SECTION 10 –ENGINE – CHAPTER 2 1

SECTION 10 – ENGINE

Chapter 2 – 7.5L CNH Engine

CONTENTS

Section Description Page

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Greases and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 001 Engine Overhaul–Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Injection Pump Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 100 Engine Disassembly and Overhaul:–
10 101 Cylinder Head, Valves and Related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 101 Hydraulic Tappets–Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 106 Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10 102 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10 103 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10 102 Rear cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10 102 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10 102 Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10 106 Camshaft, tappets and camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10 105 Pistons and Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10 103 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10 003 Crankshaft Front Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10 001 Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10200 Cooling System
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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2 SECTION 10 – ENGINE – CHAPTER 2

SPECIFICATIONS
TM120 TM130 TM140 TM155 TM175 TM190
Engine Type TA/HD TA/HC TA/HB TA/HA TA/FB TA/FA
Gross power 90kW 98 kW 107 kW 114Kw 156Kw 168Kw
(ISO TR14396) 121 Bhp 131 Bhp 143 Bhp 209 Bhp
153 Bhp 225 Bhp
Governor Mechanical Electronic
Boost No Yes
Rated speed 2200 rpm
Low idle speed 800 rpm 920 rpm
High idle speed 2375 rpm 2380 rpm
No of Cylinders 6 – (153624 Firing Order)
Cylinder displacement 7500 cc
Bore 111.8 mm
Stroke 127.0 mm
Compression Ratio 17.5 : 1
Cylinder Bore 25.5bar (375lbf/in2)
Compression at Cranking
Speed of 200R.P.M.
Waterpump speed 3859 rpm
Ventilator speed 1531 rpm
Crankcase cap. 19 litres
(with filters)
Starter motor 3.0 kW (12 Volt)

CYLINDER BLOCK
Taper of Cylinder Bore 0.025mm (0.001 in ) Repair Limit
0.127mm (0.005 in ) Wear Limit
Cylinder Bore out of Round 0.030mm (0.0015 in) Repair Limit
0.127mm (0.0050 in) Wear Limit
Cylinder Bore Diameters 111.778–111.803mm (4.4007–4.4017 in)
Rear Oil Seal Bore Diameter 140.77–140.87mm (5.542–5.546 in)
Block to Head Surface Flatness 0.08mm (0.003 in) in any 152mm (6 in)
0.03mm (0.001 in) in any 25.40mm (1 in)

CYLINDER HEAD
Valve Guide Bore Diameter 9.469–9.495mm (0.3728–0.3738 in)
Head to Block Surface Flatness 0.03mm (0.001 in) in any 25.40mm (1 in),
or 0.127mm (0.005 in) overall limit

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 SECTION 10 –ENGINE – CHAPTER 2 3

EXHAUST VALVES
Face Angle 44°15’–44°30’ Relative to the Head of Valve
Stem Diameter Std : 9.401–9.421mm (0.3701–0.3709 in)
Oversize : 0.38mm (0.015 in)
9.781–9.802mm (0.3851–0.3859 in)
Head Diameter 42.88–43.13mm (1.688–1.698 in)
Stem to Guide Clearance 0.048–0.094mm (0.0019–0.0037 in)
Lash Clearance (Cold) 0.43–0.53mm (0.017–0.021 in)

INTAKE VALVES
Face Angle 29°15’–29°30’ Relative to Head of Valve
Stem Diameter Std : 9.426–9.446mm (0.3711–0.3719 in)
Oversize : 0.381mm (0.015 in)
9.807–9.825mm (0.3861–0.3868 in)
Head Diameter 47.37–47.63mm (1.865–1.875 in)
Stem to Guide Clearance 0.023–0.069mm (0.0009–0.0027 in)
Lash Clearance (Cold) 0.36–0.46mm (0.014–0.018 in)

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, loaded at 61–69kg (135–153 lb) 35.69mm (1.405 in)

CAMSHAFT LOBE LIFT

Intake 8.36mm (0.330 in)
Exhaust. 8.36mm (0.330 in)

INSTALLED VALVE RECESSION

Intake 0.86– 1.32 mm (0.034 – 0.052 in)
Exhaust. 1.17– 1.65 mm (0.046 – 0.065 in)

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4 SECTION 10 – ENGINE – CHAPTER 2

VALVE INSERTS
Exhaust Valve Insert Intake Valve Seat Insert
Insert Oversize Counterbore Diameter in Counterbore Diameter in
Cylinder Head 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)

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 (0.002 in) Total Indicator Reading Max
Seat Width Exhaust Valve 1.8–2.3mm (0.072–0.092 in)
Intake Valve 1.9–2.5mm (0.078–0.098 in)

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

CAMSHAFT IDLER GEAR

Number of teeth 47
End Play 0.076–0.35mm (0.003–0.014 in)
Bushing Inside Diameter 50.813–50.838mm (2.005–2.0015 in)
Adaptor Outside Diameter 50.762–50.775mm (1.9985–1.9990 in)
Backlash with Crankshaft Gear 0.10–0.36mm (0.004–0.014 in)
Backlash with Camshaft Gear 0.10–0.36mm (0.004–0.014 in)
Backlash with Fuel Injection Pump 0.10–0.48mm (0.004–0.019 in)

CAMSHAFT GEAR
Number of Teeth 52
Timing Gear Backlash with idler 0.10–0.36mm (0.004–0.014 in)

ROCKER ARM SHAFT

Shaft Diameter 25.40–25.43mm (1.000–1.001 in)
Shaft Support Internal Diameter 25.45–25.20mm (1.002–1.004 in)

ROCKER ARM
Inside Diameter 25.48–25.50mm (1.003–1.004 in)

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 SECTION 10 –ENGINE – CHAPTER 2 5

TAPPETS
Clearance to Bore 0.015–0.058mm (0.0006–0.0023 in)
Tappet Diameter 25.113–25.131mm (0.9889–0.9894 in)
Tappet Bore Diameter 25.146–25.171mm (0.9900–0.9910 in)

CAMSHAFT
Bearing Journal Diameter 60.642–60.668mm (2.3875–2.3885 in)
Bearing Clearance 0.076–0.178mm (0.003–0.007 in)
End Play 0.051–0.18mm (0.0020–0.0070 in)

CONNECTING RODS
Small End Bushing (Internal Diameter) 44.460 - 44.467 mm (1.7504-1.7507)
Big End Bearing Clearance 0.038–0.104 mm (0.0015–0.0041 in)
Clearance Bushing to Piston Pin 0.013–0.025mm (0.0005–0.0010 in)
Side Float 0.13–0.33mm (0.0050–0.0130 in)
Maximum Twist 0.30mm (0.0120 in)
Maximum Bend 0.10mm (0.0040 in)

PISTON PIN
Outside Diameter 41.270–41.275 mm (1.6248–1.6250 in)

PISTONS
Skirt to Cylinder Clearance 0.152-0.182 mm (0.0060 - 0.0072 in) New or unrun engine
0.152-0.194 mm (0.0060 - 0.0096 in) For run engines
Taper (Out of Round) 0.063-0.127 mm (0.0025- 0.0050 in)
Grading Diameter (at Right Angles to 111.64–111.74mm (4.3951–4.3991 in)
Piston Pin) in increments of 0.0127mm (0.0005 in)
Piston Pin Clearance 0.0127–0.0254mm (0.0005–0.0001 in)
at 21°C (70°F)
Piston Crown to Block Face, 0.005–0.015mm (0.13–0.38 in)

PISTON RINGS
All Engines
Top Compression Ring Keystone tapered sides With letter “O” to the top
2nd Compression Ring Parallel side external step
Side Face Clearance To Ring Groove 0.06–0.105 mm (0.0023 – 0.0041 in)
Piston Groove Width 2.435–2.455 mm (0.0959 – 0.0967 in)
Oil Control Ring 1 off,–Directly above the Piston Pin,
Type Slotted With Expander
Side Face Clearance To Ring Groove 0.030–0.070 mm (0.0011–0.0028in)
Piston Groove Width 3.02–3.04 mm (0.1189 – 0.1197 in)

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6 SECTION 10 – ENGINE – CHAPTER 2

CRANKSHAFT
Main Journal Diameter – Blue 85.631–85.644mm (3.3713–3.3718 in)
– Red 85.644–85.656mm (3.3718–3.3723 in)
Main Journal Length
(except thrust, rear, or intermediate) 36.96–37.21mm (1.455–1.465 in)
Main Journal Wear Limits 0.127mm (0.005 in) Maximum
Main and Crankpin Fillet Radius 0.25mm (0.010 in)
Thrust Bearing Journal Length 37.06–37.11mm (1.459–1.461 in)
Intermediate Bearing Journal Length 36.96–37.21mm (1.455–1.465 in)
Rear Bearing Journal Length 37.97–38.48mm (1.495–1.515 in)
Crankpin Journal Length 42.62–42.72mm (1.678–1.682 in)
Crankpin Diameter – Blue 69.840–69.850mm (2.749–2.7500 in)
– Red 69.850–69.860mm (2.750–2.7504 in)
End Play 0.10–0.36mm (0.004–0.014 in)
Crankpin Out of Round 0.005mm (0.0002 in) Total Indicator Reading
Taper Surface Parallel to Centre Line
of Main Journal 0.005mm (0.0002 in)
Crankshaft Rear Oil Seal Journal Diameter 122.12–122.28mm (4.808–4.814 in)
Crankshaft Pulley Journal Diameter 51.788–51.808mm (2.0389–2.0397 in)
Crankshaft Timing Gear Journal Diameter 52.131–52.146mm (2.0524–2.0530 in)
Crankshaft Flange Runout 0.038mm (0.0015 in) Max

CRANKSHAFT DRIVE GEAR

Number of teeth 26

MAIN BEARING
Liner length (except thrust liner) 27.94–28.19mm (1.10–1.11 in)
Liner Length (Thrust Liner) 39.91–39.96mm (1.453–1.455 in)
Vertical Assembled Bearing Clearance 0.055–0.117mm (0.0021–0.0046 in)

CRANKPIN BEARINGS
Liner Length 31.5–31.75mm (1.240–1.250 in)
Vertical Assembled Bearing Clearance 0.038–0.104mm (0.0015–0.0041 in)
Bearing Clearance – Service Limit 0.127mm (0.005in)

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 SECTION 10 –ENGINE – CHAPTER 2 7

CRANKSHAFT RE–GRINDING
When re–grinding a crankshaft the main and crankpin journal diameters should be reduced the same amount
as the undersize bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60° Chamfer of the pilot bearing bore.

