REPARACION NH TM165

8/9/2019 REPARACION NH TM165

1/89

SECTION 10 - ENGINE - CHAPTER 1 1 .

84993509- 03.2003

SECTION 10 - ENGINE

Chapter 1 - Engine

CONTENT

Section Description Page10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fuel Test Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Greases and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine stripdown - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3210 001 Engine removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3210 100 Engine disassembly and overhaul:-

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Front cover and timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Oil pan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Connecting rods, bearings pistons and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Cylinder block overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Main bearings and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Rear cover plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Oil pump and oil filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Camshaft, tappets and camshaft bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

10 200 Fuel system components:-Fuel pump - Removal, Timing and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Electric lift pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

10 400 Cooling system components:Radiator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Thermostat removal, testing and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Temperature warning sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Viscous clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Fan blade removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Fan belt and tensioner removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Water pump removal, overhaul and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91


2/89

SECTION 10 - ENGINE - CHAPTER 12

84993509- 03.2003

GROUP 10 - GENERAL FEATURES AND SPECIFICATIONS

CYLINDER BLOCK

Taper of Cylinder Bore 0.025mm(0.001in ) Repair Limit0.127mm (0.005in) Wear Limit

Cylinder Bore out of Round 0.030mm (0.0015in) Repair Limit0.127mm (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

Model(T = Turbocharged)

TM115 TM125 (T) TM135 (T) TM150 (T) TM165 (T)

No of Cylinders 6 6 6 6 6Bore ins 4.4 4.4 4.4 4.4 4.4

(mm) 111.8 111.8 111.8 111.8 111.8

Stroke ins 5.0 5.0 5.0 5.0 5.0

(mm) 127.0 127.0 127.0 127.0 127.0

Displacement cu in 456 456 456 456 456

(cu cm) 7472 7472 7472 7472 7472

Compression Ratio 17:5-1 17:5-1 17:5-1 17:5-1 17:5-1

Cylinder Bore Compression atcranking speed of 200 R.P.M. lbs in 2

bar

375

25.5

375

25.5

375

25.5

375

25.5

375

25.5Firing 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


3/89


84993509- 03.2003

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)



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 VALVESFace Angle 29 15'-29 30' Relative to Head of Valve

Stem Diameter Std : 9.426-9.446mm(0.3711-0.3719in)




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 60.70mm (2.390 in)Length, loaded at 27.7-31.3kg (61-69 lb) 48.26mm (1.900 in)Length,loadedat 61-69kg (135-153lb) 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


4/89


84993509- 03.2003

VALVE INSERTS

VALVE SEATS

Exhaust Valve Seat Angle 45 00' - 45 30'

Intake Valve Seat Angle 30 00' - 30 30'

Interference Valve Face Angleto Valve Seat Angle 0 30' - 1 15'

Concentricity With GuideDiameter 0.051mm(0.002in) Total Indicator Reading Max

Seat Width Exhaust Valve 1.8-2.3mm(0.072-0.092in) Intake Valve 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 (0.004-0.006 in)

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 0.0006-0.0021in(0.015-0.053mm)

Insert OversizeExhaust Valve Insert

Counterbore Diameter inCylinder Head

Intake Valve Seat InsertCounterbore Diameter in

Cylinder Head

0.254mm (0.010 in) 44.17-44.20mm (1.739-1.740 in) 50.01-50.04mm (1.969-1.970 in)

0.508mm (0.020 in) 44.42-44.45mm (1.749-1.750 in) 50.27-50.29mm (1.979-1.980 in)

0.762mm (0.030 in) 44.68-44.70mm (1.759-1.760 in) 50.52-50.55mm (1.989-1.990 in)


5/89


84993509- 03.2003

Tappet Diameter 25.118-25.130mm(0.9889-0.9894in)

Tappet Bore Diameter 25.15-25.17mm(0.9900-0.9910in)

CAMSHAFT

Bearing Journal Diameter 60.693-60.719mm(2.3895-2.3905in)Bearing Clearance 0.025-0.076mm(0.0010-0.0030in)

End Play 0.051-0.18mm(0.0020-0.0070in)

CONNECTING RODS

Small End Bushing (Internal Diameter)Normally Aspirated 38.113-38.120mm(1.5005-1.5008in)Turbocharged 41.288-41.259mm(1.6255-1.6258in)

Clearance Bushing to Piston Pin 0.013-0.025mm(0.0005-0.0010 in)

Side Float 0.13-0.33mm(0.0050-0.0130in)Maximum Twist 0.30mm(0.0120in)

Maximum Bend 0.10mm(0.0040in)

PISTON PIN

Outside DiameterNormally Aspirated Engine 38.095-38.100mm(1.4998-1.5000in)Turbocharged Engine 41.270-41.275mm(1.6248-1.6250in)

PISTONS

Skirt to Cylinder Clearance Naturally Aspirated 0.140-0.171mm(0.0055-0.0067in) New or unrun engine0.140-0.28mm (0.0055-0.011 in.) For run engines

Skirt to Cylinder Clearance Turbocharged 0.166-0.196mm(0.0065-0.0077in) New or unrun engine0.166-0.28mm (0.0065-0.011 in.) For run engines

Grading Diameter (at Right Angles to 111.64-111.74mm(4.3951-4.3991 in)Piston Pin) in increments of 0.0127mm(0.0005in)

Piston Pin Clearance 0.0030-0.0140mm(0.00012-0.00055in)at 21 C (70 F)

Piston Crown to Block Face,Naturally Aspirated 0.28-0.58mm(0.011-0.023in)

Turbocharged 0.0-0.3mm(0.0-0.012in)

PISTON RINGS

Compression,Number and Location 2 off,1st and 2nd from the top of the piston

Naturally Aspirated,Top Compression Ring Parallel Sides-Barrelled face2nd Compression Ring Lower side internal chamfer - tapered face

Turbocharged,Top Compression Ring Keystone Tapered sides - Barrelled face2nd Compression Ring Lower side internal chamfer - tapered face

Oil Control,Number and Location 1 off,-Directly above the Piston Pin,Type Slotted With Expander


6/89


84993509- 03.2003

Side Face Clearance To Ring Groove,Top Compression Ring 0.103-0.153mm (0.0041-0.0060in)2nd Compression Ring - Turbocharged 0.075-.125mm (0.0030-0.0049in) - N.A. 0.055-0.105mm (0.0022-0.0042in)Oil Control Ring 0.040-0.090mm (0.0016-0.0035in)

Gap Width,Top Compression Ring - Turbocharged 0.40-0.90mm (0.016-0.036in) - N.A. 0.38-0.84mm (0.015-0.033in)2nd Compression Ring 0.40-0.90mm (0.016-0.036in)Oil Control Ring 0.40-0.90mm (0.016-0.036in)

CRANKSHAFT

Main Journal Diameter - Blue 85.631-85.644mm (3.3713-3.3718 in) - Red 85.644-85.656mm(3.3718-3.3723in)

Main Journal Length(except thrust, rear, or intermediate) 36.96-37.21mm(1.455-1.465 in)

Main Journal Wear Limits 0.127mm(0.005in) Maximum

Main and Crankpin Fillet Radius 3.048-3.556mm(0.12-0.14in)

Thrust Bearing Journal Length 37.06-37.11mm(1.459-1.461in)

Intermediate Bearing Journal Length 36.96-37.21mm(1.455-1.465 in)

Rear Bearing Journal Length 37.97-38.48mm(1.495-1.515in)

Crankpin Journal Length 42.62-42.72mm(1.678-1.682in)

Crankpin Diameter - Blue 69.840-69.850mm(2.749-2.7500 in) - Red 69.850-69.860mm(2.750-2.7504in)

End Play 0.10-0.20mm(0.004-0.008in)Crankpin Out of Round 0.005mm(0.0002in) Total Indicator Reading

Taper Surface Parallel to Centre Lineof Main Journal 0.005mm(0.0002in)

Crankshaft Rear Oil Seal Journal Diameter 122.12-122.28mm(4.808-4.814in)

Crankshaft Pulley Journal Diameter 44.45-44.48mm (1.750-1.751 in)

Crankshaft Timing Gear Journal Diameter 46.23-46.25mm(1.820-1.821in)

Crankshaft Flange Runout 0.038mm(0.0015in) Max

CRANKSHAFT DRIVE GEARNumber of teeth 26

MAIN BEARINGLiner length (except thrust liner) 27.94-28.19mm(1.10-1.11in)

Liner Length (Thrust Liner) 39.91-39.96mm(1.453-1.455in)

Vertical Assembled Bearing Clearance 0.055-0.117mm(0.0021-0.0046in)

CRANKPIN BEARINGSLiner Length 35.56-35.81mm (1.40-1.41in)Vertical Assembled Bearing Clearance 0.035-0.094mm(0.0014-0.0037in)


7/89


84993509- 03.2003

FLYWHEELRunout of Clutch Face ( Between OuterEdge of Friction Surface and MountingBolt Holes), 0.127mm(0.005in)Ring Gear Runout 0.63mm(0.025in)

OIL PUMPRotor Clearance 0.025-0.15mm(0.001-0.006in)Rotor to Pump Housing Clearance 0.15-0.28mm(0.006-0.011 in)Rotor End Play 0.025-0.089mm(0.001-0.0035in)Pump Gear to Camshaft Gear Backlash 0.40-0.56mm(0.016-0.022in)

OIL PRESSURE

Minimum At Engine Idle Speed 1.24 bar (18 lbf/in 2) at normal operating temperature

Minimum At Engine Rated Speed 2.76 bar (40 lbf/in 2) at normal operating temperature

OIL FILTER SUPPORT

Relief Valve, Operating Pressure 3.8-4.1bars(55-60lbf/in 2) Flow Rate 68.1-75.7 l/min. (15-16.6imp gals/min,18-20USgals/min)

NOTE : When using diesel fuel with a sulphur content below 1.0%, Series 3 diesel engine oil with an A.P.I. classification of CD may be used instead of CF-4

oil , but the oil and filter interval must be reduced to 150 hours .

