.ENGINE . Ensure the tractor has adequate fuel and the battery is fully charged. 2. 84993509-03. replacement of injector high pressure lines or after running out of fuel. Ensure the areas around the injectors and fuel pump are clean prior to disassembly. Remove the injector high pressure lines.66 SECTION 10 . Fuel may be expelled under high pressure. If possible. remove the seal from either the cylinder head or injector and discard. 4. 3. collect the spray in a container partly filled with rags to absorb the spray. Open the pressure gauge valve and begin injector testing.67. 84993509-03.290284. When an injector is spraying. Tool No. Pump the tester and check the nozzle is free to open. If the nozzle is blocked or the needle jammed. the nozzle holder should be turned away from the operator and any other persons.ENGINE . 123 WARNING The spray is flammable make sure no open flames are in the area of the tester and do not generate excessive vapour.CHAPTER 1 Injector Testing and Overhaul WARNING The spray from a fuel injector tester can pierce human skin with fatal results. 2. During the Nozzle Opening Pressure and Spray Pattern Tests. Fill the injector tester.2003 . then connect the injector. SECTION 10 . Prime the tester until oil is emitted from the tester line. Make sure the knob on the right-hand side of the tester is screwed in to prevent the gauge being over-pressurized if the injector nozzle is blocked. 1. with a calibrating type fuel oil and leave the filler cap loose to prevent a vacuum forming during testing. When conducting the Nozzle Seat Leakage Test. release the injector tester pump pressure before touching the nozzle tip with a sheet of blotting paper. disassemble the injector. If there is any leakage from the nozzle seat. The pressure should drop 100-150bar in 5-45 seconds. The minimum acceptable opening pressure is 240 bar (3480 lbf/in2). the nozzle assembly must be cleaned or replaced. 6. If the opening presure is below 240 bar. reset to 270-278 bar (3915-4031 lbf/ in2).Apply a pressure 10 bar (145 lbf/in2) below the opening pressure.ENGINE .Wipe the nozzle tip dry and apply a pressure 10 bar (145 lbf/in2) below the opening pressure. NOTE: If the injectors meet the tests carried out then refit the injectors to the engine. If above 45 seconds.Slowly pump the injector tester and observe the pressure at which the needle valve lifts and fuel is injected from the nozzle tip.2003 124 . the nozzle assembly must be replaced. Nozzle Seat Leakage .) and observe the spray pattern from the holes. The nozzle tip and bottom face must remain essentially dry and there must be no tendency for blobs of fuel to collect or drip. Nozzle Back Leakage . An atomized spray free from distortion and irregular streaks of fuel should be observed. A slight dampness can be ignored. but gives an indication of the working of the nozzle. If below 5 seconds. 84993509-03.CHAPTER 1 5. check for carbon on the valve and/or blocked back leak drillings. 7. then release the handle and time the pressure drop. Nozzle Opening Pressure Setting . Spray Pattern . The tester is not regarded as providing a suitable test for atomization under working conditions.68 SECTION 10 . 8.Pump the tester rapidly (80 to 90 strokes per/min. Clean the dowelled adaptor plate using a brass wire brush. a damaged pressure face or corrosion. 127 4. 128 84993509-03.293671. 2. 125 NOTE: To prevent corrosion of injector components after cleaning. Clean the injector body by soaking in a carbon solvent and brushing with a brass wire brush.293760.CHAPTER 1 Disassembly 1. clean the nozzle as follows: NOTE: If the needle valve is in any way damaged or blued. Tool No. Place the injector in a holding fixture. Use socket tool. 126 Inspection and Repair 1. 295008. To avoid damage. 2. 3. Do not clamp the injector body in a vice. making sure the holes in the injector nozzle are thoroughly clean with no signs of corrosion or pitting. Using the tools included in the Injector Nozzle Cleaning Kit. invert and carefully remove the spring seat. Tool No. (kit 293761). 3. Inspect the plate for loose or bent dowels. Clean the spring and spring seat using a brass wire brush and check for scoring.2003 . place all dismantled components in suitable baths of clean fuel oil. to loosen the nozzle retaining nut. complete with the nozzle body. spring and adjustment shims. rinse in clean fuel oil and place in a suitable bath of clean fuel oil.69. It is not possible to grind or lap the three special angles on the valve point. pitting or corrosion. SECTION 10 . Clean the needle valve and body by soaking in a carbon solvent and brushing with a brass wire brush. needle valve and the dowelled adaptor plate. Inspect the body for damaged threads and pressure face. Remove the nozzle retaining nut. it must be discarded and a new matched needle valve and nozzle body assembly obtained. with the nozzle uppermost.ENGINE . Remove the injector body from the holding fixture. B.CHAPTER 1 A. 130 i h 6. After flushing the nozzle. Clean the fuel port using the fuel port scraper. 