UNDERSIZE BEARING AVAILABLE MAIN JOURNAL DIAMETERS

0.051mm (0.002 in) 85.580–85.593mm (3.3693–3.3698 in)
0.254mm (0.010 in) 85.390–85.402mm (3.3618–3.3623 in)
0.508mm (0.020 in) 85.136–85.148mm (3.3518–3.3523 in)
0.762mm (0.030 in) 84.882–84.894mm (3.3418–3.3423 in)
1.016mm (0.040 in) 84.628–84.640mm (3.3318–3.3323 in)

UNDERSIZE BEARING AVAILABLE CRANKPIN JOURNAL DIAMETERS

0.051mm (0.002 in) 69.789–69.799mm (2.7476–2.7480 in)
0.254mm (0.010 in) 69.956–69.606mm (2.7400–2.7404 in)
0.508mm (0.020 in) 69.342–69.352mm (2.7300–2.7304 in)
0.762mm (0.030 in) 69.088–69.098mm (2.7200–2.7204 in)
1.016mm (0.040 in) 68.834–68.844mm (2.7100–2.7104 in)

FLYWHEEL
Runout of Clutch Face ( Between Outer
Edge of Friction Surface and Mounting
Bolt Holes), 0.127mm (0.005 in)
Ring Gear Runout 0.63mm (0.025 in)

OIL PUMP
Flow Rate 20 Gpm@2100 Engine RPM and 20lbf/in2
Rotor Clearance 0.025–0.15mm (0.001–0.006 in)
Rotor to Pump Housing Clearance 0.15–0.28mm (0.006–0.011 in)
Rotor End Play 0.025–0.089mm (0.001–0.0035 in)
Pump Gear to Camshaft Gear Backlash 0.40–0.56mm (0.016–0.022 in)

OIL PRESSURE
Minimum At Low Idle Speed 0.83 bar (12 lbf/in2) at normal operating temperature
Minimum At Engine Rated Speed 2.41 bar (35 lbf/in2) at normal operating temperature

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8 SECTION 10 – ENGINE – CHAPTER 2

OIL FILTER SUPPORT

Relief Valve, Operating Pressure 3.8–4.1 bars (55–60 lbf/in2)
Flow Rate 68.1–75.7 l/min. (15–16.6 imp gals/min,18–20 US gals/min)

ENGINE OILS AND CHANGE PERIODS

Refer to Operators Manual

ENGINE OIL CAPACITIES

Model Imp Pints U.S Gals Litres
6 CYL 33.5 5.01 19.0

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

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 SECTION 10 –ENGINE – CHAPTER 2 9

THERMOSTAT
Opening Temperature 79–83°C (174–181°F)
Fully Open 93–96°C (199–205°F)

RADIATOR CAP
Opening Pressure 1.0 bar (14.5 lbs in2)

WATER PUMP
Type Centrifugal
Drive Poly V Belt, 8 rib

FAN BELT
Belt Tension Maintained by Automatic Tensioner

COOLING SYSTEM CAPACITIES

See Operators Manual

COOLING FLUID
Content Mixture – Water 50%, New Holland Antifreeze 50%.
( New Holland Antifreeze specification: NH900A)

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10 SECTION 10 – ENGINE – CHAPTER 2

TORQUE VALUES – VARIOUS Nm lbf ft

Main Bearing Bolts 81 + 90° 60 + 90°
Connecting Rod Bolts 149 110
Cylinder Head Bolts (with Engine Cold) 55–95+90° 40–70+90°
Cylinder Head through Rocker Shaft Bolts As above +45° As above +45°
Intake Manifold–to–Cylinder Head 35 26
Exhaust Manifold–to–Cylinder Head 61 45
Exhaust Pipe–to–Flange 31 23
Flywheel–to–Crankshaft 197 145
Oil Pan Drain Plug 41 30
Valve Rocker Cover Bolts 24 18
Crankshaft Pulley–to–Crankshaft 224 210
Self–Locking Screw – Valve Rocker Arm 24 18
Injector Attachment Bolts 23 17
Cover Bolts (Blanks Oil Drilling) 31 23
Oil Pump to Block 23 17
Water Pump–to–Cylinder Block 65 48
Water Pump Cover–to–Pump 61 45
Oil Pan–to–Cylinder Block 44 33
Injector Line Nuts 24 18
Leak–off Tube Banjo Fitting Bolts 6 4.4
Injection Pump–to–Front Cover 24 18
Camshaft Idler Drive Gear–to–Block 237 175
Front Cover–to–Cylinder Block 24 18
Thermostat Housing Bolts 24 18
Camshaft Gear Bolt 69 51
Camshaft Rear Gear Plate Bolts 47 35
Oil Filter Adaptor Bolts 42 31
Oil Filter Mounting Bolt Insert 34 25
Starting Motor–to–Rear Adaptor Plate 31 23
Injection Pump–to–Gear Nut 92 68
Oil Pressure Switch Assembly 31 23
Turbocharger–to–Exhaust Manifold Nut 44 33
Fan Blade to Viscous Unit 27 21
Viscous Unit to Pulley 54 40
Crankshaft Rear Oil Seal Retainer 20 15
Belt Tensioner Pulley Bolt 54 40
Temperature Senders 20 15
Tensioner to Water Pump Bolt 54 40
Idler Pulley Bolt 54 40
Pump Connector to Block 24 18

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 SECTION 10 –ENGINE – CHAPTER 2 11

The following general nut and bolt installation torque

requirements (lubricated) apply to any operation not
previously listed.
INCH SERIES Nm lbf ft
1/ – 20 11 8
4
1/ – 28 11 8
4
5/ –18 19 14
16
5/ –24 23 17
16
3/ – 16 31 23
4
3/ – 24 45 33
4
7/ –14 65 48
16
7/ –20 75 55
16
1/ – 13 88 65
2
1/ – 20 102 75
2
9/ –18 122 90
16
5/ –18 187 138
6
CYLINDER BLOCK PLUGS
1/ – 27 NPT 11 8
4
1/ – 18 NPT 29.8 22
4
3/ – 18 NPT 38 28
4
3/ – 14 NPT 27 20
4

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12 SECTION 10 – ENGINE – CHAPTER 2

SPECIAL TOOLS
Description CNH Tool Number SPX Ltd Tool Nuday Tool
Number Number
Engine sling hook, 290740 – –
(use with brackets 82852825 and
82932534)
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 297116 – –
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 297102 518 9539
Shaft protector 297107 625–A 9212
Step plate adaptors 297108 630–S 9210
Bushing kit 297103 818 9514
Con rod bush – remove/install tool 297199 – –
Camshaft bearing installer 297117 FT.6203 1255 (SW.506)
Handle (for camshaft bearing installer) – N6261–A 1442
Crankshaft Timing Pin 297672 – –
Fuel Injection Pump Timing Pin 380000404 – –

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 SECTION 10 –ENGINE – CHAPTER 2 13

FAULT FINDING
IMPORTANT: When effecting a repair the cause of The following table lists problems and their possible
the problem must be investigated and corrected to causes with recommended remedial action.
avoid repeat failures.
PROBLEM POSSIBLE CAUSES REMEDY
Engine does not 1. Clogged air cleaner 1. Clean or renew element
develop full power
2. Fuel line obstructed 2. Clean
3. Faulty injectors 3. Clean and reset
4. Incorrect valve clearance 4. Check and reset
adjustment
5. Burnt, worn or sticking valves 5. Replace valves with new or
oversize, and/or machine the
valve guide bores
6. Blown head gasket 6. Check head flatness and fit new
gasket
7. Incorrect fuel delivery 7. Check injectors and pump
8. Low cylinder compression 8. Renew piston rings or
re–bore/re–sleeve as necessary
Oil pressure warning 1. Bulb burnt out 1. Renew bulb
light fails to operate
2. Warning Light pressure switch 2. Renew pressure switch
faulty
3. Warning light circuit faulty 3. Check and renew wiring
Excessive exhaust 1. Oil leak on compressor or turbine 1. Overhaul turbocharger
smoke side of turbocharger, where fitted
2. Exhaust leak on exhaust manifold 2. Fit new gasket
side of turbocharger, where fitted
3. Air cleaner dirty or restricted 3. Clean
4. Excessive fuel delivery 4. Overhaul injection pump and
injectors

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14 SECTION 10 – ENGINE – CHAPTER 2

PROBLEM POSSIBLE CAUSES REMEDY

Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for
damage, change as required.
Drain and refill with specified oil
and renew filter. Ascertain cause of
dilution
2. Insufficient oil supply 2. Check oil level and top up as
necessary. Overhaul or renew
pump as necessary. Check oil filter
is not clogged
3. Low oil pressure 3. Overhaul pump or relief valve as
necessary
4. Excessive crankshaft end play 4. Install new thrust bearing liner
5. Flywheel or ring gear run–out 5. Skim flywheel or fit new ring gear
excessive
6. Excessive connecting rod or main 6. Install new bearing inserts and/or
bearing clearance re–grind crankshaft
7. Bent or twisted connecting rods 7. Renew connecting rods
8. Crankshaft journals out– of–round 8. Re–grind crankshaft and fit
undersize bearing inserts
9. Excessive piston–to– cylinder 9. Re–bore/re–sleeve block and fit
bore clearance new pistons
10. Excessive piston ring clearance 10. Fit new pistons and rings
11. Broken rings 11. Fit new rings, check bore and
pistons for damage
12. Excessive piston pin clearance 12. Fit new piston or pin
13. Piston pin retainer loose or missing 13. Install new retainer, and check
bore/pistons for damage
14. Excessive camshaft play 14. Install new thrust plate
15. Imperfections on timing gear teeth 15. Renew timing gear
16. Excessive timing gear backlash 16. Check and adjust backlash /renew
timing gear

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 15

PROBLEM POSSIBLE CAUSES REMEDY

Engine overheats 1. Hose connection leaking or 1. Tighten hose connection, renew
collapsed hose if damaged
2. Radiator cap defective or not 2. Renew radiator cap
sealing
3. Radiator leakage 3. Repair/renew radiator
4. Improper fan belt adjustment 4. Re–adjust fan belt
5. Radiator fins restricted 5. Clean with compressed air
6. Faulty thermostat 6. Renew thermostat
7. Internal engine leakage 7. Check for source of leakage,
renew gasket or defective parts
8. Water pump faulty 8. Overhaul water pump
9. Exhaust gas leakage into cooling 9. Renew cylinder head gasket,
system check head for damage or
distortion
10. Coolant aeration 10. Tighten all connections and check
coolant level is correct. Ensure
cylinder head gasket has not blown
11. Cylinder head gasket improperly 11. Renew cylinder head gasket
installed
12. Hot spot due to rust and scale or 12. Reverse flush entire cooling
clogged water jackets system
13. Obstruction to radiator air flow 13. Remove the obstruction
14. Extended engine idling 14. Do not allow engine to idle for long
periods
15. Oil cooler tube blocked 15. Clean
16. Radiator core tubes blocked 16. Check free flow
Water temperature gauge 1. Faulty temperature sender 1. Renew sender switch
fails to reach normal
operating temperature 2. Incorrect or faulty thermostat 2. Renew thermostat
3. Faulty water temperature gauge 3. Renew temperature gauge

604.55.111.00 – 06 – 2002
16 SECTION 10 – ENGINE – CHAPTER 2

PROBLEM POSSIBLE CAUSES REMEDY

Low oil pressure 1. Engine oil level low 1. Top up, as necessary
2. Wrong grade of oil 2. Drain and refill with correct grade
of oil
3. Blocked oil pump sump screen 3. Clean pump screen
4. Oil pressure relief valve faulty 4. Fit new relief valve
5. Oil pump worn 5. Renew oil pump
6. Excessive oil pump rotor and shaft 6. Overhaul pump
assembly clearance
7. Excessive main or connecting rod 7. Install new bearings inserts and /
bearing clearance or re–grind crankshaft if necessary
Excessive oil 1. Engine oil level too high 1. Reduce oil level
consumption
2. External oil leaks 2. Renew gaskets and seals, where
necessary. Check mating surfaces
for damage or distortion
3. Worn valves, valve guides or bores 3. Renew
4. Cylinder head gasket leaking 4. Renew gasket. Check head for
damage or distortion
5. Oil loss past the pistons and rings 5. Renew rings and/or rebore/
re–sleeve block as necessary
6. Oil cooler leak 6. Repair/renew oil cooler assembly
Engine tends to keep 1. Air cleaner dirty or restricted 1. Clean or renew element
firing after fuel is shut off
2. Oil leak on compressor side of 2. Overhaul turbocharger
turbocharger where fitted

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 17

DESCRIPTION AND OPERATION

1
The CNH 7.5 Litre engine is a 6-cylinder CYLINDER BLOCK ASSEMBLY
turbocharged and aftercooled unit, having a bore of The cylinder block is an alloy cast iron with deep
4.4″ (111.8 mm) and a stroke of 5.0″ (127 mm) which cylinder skirts, and water jackets for cooling the
generates a displacement of 456 in3. cylinders. The cylinder bores are machined integral
The engine uses a mechanical or electronically with the cylinder block, during the manufacturing
controlled rotary injection pump depending on model process. The block incorporates hydraulic tappets
and has been designed to meet current emission which do not require adjustment unless engine is
regulations and must only be serviced by an being re–assembled.
authorised service agent. For a detailed Description Cylinders are in line and vertical and numbered 1 to
and Operation of the fuel system reference must be 6 from the front to the rear of the engine. They can
made to the Fuel System Chapter in this Section of be bored oversize for the fitment of sleeves, which
the manual. are available in service.
All engines feature cross flow cylinder heads, with The oil pan is the reservoir for the engine oil
the inlet and exhaust manifolds on opposite sides of lubrication system and a cast iron front cover on the
the cylinder head. The fuel and air combustion front of the engine covers the timing gear assembly.
process, takes place in the specially designed bowl
in the crown of the pistons.