When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the oil andfilter change period to every 50 hours .

ENGINE OIL CAPACITIES (LESS OIL FILTER)

ENGINE OIL CAPACITIES (WITH OIL FILTER)

Temperature Oil Viscosity and Type APIClassification

Engine Oil & FilterChange Period (hours)

Below-12 C( 10 F )

SAE 5Wor SAE 5W-30or SAE 10W-30

CD/SFCD/SFCF-4/SG

150150150

-12 C to 4 C(10 F to 40 F)

SAE 10WSAE 10W-30

CD/SFCF-4/SG

200300

0 C to 32 C(32 F to 90 F)

SAE 20WSAE 15W-40

CD/SFCF-4/SG

200300

Above 24 C(75 F)

SAE 30Wor SAE 15W-40

CF-4/SG 200300

Model Imp Pints U.S Qts Litres

6 CYL 31.6 19.0 18.0

Model Imp Pints U.S Qts Litres

6 CYL 33.4 20.0 19.0


8/89


84993509- 03.2003

THERMOSTATOpening Temperature 79-83 C (174-181 F)Fully Open 93-96 C (199-205 F)

RADIATOR CAP

Opening Pressure 1.0bar (14.5 lbsin 2)

WATER PUMPType CentrifugalDrive Poly V Belt, 8 rib

FAN BELTBelt Tension Maintained by Automatic Tensioner

COOLING SYSTEM CAPACITIES

COOLING FLUIDContent Mixture - Water50%, New Holland Antifreeze 50%.( New Holland Antifreeze specification: NH900A)

Model Imp Galls U.S. Galls Litres

TM115, TM125, TM135 5.6 6.7 25.5

TM150, TM165 5.7 6.9 26.0


9/89


84993509- 03.2003

FUEL SYSTEM MAIN DATA

Turbocharger type: Garrett GT35

Fuel Supply Pump: Electric pump - 12Volt / 5 lbf/in2

Fuel Injection Pump Distributor type, integral speed governor and advance device

BOSCH pumpTM115 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 3.5 All models

Pulley timing mark to pointer check (using piston number 2 depth, from block face)

MODELS PISTON No.2 DEPTH

All Models (No.1 @ 3.5 ) 104.85mm

Injectors:

Type BOSCH Multi Hole

Quantity, nozzle holes 5

Diameter, nozzle holes 0.254mm 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


10/89


84993509- 03.2003

TEST PLAN - TM115 7.5 litre (456 cu in.)

BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF(12mm diameter plunger , 3.2mm lift)

PUMP NH NUMBER: 87801834 TYPE NUMBER: 0 460 426 303 SHEET 1 of 1Test No. Test Description Pump rpm Strokes Overcheck

1 Return fuel 1100 - 58.0 1.0 l/hr

2 Timing piston travel 900650

--

2.1 0.7mm0.9 0.6mm

3 Start fuel 100350

10001000

90.0 cc min.90.0 cc max.

4 Full load fuela) Rated speedb) Peak torquec) Port to port variation

1100800

-

100010001000

65.8 3.0 cc77.0 3.0 cc6.0 cc max.

5 Hydraulic torque control 600 1000 71.3 3.5 cc6 Governor breakaway 1150 1000 52.0 10.0 cc

7 Low idle fuel 375 1000 20.0 5.0 cc

8 Fuel shutoff solenoid 375 1000 1.5 1.5 cc

9 Static timing lock plunger lift onport B''

- - 1.30 0.06mm

10 Test stand equipment

a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressure

b) High pressure pipes - 840mm long with 2.0mm diameter and 6.00mm O.D.

c) Fuel gallery inlet pressure 0.3-0.4 bar

d) Calibrating fluid - ISO 4113 at 44 - 46 C outlet temperature


11/89


84993509- 03.2003

TEST PLAN - TM125 7.5 LITRE (456 CU IN.)

BOSCH VE DISTRIBUTOR TYPE FUEL INJECTION PUMP WITH ELECTRICAL FUEL SHUT-OFF (12MMDIAMETER PLUNGER , 3.2MM LIFT)

PUMP NH NUMBER: 87801835 TYPE NUMBER: 0 460 426 307 SHEET 1 OF 1Test No. Test Description Pump rpm Strokes Overcheck

1 Return fuel 1100 - 56.0 1.0 l/hr


--

3.4 0.7mm1.7 0.7mm

3 Start fuel 100230

10001000



1100700

-

100010001000

67.8 3.0 cc77.7 2.5 cc6.0 cc max.

5 Boost control 650 1000 70.0 2.5cc@400mbar

6 Unboosted fuel 500 1000 66.8 2.5cc@0mbar

7 Governor breakaway 1170 1000 50.0 10.0 cc

8 Low idle fuel 375 1000 15.0 5.0 cc



- - 0.95 0.06mm


a) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressureb) High pressure pipes - 840mm long with 2.0mm diameter and 6.00mm O.D.c) Fuel gallery inlet pressure 0.3-0.4 bard) Calibrating fluid - ISO 4113 at 44 - 46 C outlet temperature


12/89


84993509- 03.2003




1 Return fuel 1100 - 57.0 10.0 l/hr


--

3.1 0.6mm1.1 0.7mm

3 Start fuel 100200

10001000



1100700

-

100010001000

75.5 3.0 cc9.0 3.0 cc6.0 cc max.

5 Boost control 650 1000 85.0 4.0 cc@ 600 mbar

6 Unboosted fuel 500 1000 80.8 3.5cc@ 0 mbar


8 Low idle fuel 375 1000 15.0 5.0 cc


10 Static timing lock plunger lift n portB''

- - 1.00 0.06mm

11 Test stand equipmenta) Bosch nozzle 1 688 901 110 at 250-253 bar nozzle opening pressureb) High pressure pipes - 840mm long with 2.0mm diameter and 6.00mm O.D.c) Fuel gallery inlet pressure 0.3-0.4 bard) Calibrating fluid - ISO 4113 at 44 - 46 C outlet temperature


13/89


84993509- 03.2003




1 Return fuel 1100 - 52.0 10.0 l/hr

2 Timing piston travel 900 - 2.8 0.6mm

700 - 1.7 0.7mm

500 - 1.2 0.6mm

3 Start fuel 100 1000 130.0 cc min.

230 1000 90.0 cc max.

4 Full load fuel

a) Rated speed 1100 1000 80.0

3.0 ccb) Peak torque 700 1000 94.7 3.0 cc

c) Port to port variation - 1000 6.0 cc max.


6 Unboosted fuel 500 1000 86.0 3.5cc@ 0 mbar


8 Low idle fuel 375 1000 15.0 5.0 cc



- - 1.00 0.06mm







14/89


84993509- 03.2003




1 Return fuel 1150 - 57.0 10.0 l/hr

2 Timing piston travel 950 - 3.2 0.6mm

600 - 1.1 0.7mm

3 Start fuel 100 1000 85.0 cc min.

230 1000 89.0 cc max.

4 Full load fuel

a) Rated speed 1150 1000 89.5 3.0 cc

b) Peak torque 700 1000 108.0

2.5 ccc) Port to port variation - 1000 6.0 cc max.


6 Unboosted fuel 500 1000 86.0 3.0 cc@ 0 mbar


8 Low idle fuel 375 1000 15.0 5.0 cc



- - 1.10 0.06mm







15/89


84993509- 03.2003

TORQUE VALUES - VARIOUS lbf ft Nm

Main Bearing Bolts 60 + 90 81 + 90

Connecting Rod Bolts 110 149

Cylinder Head Bolts (with Engine Cold) 40-70+90 55-95+90 Cylinder Head through Rocker Shaft Bolts 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 - 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 4.4 6

Injection Pump-to-Front Cover 18 24

Camshaft Idler Drive Gear-to-Block 175 237Front 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 31Turbocharger-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

Tensioner to Water Pump Bolt 40 54

Idler Pulley Bolt 40 54

Pump Connector to Block 18 24


16/89


84993509- 03.2003

TORQUE VALUES

The following general nut and bolt installation torque re-quirements (lubricated) apply to any operation not previ-ously listed.