8. Clean the spray holes with a nozzle cleaning wire held in a pin vise so that it protrudes for only 1. 5.5 mm (0. press hard against the side of the cavity and rotate to clear all carbon deposits from this area. Clean the nozzle retaining nut using a brass wire brush and check to see that the threads are not damaged and are free from carbon deposits. Clean the top of the needle valve using a needle valve scraper.2003 . 132 84993509-03. 131 7.70 SECTION 10 . polish the valve seat by placing a very small amount of tallow on the end of a polishing stick and rotate in the nozzle.ENGINE . Insert the scraper into the port. pushing and rotating gently until each hole is cleared.). Insert the wire into each hole.06 in. Use a Reverse Flush Nozzle Adaptor on the injector tester and reverse flush the nozzle to remove the carbon loosened during cleaning. Clean the needle valve seat using the valve seat scraper by rotating and pushing the tool onto the valve seating. 129 i h C. Step 4. thereby giving maximum resistance to bending. Insert this assembly into the nozzle retaining nut. Assemble the needle valve into the nozzle body and then position the dowelled adaptor plate onto the nozzle body. 134 Injector Installation The installation is the reverse of the removal procedure noting the following points. 3. 135 84993509-03. Carefully assemble the dowelled adaptor plate and the nozzle retaining nut assembly onto the injector body. Install a new cork seal to the underside of the retaining flange. 1. lbs) torque. Rinse all parts in clean fuel oil and assemble the components while still wet.ENGINE . 133 4. connect the injector to the test rig as described in ‘‘Testing'' and add or subtract shims from the spring until the specified initial setting opening pressure of between 270-278 bar (39154031 lbf. Make sure all parts are absolutely clean and undamaged prior to re-assembly. It may be necessary to bleed the fuel system of air in order to start the engine.71. (17lbf. 2. ‘Injection System Bleeding'. Tighten the retaining bolts to a torque of 23Nm. Place the injector body into the holding fixture.2003 . spring and spring seat into the injector body bore.CHAPTER 1 Re-assembly 1. Refer to. Place the shims.in2) is achieved. 2. To set the nozzle opening pressure. tighten the retaining nut to 45 Nm (33 ft. 3. SECTION 10 .ft). Reinstall the filter. Remove the two support bracket bolts and withdraw the pump from the engine.CHAPTER 1 Electric Lift Pump . 1. 84993509-03. Disconnect the electrical connection. Remove the fuel inlet and outlet tubes. seal and cover.ENGINE . 3.72 SECTION 10 . 2. The pump does contain a filter in the base of the unit which should be cleaned periodically. Electric Pump Testing and Servicing The electric pump is basically a sealed unit and failure of it will require a new pump to be installed. 136 Servicing The pump can be serviced installed on the engine. To clean the filter remove the cover(2) and seal (1) at the bottom of the pump and withdraw the filter(3). 2.Removal 1. 3. Clean the filter in a suitable cleaning solvent. NOTE: Place a suitable container under the pump as there will be some fuel leakage when the pump cover is removed.2003 137 . Remove the turbocharger (6) and gasket (5) from the exhaust manifold. 138 The pump should deliver a minimum of 1. 139 5. If the pump can be heard running with voltage applied check the pump output. Disconnect the air cleaner to turbocharger tube (4) and the turbocharger to intake manifold tube(1). With the pump removed as described above. Cap all tube openings to prevent dirt ingress. apply 12 volts onto the connector pins. also wheel damage which may not be evident after cleaning. Cover the exhaust manifold opening to prevent dirt ingress. 2. Replace the pump if the output is less than specified.Removal With reference to Figure 139. NOTE: Ensure the pump is at approximately the same level as the fuel in the two containers. 4. allow the pump to run for a minute and measure the quantity of fuel delivered. NOTE: Before removing and cleaning the unit look for signs of oil and/or gas leakage. Pump Testing 1. If the pumps fails to operate a new pump will be required. 