604.55.111.00 – 06 – 2002
18 SECTION 10 – ENGINE – CHAPTER 2

CYLINDER HEAD ASSEMBLY

The cylinder head incorporates an inlet and exhaust
valve per cylinder with the valve rocker arm shaft
assembly bolted to the cylinder block through the
cylinder head. Cylinder head retaining bolts are
evenly spaced with a six point pattern around each
cylinder, this ensures an even clamping load across
the cylinder head area.
The intake and exhaust manifolds are bolted to the
head, the intake manifold is mounted on the right
hand side of the engine, with the diesel injectors
mounted outside the rocker cover. The exhaust
manifold is mounted on the left hand side of the
engine. Water outlet connections and thermostats 2
being attached to the front of the cylinder block.
Valve guides are integral in the cylinder head, and
valves with oversize stems are available in service.
Special replaceable sintered iron valve seats are
pressed into each valve port during manufacture and
oversize valve seats also available in service.
All valves are fitted with positive valve rotators and
valve stem oil seals. Valve clearance is maintained
by adjustment of the self locking adjusting screw,
mounted in each of the rocker arms.
CAMSHAFT ASSEMBLY
The camshaft runs in 5 replaceable bearings. The
camshaft drive gear is in mesh with and driven by the
camshaft idler gear which is driven by the crankshaft
timing gear.
Camshaft end thrust is controlled by a thrust plate
bolted to the block, and located between the
camshaft gear and the front camshaft journal.
A helical gear is mounted on the rear of the camshaft,
and drives the engine oil lubrication pump mounted
forward of the flywheel.

396–E–16 TI
3
CRANKSHAFT ASSEMBLY
The crankshaft is supported in the cylinder block by
7 main bearings.
The crankshaft is manufactured from steel with
machined finished crank webs
End thrust is controlled by a thrust bearing
incorporated in the fifth main bearing of the
crankshaft.
An external damper is fitted to the crankshaft pulley
to ensure smooth running operation. Front and rear
crankshaft oil sealing is effected by cassette type
seals that are designed for long and durable service
life.
4

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 19

CONNECTING RODS
Connecting rods ‘‘Teepee” (wedge) shaped at the
small end have been designed to reduce the
reciprocating weight at the piston end. The
connecting rods are of a heavy beam construction
and are assembled as a matched set to each engine.
They are retained in position by the connecting rod
big end cap and secured by two bolts per rod. The
small end of the connecting rod is fitted with a
replaceable bronze bushing, through which the free
floating piston pin is fitted. The steel pin being held
in place within the piston by two snap rings.

5
PISTONS
Pistons are constructed of an aluminium silicon alloy
with an iron insert for the top ring. The combustion
chamber being recessed into the piston crowns.
Each piston has two compression rings and one oil
control ring, to reduce friction and increase positive
sealing. All rings are located above the piston pin.

6
MANIFOLDS
The cross flow design aluminium intake, and cast
iron exhaust manifolds, are on opposite sides of the
cylinder head. This is designed to maintain balanced
heat distribution within the cylinder head. The
configuration of the manifolds also ensures minimum
heat transfer to the intake manifold.

7
TIMING GEARS 4 1
The crankshaft timing gear is heated and press fitted
on to the front of the crankshaft, to a high degree of
accuracy during manufacturing. This enables
precise timing being maintained during the life of the
engine. The crankshaft gear (2) drives the idler gear . ..
(3) which is attached to the front of the cylinder block.
The idler gear then drives the camshaft gear (1) and
the injection pump gear (4). ..
The camshaft gear is bolted to the front of the
camshaft, and is keyed to maintain position of the 3 2
gear on the camshaft.
P396–E–36
8

604.55.111.00 – 06 – 2002
20 SECTION 10 – ENGINE – CHAPTER 2

LUBRICATION SYSTEM

1
Engine Lubrication System
Lubrication of the engine, Figure 1, is maintained by
a rotor type oil pump mounted in the rear of the
engine block, forward of the flywheel on the left hand
side of the engine.

TA6010058
2
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.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 21

A spring loaded relief valve is integral with the

dummy oil filter head mounted on the left hand side
of the engine block and prevents over pressurisation
of the system.

396–E–18 TI
4

The spin on type oil filter is mounted next to the oil

cooler.

60–10–064
5
Oil flows from the filter to the main oil gallery, which
runs the length of the cylinder block and also
intersects the camshaft follower chamber.
The main gallery supplies oil to the crankshaft main
bearings, connecting rods and both big and small
ends. The underside of the pistons and pins, are
lubricated by oil pressure jets mounted adjacent to
each main journal housing.
The camshaft drive gear bushing is pressure
lubricated through a drilled passage from the front
main bearing. The gear has small oil passages
machined on both sides allowing excess oil to
escape. 396–E–26 TI
6
An intermittent flow of oil is directed to the valve
rocker arm shaft assembly via a drilled passage in 1
the cylinder block. This is located vertically above
No.1 camshaft bearing (1) and aligns to a hole in the
cylinder head. The rotation of the camshaft allows a
controlled intermediate flow of lubrication.

396–E–16 TI
7

604.55.111.00 – 06 – 2002
22 SECTION 10 – ENGINE – CHAPTER 2

Timing gears are lubricated by splashed oil from the

cam follower chamber, and the pressure lubricated
camshaft drive gear bushing.

P396–E–36
8

The turbocharger is supplied with oil from the oil filter

support housing, mounted on the left hand side of the
engine.

9
The fuel injection pump is pressure lubricated from
a port on the right hand side of the engine block.
The fuel pump is either electronically controlled using
an electronic control unit

10
or
Mechanically controlled depending on model.

11

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 23

CRANKCASE BREATHER

All engines feature a Closed Crankcase Ventilation

System which is specifically designed to reduce
emmisions. Crankcase blow–by is produced when
the combustion gases, under high pressure, become
contaminated with oil droplets when blown past the
piston rings into the crankcase. The breather system
filters the blow–by gas and channels it into the air
intake system. The oil droplets are collected in the
breather and then returned to the engine oil pan.

12

604.55.111.00 – 06 – 2002
24 SECTION 10 – ENGINE – CHAPTER 2

ENGINE OVERHAUL–INTRODUCTION
In the following procedures and illustrations the For concerns relating to the fuel system refer to the
engine is shown removed from the vehicle however fuel system Chapter in this manual. On engines fitted
there are certain operations that can be performed with the electronically controlled fuel injection pump
with the engine installed. refer to the “Engine Fault Codes” chapter in the
Where it is necessary to remove the engine use a electrical section of the manual.
suitable hoist or overhead gantry and standard
engineering procedures. Removal of the engine is Operations or repairs that can be performed
described in Chapter 1 of Section 10 of this manual. with the engine still in the vehicle.
Dismantle the engine following conventional 1. Front timing cover, Pump drive gear and idler
techniques and by referring to the appropriate gear. Removal of engine is required in order to
overhaul sections of this chapter. Always refer to the remove and replace the camshaft timing gear.
specification section as necessary. 2. Front pulley and damper assembly.
NOTE: Where it is necessary to remove additional 3. Cylinder head and associated inlet and exhaust
items to gain access to the components on the components.
engine Refer to Chapter 1 “Separating and
4. Fuel injection pump removal and timing.
Removing Engine”.
5. Water pump, thermostat, and associated
NOTE: All gaskets, seals, and ‘O’ rings must be
components .
replaced during re–assembly. Where new sealant is
to be applied refer to ‘‘Engine Specifications”. 6. Oil pump relief valve.
7. Turbocharger.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 25

TIMING CHECK
If a fuel related concern is identified check the
injection pump timing before proceeding with any
other disassembly.
NOTE: Where it is necessary to remove additional
items to gain access to the components on the
engine Refer to Chapter 1 “Separating/Removing
Enginet”.
1. Remove engine drive belts.

13
1. Remove injection pump timing cover.

14
2. Using 29mm socket (1–1/8 inch) socket rotate
crankshaft to top dead centre (TDC) with number
1 cylinder firing. This indicated by the ‘V‘ cut into
the notch of the sensor wheel (Electronically
governed Pump) which should align with the
sensor. Mechanically governed engines will
indicate TDC with an ‘O‘ on the pulley in line with
the pin on the block. (Refer to Fuel System
Chapter).

15
3. When engine is at TDC the hole in the injection
pump drive flange aligns with the pump timing
plate.

16

604.55.111.00 – 06 – 2002
26 SECTION 10 – ENGINE – CHAPTER 2

4. To ensure the crankshaft is accurately positioned

at TDC remove the crankshaft timing plug (1)
from the side of the engine block.
IMPORTANT: DO NOT disturb the timing pin bush
(2). This has been accurately set during original
manufacture. If the bush is moved then pump timing
CAN NOT be accurately set.

17
5. Insert the crankshaft timing pin 297672 into the
side of the block.

18
6. If necessary gently turn the crankshaft to engage
the rounded end of the timing pin in the slot of the
crankshaft. This is not visible and must be
performed by ‘feel’.

19
7. When the timing pin is located in the slot of the
crankshaft the pin is fully seated.
Do not attempt to rotate the crankshaft when
timing pin is fully inserted as damage will occur.

20

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 27

8. Check that the injection pump timing pin Tool No

3800000404 will screw into the pump hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
9. If the pin (1) engages in the pump timing plate
(inset, Figure 21 ) when the crankshaft is at TDC
the pump timing is correct.
10. If pump timing is incorrect and timing pin can not
be screwed into pump, remove pump timing
gear, install timing pin 380000404 into pump and
refit timing gear. Refer to Fuel System Chapter
for detailed description.

21
NOTE: This injection pump timing check assumes
that the crankshaft and camshaft timing gears were
correctly positioned during engine assembly. To
check the position of these timing gears it is
necessary to remove the engine front cover.

604.55.111.00 – 06 – 2002
28 SECTION 10 – ENGINE – CHAPTER 2

OVERHAUL

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.
1. Check that the heater shutoff valve (1) is open.
This valve is on the rear, right-hand side of the
engine cylinder head.Drain the engine coolant by
placing a suitable container below the coolant
drain hose .
22
2. Drain the coolant using drain tap (1) on left hand
rear of the engine block.

23
3. Remove all necessary hardware and
components in order to gain access to the
cylinder head. Refer to Chapter 1
“Separating/Removing Engine” for further
details.

24
4. Remove the fan belt.Using a 50mm spanner
remove the fan complete with the visctronic
sensor.

25

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 29

5. Clean the area surrounding the fuel injectors.

Disconnect and remove injector lines (1) and
leak off lines (2) from the fuel injectors and 1
injection pump. Cap all exposed openings.
2

26
6. Remove injectors from the cylinder head.

27
7. Remove the turbocharger assembly, ensuring all
openings are capped to prevent dirt ingress.

28
8. Remove the thermostat housing and water pump
housing .

29

604.55.111.00 – 06 – 2002
30 SECTION 10 – ENGINE – CHAPTER 2

9. Remove the rocker cover and gasket.

30
10. Loosen the rocker shaft retaining bolts (which
also serve as head bolts) evenly and alternately
and remove the rocker shaft assembly.

31
NOTE: Leave bolts in the rocker shaft supports
during removal, as they retain the support on the
shaft.
11. Remove pushrods in turn and place in a
numbered rack to maintain the same position for
reassembly.

32
12. Remove remaining cylinder head bolts by
working progressively from each end of the
cylinder head towards the centre.
13. Carefully lift the cylinder head assembly away
from the engine block.