SPECIAL TOOLS

Fuel Injection Pump Drive Gear Puller(Local manufacture or Special Tool No.295042)

1. Bolt 5/16-UNF x 2 in. (51mm) with integral washer (3 bolts required)

2. Bolt 3/4x16-UNC x 2 in.(51mm)3. Three holes 0.375in (9.5mm) dia. on 2.2in (56.87mm) dia. equally spaced material of 0.394 in. (10mm) Plate HRLC P&O Steel

(Prior Tool Numbers, where applicable, shown in brackets)

INCH SERIES lbf ft Nm1 / 4 - 20 8 11

1 / 4 - 28 8 11

5 / 16 -18 14 19

5 / 16 -24 17 23

3 / 4 - 16 23 31

3 / 4 - 24 33 45

7

/ 16 -1448 65

7 / 16 -20 55 75

1 / 2 - 13 65 88

1 / 2 - 20 75 102

9 / 16 -18 90 122

5 / 6 -18 138 187

CYLINDER BLOCK PLUGS1 / 4 - 27 NPT 8 11

1 / 4 - 18 NPT 22 29.8

3 / 4 - 18 NPT 28 38

3 / 4 - 14 NPT 20 27

1


17/89


84993509- 03.2003

GREASE AND SEALANTS

Description New Holland ToolNumber

SPX Ltd Tool Num-ber

Nuday ToolNumber

Engine sling hook,(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.6212 -

Crankshaft front seal installer - NH 10-103 -

Valve guide set reamers 295006 FT.6202 (SW.502) 2136 (SW.502)

Valve spring compressor 291050 - -Water pump impeller seal installer 295007 FT.6209 4672

Injector - hand pump tester 290284 - -

Injector - cleaning kit 293671 - -

Injector - 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

Con rod bush - remove/install tool FNH00035OTC 134-00002

- -

Camshaft bearing installer - FT.6203 1255 (SW.506)

Handle (for camshaft bearing installer) N6261-A 1442

Tractor splitting kit 292320 MS.2700 C -

Engine support brackets (for use with tractorsplitting kit)

- MS.2700 C8 or297617

-

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


18/89


84993509- 03.2003

FAULT FINDING

IMPORTANT: When effecting a repair the cause of the problem must be investigated and corrected to avoid repeat failures.

The following table lists problems and their possiblecauses with recommended remedial action.

PROBLEM

Enginedoesnotdevelopfullpower

POSSIBLE CAUSES

1. Clogged air cleaner

2. Fuel line obstructed

3. Faulty injectors

4. Incorrect valve clearanceadjustment

5. Burnt, worn or sticking valves

6. Blown head gasket

7. Incorrect fuel delivery

8. Low cylinder compression

REMEDY

1. Clean or renew element

2. Clean

3. Clean and reset

4. Check and reset

5. Replace valves with new oroversize,and/ormachine the valve

guide bores6. Check head flatness and fit new

gasket

7. Check injectors and pump

8. Renew piston rings or re-bore/re-sleeve as necessary

Oil pressure warning lightfails to operate

1. Bulb burnt out.

2. Warning Light pressure switchfaulty

3. Warning light circuit faulty

1. Renew bulb

2. Renew pressure switch

3. Check and renew wiring

Excessive exhaust smoke 1. Oil leak on compressor or turbineside of turbocharger, where fitted

2. Exhaust leak on exhaust manifoldside of turbocharger, where fitted

3. Air cleaner dirty or restricted

4. Excessive fuel delivery

1. Overhaul turbocharger

2. Fit new gasket

3. Clean

4. Overhaulinjectionpump andinjectors


19/89


84993509- 03.2003

POSSIBLE CAUSES REMEDYPROBLEM

1. Hose connection leaking or

collapsed

2. Radiator cap defective or notsealing

3. Radiator leakage

4. Improperfanbelt adjustment

5. Radiator fins restricted

6. Faulty thermostat

7. Internal engine leakage

8. Water pump faulty

9. Exhaust gas leakage into coolingsystem

10. Coolant aeration

11. Cylinder head gasket improperlyinstalled

12. Hot spot due to rust and scale orclogged water jackets

13. Obstruction to radiator air flow

14. Extended engine idling

15. Oil cooler tube blocked

16. Radiatorcoretubes blocked

1. Tighten hose connection, renew

hose if damaged

2. Renew radiator cap

3. Repair/renew radiator

4. Re-adjust fan belt

5. Clean with compressed air

6. Renew thermostat

7. Check for source of leakage, renewgasket or defective parts

8. Overhaul water pump

9. Renew cylinder head gasket, checkhead for damage or distortion

10. Tighten all connections and checkcoolant level is correct. Ensurecylinder head gasket has not blown

11. Renew cylinder head gasket

12. Reverse flush entire cooling system

13. Remove the obstruction

14. Do not allow engine to idle for longperiods

15. Clean

16. Check free flow

Water temperature gaugefails to reach normal oper-ating temperature

1. Faulty temperature sender

2. Incorrectorfaulty thermostat

3. Faulty water temperature gauge

1. Renew sender switch

2. Renew thermostat

3. Renew temperature gauge

Engine overheats


20/89


84993509- 03.2003

POSSIBLE CAUSES REMEDYPROBLEM

1. Engine oil level low

2. Wrong grade of oil

3. Blocked oil pump sump screen

4. Oil pressure relief valve faulty

5. Oil pump worn

6. Excessive oil pump rotor and shaftassembly clearance

7. Excessive main or connecting rodbearing clearance

1. Top up, as necessary

2. Drain and refill with correct grade ofoil

3. Clean pump screen

4. Fit new relief valve

5. Renew oil pump

6. Overhaul pump

7. Install new bearings inserts and / orre-grind crankshaft if necessary

Excessiveoil consump-tion

1. Engine oil level too high

2. External oil leaks

3. Worn valves, valve guides or bores

4. Cylinder head gasket leaking

5. Oil loss past the pistons and rings

6. Oil cooler leak

1. Reduce oil level

2. Renew gaskets and seals, wherenecessary. Check mating surfacesfor damage or distortion

3. Renew

4. Renew gasket. Check head fordamage or distortion

5. Renew rings and/or rebore/ re-sleeve block as necessary

6. Repair/renew oil cooler assembly

Engine tends to keepfiring after fuel is shut

off

1. Aircleanerdirtyorrestricted

2. Oil leak on compressor side ofturbocharger where fitted

1. Clean or renew element

2. Overhaul turbocharger

Low oil pressure


21/89


84993509- 03.2003

DIESEL ENGINE - DESCRIPTION AND OPERATION

The engines are 6 cylinder and available in naturally as-pirated and turbocharged forms.

All engines feature cross flow cylinder heads, with theinlet and exhaust manifolds on opposite sides of the cyl-inder head. The fuel and air combustion process, takesplace in the specially designed bowl in the crown of thepistons.

CYLINDER HEAD ASSEMBLY

The cylinder head incorporates valves and springs, withthe valve rocker arm shaft assembly bolted to the cylin-

der block through the cylinder head. Cylinder head re-taining bolts are evenly spaced with a six point patternaround each cylinder, this ensures an even clampingload across the cylinder head area.

The intake and exhaust manifolds are bolted to thehead, the intake manifold is mounted on the right handside of the engine, with the diesel injectors mounted out-side the rocker cover. The exhaust manifold is mountedon the left hand side of the engine. Water outlet connec-tions and thermostat being attached to the front of thecylinder block directly behind the radiator.

Valve guides are integral in the cylinder head, andvalves with oversize stems are available in service. Spe-cial replaceable cast alloy valve seats are pressed intoeach valve port during manufacture, with oversize valveseats also available in service.

All valves are fitted with positive valve rotators, with bothIntake and exhaust valves using umbrella type oil seals.Valve clearance is maintained by adjustment of the selflocking adjusting screw, mounted in each of the rockerarms.

CAMSHAFT ASSEMBLY

The camshaft runs in 5 replaceable bearings. The cam-shaft drive gear is in mesh with and driven by the cam-shaft idler gear which is driven by the crankshaft timinggear.

Camshaft end thrust is controlled by a thrust plate boltedto the block, and located between the camshaft gearand the front camshaft journal.

A helical gear is mounted on the rear of the camshaft,and drives the engine oil lubrication pump mounted for-ward of the flywheel.

CRANKSHAFT ASSEMBLY

The crankshaft is supported in the cylinder block by 7main bearings.

The crankshaft is manufactured from steel with ma-chined finished crank webs

End thrust is controlled by a thrust bearing incorporatedin the centre main bearing of the crankshaft.

An external damper is fitted to the crankshaft pulley toensure smooth running operation. Front and rear crank-shaft oil sealing is effected by one piece seals that aredesigned for long and durable service life.