1.2003 . place the outlet into an empty container.5L/min. Lift the engine hood. 84993509-03. Place the inlet tube into a container of fuel.CHAPTER 1 73. Turbocharger . 3.ENGINE . 2. Disconnect the oil supply (2) and return (3) tubes from the turbocharger (6). Remove the exhaust muffler.SECTION 10 . Before the removal of the end housings the end of each shaft should be rotated with slight pressure in both the axial and radial direction.blow under the compressor wheel with compressed air. then the bearings may be worn.immerse the centre housing and rotating assembly in solvent. 84993509-03.ENGINE . • DO NOT . Scribe a mark on the components of the turbocharger to facilitate reassembly.2003 140 . 2. Remove the four bolts from the turbine housing and the six bolts from the compressor housing. unless another cause such as dirt build up is found. The cause of bearing failure should be established as they seldom fail during normal operation of a well maintained engined. rubbing or impact damage that may not be evident after cleaning. Clean all parts in a non caustic solution. Clean the exterior of the turbocharger with a non caustic cleaning solvent.CHAPTER 1 Turbocharger . If any contact is present. Remove the clamp plates and carefully separate the end housings from the centre housing rotating assembly. • DO NOT . has been balanced during manufacture under precision conditons. using a soft bristle brush.Disassembly NOTE: Figure 147 details the only components that are serviced for the turbocharger. • DO NOT . Cleaning Before cleaning inspect all parts for burning. If it has been determined that a major component of the turbocharger needs replacing.use abrasive cleaning methods which might damage or destroy machined surfaces. use the following procedure to disassemble: 1. No sign of contact should be present between the wheels and the housings. a plastic blade scraper and dry compressed air to remove residue.permit wheel/shaft assembly to spin when blowing off solvent and residue. The centre housing and rotating assembly.74 SECTION 10 . The assembly should not be disassembled in any way and is only serviced as an assembly. If the bearings are worn the entire centre housing rotating assembly should be replaced. For example engine oil/filter requires replacement. item 1 Figure 147. • DO NOT . 3. 2003 . SECTION 10 .75. and rotate the main shaft to lubricate the bearings.1lbf. Rotate the turbine by hand ensuring that it rotates freely without rubbing. Blades cannot be straightened in service.ft) for the compressor housing 4. 141 Centre Housing and Rotating Assembly (CHRA) NOTE: If there is any compressor or turbine wheel blade damage. (1). 2. Coat the bolts in a suitable non-seize compound and tighten to a torque of 22Nm (16. taking extreme care not to damage the turbine blades. Installation of the turbocharger. • Nicks. Install a new manifold gasket (2). follows the removal procedure in reverse. Ensure all parts to be reassembled are completely clean. Turbocharger . the CHRA must be replaced.ENGINE .CHAPTER 1 Inspection Inspect the housings for the following defects: • Wheel rub damage in the contour area that cannot be polished out with 80 grit silicon carbide abrasive cloth (compressor housing) or 60grit (turbine housing).ft) for the turbine housing and 11Nm (8.Installaton 1. reference Figure . A housing should be replaced if any of the above defects are found. dents or distortion that could prevent proper sealing between the housings and the centre housing rotating assembly. to 41-47Nm(30-35lbfft). Operating a turbocharger with damaged blades will result in further damage to component parts or the engine. Reassembly 1. and tighten retaining nuts. It is recommended that the following parts are replaced after removal: • • The compressor housing clamp plates and bolts The turbine housing bolts 2. 3. Prior to installation fill the turbocharger centre housing with new clean oil. Ensure all scribe marks align and install the new clamp plates and bolts. Assemble the outer housings to the centre housing assembly. 142 84993509-03. If new components are being used transfer the scribe marks from the old components to ensure correct assembly.3lbf. 1116Nm (8-12lbf.2003 143 . Reconnect the fuel shut-off solenoid wire. the rotating assembly should coast freely to a stop after the engine is stopped. and tighten to. ‘‘See Specifications" and torqued to 34-47Nm (2535lbf. should be refitted.in) for the inlet and 6-7Nm (50-65 lb. WITH THE SHUT-OFF SOLENOID WIRE DISCONNECTED AT THE FUEL INJECTION PUMP. NOTE: After the unit has obtained operating temperature. Idle the engine and check all tubes and gaskets for leaks. to oil filter head assembly. 