33

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 31

Cylinder Head Disassembly

1
1. Using a valve spring compressor, tool
No.291050,(1) remove the retainer locks (2) and
place in a numbered rack..
2. Clean the cylinder head, and remove carbon
deposits from around the valve heads.

TA6010011
34

35
Inlet and Exhaust Valves
1. Inlet Valve 5. Retainer Key
2. Spring 6. Spring Retainer
3. Spring Retainer 7. Spring
4. Retainer Key 8. Exhaust Valve

604.55.111.00 – 06 – 2002
32 SECTION 10 – ENGINE – CHAPTER 2

Inspection and Repair, Cylinder Head

1. Replace cylinder head core plugs if discoloured
(rusty), or leaking. Before fitting new plugs
remove all old sealer from the cylinder head.
Apply sealant G, see ‘‘SPECIFICATIONS”, to
the new plug mating faces, and drive the new
plugs into location.
The core plugs fitted to the Cylinder Head are:–
6 off, In the top, and 1 off, in the rear of the
cylinder head.
5 off, in the intake face.
2. Scrape all gasket surfaces clean, wash cylinder TA6010008
head in a suitable solvent and clean valve guide
36
bores.
NOTE: Ensure injector washers have been removed
prior to cleaning.
3. Inspect cylinder head for nicks and burrs on
mating face, Remove using a suitable abrasive
and ensure faces are clean after repair.
4. Using a straight edge and feeler gauges, check
that the flatness of the cylinder head in all
directions does not exceed,
0.001 in (0.03mm) in any 1 in (25.4mm), or 2 3 4 5 6 6 7 8
0.005 in (0.127mm), overall limit.
5. If the cylinder head has been resurfaced,
determine that all head bolt faces will seat by
placing the cylinder head less gasket, on the
cylinder block and installing bolts hand tight.
TA6010012
37
6. Ensure rocker shaft supports are fitted with long
bolts. Using a feeler gauge, check clearance
between underside of bolt heads and cylinder
head or rocker shaft support.
7. If a 0.010 in (0.25mm) feeler gauge can be
inserted under the bolt head the bolt has
bottomed. Therefore the cylinder block thread
must be increased using a 9/16–13 UNC–2A
Thread tap. Identify each head bolt to ensure
they are reinstalled in the bolt holes they were
checked in.

38

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 33

Valve Inserts
Counter Bore in Cylinder Head
Insert Oversize
Exhaust valve insert Intake valve insert
0.010 in (0.25mm) 1.739–1.740 in (44.17–44.20mm) 1.969–1.970 in (50.01–50.04mm)
0.020 in (0.58mm) 1.749–1.750 in (44.42–44.45mm) 1.979–1.980 in (50.27–50.29mm)
0.030 in (0.76mm) 1.759–1.760 in (44.68–44.70mm) 1.989–1.990 in (50.52–50.55mm)

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
must be counter bored, as described in the
above chart. The new insert must be chilled in dry
ice prior to installation.
Valve Seat Specifications, Figure 39.
1. Valve seat angle 3
Intake 30.0°–30.30° 1
Exhaust 45.0°–45.30°
2. Valve seat width
Intake 0.078–0.098 in
(1.9–2.4mm)
Exhaust 0.072–0.092 in (1.8–2.3mm)
3. Valve Head Face to Cylinder Head Face Depth
Intake 0.035–0.051 in (0.89–1.29mm)
Exhaust 0.048–0.064 in (1.2–1.6mm) 2
NOTE: Valve inserts of 0.010 in (0.25mm) and TA6010013
0.020 in (0.5mm) oversize on diameter are 39
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 as
required reface by grinding to dimensions
detailed above.
4. Measure the concentricity of valve seats, using
a dial indicator and measure concentricity of seat
to the valve guide bore.
Total Indicator Reading should not exceed
0.002 in (0.051mm), Figure 40.

40

604.55.111.00 – 06 – 2002
34 SECTION 10 – ENGINE – CHAPTER 2

5. Use a seat cutter to correct any seat eccentricity,

or clean up of pits and grooves. Ensure after any
rework that seat width is within specified limits.
6. Rotate a new or refaced valve in the seat using
engineering blue, ensure all the blue is
transferred to the valve head protrusion, If any
blue remains below or around the seat raise or
lower the seat accordingly, Figure 41, in the
following manner.
7. Lower, the valve seats, item 1 Figure 41, by
removing material from the top of seat using a,
30° grinding wheel for exhaust valves and a 15°
grinding wheel for intake valves. TA6010016

8. Raise, the valve seats, item 2 Figure 41, by 41

removing material 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 42:

1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valve Face
5. Valve Stem
6. Valve Tip

Valve Guides
1. Using a telescopic gauge, and micrometer, 42
measure the valve guide bore clearance, and
ensure it does not exceed,
0.0045 in (0.114mm),
on the intake valve stem,
0.0055 in (0.140mm),
on the exhaust valve stem, Figure 43.
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed, 0.015 in (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
stem guide, with three reamer and pilot
combinations as follows:–
When going from a standard valve stem to an
oversize, always use reamers in sequence
0.015 in (0.38mm) oversize reamer, and
0.003 in (0.076mm) oversize pilot. TA6010018
43

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 35

Valve Springs
1. Checked on a flat surface squareness, should
not exceed 0.060 in (1.52mm), between the
square, and spring at the top edge, Figure 44.
Length of valve springs should be checked on
both free length, and loaded length.
Free length = 2.39 in (60.7mm)
Installed length =1.86–1.95 in (47–49.6mm)
Loaded length = 1.9 in (48.26mm) using a
weight of 61.96 lb (28–31 kg)
Loaded length = 1.4 in (35.69mm) using a
weight of 135–153 lb (61–69 kg)
Ensure the valve spring retainer locks are in good 44
condition, and replace if worn or damaged.
Rocker Shaft Inspection and Reassembly
1 2 3
1. Separate rocker shaft assembly by removing the
cylinder head bolts (3) and withdraw the supports
(2), springs (1), rockers (4) and spacers (6).
2. Clean all components using approved cleaning
solution and make sure all oil passages are clear.
3. Inspect rocker arm adjusting screws, and push
rod ends of the rocker arm, including the ball end
of the screws for nicks, damage, or excessive
wear.
4. Inspect the inside diameter of the rocker arm for
damage or wear. If any of these characteristics 6 5 4
are not to specification replace with new parts. TA6010010
45
5. Check the ends of the push rods for damage or
wear. If not to specification or push rods were
found not to be straight during dismantling install
new rods.
NOTE: Do not attempt to straighten bent push rods,
replace with new.
6. Check the rocker shaft for signs of wear or
damage on internal and external diameters
respectively.
7. Re–assemble the rocker shaft components onto
the shaft ensuring the shaft identification groove
(1), is positioned forwards and upwards. This
ensures oil grooves and holes face downwards.
46

604.55.111.00 – 06 – 2002
36 SECTION 10 – ENGINE – CHAPTER 2

Cylinder Head Re–assembly

1. Insert the valves into the guide bores from which
they were removed and lap with a suitable paste.
Ensure all traces of paste is removed after
lapping.
NOTE: Lubricate all components with clean engine
oil on re–assembly.
2. Use a spring compressor to reassemble the
valves, valve springs, retainers, rotators, and
collets, and install new valve stem seals. Do not
compress below 34.5mm to install retainer keys.

TA6010011
47
3. Install new gasket and lower cylinder head into
place while ensuring the gasket remains in
position.
4. loosely position all cylinder head bolts except
those which retain the rocker shaft assembly.
NOTE: Cylinder head bolts may only be removed
and refitted four times after which they must be
replaced with new parts.

48
5. Install rocker push rods in cylinder head and
locate rocker shaft assembly onto cylinder head
using the longer cylinder head bolts.

49
6. Tighten the cylinder head bolts in sequence
progressively in the following stages, Figure 50.
NOTE: Lightly lubricate the bolts prior to assembly,
and tighten to the torque specification, with the
engine cold.

50

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 37

Stage 1, all bolts, 55 Nm (40 lbf ft)

51
Stage 2, all bolts, 95Nm (70 lbf ft)

52
Stage 3, all bolts, a further 90° using a torque angle
gauge, Figure 53.

53
Stage 4, Rocker shaft securing bolts only, tighten
a further 45°, Figure 55, using a torque angle gauge.
24 16 8 2 10 18 26
In sequence, 2,8,10,16,18,24,26.

54

604.55.111.00 – 06 – 2002
38 SECTION 10 – ENGINE – CHAPTER 2

Stage 4 Rocker shaft bolts

45°

55
Hydraulic Tappets
NOTE: Engines fitted with hydraulic tappets are
set on assembly and do not require any further
adjustment..
If engine is being re–assembled set hydraulic
tappets as follows:
7. Ensure pushrod cup end is properly located on
ball end of tappet.
8. Rotate no.1 cylinder to TDC firing stroke (Both
valves closed).
9. Adjust valves 1,2,3,6,7,10 as follows: Loosen
adjusting screw anticlockwise so rocker arm
clearance can be freely felt by light 56
rocking.(approximately.020”/0.5mm clearance
at valve to ensure tappet is fully extended).
10. Tighten adjusting screw clockwise until light
rocking clearance is nearly taken up
(approximately .004”/0.1mm clearance is ideal).
11. Tighten adjusting screw one complete turn
clockwise.
12. Rotate engine 360 degrees so no.1 cylinder is at
TDC exhaust stroke.
13. Adjust valves 4,5,8,9,11,12 as above.

57
14. Install the injectors with new seat washers, cork
seals, and torque to 23N m (17 lbf ft) Figure 58.
15. 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 (4.4 lbf ft)
NOTE: Hold the leak off plastic tubing when
tightening to prevent the pipes pivoting, during
torque up.
16. Exhaust manifold bolts are to be refitted and
tightened to a torque of, 38Nm (28 lbf ft).
17. Intake manifold bolts are to be refitted and
tightened to a torque of, 38Nm (28 lbf ft).
58

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 39

18. Using new gaskets install intake and exhaust

manifolds. Initially install all bolts finger tight
ensuring the gaskets are aligned with the inlet
and exhaust ports.
19. Tighten the bolts to a torque of 61 Nm working
from the central bolts outwards.
20. Re tighten the bolts to a torque of 61 Nm.
NOTE: When the manifold bolts are torqued the
gaskets may show signs of distortion between the
inlet and exhaust ports. This is normal for this type
of gasket and is the reason for the retorquing
procedure.

59

604.55.111.00 – 06 – 2002
40 SECTION 10 – ENGINE – CHAPTER 2

ENGINE FRONT COVER AND TIMING

GEARS (OP. 10 102 & 10 106)

Timing Gears Checking and Removal

IMPORTANT: If the injection pump timing has been
checked ensure the timing pins 380000404 and
297672 have been removed before proceeding.
Refer to Page 25.
1. Using puller, 297102), and shaft protector
297107 ), remove crankshaft damper.

TA6010027
60
2. Remove the injection pump cover plate.
3. Remove front cover plate.

61
4. When the engine timing has been checked as
described on Page 25 the timing marks (dots) on 4 1
the crankshaft and camshaft timing gears align.
1. Camshaft Gear
2. Crankshaft Timing Gear
3. Camshaft Idler Gear .
4. Injection Pump Drive Gear ..
NOTE: The crankshaft timing gear (2), should not be
removed. The gear is heat shrunk on to the ..
crankshaft and aligned to the crankshaft No1 pin, to
within 0.10mm (0.004 in). If the gear is damaged a 3 2
new crankshaft is required.
P396–E–36
62
5. Before removing the timing gears perform the
following checks:–
Use a dial indicator or feeler gauge, Figure 63,
to measure the backlash between each set of
gears.
Rotate the gears and check the backlash at four
equal points on the gears. Renew if the backlash
exceeds the following:–
Crankshaft to camshaft idler gear,
0.1–0.36mm (0.004–0.014 in)
Camshaft to camshaft idler gear,
0.1–0.36mm (0.004–0.014 in)
TA6010029
Fuel injection pump to camshaft idler gear
63
0.10–0.48mm (0.004–0.019 in)

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 41

6. Check camshaft gear end float as follows:–

Pry the camshaft gear using a lever, away from
thrust plate. Using a dial indicator or feeler
gauge, check the clearance.