CONNECTING RODS

Connecting rods `Teepee" (wedge) shaped at the smallend have been designed to reduce the reciprocatingweight at the piston end. The connecting rods are of aheavy beam construction and are assembled as amatched set to each engine, attached to the crankshaft,by means of insert-type bearings.

They are retained in position by the connecting rod bigend cap and secured by two bolts per rod. The small endof the connecting rod is fitted with a replaceable bronzebushing, through which the free floating piston pin is fit-ted. The steel pin being held in place within the piston bytwo snap rings.


22/89


84993509- 03.2003

PISTONS

Pistons are constructed of an aluminium silicon alloywith an iron insert for the top ring. The combustionchamber being recessed into the piston crowns.

Each piston has two compression rings and one oil con-trol ring, to reduce friction and increase positive sealing.All rings are located above the piston pin.

MANIFOLDS

The cross flow design aluminium intake, and cast ironexhaust manifolds, are on opposite sides of the cylinderhead. This is designed to maintain balanced heat distri-bution within the cylinder head. The configuration of themanifolds also ensures minimum heat transfer to the in-take manifold.

The intake manifold is connected through tubing to theair cleaner and at the inlet of the manifold a tapped holeis provided for installation of a thermostart or an ethercold starting aid.

NOTE : On tractors where cold start equipment is not installed ensure the plug in the intake manifold is kept tight at all times. Considerable damage to the cylinder bores,may be incurred by entry of grit or other foreign material if the plug is left loose or missing. Also dirt and grit may be drawn through the air cleaner connections if they are not properly secured.

CYLINDER BLOCK ASSEMBLY

The cylinder block is an alloy cast iron with deep cylinderskirts, and water jackets for cooling the cylinders. Thecylinder bores are machined integral with the cylinderblock, during the manufacturing process.

Cylinders are in line and vertical and numbered from 1to 6 from the front to the rear of the engine. They can bebored oversize for the fitment of sleeves, which areavailable in service.

The oil pan which is attached to the bottom of the cylin-der block, is the reservoir for the engine oil lubricationsystem. A cast iron engine front cover and front plate isattached to the front of the engine and covers all of thetiming gear assembly.

TIMING GEARS

The crankshaft timing gear is heated and press fitted onto the front of the crankshaft, to a high degree of accu-racy during manufacturing. This enables precise timingbeing maintained during the life of the engine. Thecrankshaft gear drives the camshaft idler gear which isattached to the front of the cylinder block. The idler gearthen drives the camshaft and the injection pump viameshing helical gears. The camshaft gear is bolted tothe front of the camshaft, and is keyed to maintain posi-tion of the gear on the camshaft.


23/89


84993509- 03.2003

LUBRICATION SYSTEM

Lubrication of the engine, Figure 1, is maintained by arotor type oil pump mounted in the rear of the engine

block, forward of the flywheel on the left hand side of theengine. The oil pump is driven from the rear of the cam-shaft and draws oil from the engine oil pan through atube and screen assembly.

A spring loaded relief valve is integral with the oil filterbody mounted on the left hand side of the engine block,and prevents over pressurisation of the system.

A spin on type oil filter is mounted externally to its sup-port housing, on the left hand side of the engine. Oil

flows from the filter to the main oil gallery, which runs thelength of the cylinder block, which also intersects thecamshaft follower chamber.

The main gallery also supplies oil to the crankshaft mainbearings and connecting rods both big and small ends.The underside of the pistons and pins, are lubricated byoil pressure jets mounted adjacent to each main journalhousing.

The camshaft drive gear bushing is pressure lubricatedthrough a drilled passage from the front main bearing.

The gear has small oil passages machined on bothsides allowing excess oil to escape.

Timing gears are lubricated by splashed oil from thecam follower chamber, and the pressure lubricated cam-shaft drive gear bushing.

An intermittent flow of oil is directed to the valve rockerarm shaft assembly via a drilled passage in the cylinderblock. This is located vertically above No.1 camshaftbearing, and aligns to a hole in the cylinder head. The

rotation of the camshaft allows a controlled intermediateflow of lubrication.

The turbocharger where fitted, is supplied with oil fromthe oil filter support housing, mounted on the left handside of the engine.

Engine Lubrication System With Turbocharger Fitted


24/89


84993509- 03.2003

COOLING SYSTEM

The function of the water pump mounted at the front ofthe engine, is to maintain a continuous flow of wateraround the cooling system. This is essential to ensure

correct engine temperature, and performance, duringvehicle operation.

The pump is driven by a Poly V"Belt from the crank-shaft pulley, when the engine is running. The fan belttension 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, whichpasses the coolant to the cylinder block. This coolantthen flows through cored passages to cool the cylinderwalls.

Passages in the cylinder head gasket allow coolant toflow from the cylinder block, into the cylinder head.Cored passages also conduct the coolant to the fuel in-

jector nozzle locations, before re-entering the waterpump below the thermostat.

The thermostat is located in the top of the water pumpbody, and controls the flow of the water as required bytemperature 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 isprovided to allow the coolant to recirculate from thehead to the block to effect a faster warm-up.

Once the engine has reached its normal operating tem-perature, the thermostat will open and allow water to bedrawn through the radiator by the pump action. Cooledwater then returns to the engine system.

Cooling System

3

1. Cab Heater Core2. Engine OIl Cooler (Turbo En-

gines)3. Engine Block4. Water Pump

5. Radiator6. Radiator Blanking Cap7. Thermostat8. Header Tank9. Cylinder Head

10. Water Filter11. Cab Heater Tap12. Fan and Viscous Unit13. System Pressure Cap14. Cold Coolant Level sender


25/89


84993509- 03.2003

Cooling occurs as the coolant passes down through theradiator cores, which are exposed to the air as it isdrawn 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), Figure3, on the left hand side of the cylinder block. The systempressure cap is located on the header tank. The cap onthe radiator is a blanking cap and should not be removedunless refilling the system from empty. Normal toppingup should occur at the header tank.

The engine cooling fan is mounted on a viscous drivehub (1), Figure 4, which is belt driven from the crank-shaft. The viscous drive allows the fan to operate onlywhen required by the cooling system permitting a fasterengine warm up, reduced parasitic power loss when thefan is not engaged and reduced noise levels.

4

5


26/89


84993509- 03.2003

Figure 5 - A, Cool air from radiator, fan idling

Figure 6 - B, Hot air from radiator, fan driving

Air temperature behind the radiator is sensed by a Bi-metallic coil (4), Figure 6, located in the centre of the fanhub face. As the temperature increases the coil gradual-ly opens a valve (5), Figure 6, within the hub (3), Figure5, which allows a modulated flow of viscous fluid (3), Fig-ure 5, to pass from an integral reservoir (2), Figure 5, tothe drive area, due to centrifugal force, providing a grad-ual take up of fan drive.

Within the drive area are two sets of interlocking annularfins, one set on the drive member (1), Figure 5, and theother on the free-wheeling hub body (4), Figure 5, towhich the fan blade assembly (2), Figure 5, is attached.Viscous liquid passes between the interlocking bladesand the resulting drag transmits torque to the fan. Thefluid is then recirculated to the reservoir by a pump plate(6), Figure 6, incorporated in the drive member (1), Fig-ure 6.

When the air temperature behind the radiator drops suf-ficiently, the Bi-metallic coil closes the valve preventingfluid from entering the drive area and the fan hub is al-lowed to idle with respect to the drive member.

6

7


27/89


84993509- 03.2003

FUEL SYSTEM

Fuel System1. Injectors2. Shut-off Solenoid3. Fuel Injection Pump4. Fuel Filter5. Fuel sedimenter

6. Electric Lift Pump7. Right Hand Fuel Tank8. Left Hand Fuel Tank9. Fuel Gauge Sender Unit10. Thermostart

The diesel fuel system consists of fuel tank, fuel sedi-menter, electric lift pump, fuel filter, BOSCH VE distrib-utor type fuel injection pump, fuel injectors, and inter-connecting tubes and lines, Figure 7.

The fuel injection pump is pressure fed from an electriclift pump. Fuel flows from the fuel tank to the sedimentseparator, through the electric lift pump and thenthrough the fuel filter. From the filter the fuel passes tothe transfer pump which is an integral part of the fuel in-

jection pump.

The transfer pump delivers fuel to the injection pump tosupply fuel at high pressure to each injector and alsoprovides extra fuel which lubricates and cools the injec-tion 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.

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.

Fuel Shut Off (Injection Pump)

All fuel injection pumps are equipped with an electricallyoperated fuel shut off solenoid.

The fuel shut off solenoid is energised by operation ofthe ignition switch mounted in the instrument panel.

With the ignition switched OFF" a spring loaded plung-er in the solenoid (held in position by the spring tension),prevents fuel flowing into the pump from the main fuelfeed port.