13. Reconnect the oil outlet tube (5) Figure .ft). should have sealer applied. Figure . the cause should be corrected immediately.ft).7-2. The oil feed tube connector. if disturbed.CHAPTER 1 3. and torque to 3040Nm (22-30lbfft).in. Place a suitable receptacle below the oil outlet port and. ‘‘See Specifications".). Tighten the oil return tube to cylinder block connector clamps (6). 10. stop the engine immediately and correct the cause. to 2-3Nm (20-30lb. item (7) Figure 150.ENGINE . crank the engine until oil flows from the outlet port. 7. 9. 8. Replace the washers (2) and re-connect the oil feed tube banjo bolt (1) Figure 150. 84993509-03. Run the engine at rated speed and listen for sounds of metallic contact from the turbocharger. 18-20Nm (13-15lbf. 6. 5. and outlet (9) tubes. and torque to 1. using a new gasket (4) and tighten the retaining bolts at the turbocharger to 20-25Nm (15-18lbfft). If the rotating assembly jerks to a sudden stop. 11. Figure 150. If any noise is apparent. If disturbed. 12. oil return tube to block connector.76 SECTION 10 . Apply sealer to connector ‘‘See Specifications'' and torque to. Reconnect the air inlet (8).3Nm(1520lb. Apply sealer.in) for the outlet. Check the engine oil level and add oil if required. assemble the oil feed tube to the oil filter head connector (3) Figure 150. with the hose clamps. 4.ft). Blow loose particles from the outside of the element by holding the nozzle at least 150 mm(6 in.ENGINE . Slacken and remove the hose clamps on the aspirator tube to muffler. If satisfactory clean the element by tapping both ends on the palm of the hand.2003 . compressed air. Outer Element 1. 147 84993509-03. 2. as described below. Figure 153. To remove the air cleaner body from the vehicle. should not be removed or disturbed unless it is damaged or contaminated with dirt by a faulty outer element . 146 WARNING Wear eye protection and a face mask when carrying out this operation. Clean and examine the outer casing and repair or seal any damaged seams. 144 Disassembly 1. to service the air cleaner elements. Alternatively. turbocharged models. If dust is present inside the the outer element it must be renewed. Figure 151. raise the engine hood. Figure 152. 2. inlet manifold and or turbocharger connection when fitted. Remove the retaining locknut and extract the inner element. SECTION 10 . naturally aspirated models. Figure 153.77. not exceeding 2 bar (30 lbf in2) may be used. IMPORTANT: The inner safety element. Do not tap the element against a hard surface as it will be damaged or distorted.CHAPTER 1 Air Cleaner NOTE: It is not necessary to remove the complete air cleaner body. Remove the air cleaner attaching bolts from the engine hood frame and remove the air cleaner body from the vehicle. Removal 1. 145 Inspection and Repair 1. Insert the air line nozzle inside the element and blow the dust from the inside through the element to the outside.) from the element. Figure 154. 2. Unscrew the wing nut and extract the outer element as the nut is unscrewed. Add warm water 35°C(100°F) to the inside of the element until the level in the container is just below the open end of the element. Seal the small hole at the closed end of the filter with a strip of adhesive tape and place the filter open end up in a deep flat bottomed container or tub. The element will need 24-48 hours to dry thoroughly.78 SECTION 10 . or after five dry cleanings. Use only water but not hotter than the hand can stand. IMPORTANT: Never use oil. 3. Rinse the element in clean cold water allowing water to flow from the inside through the element until the water comes through clear. 148 4. After soaking gently agitate the element being careful not to allow dirty cleaning solution from the container to splash into the inside of the element.ENGINE . this can be done by inserting a lamp into the middle of the element and observing the element surface.2003 150 Turbocharged Air Cleaner Components . otherwise the element may be damaged. Every 600 hours the element must be renewed. It is recommended that a new element is installed at this service and the washed element allowed to dry and retained for installation at the next service. Remove the adhesive tape and shake excess water from the filter element and allow to dry naturally. 