P396–E–28 TI
64
if clearance is outside 0.05–1.8mm
(0.002–0.007 in) limit, fit a new camshaft thrust
plate, item 1, Figure 65. 1
NOTE: The camshaft gear is an interference fit with
the camshaft and removal requires a three legged
puller. It is recommended that this gear is only
removed when necessary and during a total engine
rebuild. This will enable both the gear and camshaft
to be removed from the front of the engine.

396–E–45 TI
65
7. Check idler gear end float using similar
procedure described for the camshaft gear. If
outside limits of 0.003″–0.014″ (0.073–0.35 mm)
fit a new idler gear wear plate (1).

66
8. To remove the fuel pump drive gear remove the
4 retaining bolts.

..
1
..

P396–E–36 TI
67

604.55.111.00 – 06 – 2002
42 SECTION 10 – ENGINE – CHAPTER 2

9. If required the timing gear rear cover plate may

now be removed. Remove the six retaining bolts
and carefully pry the cover from the engine block.
When replacing the cover tighten retaining bolts
to a torque of 24Nm (18lbf.ft).

68
Inspection and repair of gears
1. Wash the gears using a suitable solvent, and
examine 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
from obstruction and bushing is not damaged.
Camshaft key and key–way should be checked
for damage and repaired as required.

TI
69
Installation
1. Position piston no.1 at Top Dead Centre and
install timing pin 297672.

70
2. Ensure the timing holes on the pump are aligned
and screw the timing pin 380000404 through the
pump flange and timing plate.

71

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 43

3. If the pump has been removed during engine

overhaul refit pump onto engine.

72
4. Install timing gears ensuring the timing marks on
the crankshaft, idler and camshaft gears align.
5. Fit the pump drive gear and remove pump timing
pin.
6. Torque bolts as follows.
Camshaft gear 69Nm (51 lbf ft) ..
Idler Gear 204–279Nm (150–205lbft)
Pump Drive Gear 38N (28 lbf.ft). ..

P396–E–36 TI
73
7. Remove crankshaft timing pin and install plug.

74
8. Position gasket on the front cover plate.
9. Install the front cover, ensuring alignment with
dowel pins. Tighten the retaining bolts in the 1–4
sequence shown to a torque of 25-30 lbf.ft
(34–41Nm).
10. Install the oil pan as described on Page 44.
11. Install new front crankshaft oil seal as described
in Front Crankshaft Cassette Oil Seal
Replacement on page 66.

75

604.55.111.00 – 06 – 2002
44 SECTION 10 – ENGINE – CHAPTER 2

OIL PAN (OP. 10 102)

Removal
1. Remove engine as described in the engine
removal chapter in this section of the manual.
2. Drain engine oil through oil pan drain plug and
remove the dipstick.
3. Remove oil pan bolts and lower pan to the
ground.

Inspection and repair

1. Clean gasket material from sump face, clean
sump in a suitable solvent, inspect sump for 76
cracks damaged threads or damaged sump
face.

Installation
1. Installation is the reverse of removal but with the
following requirements.
2. Ensure block face is clean and free of gasket
material.
+0.15
NOTE: Before installing the oil pan ensure that the
–0.22
rear oil seal carrier (2), is correctly aligned with the
block,(1), ie, less than 0.15mm protrusion or 0.22mm
recessed.

77
3. Apply gasket sealant 82995770 to the areas
shown and install a new gasket to the oil pan.

78
4. Position the oil pan and install a bolt finger tight
at each corner. Install remaining bolts, and
torque to 44Nm (33 lbf.ft).

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 45

FLYWHEEL (OP. 10 103)

Removal
1. To gain access to the flywheel remove the
engine.
2. Prior to removing flywheel use a dial indicator to
measure flywheel run–out. The maximum total
indicator reading should be 0.127mm (0.005 in)
If not to specification check crankshaft to
flywheel seating.

TA6010053
79
3. Remove damper assembly from flywheel.
4. Support flywheel, remove retaining bolts and
separate flywheel from crankshaft.

80
Inspection and Repair
1. Inspect the flywheel ring gear, and if damaged
renew in the following manner,
2. Cut old ring gear free from the flywheel.
3. Clean the mating surfaces of the new ring gear,
and flywheel.
4. Use temperature indicating crayons to mark the
side face of the ring gear in six equal places,
mark with a 204°C (400°F) crayon at a point
13mm (0.5 in) below the root of the teeth, and
mark with a 212°C ( 450°) crayon at a point just
below root of the teeth.
5. Use an oxy–acetylene torch with a tip size of 81
No.2 maximum, and direct the flame against the
internal face of the gear.
6. Quickly place the hot gear on the flywheel, with
flat face against the shoulder on the flywheel.
The gear to flywheel runout should be checked
using a dial indicator and should not exceed a
Total Indicator Reading of 0.63mm (0.025 in).

Installation
1. Clean the crankshaft rear flange and mating
surface of the flywheel. Install the flywheel,
torquing the bolts to, 197Nm (145 lbf ft).

604.55.111.00 – 06 – 2002
46 SECTION 10 – ENGINE – CHAPTER 2

REAR COVER PLATE (OP. 10 102)

1
Removal 11 9
1. To gain access to the engine oil pump, camshaft
2 5
gear, or end of crankshaft remove the oil pan and
flywheel as previously described. 3

2. Remove the 12 attaching bolts, and gently pry off 4

cover plate (1),
6 1
3. Clean off all sealer, remove crankshaft oil seal, 8
and check for damage or distortion around the
sealing faces. 10 12

P396–E–54 TI
82
Installation
1
1. Install new gasket and rear plate, tightening the
retaining bolts (2) and (3) finger tight, Figure 82.
2. Apply a liberal coating of new engine oil on a new
oil seal. and position the rear seal over the end
of the crankshaft. Locate tool, No 297252 (1),
Figure 83, on the end of the crankshaft using the
three attaching bolts. Tighten evenly, and
squarely, until the seal is fully seated.
As an alternative the rear crankshaft oil seal can be
installed using the following installation tool.

TA6010054
83
3. Apply a liberal coating of clean engine oil to the
rear seal retainer, seal, and journal. A new seal 1
should be mounted on the crankshaft, then bolt
tool 297194, (1), Figure 84, to the crankshaft
end and install the new seal squarely.
4. Secure centre stock of tool to crankshaft flange
with two screws. Assemble cylinder end plate to
centre stock and secure with nut and washer as
in, Figure 84. Tighten the nut until outer diameter
of tool abuts retainer. Tool must not be over
tightened as stress and distortion could be
imposed on the retainer.
TA6010055
84
5. Remove the tool after assembly.
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 1.52mm (0.060 in) further in.

TA6010056
85

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 47

6. Place a straight edge along the rear of the engine

block above the seal carrier. Ensure the edge of
the carrier is aligned to the block to within
0.15mm, protruding or 0.22mm recessed. If not
within this specification orientate the carrier
around the slotted bolts (2) and (3) Figure 82. +0.15
Hand tighten this bolt followed by the remaining –0.22
bolts and ensure the carrier is still correctly
aligned. Fully tighten the twelve bolts, in
sequence to 11–14Nm (8–10lbf ft) and then
16–23Nm (12–17 lbf ft), Figure 82.

86
7. Place a dial indicator, on the end of the
crankshaft and ensure seal runout is within
0.51mm (0.020 in) Total Indicator Reading.
8. Refit the oil pan.

TA6010056
87

OIL PUMP (OP. 10 102)

Removal
NOTE: The oil pump can only be removed with the
engine split from the transmission and the flywheel,
back plate, engine oil pan, and oil pump tube
removed.
1. Prior to pump removal check pump gear to
camshaft gear backlash does not
exceed, 0.40–0.56mm (0.016–0.022 in). TA6010057
88
2. Loosen and remove the camshaft gear, to
expose the oil pump, detach the 3 pump
mounting bolts, and withdraw the pump from the
block.

TA6010058
89

604.55.111.00 – 06 – 2002
48 SECTION 10 – ENGINE – CHAPTER 2

Disassembly
1. Loosen and remove the pump face plate to body
bolts, 4 off. Disassemble the pump and discard
the O–rings.

TA6010059

90
Inspection and Repair
1. Wash all parts in a suitable solvent and inspect
inside of pump plate, and body, for excessive
wear or damage. If visually okay check in the
following manner.
2. Invert pump plate/rotor assembly, and place
outer rotor over inner rotor. Placing a ruler across
top of both, slide a feeler gauge, between ruler
and inner rotor and measure clearance which
must be 0.025–0.089 mm (0.001–0.0035 in),
Figure 91.

TA6010060
91
3. Place outer rotor in pump body and check
clearance, by inserting a feeler gauge between
the rotor and body. Check clearance does not
exceed a maximum of 0.55mm (0.022 in). If
exceeded a new pump is required.
NOTE: If not to specification replace the oil pump, as
reduced pump pressure through wear could result in
reduced engine life.

TA6010061
92
Installation 1
1. Clean and coat parts in new engine oil. Place
outer rotor in pump body, and ensure free
rotation. Insert inner rotor, and pump plate
assembly, into the body and ensure that shaft is
fully seated into bushing.
2. Assemble the front plate to the body
and torque the retaining bolts to, 23.0–28.4Nm
(17–21 lbf.ft).
NOTE: After tightening ensure the drive gear rotates
freely by hand, at least 5 revolutions, if not 2
‘‘disassemble” and repeat the exercise.
TA6010059
93

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 49

3. Fit a new O–Ring, item 1, Figure 93, to the

output tube, lubricate and insert the pump into
the block tightening the bolts to 23.0 – 28.4 Nm
(17–21lbf ft).
4. Fit a new O–Ring, item 2 Figure 93, into the
suction port. Lubricate and insert tube/screen
assembly(2) into pump(1) through bottom of
engine. Fitting a new gasket (4), and torque the
attaching bolts (3), Figure 95, to,
27–34N m (20–25 lbf ft).

TA6010058
94
NOTE: Plug item 5, in Figure 95, is factory installed
to facilitate machining, and should not be removed
during the life of the engine. 1
5. Refit gears as previously described along with
the rear plate, and flywheel.

5
2
4

3
TA6010062
95
OIL PRESSURE RELIEF VALVE

Removal
1. Remove plug (3), spring (2) and valve (1) To
ensure correct operation of the pressure relief 3
valve, check spring length,
Free length = 52.8mm (2.08 in).
Compressed length = 37.0mm (1.46 in) using a
weight of 15.6 kgs (34.3 lbs).
2. Clean assembly in a suitable solvent and ensure
all ports are free of dirt. 3
3. Check the parts for damage, wear, and replace
as necessary. Failure to do so could result in
premature wear to the engine, due to oil 1
bypassing the filter and returning back to the
system. 396–E–18 2 TI
96
Installation
1. Lubricate the pressure relief valve(1) and
spring(2) and insert into housing, ensuring free
movement.
Fit a new O–Ring to plug (3) and torque to,
55N m (42 lbf ft)..

604.55.111.00 – 06 – 2002
50 SECTION 10 – ENGINE – CHAPTER 2

CAMSHAFT (OP. 10 106)

1
Removal
NOTE: The camshaft bearings and tappets can only
be serviced with engine removed from the vehicle.
1. Remove the engine front cover, and cylinder
head.
2. Check the camshaft end play, see timing gears
section, and remove gear, install a new thrust
plate prior to re–assembly if required.
3. After removal of the flywheel, and rear cover,
remove the camshaft oil pump drive gear (1). TA6010057
97
4. Invert the engine on the stand, if camshaft
bearings are to be replaced, and remove the oil
pan.
5. Carefully withdraw the camshaft from the front of
engine.

396–E–16 TI
98
6. Lift out the tappets and place in a numbered rack
for reassembly.