With the ignition switched ON" the magnetised plungeris energised by an internal coil and is drawn up into thebody of the solenoid. Fuel is then allowed to flow throughthe open port into the pump.

8


28/89


84993509- 03.2003

Fuel Sedimenter

The sedimenter, Figure 8 is positioned between the fuel tank,and the electric lift pump, on the right hand side of the engine.The fuel enters the sedimenter and flows into the head, to bedirected down, and around the edges of the sediment separator

cone.

The larger particles of dirt and water (which are heavier than fueloil), are separated out and sink to the collecting bowl which canbe removed and cleaned. The clean fuel is then drawn backthrough the top of the unit by the electric lift pump and on to thefuel filter.

Electric Lift Pump

An electric fuel lift pump is fitted to all models. Located in thehead of the sedimenter, (1) Figure 9, the pump draws fuel fromthe tank, via the sedimenter/filter and passes fuel under pres-sure to the secondary filter and onto the fuel injection pump.

Fuel Filter

The secondary fuel filter situated to the right hand side of the en-gine, close to the sedimenter/primary filter, receives the cleanfuel from the electric pump. From the filter head the fuel is direct-ed down, through the filter paper and into the base chamber,Figure 11.

The filtered fuel then flows up the centre tube of the element tothe filter head outlet, and into the injection pump.

Thermostart

To aid engine starting in cold weather conditions, a thermostartis standard on all models, Figure 11.

The thermostart is screwed into the inlet of the intake manifold.A fuel line connects the thermostart to the secondary fuel filterhead and the electrical terminal is connected to the ignitionswitch via the electronic management unit which controls theduration of thermostart operation.When

When electrical current is applied, by operating the ignitionswitch, the heater coil is energised.As the coil heats up a check valve opens which allows fuel toflow over the hot coil. The fuel is ignited by the coil producing aflame in the manifold which heats the intake air prior to it enter-ing the combustion chamber.

9

10

11

12


29/89


84993509- 03.2003

DIESEL ENGINE STRIPDOWN

In the following procedures and illustrations the engine

in the main is shown removed from the tractor.

However there are certain operations that can be per-formed with the engine still in the tractor, or separated atthe connection to the front axle support, or separatedfrom the transmission housing.

The engine overhaul procedure initially describes theassembly process for rebuilding an engine using all newcomponents. Following this section are defined head-ings which describe detailed repair specifications andprocedures, where components are suitable for re-use.Refer to the specifications section to ensure compo-nents are serviceable.

Where overhaul of components is required without en-gine being removed from the tractor refer to the follow-ing headings, and the relevant paragraphs, in the mainoverhaul procedure.

Operations or repairs that can be performed with theengine still in the tractor.

1. Cylinder head and associated inlet and exhaustcomponents.

2. Fuel injection pump and related parts.3. Water pump, thermostat, and associated com-

ponents .

4. Oil pump relief valve.

5. Turbocharger.6. Front timing cover/timing gear removal.7. Front pulley and damper assembly.

Operations or repairs that can be performedwith the engine separated from the front axle1. Oil pan removal for access to oil pan gasket,

crankshaft, bearing shells, piston removal, andoil pump suction tubing.

Operations or repairs that can be performedwith the engine separated from the transmissionhousing, and with oil pan removed1. Crankshaft rear oil seal and carrier removal,

(with oil pan removed).2. Oil pump and drive gear removal.Dismantle the engine following conventional tech-niques, or by referring to the following removal pro-cedure. Referring to the specification section asnecessary.

NOTE: All gaskets, seals, and O' rings must be replaced with new upon re-assembly. Where new sealant is to be applied refer to Engine Specifica- tions".


30/89


84993509- 03.2003

ENGINE REMOVAL - INSTALLATION (OP. 10 001 10)

Right hand View of Tractor

Left hand View of Tractor

13

14


31/89


84993509- 03.2003

Separating Front Axle from Engine(with reference to Figures and )

1. Disconnect battery , earth lead first.

2. Disconnect power steering hoses from cylinder.Figure 15.

3. Remove front wheel drive propshaft guard andpropshaft , if fitted.

4. Disconnect Front Hitch hydraulic tube , if fitted anddrain oil into a clean container.

5. Disconnect the front differential lock hydraulictube on FWD models. Figure 16.

6. If air conditioning is fitted, withdraw the condenser

from the radiator and remove the receiver dryer.Carefully move both items away from the front of thetractor and secure to the side of the engine ensuringthat they are not allowed to hang on their tubes.

7. Slide out the oil cooler from the radiator and tie upout of the way, again ensuring that the cooler is notallowed to hang on its hoses.

8. Disconnect electrical connection to the steeringangle sensor, if fitted, Figure 16.

9. Drain the cooling system fluid into a clean

container and disconnect the radiator hoses.Disconnection of the radiator lower hose provides asuitable drain point. Place a large clean tray underthe vehicle to capture the fluid for future use. Figure13, (2)

10. Remove the radiator fan shroud hardware, leavingshroud in position. Figures 12, (2) and 13, (3).

11. Disconnect air cleaner inlet tube. Figure 13, (4).

12. Position Splitting Tool, MS2700.C with enginesupports, MS2700.C-8 in position. If splitting tool is

not available use an overhead crane with suitablestraps. Strap at the front and rear of the front supportto maintain balance. NOTE: It will be necessary to remove the engine hood.Support the engine at the front of the transmissionand position wedges between axle and support toprevent articulation. Remove hardware securing theengine to the front support and wheel the front axleand support away from the engine.

15

16

17

18


32/89


84993509- 03.2003

Separating Engine From Transmission(with reference to Figures and )With engine previously separated from front axle.

1. Remove the exhaust muffler . Figure 13, (8).

2. Disconnect hood harness connector, Figure 19 andremove the engine hood assembly, Figure 20.

3. Disconnect starter motor wiring and retaining boltsand remove starter motor, Figure 21.

4. Disconnect the fuel lines to the fuel sedimenter andthe overflow return to tank, Figure 13 (3).

5. Disconnect the main harness to engine harnessconnector. Figure 13 (5).

6. Disconnect water pipe to heater shut off tap locatedat rear of cylinder head, Figure 13 (6).

7. Disconnect steering tubes , near bellhousing,Figure 13 (4).

8. Disconnect brake tubes to master cylinder, Figure13 (7).

9. Disconnect front hitch supply tube , if fitted.

10 Disconnect the left hand water hose to the cab,near bellhousing.

11. Disconnect air conditioning at quick releaseconnectors, Figure 14 (1).

12. Support the engine using a suitable hoist, toolNo.290740 with brackets 50075 and 50076.Remove the buckle up bolts between the engine andtransmission. Carefully prise the engine from thetransmission, ensuring that all wires and tubes aredisconnected. Place the engine onto a suitablestand for repair.

Engine Installation

Installation of the engine is the reversal of the removalprocedure, noting the following points:

Ensure all attaching hardware is tightened to thecorrect torque value as detailed in the specifications.

After connection of the battery it will be necessary toreset the radio / clock.

Ensure after installation that all fluid levels arecorrect prior to start up. Start and run the engine untilcorrect operating temperature is achieved to purgeair from cooling system. Stop engine, check forleaks, rectify as required and recheck fluid levels.

19

20

21

22


33/89


84993509- 03.2003

ENGINE DISASSEMBLY

Cylinder Head, Valves, And Related Parts(Op. 10 101)

Cylinder head removal

NOTE: The cylinder head can be removed with the engine installed in the tractor.

Remove or disconnect the following components toallow removal of the cylinder head:-

Remove the engine hood.

Drain the engine coolant, Using the Drain plug onthe block, (1), Figure 23, into a clean receptacle.

Disconnect air cleaner tubes, water hoses to theexpansion bottle and water filter and air cleaner toexhaust tube. Disconnect and remove the enginehood frame with the air cleaner and water expansionbottle.

Disconnect the low pressure fuel lines to the filters,the injector leak off tube, thermostart feed tube,injector to injection pump high pressure tubes and,where fitted, the vacuum tube to boost control unit.(cap all exposed openings).

Remove the inlet manifold, if necessary.

Disconnect and remove the rocker cover ventilationtube.

Remove the turbocharger assembly, if fitted,ensuring all openings are capped to prevent dirtingress.

Remove the fan drive belt (1) and the water pump(2), Figure 24.

Remove the exhaust manifold if necessary.

Remove the engine breather tube(3), rocker coverbolts (2),14 off, rocker cover(1) and gasket, Figure25.

Remove the cylinder head bolts which pass throughthe rocker shaft supports and the rocker shaftassembly together as an assembly. Remove thepush rods, check for concentricity and place in anumbered rack for reassembly.

Remove remaining cylinder head bolts workinginwards from the end of the cylinder head,alternately to the centre of the cylinder head.

Carefully lift the cylinder head assembly away fromthe engine block.

23

24

25


34/89


84993509- 03.2003

CYLINDER HEAD DISASSEMBLY

1. Clean the area surrounding the fuel injectors.Disconnect leak off tubes and remove injectors fromthe cylinder head Figure 26.