7. An even. 84993509-03. Ensure water is allowed to flow through the entire element.CHAPTER 1 If the filter element is undamaged wash the element every 300 hrs. Add a small amount of non-sudsing washing powder (automatic washing machine type) to the inside of the filter element. Install a new element at this stage retaining the washed element for the next service. examine the paper pleats carefully. If using a hose do not use a pressured flow a slow trickle is sufficient. or solvent. If this is not the case discard the element. petrol. undamaged and suitable for further service. After drying thoroughly. 8. 149 6. 5. IMPORTANT: Do not attempt to dry the element with compressed air or install before thoroughly dry as it may rupture. Allow the element to soak for at least 15 minutes (but never more than 24 hours) in the cleaning solution. fine pattern of light indicates the element is clean. or every 1200 hours whichever occurs first. Ensure that the rubber sealing rings on the ends are secure and undamaged. insert a suitable pump into the tank filler inlet to withdraw the fuel. and change only annually. front of the tank. Disconnect the wiring harness from the sender. Attach cab lifting tool. Figure 11 1. carefully raise the cab. located at the top. 154 .ENGINE . The inner element should not be disturbed unless damaged. is the reverse procedure to disassembly. The element is impregnated with oil and should therefore only be replaced and not cleaned when contaminated. Another method of emptying the tank is to disconnect the fuel filter feed tube and redirect into a suitable container. 4. 4A. If the inner element is okay leave assembled in the cleaner body. or contaminated by dirt through failure of the outer element. 153 NOTE: There is no fuel drain tap or tank bung on the main fuel tank. FT10 000.CHAPTER 1 Inner Element 1. 2. Remove the floor mat and remove both front mounting bolts and loosen the two rear mounting bolts. lint-free cloth and install the inner and outer element. Disconnect the battery. SECTION 10 . Re-Assembly Naturally Aspirated Air Cleaner Components 1. securing the left hand foot step and remove the step.Removal and Installlation It is necessary to raise the cab approximately 4 inches in order to remove the main fuel tank. Refitting of the filter body to the vehicle. 84993509-03. 151 2. the fuel from both tanks can be drained from a plug (1) in the auxiliary tank. If available. 152 NOTE: It is recommended that the fuel tanks are drained prior to removal from the tractor. Using a suitable lifting hoist.79. Drain the fuel tank.2003 . Remove the two bolts (2) & (3) Figure 9. 3. Main Fuel Tank . Turn on the key start switch to activate the electric fuel pump and allow to empty tank. 2. If an auxiliary tank is fitted. Clean the inside of the air cleaner casing with a damp. If not achieved adjust the stop bolt. to remove all slack at the idle position. Figure 9. Installation is the reverse of removal. from the fuel tank strap and position strap out of the way. Foot Throttle Cable Replacement and Adjustment A single cable directly from the foot pedal operates the fuel pump lever. 155 2. 6. Auxiliary Fuel Tank Removal and Installation 1. 7. Slacken the cable adjusting nuts and remove the clip retaining the cable to the fuel injection pump lever. If full throttle is achieved too early in the pedal movement again adjust the pedal stop to coincide with injection pump full throttle. Remove the cable from the engine side. removing bolts (1) and (2) Figure 153. on the pedal to allow further movement.CHAPTER 1 5. 5. the cross-over tube and the rear vent tube from the tank. 156 3. Figure 10. Adjust the cable at the injection pump. (1). 4. Remove the right hand foot step. Remove the nut (1). Adjustment 1. Installation is the reverse of the removal. Disconnect the remaining fuel lines and remove the tank from the tractor. Figure 151. Remove the remove the tank from the tractor. 8. Raise the engine hood. (2). Depress the pedal fully and ensure that full throttle is achieved. Figure 164. Remove the strap bracket. Slacken the worm drive clip on the connector tube.80 SECTION 10 . (1) Figure 165. Remove the right hand instrument console lower panel and remove the clip retaining the cable to the foot throttle linkage (2). Place a suitable container under the drain plug and drain the fuel. Installation is the reverse of the removal.2003 157 . Disconnect the battery. 1. 84993509-03. Figure 165.ENGINE . Disconnect the remainder of the fuel lines. 2. 3. Ensure that there is a slight clearance between the hand throttle pivot plate and the foot throttle assembly. Ensure that the foot throttle cable is correctly adjusted as described above. SECTION 10 . 