Inspection and Repair

1. Inspect the camshaft journals, lobes, for
damage, pitting, or heat discolouration. If any of
these conditions exist install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage is apparent fit new
gears.
3. Check each tappet for wear or damage and
check diameters, if not to specification renew, 396–E–23 TI
25.113–25.131mm (0.99887–0.9894 in). 99
4. Measure the diameter and out–of–round
condition of bearing journals, if exceeded fit a
new camshaft,
60.642–60.668mm (2.3875–2.3885 in).

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 51

CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or
damage. Measure the clearance between the
internal diameter of bearing and outside
diameter of respective journal,
0.074–0.178mm (0.003–0.007 in).
2. If specification is exceeded install new bearings
using, Remover/Replacer Tool No 297117 and
handle, Tool No 291896.
3. To remove, position tool against bearing to be
removed and attach handle, driving bearing from
bore.
TA6010071
4. To install, align oil holes of new bearing with holes
in block, and drive bearing into bore using tools 100
as described.
NOTE: A positive alignment check can only be made
with crankshaft removed when a 4.6mm (0.018 in)
rod can be passed down the oil passage from the
crankshaft main bearing. Bearing is correctly
positioned when end of rod passes through oil hole
in the bearing.
Installation
1. Apply petroleum jelly to each tappet foot, and
coat tappet body with oil. Install tappets in bores
from which they were removed.

396–E–23 TI
101
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes.
3. Install camshaft through front of engine.

396–E–16 TI
102

604.55.111.00 – 06 – 2002
52 SECTION 10 – ENGINE – CHAPTER 2

4. Align the camshaft gear timing mark. Recheck

end play.

..
..

P396–E–36 TI
103
5. Install camshaft pump drive gear at rear of
engine. Tighten bolt to torque of 57–77Nm
(43–58lbf ft).

104

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 53

PISTONS (OP. 10 105)

Removal
NOTE: The pistons, crankshaft and cylinder block
can only be serviced with the engine removed from
the vehicle.See Chapter 1.
1. Remove the oil pan
2. With cylinder head removed clean off any ridge
from the top of the cylinder bores, with a ridge
remover to enable removal of the pistons, this is
essential if old pistons are to be re–used as
failure to do so could result in ring land damage.
105
3. With the piston at the bottom of the stroke
remove the end cap bolts, cap, and liner.

TA6010033
106
4. Using the handle end of a hammer push the
piston assembly out through the top of the block,
and remove the bearing liner from the connecting
rod, Fig. 106.
NOTE: Bearing caps and liners must be kept with
their respective connecting rods.
5. Turn the crankshaft again and repeat the
process for the remaining pistons.

107
Inspection and Repair
1. Remove piston pin snap rings from each side of
piston and remove pin. Using an expander, Tool
No.296028, remove the piston rings.
2. Ensure each piston and rod assembly, remains
matched together for re–assembly into the
cylinder block.

TA6010034
108

604.55.111.00 – 06 – 2002
54 SECTION 10 – ENGINE – CHAPTER 2

109
Piston Assembly
1. Con Rod 7. Piston Ring (Oil Control)
2. Piston 8. Bolt
3. Piston Pin 9. Bearing Cap
4. Retainer 10. Bearing Liner
5. Piston Ring (Compression) 11. Bearing Liner
6. Piston Ring (Compression) 12. Bush

3. Clean the piston, and connecting rod assembly, Measure the outside diameter of the piston pin, and
in a suitable solvent and inspect for damage to inside diameter of the connecting rod bushing, to the
ring lands, skirts, or pin bosses. following:–
4. Check connecting rod components for damage,
and place in an alignment fixture to check for Piston Pin Outside Diameter
distortion, and ensure that any distortion, is 41.270–41.275mm (1.6248–1.6250 in)
within specification as follows.
Maximum Twist 0.30mm (0.012 in). Connecting Rod Bush internal Diameter
Maximum Bend 0.10mm (0.004 in). 44.460–44.467mm (1.750–1.751 in)
5. Check piston pin bushing for damage or wear in
the following manner.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 55

CONNECTING ROD BUSH REPLACEMENT

1. If connecting rod bushes are not to specification
replace the old bush using using the following
procedure.
2. Place the connecting rod securely in a bench
press. Manufacture from suitable bar stock, a
press tool with the end face ground at an angle,
to suit the connecting rod bush side face.
Position the tool on the bush, and gently drive the
bush from its position. It is recommended a guide
is manufactured to assist alignment of the bar
stock during this operation.
3. A new bush can then be fitted in a similar manner,
by using a suitable piece of bar stock, with an end
face machined flat to suit the standard parallel
bush. Use a guide as described, and gently drive
in the new bush into the connecting rod.
NOTE: Ensure the split in the small end bush is at
right angles to centre line of connecting rod.

6010035
110
4. After installation grind the side faces of the new
bush to match the side faces of the connecting
rod. Ensure all sharp edges are removed, and
loose chippings are cleaned from the connecting
rod before re–assembly into the engine.
5. With a new bush fitted drill a hole through the top
of the connecting rod using a 4.6mm (0.187 in)
bit. Drill through the existing oil hole, Figure 111.

TA6010036
111
6. Use an expanding reamer to obtain correct
bushing to piston pin clearance referring to
specification section. Remove burrs, and
chippings, before refitting.
7. On re–assembly of piston lubricate all of the
components with engine oil. Assemble the
connecting rod, and piston, with the letter or
grade mark on the piston, aligned to the pip (1),
Figure 112 , on the connecting rod. Install the
piston pin and retainers.

TA6010045
112

604.55.111.00 – 06 – 2002
56 SECTION 10 – ENGINE – CHAPTER 2

CYLINDER BLOCK OVERHAUL.

(Op. 10 105)

T A6010038
3 2 1

113
Cylinder Block Core Plug and Sensor Ports, Front and Left Hand Side

3 1
4 5

2
T A6010039
114
Cylinder Block Core Plug and Sensor Ports, Rear and Right Hand Side
1. Cylinder block plugs, and senders, require Plug (4) drive in to block. Use sealant G.
changing if leaking or rusty, and must be Figure 114, refers to the rear and right hand side of
replaced. Clean the old sealant off the block, and the block.
fit new plugs with sealer.
Pipe plug (1) torque to 8–14N m (6–10 lbf ft).
Figure 113, refers to the front and left hand side of Use sealant, E.
the cylinder block.
Pipe plug (2) torque to 24–34N m (18–25 lbf ft).
NOTE: New part mating faces, and threads, should Use sealant, E.
be coated in sealant, refer to ‘‘Specifications”.
Plug (3) drive into block.
Assemble in the following manner.
Use sealant, G.
Plug (1) torque to 8–14N m (6–10 lbf.ft)
Plug (4) torque to 54–81N m (40–60 lbf ft), Use
Use sealant, E.
sealant, E.
Plug (2) torque 27–47Nm (20–35 lbf ft)
Oil Jets (5) replace with new if damaged, apply
Use sealant, E.
engine oil only on re–assembly ‘‘Do not use sealant”.
Pipe Plug (3) torque to 24–34N m (18–25 lbf ft)
Use sealant, E.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 57

CYLINDER BORE
1. Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can be
felt by running a finger over the surface. To check
out–of–roundness, wear, or taper, use a
telescopic gauge, Figure 115.
Measure lengthwise,
A, to B, and C, to D, and compare dimensions.
Variances 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.
TA6010040
115
Specifications C
NOTE: Repair Limit’ refers to the tolerance allowed
after a repair has been performed, i.e. the repair A
must be within the repair limit. The ‘Wear Limit’ is the
tolerance prior to repair.
Taper of cylinder bore,
repair limit– 0.025mm (0.001 in)
wear limit – 0.127mm (0.005 in)
Cylinder bore out of round,
repair limit – 0.03mm (0.0015 in) B
wear limit– 0.127mm (0.005 in)
Cylinder bore diameter, D
TA6010041
111.778–111.803mm (4.4007–4.4017 in).
116
1. Where only minor imperfections exist and bores
are to specification, hone the bores prior to
installing new piston rings. Provided piston to
bore clearance, does not exceed 0.250mm
(0.011 in).
2. Sleeving of the cylinder bores becomes
expedient when.:–
Minor imperfections to the bores are outside of
the specification.
Oil consumption is high.
Replacing sleeves, installed in service.
Cylinder bore is damaged beyond re–boring
limits.
NOTE: Oversize pistons are available in specific
markets only. In markets where these are available
the bore should be bored or honed to fit the next
oversize piston.
Oversize pistons available:
0.020in ((0.51 mm)
0.040in ((1.00 mm)

604.55.111.00 – 06 – 2002
58 SECTION 10 – ENGINE – CHAPTER 2

SLEEVING – BORING AND HONING 0.005

0.06
45°
0.040
3. Measure the outside diameter (1) of the sleeve
in several places, and average the dimension.
Counter bore the cylinder block (see step 2)
using the average dimension to obtain a press fit, 8.31

between bore and sleeve. Interference of sleeve

8.46 8.06
to the cylinder bore to be 0.025–0.076mm
(0.001–0.003 in).
4. Counter bore to a depth of 204.7mm (8.06 in), 0.38
0.40
from the block face, surface finish of the bore is
not to exceed (80 microns). Leave a step at the 4.454/4.456

bottom of the bore a minimum of 9.60–10.16mm

1
(0.38–0.400 in), allowing for run out of chamfers. TA6010042

5. Bore through diameter, to the diameter of, 117

114.3–116.0mm (4.454–4.456 in).
6. Clean the cylinder bores and thoroughly dry.
7. Grease the sleeve with a general purpose
grease and press the sleeve home to the lip in the
bore. The top of the sleeve should protrude
through the top of the block,
0.127–1.0mm (0.005–0.040 in).
8. Bore the sleeve to,
110.00–111.76mm (4.3985–4.400 in).
9. Skim the block face, and top of sleeves, to
achieve the specified flatness of
0.08mm (0.003 in) in any 152mm (6 in)
0.03mm (0.001 in) in any 25.4mm (1 in).
A chamfer in the internal diameter at the top of
the sleeve to 45° x 0.5mm (0.020 in) should be
maintained, to prevent piston damage on
re–assembly.
10. Break the sharp edge at the bottom of the sleeve
prior to honing.
11. Hone the cylinder bore to,
Grade B, 111.790–111.803mm
(4.4012–4.4017 in.)
NOTE: Surface finish to be an average of 20 to 30
Microns, cross hatched at 355–555.
Maximum Taper,
0.025mm (0.001 in) through to bottom of the bore.
Maximum Ovality,
0.038mm (0.0015 in)

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 59

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
Centre, ensure the piston to block height is
correct using a dial indicator to, Figure 118.
0.13–0.38mm (0.005–0.015 in)

TA6010043
118
2. Check the piston to bore clearance in the
following manner.
A, Measure the cylinder bore diameter at point A,
82.6mm (3.25 in.) from the top of the block. A
B, Measure the diameter of the piston at point B,
25.4mm (1.00in) from the bottom of the piston.
C, Subtract piston diameter from the bore diameter
and the resultant figure for a new, unused engine
should be,
B
0.152–0.178mm (0.0060–0.0070 in)
TA6010044
119
After an engine has run and settled down the
maximum bore to piston clearance allowed is
0.250mm. (0.011in).
Where pistons are only available as standard.
New pistons should always be fitted if the
clearance exceeds specification.
D, If clearance is ‘‘greater” try a similar new
piston, if limit is still exceeded it will be necessary
to rebore and resleeve.
E, If the clearance is ‘‘less” hone bore to obtain
desired clearance.
3. Lubricate all of the components with engine oil TA6010045
and assemble the connecting rod, and piston,
with the letter or grade mark on the piston, 120
aligned to the pip (1) on the connecting rod.
Install the piston pin and retainers.

604.55.111.00 – 06 – 2002
60 SECTION 10 – ENGINE – CHAPTER 2

4. Check the piston ring gap width, using a feeler

gauge, in a vertical position at the top, middle,
and bottom of the bore, Figure 121.
Ring Gap Specifications(new rings and bore):
Top compression ring
0.29–0.53mm (0.012–0.021in),

2nd compression ring

0.49–0.63mm (0.020–0.029 in),

Oil control ring.