Rocker Shaft Disassembly

NOTE: Leave bolts in the rocker shaft supports during removal as they retain the support on the shaft(5).

1. Remove the cylinder head bolts (3) and withdraw thesupports(2), springs(1), rockers(4) and spacers(6).

Valve and Spring Assembly Removal

1. Using a valve spring compressor, toolNo.291050,(1) remove the retainer locks(2),springs(3), seals, rotators, and place in a numberedrack, Figure 28.

Inspection and Repair, Cylinder Head

1. Clean the cylinder head, and remove carbondeposits from around the valve heads.

2. Cylinder head core plugs if discoloured (rusty), orleaking require changing. Before fitting new plugsremove all old sealer from the cylinder head. Applysealant G, see SPECIFICATIONS", to the new plugmating faces, and drive the new plugs into location,Figure 29.

Core plugs required in the Cylinder Head,

6 off, In the top, and 1 off, in the rear of the cylinder head.5 off, in the intake face.

3. Scrape all gasket surfaces clean and wash cylinderhead in a suitable solvent, also cleaning valve guidebores.

NOTE : Ensure injector washers have been removed prior to cleaning.

26

27

28

29


35/89


84993509- 03.2003

4. Inspect cylinder head for nicks and burrs on matingface, Remove using a suitable abrasive and ensurefaces are clean after repair.

5. Using a straight edge and feeler gauges, check theflatness of the cylinder head in all directions doesnot exceed,0.001in(0.03mm) in any 1in (25.4mm), or0.005in(0.127mm), overall limit Figure 30.

6. If the cylinder head has been resurfaced, determineall head bolt faces will seat. By placing the cylinderhead less gasket, on the cylinder block and installingbolts hand tight.

7. Ensure rocker shaft supports are fitted with longbolts. Using a feeler gauge, check clearancebetween underside of bolt heads and cylinder heador rocker shaft support.

8. If a 0.010in (0.25mm) feeler gauge can be insertedunder the bolt head the bolt has bottomed.Therefore the cylinder block thread must beincreased using a 9/16-13UNC-2A Thread tap.Identify the bolt heads and ensure they arereinstalled in the bolt holes they were checked in.

30


36/89


84993509- 03.2003

Valve Inserts

NOTE: Refacing the valve seat should always be co- ordinated with refacing of the valve to ensure a compression tight fit.

1. Examine the valve seat inserts and reface if pitted,renew if loose or damaged.

2. To install a new valve insert, the cylinder head mustbe counter bored, as described in the above chart.The new insert must be chilled in dry ice prior toinstallation.

Valve Seat Specifications, Figure 31.1, Valve seat angle,Intake =30.0 -30.30 Exhaust =45.0 -45.30

2, Valve seat width,Intake =0.078-0.098 in (1.9-2.4mm)Exhaust =0.072-0.092in (1.8-2.3mm)

3, Valve Head Face to Cylinder Head Face Depth,Intake =0.034-0.052in (0.86-1.32mm)Exhaust =0.047-0.065in (1.2-1.6mm)

NOTE: Valve inserts of 0.010in(0.25mm) and 0.020in(0.5mm) oversize on diameter are sometimes installed during manufacture. Cylinder Heads with oversize inserts are stamped so10/os, so20/os, on the

exhaust manifold side in line with the valve seat concerned.

3. Check the width of the valve seat inserts, and asrequired reface by grinding to dimensions detailedabove.

4. Measure the concentricity of valve seats, using adial indicator and measure concentricity of seat tothe valve guide bore.Total Indicator Reading should not exceed0.002in(0.051mm), Figure 32.

Insert Oversize

Counter Bore in Cylinder Head

Exhaust valve insert Intake valve insert

0.010in (0.25mm) 1.739-1.740in(44.17-44.20mm) 1.969-1.970in(50.01-50.04mm)

0.020in (0.58mm) 1.749-1.750in(44.42-44.45mm) 1.979-1.980in(50.27-50.29mm)

0.030in (0.76mm) 1.759-1.760in(44.68-44.70mm) 1.989-1.990in(50.52-50.55mm)

31

32


37/89


84993509- 03.2003

5. Use a seat cutter to correct any seat eccentricity, orclean up of pits and grooves. Ensure after anyrework that seat width is within specified limits.

6. Rotate a new or refaced valve in the seat usingengineering blue, ensure all the blue is transferred tothe valve head protrusion, If any blue remains belowor around the seat raise or lower the seataccordingly, Figure 33, in the following manner.

Lower, the valve seats, item 1 Figure 33, by removingmaterial from the top of seat using a,30 grinding wheel for, Exhaust valves and a 15 grinding wheel for, Intake valves.

Raise, the valve seats, item 2 Figure 33, by removingmaterial from the bottom of seat using a,60 grinding wheel for, Exhaust valves and a 45

grinding wheel for, Intake valves.

Critical valve points, Figure 34:Valve land edgeValve headValve face angleValve faceValve stem Valve tip

Valve Guides

1. Using a telescopic gauge, and micrometer, measurethe valve guide bore clearance, and ensure it doesnot exceed,0.0009-0.0027in(0.023-0.069mm),

ontheintakevalvestem,0.0019-0.0037in(0.048-0.094mm),ontheexhaustvalvestem, Figure 35.

NOTE: Production cylinder heads may have one or more machined, oversize valve guide bores, or valves installed, 0.015in(0.38mm). Such cylinder heads have 15 or VO15OS stamped on the cylinder head exhaust manifold side adjacent to the valve concerned.

2. Using reamer set, 295006, ream out the valve stemguide, with three reamer and pilot combinations asfollows:-

3. When going from a standard valve stem to anoversize, always use reamers in sequence.

0.003in(0.076mm) oversize reamer, and standarddiameter pilot.

0.015in(0.38mm) oversize reamer, and0.003in(0.076mm) oversize pilot.

0.030in(0.76mm) oversize reamer, and0.015in(0.38mm) oversize pilot.

33

34

35


38/89


84993509- 03.2003

Valve Springs

1. Checked on a flat surface squareness, should notexceed 0.060in (1.52mm), between the square, andspring at the top edge, Figure 36.

Length of valve springs should be checked on both freelength, and loaded length.

Free length = 2.39in (60.7mm)

Installedlength=1.86-1.95in(47-49.6mm)

Loadedlength=1.9in(48.26mm) using a weight of61.96lb(28-31kg)

Loadedlength=1.4in(35.69mm) using a weight of 135-153lb(61-69kg)

Ensure the valve spring retainer locks are in goodcondition, and replace if worn or damaged.

Rocker Shaft inspection and Reassembly

1. Inspect rocker arm adjusting screws, and push rodends of the rocker arm, including the ball end of thescrews for nicks, damage, or excessive wear, Figure37.

2. Also inspect the inside diameter of the rocker armfor damage or wear. If any of these characteristicsare not to specification replace with new parts.

3. Check the ends of the push rods for damage orwear. If not to specification or push rods were foundnot to be straight during dismantling install new rods.

NOTE: Do not attempt to straighten bent push rods,replace with new .

4. Check the rocker shaft for signs of wear or damage,on internal and external diameters respectively. Ifnot to specification replace with new. If re-used,before reassembly clean thoroughly in solventmaking sure all oil passages are clear.

5. Position the shaft identification groove, forwards andupwards. This ensures oil grooves and holes facedownwards.

3. Assemble rocker shaft support with long head bolts,ensuring springs and spacers are re-assembled asin, Figure 37.

36

37

38


39/89


84993509- 03.2003

CYLINDER HEAD RE-ASSEMBLY

1. Insert the valves into the guide bores from whichthey were removed and lap with a suitable paste,ensure all traces of paste are removed after lapping.Figure 39: A=Exhaust B=Inlet

2. Lubricate all components with clean engine oil on re-assembly. Use a spring compressor to reassemblethe valves, valve springs, retainers, rotators, andcollets, and install new umbrella seals.

3. Coat all components with clean engine oil prior toassembly, and insert each push rod into its originalposition, ensuring each ball end is seated in its camfollower, Figure 37.

CYLINDER HEAD INSTALLATION

Installation of the cylinder head assembly andcomponents is the reverse of the removal procedure,observing the following,

1. Install new cylinder head, intake and exhaustmanifold gaskets, Figure 40.

NOTE: Ensure exhaust manifold gasket is fitted correctly to suit profile of exhaust ports.

2. Tighten the cylinder head bolts in sequenceprogressively in three stages, Figure 41.

Stage1, 156Nm (115lbfft)

Stage2, 190Nm(140lbfft)

Stage3, 217Nm(160lbfft)

NOTE: Bolts to be lubricated prior to assembly, and should be tightened to torque specification, with the engine cold.

3. Adjust valve clearance setting with each piston inturn at Top Dead Centre, and rockers free to move,Figure 42.

Intake Valve clearance,0.36-0.46mm(0.014-0.018in).