3. using the two outer cable nuts. Remove the right hand instrument console lower panel and remove the clip retaining the cable to the pivot plate (1) Figure 168.81.CHAPTER 1 Hand Throttle Cable Replacement and Adjustment A single cable from the hand lever attaches to a pivot plate at the foot pedal assembly. and slacken the outer cable adjusting nuts(2 and (3) Figure 167. 160 84993509-03.2003 . 158 2. Installation is the reverse of removal. This actuates the injection pump. Remove the transmisson lever console lower panel. 159 Adjustment 1. to remove all slack from the cable when in the idle position. Adjust the hand throttle cable. and slide the cable from the bracket. via the foot throttle cable.ENGINE . Remove the clip retaining the cable to the lever. (1) Figure 167. Remove the cable from the tractor. 4. 1. Figure 166. 8. 6. situated to the rear of the right hand side of the engine. on the right hand side. Lift the radiator up and clear of the vehicle. using caution if the system is hot. This is important where air conditioning is fitted. Loosen the ‘‘D" bolts of both coolers and slide out. Close the cab heater hose tap. Remove the radiator cap to speed up the draining. Lift the engine hood. Ensuring all pipes are disconnected. 2. as refrigerant could be lost. 162 WARNING Do not allow anti-freeze to contact skin. (1) Figure and (1) Figure 172.CHAPTER 1 COOLING SYSTEM Radiator Removal (Op 10 406) 1. Disconnect the radiator top hose. Place a suitable container under the tractor. 164 84993509-03. placing them carefully out of the way with their respective hoses still attached. 4. Adhere to instructions detailed on anti-freeze container. Remove the two bolts securing the radiator to the front support. Loosen the radiator lower hose at the base of the radiator and drain the coolant off. Loosen the fan shroud screws. 161 3. and oil cooler pipes in the lower part of the radiator. (1) Figure 169 and turn the heater control knob in the cab to the coldest setting.ENGINE .82 SECTION 10 . if hoses are disconnected from the condenser. and away from the radiator assembly. 163 7. is the transmission oil cooler radiator and the air-conditioning condenser (when fitted). placing the fan shroud behind the fan blade. 5. Figure 170. and looms are unclipped.2003 . Attached to the front of the radiator by means of ‘‘D" handle bolts. Ensure the correct grade. and repair as required.CHAPTER 1 Inspection and Repair 9. Inspect the fins for damage and repair as required. Run the engine for several minutes checking for leaks. ensuring they are free from any obstruction. with 50% New holland Antifreeze. NOTE: It is necessary to replace the filter/conditioner if the cooling system is drained or a large water loss has occured.2003 . 166 84993509-03.5lb/in2 (1 bar) radiator cap and continue filling through the expansion tank until the coolant is seen through the sight glass. Re-install the 14. Refit expansion cap. 1. The radiator is fitted with an engine oil heat exchanger in the lower tank which should be checked for leaks. but upon installation observe the following requirements. Installation Installation of the radiator follows the removal procedure in reverse. and quantity of antifreeze is added to the coolant. to ensure maximum engine protection is maintained. If engine oil cooler tubes have been disturbed check the engine oil level. 4. If the lower tank is found to be leaking replace the radiator. 10. Figure 173. topping up any fluid levels that may have settled during testing. Check the radiator for leaks. SECTION 10 . Refill the system through the radiator pressure cap until completely full.ENGINE . 165 2. Recommended content mixture is 50% Water.83. 3. If the thermostat fails to open when hot. Figure 176. Coat the edge of the thermostat with grease and install. it must be replaced. 167 3. 3. shut off heater hose tap. 84993509-03.84 SECTION 10 . Place the thermostat in a container of water. Refit the thermostat housing and torque the bolts to 20-28Nm (15-21lbf. and raise the temperature to 212°F(100°C). Coat a new gasket with sealer and position in the recess on the thermostat housing. along with the gasket.ENGINE . 1. Inspection and Repair 1.ft). Withdraw the thermostat from the housing. 2. 