0.29–0.58mm (0.012–0.023in),
TA6010046
121
5. Using a new piston ring, check with a feeler
gauge, the gap between the ring and groove.
2nd compression ring – .
0.12–0.075 mm (0.005 – 0.003 in),
Oil control ring
0.07–0.03 mm (0.003–0.001in),.
6. Install the piston rings, but note the following:

6010048
122
7. Always ensure the correct expander, Tool
No.296028, is used to remove or install rings,
Figure 122.

6010047
123
8. Install top and second compression rings with
the word top towards the top of the piston.
Ensure the ring gaps are staggered a minimum
of 120° from each other on the diameter, and with
no gap on the thrust side of the piston.
NOTE: Before installing new pistons and rings into
a used cylinder bore, remove the high polish from the
cylinder walls by honing as previously described.

124

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 61

INSTALLING PISTON ASSEMBLY INTO

BLOCK
1. Select the correct bearing liners as in the
following crankshaft section, and install in the rod
and cap, ensure the liner tang locates in the slots
of the rod and cap.
2. Turn the crankshaft to position No 1 crankpin at
the bottom of the stroke, and lubricate all parts
with new engine oil.
3. Locate piston into bore ensuring the dot on the
connecting rod and arrow or grade letter on the
pistons face towards the front of the engine.

125
4. Using ring compressor, Tool No.296042, and a
soft drive, slide pistons into bores

6010050
126
5. Ensure the connecting rod bearing liner, seats on
the crankpin with the bearing cap fitted, to the
connecting rod as a matched assembly. Fit new
bolts lubricated with oil, and tighten to a torque
value of 149 Nm (15 Kgf m, 110 lbf ft)
6. Using feeler gauges, check the side clearance of
each connecting rod to crankshaft, Figure 127,
0.13–0.33mm (0.005–0.013 in) and continue for
remaining assemblies.
7. Refit the oil pump tube/screen,and oil pan as
previously described, refill engine oil and
coolant, and run the engine checking for leaks.
TA6010051
127

604.55.111.00 – 06 – 2002
62 SECTION 10 – ENGINE – CHAPTER 2

CRANKSHAFT (OP. 10 103)

Removal
1. Remove the engine, flywheel and oil pan as
previously described.
2. Remove the connecting rod caps, main bearing
caps and liners, and identify to facilitate
re–assembly.

396–E–13 TI
128
3. Carefully remove crankshaft from cylinder block.

6010065
129
Inspection and Repair
NOTE: Current production engines may have a
crankshaft with main or crankpin journals ground
0.010 in (0.25mm) undersize. These are identified
with the letters 010 MUS and/or 010 PUS
respectively, letters being stamped on one of the
crankshaft counter balance weights.
1. Thoroughly clean bearings, journals, and caps,
and inspect for wear, scores, or damage replace
as required.
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.
130
2. If crankshaft timing gear teeth are worn or
damaged it will be necessary to replace the
complete crankshaft assembly.

131

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 63

3. Wash the crankshaft and drilled passages in a

suitable solvent. Dress minor imperfections
using an oil stone but for severely marked
journals machine to the next undersize bearing
size.
4. Measure diameter of each journal, Figure 132,
in four places to determine out–of–round, taper, B
or wear. A D
Measuring, A, compared with B, indicates C
vertical taper.
Measuring, C, compared with D, indicates
horizontal taper.
Measuring, A and B, compared with C and D, TA6010067
indicates journal out–of–round.
132
5. If the journal exceeds specified limits refer to
‘‘specifications” and refinish journal to the next
undersize bearing.
6. Examine the rear oil seal journal for score marks,
remove minor imperfections with fine emery
cloth, and if severely damaged renew the
crankshaft.
Re–Assembly
1. Check the crankshaft bearing clearance using a
plastigauge as follows.
2. Position a piece of correct size plastigauge
across the full width of the bearing cap,
approximately 6.35mm (0.25 in) off centre,
Figure 133.

TA6010068
133
3. Install the cap and tighten bolts to 149Nm
(110 lbf ft).
4. Remove the cap and use the scale to check the
width of the flattened plastigauge, Figure 133.
5. Widest point, of gauge establishes the minimum
clearance.
6. Narrowest point, of gauge establishes maximum
clearance. The difference between the two
readings is the taper.
NOTE: Normally main bearing journals wear evenly
and will not be out–of–round, but if a bearing which
is to specification is fitted to an out–of round journal,
6010069
ensure liner suits maximum diameter of journal.
134

604.55.111.00 – 06 – 2002
64 SECTION 10 – ENGINE – CHAPTER 2

7. If the combinations of bearings do not produce

specified clearance, refinish crankshaft and fit
appropriate size service bearings.
IMPORTANT: Engines may be assembled with
bearings of different material, but bearings of the
same material must be used on the same journal.
8. Ensure bearing liners are clean and align with the
oil galleries and integral oil jets. The tang on the
bearing must align with the slots in the block and
cap.

396–E–26 TI
135
9. Coat liners with oil and install crankshaft

6010065
136
10. Install a thrust bearing cap with flange type
bearing first, installing remaining bearing caps to
their original location and tightening finger tight.

396–E–9 TI
137
11. Tighten the main bearing caps in two stages:

Stage 1, tighten all bolts to a torque of 81Nm 81

(60lbf.ft) 60

138

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 65

Stage 2, using a torque angle gauge tighten all

bolts a further 90° in a single stroke.
12. Check crankshaft end play with a dial indicator
gauge, pry crankshaft towards front of engine
and set dial indicator to zero. Pry crankshaft
towards rear of engine and note reading on dial
if end play exceeds 0.10–0.20mm
(0.004–0.008 in) fit a new thrust bearing.

139
13. If the end play is less than specification check
thrust bearing for burrs, scratches, or dirt, and
re–align thrust bearing as in operation 12.
14. Install rear crankshaft oil seal as previously
described in rear cover plate removal.
NOTE: Do not pre–install seal into retainer. To
ensure seal concentricity, it must be assembled with
rear plate and installation tool when fitted to
crankshaft.

TA6010070
1
15. Install the camshaft idler gear ensuring the timing
marks are correctly alligned.

604.55.111.00 – 06 – 2002
66 SECTION 10 – ENGINE – CHAPTER 2

Front Seal Installation(OP.10 003)

1. The front oil seal should be replaced every time
the front plate is removed. Drive out the old seal
using a punch taking care not to damage the front
plate.
2. Thoroughly clean the mating surfaces between
the cover and plate using a suitable solvent
cleaner and carefully apply a thin bead, approxi-
mately 2mm, of the recommended flexible
gasket sealant, Type ‘L’, to the front plate. As-
semble the plate to the cover and tighten the re-
taining bolts to a torque of 37Nm, 28lbf.ft.

3
3. Lubricate the new seal (1) and place onto the
seal installer tool, (3), NH.10–103, ensuring the
tool shim (2) is installed.
4. Locate tool onto crankshaft. Screw bolt into end
of crankshaft and slowly turn the nut to install
seal. Continue turning nut until face of tool (3) Al-
most Touches face of front timing cover (4).
IMPORTANT: Use the minimum of effort when turn-
ing nut and DO NOT force tool against face of front
cover.

4
5. Lubricate the crankshaft, fitting a new ‘O’ ring(1)
first, slide the pulley spacer(2) over the key(4).
Place pulley(3), Figure 5, onto the crankshaft.
Install tool No.938 to push the crankshaft pulley
onto the crankshaft. Tighten the securing bolt to,
284Nm (210 lbf ft).

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 67

ENGINE COMPRESSION TEST TEST READINGS

(OP. 10 001) 1. All cylinder compressions should be uniformly
within 25 lbf in2 (1.7 bar) of each other.
TEST PROCEDURE 2. A reading of more than the 25 lbf in2 (1.7 bar)
1. Be sure battery performance meets below the other cylinders indicates leakage at
specifications. the cylinder head gasket, piston rings or valves.
2. Warm up the engine by operating for a minimum 3. A reading of more than 25 lbf in2 (1.7 bar) above
of half an hour at 1200 rev / min. the other cylinders indicates excessive carbon
deposits on the piston and cylinder head.
3. Stop the engine and remove the injector and seat
washer from no1 cylinder. 4. A low even compression in two adjacent
cylinders indicates a cylinder head gasket leak.
4. Clean the injector bore and crank the engine to
blow out any loose carbon particles. Check this item before condemning the rings or
valves.
5. Install an engine compression test gauge, From
kit No.291309 with fault injector 295039, into the
TEST CONCLUSION
injector bore, using a new seat washer and the
injector mounting bolts. To determine whether the rings or the valves are at
fault, squirt the equivalent of a tablespoon of heavy
6. Connect the gauge and hose to the adapter.
oil into the combustion chamber. Crank the engine to
7. Crank the engine at 200 rev/min with the electric distribute the oil and repeat the compression test.
fuel shut off wire disconnected to prevent engine
The oil will temporarily seal any leakage past the
start up.
rings. If approximately the same reading is obtained,
NOTE: On models with Electronic Injection pumps the rings are satisfactory, but the valves are leaking.
disconnect the main harness from pump. When
If compression has increased over the original
re–connecting harness after test there may be error
reading, there is leakage past the rings.
codes shown on the instrument panel. Refer to
Section 55 to clear these codes through the ‘H‘ During a compression test, if the pressure fails to
menu mode. climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
8. Observe the gauge reading, and repeat the
succeeding strokes, or fails to climb during the entire
compression test, steps 5–7 for each cylinder.
test, suspect a sticking valve.

604.55.111.00 – 06 – 2002
68 SECTION 10 – ENGINE – CHAPTER 2

DESCRIPTION OF OPERATION

COOLING SYSTEM
(CNH 7.5 litre Engine)
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 en-
sure correct engine temperature and performance
during vehicle operation.

The water pump, is driven by a Poly V-belt, from the

crankshaft pulley when the engine is running. The
drive belt tension is maintained by a spring-loaded
belt tensioner bolted to the front cover.

The thermostats are located in the top of the housing

above the water pump body and control the flow of
the water as required by temperature changes.

NOTE: A faulty thermostat may cause the engine to

operate at a too hot or too cold operating tempera-
ture. If not replaced, this could result in damage to
the engine or impaired engine performance.

IMPORTANT: Do not operate an engine without

a thermostat.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 69

The cooling system is of the recirculating bypass

type with full-length water jackets for each cylinder.
The coolant is drawn from the bottom of the radiator
by the water pump which passes the coolant to the
cylinder block. The coolant then flows through cored
passages to cool the cylinder walls.

NOTE: These engines are also fitted with an oil

cooler in the circuit. Coolant from the radiator passes
through the oil cooler before entering the cylinder
block.

Passages in the cylinder head gasket allow coolant

to flow from the cylinder block into the cylinder head.
Cored passages also direct the coolant to the fuel in-
jector nozzle locations before entering the thermo-
stat housing. Dependent upon water temperature,
water either re–enters the water pump or is circu-
lated through the radiator for cooling.

When the thermostat is closed, a recirculating by-

pass allows the coolant to recirculate from the head
to the block, to effect faster warm-up.

10

Once the engine has reached its normal operating

temperature, the thermostat will open and allow wa-
ter to be drawn through the radiator by the pump ac-
tion. Cooled water then returns to the engine system.

Cooling occurs as the coolant passes down through

the radiator cores which are exposed to the cooling
system. Air is pushed through the radiator by means
of a visctronic fan situated between the radiator and
engine block. High pressure created in the front of
the radiator pushes air through the full area of the ra-
diator core producing a highly efficient cooling sys-
tem. TA6010091
11

604.55.111.00 – 06 – 2002
70 SECTION 10 – ENGINE – CHAPTER 2

TROUBLESHOOTING1.
IMPORTANT: Whenever effecting a repair, the cause of the problem must be identified and corrected to avoid
repeat failures. The following table lists problems and their possible causes with recommended remedial action.