Exhaust Valve clearance,0.43-0.53mm(0.017-0.021in).

NOTE: Valve clearance is to be set, only when the engine is cold.

39

40

41

42


40/89


84993509- 03.2003

4. Install the injectors with new seat washers, corkseals, and torque to 23Nm (17lbfft) Figure 43.

5. Install the injector lines and torque to 24Nm(18lbf.ft). Install the leak off line with new washers,and torque the leak off banjo bolts to, 6Nm (4.4lbfft)

NOTE: Hold the leak off plastic tubing when tightening to prevent the pipes pivoting, during torque up.

6. Exhaust manifold bolts are to be refitted andtightened to a torque of, 38Nm (28lbfft).

7. Intake manifold bolts are to be refitted and tightenedto a torque of, 38Nm (28lbf ft).

ENGINE FRONT COVER AND TIMING GEARREMOVAL(Op. 10 102 & 10 106)

NOTE: Timing cover and gears can only be serviced after removing the radiator.

1. Remove the fan belt, and tensioner, and withdrawthe bolt and washer, from the crankshaft pulley.

2. Using puller, No.518 or FT.9539, and shaft protectorNo 625-A or 9212, remove pulley, spacer and O-ringfrom the shaft, Figure 44.

3. Withdraw the bolts retaining the front cover plate,and remove the front plate(1), Figure .

44

43

45


41/89


84993509- 03.2003

NOTE: The crankshaft timing gear (1), Figure 46, should not be removed. The gear is heat shrunk on to the crankshaft and aligned to the crankshaft No1 pin, to within 0.10mm (0.004in). If the gear is damaged a new crankshaft is required.

4. Before removing the timing gears use a dial indicatoror feeler gauge, Figure 46, to measure the backlashbetween each set of gears.

5. Rotate the gears and check the backlash at fourequal points on the gears. Renew if the backlashexceeds the following:-

Backlash to crankshaft gear,0.15-0.46mm(0.006-0.018in)

Backlash to camshaft gear,0.15-0.46mm(0.006-0.018in)

Backlashtofuelinjectionpumpgear,0.10-0.15mm(0.004-0.006in)

CAMSHAFT and FUEL INJECTION PUMP DRIVEGEARS REMOVAL

1. Pry the camshaft gear using a lever, away fromthrust plate. Using a dial indicator or feeler gauge,check the clearance, Figure 47, if outside of 0.076-0.35mm(0.002-0.007in) limit, fit a new camshaftthrust plate, item 1, Figure 48.

2. Remove the camshaft idler gear retaining bolt, gear,and adaptor from the block, then remove thecamshaft gear bolt and disassemble.

3. Remove retaining nut, and washer from the fuelpump and remove the gear from the shaft.Manufacture a suitable gear puller (1) Figure , asshown in Special Tools listing or use ToolNo.295042 .

4. If required the timing gear rear cover may now beremoved. Remove the six retaining bolts andcarefully pry the cover from the engine block.

46

47

48

49


42/89


84993509- 03.2003

Inspection and repair of gears

1. Wash the gears using a suitable solvent, andexamine gear teeth for wear, burrs, or scratches.Minor marks can be removed using a fine abrasive,thoroughly clean before re-assembly.

2. Ensure the camshaft idler gear adaptor is free fromobstruction and bushing is not damaged. Camshaftkey and key-way should be checked for damage andrepaired as required.

Installation

1. If the rear cover was removed thoroughly clean themating surfaces between the cover and engineblock, using a suitable solvent cleaner and carefullyapply a thin bead, approximately 2mm, of therecommended flexible gasket sealant, Type L', tothe cover. Assemble the cover to the engine and

tighten the two lower retaining bolts to a torque of37Nm, (28lbf.ft.) and the remaining four bolts to atorque of 24Nm (18lbf.ft)

2. Position piston no.1 at Top Dead Centre, install thespacer, key, and camshaft gear, and tighten to69Nm(51lbfft) Figure 50.

3. Install the camshaft idler gear to the block, aligningthe timing marks to the crankshaft and camshaftgears. Install the eccentric adjuster into the idlergear and initially position the larger of the two holesof the eccentric in the 6-9 O,Clock position, relative

to the oil pan face of the block.

4. With piston No1 at Top Dead Centre, assemble theLOCKED' pre-timed fuel injection pump with a newO' ring, aligning the mark on pump flange to thetiming mark on the front cover. Torque pumpretaining boltsto 24Nm(18lbfft) Install the pumpgear over the pump shaft. Assemble the washer andnut to the shaft, leaving loose at this stage to allowthe gear to rotate freely on the pump shaft. Holdingthe idler gear, check the backlash between thepump and idler gear with a feeler gauge or dialindicator. If the backlash is outside the specificationof 0.010-0.015mm (0.004-0.006in), rotate theeccentric until the backlash is correct and tighten theidler gear retaining bolt to a torque value of 242Nm(180lbf.ft.).

NOTE: DO NOT TIGHTEN THE INJECTION PUMP SHAFT NUT AT THIS STAGE. PROCEED TO REASSEMBLE THE FRONT COVER.

50

51

52

53


43/89


84993509- 03.2003

5. The front oil seal should be replaced, every time thefront plate is removed. Drive out the old seal using apunch taking care not to damage the front plate.

6. Coat a new seal in a suitable lubricant, and drive theseal into the rear of the front plate using, Tool No630-16 as in, Figure 54. Alternatively use, Tool NoT87T-6019-A, and drive the seal into position fromthe front of the plate.

7. Thoroughly clean the mating surfaces between thecover and plate using a suitable solvent cleaner andcarefully apply a thin bead, approximately 2mm, ofthe recommended flexible gasket sealant, Type L',to the front plate. Assemble the plate to the coverand tighten the retaining bolts to a torque of 37Nm,28lbf.ft.

8. Lubricate the crankshaft, fitting a new O' ring(1)

first, slide the pulley spacer(2) over the key(4). Placepulley(3), Figure 56, onto the crankshaft and pushfully home, tightening the securing bolt to, 284Nm(210lbfft).NOTE: Gentle and careful heating of the centre of the pulley will assist fitment. Do not overheat as the damper assembly will be damaged.

9. Rotate the crankshaft two revolutions, stopping withthe cover pointer aligned with either the 6 or 6.5 marking on the front pulley, depending on enginetype.

10. Initially tighten the injection pump gear nut to atorque of 20Nm, (15lbf.ft.), while holding the gear ina counter clockwise position to remove backlashfrom gears. UNLOCK' the pump by releasing thelocking bolt and installing the spacer between thepump body and bolt head. The pump gear retainingnut can now be fully tightened to a torque value of92Nm, (68lbf.ft.)

NOTE: Fuel pump (injection) timing is set at 6 Before Top Dead Centre (BTDC) for 100, 115 and 135PS models and 6.5 BTDC on the 160PS model.

11. Install the access cover for the injection pump gearnut. Clean surfaces and apply a 2mm bead offlexible gasket sealant, type L'. Tighten the retainingbolts to 37Nm (28lbf.ft).

12. Install the radiator and refill with the specifiedquantity and type of coolant fluid.

Pulley Timing Mark to Pointer Check, Figure

The degrees BTDC timing, can be equated to a pistondepth, using number 2 cylinder, to verify pulley topointer timing marks. The Number 2 cylinderdimensions are:Models Piston depth, (A)100-115PS (6 ) 106.81mm135PS (6 ) 107.37mm160PS (6.5 ) 108.56mm

54

55

56

57


44/89


84993509- 03.2003

OIL PAN REMOVAL (OP. 10 102)

NOTE: It is necessary to move the front support forward a couple of inches to allow removal of the oil pan. Refer to engine removal at begining of chapter.

1. Drain engine oil through oil pan plug and remove oillevel indicator.

2. Remove oil pan bolts including those through thetransmission and lower to ground.

Inspection and repair1. Clean gasket material from sump face, clean sump

in a suitable solvent, inspect sump for cracks dam-aged threads or damaged sump face.

Installation

1. Installation is the reverse of removal but with the fol-lowing requirements.

2. Ensure block face is clean and free of gasket mate-rial. Install a new gasket to the oil pan.

NOTE: Before installing the oil pan ensure that the rear oil seal carrier (2), is correctly aligned with the block,(1),ie, less than 0.15mm protrusion or 0.33mm recessed.

3. Position the oil pan and install a bolt at each cornerfinger tight to hold in position, install remaining bolts,and torque to 44Nm (33lbf.ft).

CONNECTING RODS, BEARINGS, PISTONS, ANDRINGS, REMOVAL. (OP. 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 .

1. With cylinder head removed clean off any ridge fromthe top of the cylinder bores, with a ridge remover toenable removal of the pistons, this is essential if oldpistons are to be re-used as failure to do so could re-sult in ring land damage.

2. With the piston at the bottom of the stroke removethe end cap bolts, cap, and liner. Using the handleend of a hammer push the piston assembly outthrough the top of the block, and remove the bearingliner from the connecting rod, .