2. Figure 175. Drain the coolant system below that of the level of the thermostat housing.CHAPTER 1 Thermostat Removal (Op 10 402) 1. Remove the thermostat housing retaining bolts and move the housing with tube attached to one side. prior to installing the thermostat. Installation 168 Installation of the thermostat is the reverse of the removal procedure but observing the following. or close properly when cooled. Where a cab is fitted. (1) Figure 174 and turn the heater control knob in the cab down to the coldest setting. with the heat element located in the cylinder head.2003 169 . The temperature sender for the gauge is located on the left hand side of the thermostat housing. On re-assembly of the fan assembly tighten the attaching nut in an anti-clockwise direction. If the fan speed is less than 85% of the fan pulley speed then the unit is not operating correctly and should be replaced. 2. Installation 1. If a new sender is to be fitted apply sealant to the threaded portion of the new sender body and torque the sender to. Installation 1. To remove the fan and clutch assembly (where fitted). NOTE: Hold the pulley by inserting a suitably sized punch/rod through the hole in the pulley and wedge against the flange of the water pump cover. 16-24Nm(12-18lbf.67x1800=3006 = 2600x100 = 86. If the sender is suspected of being faulty refer to the ‘‘Electrical System" section to correctly diagnose the fault.ft). The following table gives an example of calculating the percentage: Obseved fan speed Engine speed Pulley ratio Fan pulley speed Percentage = 2600 rev/min = 1800 rev/min = 1. 170 Viscous Clutch Testing Where it is suspected that the viscous clutch is not operating correctly. 1800 rev/min.2003 .CHAPTER 1 Temperature Warning Sender 1. undo the nut in a clockwise direction. hold the pump pulley in a fixed position. determine the engaged speed of the fan while operating the engine at approx. counting device. with the engine coolant temperature above the normal operating range. Figure 177. Figure 179. it should be tested as follows:1.5% 3006 171 Viscous Clutch Assembly Removal (Op 10 414) 1. Using an electronic stroboscopic rev/min.85.ENGINE .ft). 54Nm (40lbf.67:1 = 1. SECTION 10 . 172 84993509-03. Placing an open ended spanner on the nut to the rear of the clutch assembly spacer. and torque to. 560Nm(34. Refitment of the fan belt is the reverse of the removal procedure. If the torque bar does not ‘‘break" within the range a new tensioner assembly is required. 3. 5. To check the spring load. To re-assemble the arm assembly.CHAPTER 1 173 Fan Belt Tensioner A. 3. 7085Nm (52-63lbfft) on to the pulley attaching bolt. . but ensure the ‘‘Poly V'' belt. Checking of the tensioner assembly operation should be carried out. is positioned correctly onto all of the pulleys. Fan Belt With Air Conditioning 1.5-60Nm(34. Fan Belt Less Air Conditioning B.2003 1. 8.86 SECTION 10 .ENGINE . 2. fit the mounting bolt through the assembly. Remove the tensioner from the pump by loosening and removing the centre attaching bolt. Water Pump Pulley Air Conditioning Compressor Crankshaft Pulley Tensioner Pulley Fan Blade Removal (Op 10 414) Tensioner Attaching Bolt 1/2in. position the tensioner on to the front cover. 1.5-44lbfft). 6. 84993509-03. If not replace with new parts. (6) Figure 180. 7. 2. with the tensioner assembly still attached to the front cover. 4. Attach a 1/2in. Re-assemble the fan blade using the four attaching bolts and torque the bolts to. Rotate clockwise and remove the fan belt from the pulley and allow the tensioner to return to its untensioned position once the belt has been removed. and torque the bolt to. Re-Assembly 1.Square Drive Hole Alternator Idler Pulley with Air Conditioning Only Inspection and Repair 1. 46. Raise the lever up through an arc of 20° maximum. 20-25Nm (15-18lbfft) Re-Install fan and viscous unit. place a ‘‘break back" torque bar pre-set to. Remove the four nuts retaining the fan blade to the viscous unit and remove the fan. Remove the viscous clutch assembly as described above. rotates freely by hand. Ensure the tensioner pulley. 2. square drive ratchet into the tensioner arm. 46.5-44lbfft) 2. and torque the attaching bolt to. Fit a new pulley to the assembly if required. Fan Belt Tensioner Removal (Op 10 414) Re-Assembly 1. The fan belt should be removed in the following manner. impeller or shaft seal.2003 . leaving the body bolted to the cylinder block and withdraw the cover assembly complete with fan and viscous unit. Water Pump Removal (Op 10 402) 174 To overhaul the water pump components. 2. 177 84993509-03. Using a puller. (1).e. Tool No 1002 or 9198 and a sleeve slightly smaller than the pulley shaft.5-44lbfft). To remove the fan and clutch assembly hold the pump pulley in a fixed position. 5. Located on the right hand side of the engine. Note the sealing O-ring which may come off with the pump or be left on the block.87. Drain the cooling system. Torque the bolt to.CHAPTER 1 Idler Pulley (with Air Conditioning Only) 1. SECTION 10 . 