NOTE: Bearing caps and liners must be kept with their

respective connecting rods.

Due to the weight of the oil pan it is recommended thata hydraulic jack is used to support and lower the oilpan to the ground.

WARNING

58

59

60


45/89


84993509- 03.2003

3. Turn the crankshaft again and repeat the processfor the remaining pistons.

4. Remove piston pin snap rings from each side of pis-ton and remove pin. Using an expander, Tool

No.296028, remove the piston rings.

5. Ensure each piston and rod assembly, remainsmatched together for re-assembly into the cylinderblock.

Inspection and Repair

1. Clean the piston, and connecting rod assembly, in asuitable solvent and inspect for damage to ringlands, skirts, or pin bosses.

2. Check connecting rod components for damage, andplace in an alignment fixture to check for distortion,and ensure that any distortion, is within specificationas follows.

Maximum Twist 0.30mm(0.012in).

Maximum Bend 0.10mm (0.004in).

3. Check piston pin bushing for damage or wear in thefollowing manner.

Measure the outside diameter of the piston pin, and in-side diameter of the connecting rod bushing, to the fol-lowing:-

Piston Pin Outside DiameterNaturally Aspirated,38.095-38.100mm(1.4998-1.500in).Turbocharged,41.270-41.275mm(1.6248-1.625in).

Connecting Rod Bush internal Diameter

Naturally Aspirated,38.113-38.120mm(1.5005-1.5008in).Turbocharged,41.288-41.295mm(1.6255-1.6258in)

61

63

64

62


46/89


84993509- 03.2003

CONNECTING ROD BUSH

Connecting Rod Bush InstallationA. Removal B. Installation1. Washer2. Collar3. Installation Insert 14. Bush5. Installation Insert 26. Pins7. Fixture

8. Connecting Rod Facing up9. Remover Insert 110. Remover Insert 211. Remover Insert 312. Connecting Rod Location13. Washer14. Location Plate

4. If not to specification use tool No FNH 00053, andpress out the old bush using the removal fixture asshown in, Figure . Press fit a new bush through thefixture using the installation detail, and into the con-necting rod as shown in, Figure . After fitting a new

bush ensure all sharp edges and burrs are re-moved.NOTE: Ensure the split in the small end bush is at right angles to centre line of connecting rod.5. Where special tooling is not available for the removal

or fitment of the connecting rod bush, a standardbush can be fitted in the following manner, Figure .

6. Place the connecting rod securely in a bench press.Manufacture from suitable bar stock, a press toolwith the end face ground at an angle, to suit the con-necting rod bush side face. Position the tool on thebush, and gently drive the bush from its position. It

is recommended a guide is manufactured to assistalignment of the bar stock during this operation.

7. A new bush can then be fitted in a similar manner, byusing a suitable piece of bar stock, with an end facemachined flat to suit the standard parallel bush. Usea guide as described, and gently drive in the newbush into the connecting rod.

8. After installation grind the side faces of the new bushto match the side faces of the connecting rod. En-sure all sharp edges are removed, and loose chip-pings are cleaned from the connecting rod beforere-assembly into the engine.

9. With a new bush fitted drill a hole through the top ofthe connecting rod using a 4.6mm(0.187in) bit. Drillthrough the existing oil hole, Figure .

10. Use an expanding reamer to obtain correct bushingto piston pin clearance referring to specification sec-tion. Remove burrs, and chippings, before refitting.

65


47/89


84993509- 03.2003

Cylinder Block Core Plug and Sensor Ports, Front and Left Hand Side

Cylinder Block Core Plug and Sensor Ports, Rear and Right Hand Side

CYLINDER BLOCK OVERHAUL.(Op. 10 105)

1. Cylinder block plugs, and senders, require changingif leaking or rusty, and must be replaced. Clean theold sealant off the block, and fit new plugs with seal-er.Figure 71, refers to the front and left hand side of thecylinder block.

NOTE: New part mating faces, and threads, should be coated in sealant, refer to Specifications". Assemble in the following manner.Plug (1) torque to 8-14Nm(6-10lbf.ft)Use sealant, E.Plug(2)torque 27-47Nm(20-35lbfft)Use sealant, E.

Pipe Plug(3) torque to 24-34Nm(18-25lbfft)Use sealant, E.

Plug (4) drive in to block. Use sealant G.2. Figure 72, refers to the rear and right hand side ofthe block.

Pipe plug (1) torque to8-14Nm(6-10lbfft).Use sealant, E.Pipe plug (2) torque to 24-34Nm (18-25lbfft).Use sealant, E.Plug (3) drive into block.Use sealant, G.Plug (4) torque to 54-81Nm(40-60lbfft), Use sealant, E.Oil Jets (5) replace with new if damaged, apply engineoil only on re-assembly Do not use sealant" .

CYLINDER BORE

A

67

66


48/89


84993509- 03.2003

1. Check the cylinder bore for scuffing or rings aroundthe ring travel area. Irregularities can be felt by run-ning a finger over the surface. To check out-of-roundness, wear, or taper, use a telescopic gauge,Figure 73.

Measure lengthwise,A, to B, and C, to D, and compare dimensions. Varianc-es between the readings will indicate taper".

Measure crosswise,C, to D, and compare dimensions lengthwise. A, to B.Variances will indicate an out-of-round condition.

Specifications

NOTE: Repair Limit' refers to the tolerance allowed after a repair has been performed, i.e. the repair must be within the repair limit. The Wear Limit' is the tolerance prior to repair.Taper of cylinder bore,repair limit- 0.025mm(0.001in)wear limit- 0.127mm(0.005in)

Cylinder bore out of round,repair limit - 0.03mm(0.0015in)wear limit- 0.127mm(0.005in)

Cylinder bore diameter,111.778-111.841mm (4.4007-4.4032in).

1. Where only minor imperfections exist and bores areto specification, hone the bores prior to installingnew piston rings. Provided piston to bore clearance,does not exceed 0.250mm (0.011in).

2 Sleeving of the cylinder bores becomes expedientwhen.-Oil consumption is high.

-Replacing sleeves, installed in service.-Cylinder bore is damaged beyond re-boring limits.

68

69


49/89


84993509- 03.2003

SLEEVING - BORING AND HONING

1. Measure the outside diameter (1) of the sleeve inseveral places, and average the dimension. Counterbore the cylinder block (see step 2) using the aver-age dimension to obtain a press fit, between boreand sleeve. Interference of sleeve to the cylinderbore to be 0.025-0.076mm (0.001-0.003in), Figure75.

2. Counter bore to a depth of 204.7mm (8.06in), fromthe block face, surface finish of the bore is not to ex-ceed (80 microns). Leave a step at the bottom of thebore a minimum of 9.60-10.16mm (0.38-0.400in),allowing for run out of chamfers.

3. Bore through diameter, to the diameter of, 114.3-116.0mm(4.454-4.456in).

4. Clean the cylinder bores and thoroughly dry.

5. Grease the sleeve with a general purpose greaseand press the sleeve home to the lip in the bore. Thetop of the sleeve should protrude through the top ofthe block, 0.127-1.0mm(0.005-0.040in).

6. Bore the sleeve to,110.00-111.76mm(4.3985-4.400in).

7. Skim the block face, and top of sleeves, to achievethe specified flatness of,0.08mm(0.003in)inany152mm(6in)0.03mm(0.001in)inany25.4mm(1in). A chamfer in the internal diameter at the top of thesleeve to 45 x0.5mm (0.020in) should be main-tained, to prevent piston damage on re-assembly.

8. Break the sharp edge at the bottom of the sleeveprior to honing.

9. Hone the cylinder bore to,GradeA,111.78-111.80 (4.4007-4.4015in.)GradeB,111.80-111.82 (4.4015-4.4023in.)

NOTE: Surface finish to be an average of 20 to 30 Mi- crons, cross hatched at 35 -55 .MaximumTaper,0.025mm(0.001in) through to bottom of the bore.MaximumOvality,0.038mm(0.0015in)

70


50/89


84993509- 03.2003

Re-Assembly

NOTE: Pistons that are replaced must be of the same type that were removed and have the same identification letters, and numbers, as embossed on the piston crown

1. Upon re-assembly with the piston at Top Dead Cen-tre, ensure the piston to block height is correct usinga dial indicator to, Figure 76.

Naturally Aspirated,0.28-0.58mm(0.011-0.023in)

Turbocharged,0-0.3mm(00.00-0.012in)

2. Check the piston to bore clearance in the followingmanner.

A, Measure the cylinder bore diameter at point A,

82.6mm (3.25 in.) from the top of the block.B, Measure the diameter of the piston at point B,25.0mm (0.98in) Turbocharged engine, 28.3mm(1.11in.) normally aspirated engine from the bottom ofthe piston.

C, Subtract piston diameter from the bore diameter andthe resultant figure for a new, unrun engine should be,

REPARACION NH TM165

Documents

Transcript of REPARACION NH TM165