2. Withdraw the four bolts which pass through the water pump and into the block. 1. 175 4. One idler pulley is fitted to the engine. ease the pulley from its shaft. 2. (1) Figure 183. undo the nut in a clockwise direction. and slide the complete pump forward and away from the block. Remove the fan belt from the vehicle. replace with new. Removal and replacement is by the attaching bolt through the centre of the idler pulley. Figure 184. Figure 181. Note the ‘O' ring on the rear of the cover.5-60Nm (34. it is only necessary to remove the cover assembly. and placing an open ended spanner on the nut to the rear of the clutch assembly spacer. Remove the bolts securing the fan shroud and move the shroud towards the engine. bearing. 3. under the water pump. 46. i. 176 Disassembly 1. (1) Figure 182. Check that the idler pulley rotates freely. Remove the six cover bolts. if tight or worn.ENGINE . Figure 186.076mm). Figure 185. using the correct tool. Remove and discard the seal from the bearing and shaft assembly. Clean and check the pump body for signs of cracks. and using a sleeve that contacts the bearing outer race only. Support the pump in a manner to allow the impeller diameter to drop clear of the pump. Figure 188.00-0. To install the bearing into the pump cover. place the pump body impeller side down.006in (0. place the cover rear face down onto suitable blocks to allow the shaft to protrude through. 178 4. Check the bearing shaft assembly for signs of wear or leaks. Once installed in the body the bearing case end face must be flush with the pump front face to within 0.ENGINE . press the bearing into the body. Reference ‘‘A". 2.000-0. 3. erosion or leaks. as the shaft may move. Do not press the centre shaft only. 179 Inspection and Repair 1. The impeller should be checked for worn or damaged vanes and must be replaced if not to an acceptable standard. Install the bearing with the longer stepped end of the shaft in the body. Re-Assembly 180 1. and press out the shaft assembly from the impeller. the assembly must be replaced with new parts. leaving the outer bearing case in the pump body . as it is pressed out from the pump body. NOTE: Apply pressure to the outer bearing race. and if evident. 181 84993509-03. To remove the impeller/shaft assembly. With the impeller/shaft assembly removed from the pump. the pump body must be repaired or replaced with a new one.2003 . If any of these faults are in evidence and likely to cause pump failure at a later date.CHAPTER 1 3. place the impeller on supports.88 SECTION 10 . and shaft simultaneously to remove. Clean the block face. press the pulley onto the shaft ensuring that the pulley front face to the rear face of the cover is.250. Gently lever the arm up to enable the fan belt to be seated in the grooves on the pulleys.89. Installed correctly the face of the impeller fins to the operating face of the water pump cover should be.2003 . and fit a new O-ring between the pump and block face. 182 3. Refit the fan blade assembly. 77. Figure 191. 0. After installation of the radiator. but observing the following requirements. onto the pump body. with a new O-ring fitted. Ensure after the cover is assembled to the water pump that the pulley/impeller assembly rotates freely by hand prior to re-assembly to the engine. and run the engine checking for leaks. and the swinging arm of the tensioner returns to rest freely.075 in). until the lip on the seal body seats on the pump body.88mm (0. place the impeller over the shaft and press the impeller into the water pump body. and the shaft supported. Reference‘‘A".ft) 183 6.85-78. 185 84993509-03. 4. With the water pump placed front face down and the shaft supported. With the pump rear face down and the shaft supported. If not disassemble and recheck the relevant dimensions. Reference‘‘A" Figure 190. Installation 1.CHAPTER 1 2.010-0. To insert the seal assembly place Tool No 295007 over the seal and press.ENGINE . with its smallest diameter uppermost. With the water pump rear face up.065-3. Installation of the water pump to the engine is the reverse of disassembly. 5. Ensure the fan belt tensioner pulley rotates freely. tightening the six retaining bolts to a torque of 17-26 Nm (12-19 lbf. refill the cooling system as previously described. 184 Place the water pump onto the block and install and torque the four pump bolts to 61-68Nm(45-50lbsft). place the seal assembly on the end of the shaft.10mm (3. Install the cover assembly. SECTION 10 .035in). Figure 189. (1) Figure 183.