PROBLEM POSSIBLE CAUSES CORRECTION

Engine overheats Hose connection leaking or Tighten hose connection
collapsed Replace hose if damaged
Radiator cap defective or Replace radiator cap
not sealing
Radiator leakage Repair/replace radiator
Improper fan belt adjustment Check tensioner
Check belt
Radiator fins restricted Clean with compressed air
Faulty thermostat Replace thermostat
Internal engine leakage Check for source of leakage,
replace gasket or defective parts
Water pump faulty Overhaul water pump
Exhaust gas leakage into Replace cylinder head gasket,
cooling system check head for damage or
distortion
Coolant aeration Tighten all connections and
check coolant level is correct.
Ensure cylinder head gasket is
not blown
Cylinder head gasket Replace cylinder head gasket
improperly installed
Hot spot due to rust and Reverse flush the entire
scale or clogged water jackets cooling system

Obstruction to radiator Remove the obstruction

air flow
Extended engine idling Do not allow the engine to
idle for too long a period
Oil cooler tube blocked Clean
Radiator core tubes blocked Check free flow
Water temperature gauge Faulty temperature sender Replace sender switch
fails to reach normal
operating temperature Incorrect or faulty thermostat Replace thermostat
Faulty water temperature gauge Replace temperature gauge

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 71

SPECIFICATIONS
TIGHTENING TORQUES
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm . . . . . . . . Ft.lbs

Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . 20 ........... 15

Temperature senders . . . . . . . . . . . . . . . . . . . . . . 15 ........... 20
Tensioner pulley bolt . . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Tensioner front cover . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Idler pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Pump connector to block . . . . . . . . . . . . . . . . . . . 18 ........... 24
Water pump to block . . . . . . . . . . . . . . . . . . . . . . . 48 ........... 65
Fan blade to support body . . . . . . . . . . . . . . . . . . 17 ........... 23
Fan blade to clutch support body . . . . . . . . . . . . 78 ........... 105

THERMOSTAT
Opening temperature . . . . . . . . . . . . . . . . . . . . . . 174° F - 181° F (79° C - 83° C)
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199° F - 205° F (93° C - 96° C)

WATER PUMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal . . . . . Poly V-belt drive

DRIVE BELT
Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintained by tensioner

COOLING CAPACITIES
See Operators Manual

COOLANT FLOW
Coolant flow at rated engine speed . . . . . . 340.6 L/min (90 US g/pm)

COOLING FLUID
See Operators Manual.

604.55.111.00 – 06 – 2002
72 SECTION 10 – ENGINE – CHAPTER 2

COOLING SYSTEM
Radiator Removal (Op 10 406)
1
1. Lift the engine hood.
2. Close the cab heater hose tap, situated to the
rear of the right hand side of the engine, (1)
Figure 1 and turn the heater control knob in the
cab to the coldest setting.
3. Attached to the front of the radiator by means of
‘‘D” handle bolts, on the right hand side, is the
transmission oil cooler radiator and the
air–conditioning condenser (when fitted).

1
4. Loosen the ‘‘D” bolts (1) of the transmission oil
cooler (2) and slide out, placing it carefully out of
the way with the hoses still attached. Repeat this
procedure for the air conditioner condenser (3).
This is important where air conditioning is fitted,
as refrigerant could be lost if hoses are
disconnected from the condenser.
5. Place a suitable container under the tractor.
Loosen the radiator lower hose at the base of the
radiator and drain the coolant off. Remove the
radiator cap to speed up the draining, using
caution if the system is hot.

2
WARNING
Do not allow anti–freeze to contact skin. Adhere to
instructions detailed on anti–freeze container.

6. Disconnect the radiator top hose, and oil cooler

pipes in the lower part of the radiator.
7. Loosen the jubilee clips holding the charge air
cooler tubes in place and remove tubes to the
turbocharger and inlet manifold.
8. Loosen the fan shroud screws, (1) Figure 4 ,
placing the fan shroud behind the fan blade.
9. Remove the two bolts securing the radiator to the
front support. Ensuring all pipes are 3
disconnected, and looms are unclipped, and
away from the radiator assembly. Lift the radiator
up and clear of the vehicle.
1

TA6010005
4

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 73

Inspection and Repair

10. Inspect the fins for damage and repair as
required, ensuring they are free from any
obstruction.
11. Check the radiator for leaks, and repair as
required. The radiator is fitted with an engine oil
heat exchanger in the lower tank which should be
checked for leaks. If the lower tank is found to be
leaking replace the radiator.

Installation
Installation of the radiator follows the removal proce-
dure in reverse, but upon installation observe the fol-
lowing requirements.
1. Ensure the correct grade, and quantity of
antifreeze is added to the coolant.
Recommended content mixture is 50% Water,
with 50% New holland Antifreeze.
NOTE: It is necessary to replace the filter/condi-
tioner if the cooling system is drained or a large water
loss has occured, to ensure maximum engine
protection is maintained.
2. Refill the system through the radiator pressure
cap until completely full. Re–install the
14.5 lb/in2 (1 bar) radiator cap and continue
filling through the expansion tank until the
coolant is seen through the sight glass. Refit
expansion cap, Figure 5.
3. If engine oil cooler tubes have been disturbed
check the engine oil level.
4. Run the engine for several minutes checking for
leaks, topping up any fluid levels that may have
settled during testing.

TA6010088
5

604.55.111.00 – 06 – 2002
74 SECTION 10 – ENGINE – CHAPTER 2

Thermostat Removal
(Op 10 402)
1. Drain the coolant system below that of the level 1
of the thermostat housing. Where a cab is fitted,
shut off heater hose tap, (1) Figure 6 and turn the
heater control knob in the cab down to the
coldest setting.
2. Remove the thermostat housing retaining bolts
and move the housing with tube attached to one
side.

6
3. Withdraw the thermostat from the housing, along
with the gasket, Figure 7.

Inspection and Repair

1. Place the thermostat in a container of water, and
raise the temperature to 212°F (100°C). If the
thermostat fails to open when hot, or close
properly when cooled, it must be replaced,
Figure 8.

TA6010089
7
Installation
Installation of the thermostat is the reverse of the re-
moval procedure but observing the following.
1. Coat a new gasket with sealer and position in the
recess on the thermostat housing, prior to
installing the thermostat.
2. Coat the edge of the thermostat with grease and
install, with the heat element located in the
cylinder head.
3. Refit the thermostat housing and torque the bolts
to 20–28Nm (15–21 lbf.ft).
RI–1–107 TI
8

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 75

Temperature Warning Sender

1. The temperature sender for the gauge is located
on the left hand side of the thermostat housing,
Figure 9.

Installation
1. If the sender is suspected of being faulty refer to
the ‘‘Electrical System” section to correctly
diagnose the fault. If a new sender is to be fitted
apply sealant to the threaded portion of the new
sender body and torque the sender to,
16–24Nm (12–18 lbf.ft).
TA6010090
9
Visctronic Fan Assembly Clutch Testing
Where it is suspected that the viscous clutch is not
operating correctly, it should be tested as follows:–
1. Using an electronic stroboscopic rev/min.
counting device, determine the engaged speed
of the fan while operating the engine at approx.
1800 rev/min. with the engine coolant
temperature above the normal operating range.
2. If the fan speed is less than 85% of the fan pulley
speed then the unit is not operating correctly and
should be replaced. The following table gives an
example of calculating the percentage: TA6010091
Observed fan speed = 2600 rev/min
10
Engine speed = 1800 rev/min
Pulley ratio = 1.59:1
Fan pulley speed = 1.59x1800=2862
Percentage = 2600x100 = 90.84%
2862

Visctronic Fan Assembly Removal

(Op 10 414)
1. To remove the fan and clutch assembly ,
disconnect the visctronic fan sensor harness.
Hold the pump pulley in a fixed position. Placing
an open ended spanner on the nut to the rear of
the clutch assembly spacer, undo the nut in a
clockwise direction.
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. Figure
11.

11
Installation
1. On re–assembly of the fan assembly tighten the
attaching nut in an anti–clockwise direction, and
torque to, 54 Nm (40 lbf.ft).
2. Reconnect the visctronic fan sensor harness.

604.55.111.00 – 06 – 2002
76 SECTION 10 – ENGINE – CHAPTER 2

8
1
7

4 3
TA6010093A TA6010093B
12
Fan Belt Tensioner
A. Fan Belt Less Air Conditioning B. Fan Belt With Air Conditioning
1. Water Pump Pulley 5. Tensioner Attaching Bolt
2. Air Conditioning Compressor 6. 1/2in.Square Drive Hole
3. Crankshaft Pulley 7. Alternator
4. Tensioner Pulley 8. Idler Pulley with Air Conditioning Only
Fan Blade Removal Inspection and Repair
(Op 10 414) 1. Checking of the tensioner assembly operation
1. Remove the visctronic fan clutch assembly as should be carried out, with the tensioner
described above. Remove the six nuts retaining assembly still attached to the front cover. To
the fan blade to the viscous unit and remove the check the spring load, place a ‘‘break back”
fan. torque bar pre–set to, 70–85Nm (52–63 lbf ft) on
to the pulley attaching bolt. Raise the lever up
Re–Assembly through an arc of 20° maximum. If the torque bar
does not ‘‘break” within the range a new
1. Re–assemble the fan blade using the six
tensioner assembly is required.
attaching bolts and torque the bolts to,
20–25 Nm (15–18 lbf ft) Re–Install fan and 2. Ensure the tensioner pulley, rotates freely by
viscous unit. hand. If not replace with new parts.

Fan Belt Tensioner Removal Re–Assembly

(Op 10 414)
1. Fit a new pulley to the assembly if required, and
1. The fan belt should be removed in the following torque the attaching bolt to,
manner. Attach a 1/2in. square drive ratchet into 46.5–60Nm (34.5–44 lbf ft)
the tensioner arm, (6) Figure 12. Rotate 2. To re–assemble the arm assembly, position the
clockwise and remove the fan belt from the pulley tensioner on to the front cover, fit the mounting
and allow the tensioner to return to its bolt through the assembly, and torque the bolt to,
untensioned position once the belt has been 46.5–60Nm (34.5–44 lbf ft).
removed.
3. Refitment of the fan belt is the reverse of the
2. Remove the tensioner from the pump by removal procedure, but ensure the ‘‘Poly V’’ belt,
loosening and removing the centre attaching is positioned correctly onto all of the pulleys.
bolt.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 77

Idler Pulley (with Air Conditioning Only)

1. One idler pulley is fitted to the engine. Located on
the right hand side of the engine, under the water
pump, (1), Figure 13.
2. Check that the idler pulley rotates freely, if tight
or worn, replace with new. Removal and
replacement is by the attaching bolt through the
centre of the idler pulley. Torque the bolt to, 1
46.5–60N m (34.5–44 lbf ft).

Water Pump Removal

(Op 10 402)
TA6010093B
13
To overhaul the water pump components, i.e, 1
bearing, impeller or shaft seal, it is only necessary to
remove the cover assembly.
1. Drain the cooling system.
2. Remove the fan belt from the vehicle.
3. Remove the bolts securing the fan shroud and
move the shroud towards the engine.
4. Remove the six cover bolts, (1) Figure 14,
leaving the body bolted to the cylinder block and
withdraw the cover assembly complete with fan
and viscous unit. Note the ‘O’ ring on the rear of
the cover.
6010094
14
5. Withdraw the four bolts which pass through the
water pump and into the block, and slide the
complete pump forward and away from the
block. Note the sealing O–ring which may come
off with the pump or be left on the block, (1)
Figure 15.

TA6010095
15
Disassembly
1. To remove the fan and clutch assembly hold the
pump pulley in a fixed position, and placing an
open ended spanner on the nut to the rear of the
clutch assembly spacer, undo the nut in a
clockwise direction.
2. Using a suitable puller, and a sleeve slightly
smaller than the pulley shaft, ease the pulley
from its shaft, Figure 16.

TA6010096
16

604.55.111.00 – 06 – 2002
78 SECTION 10 – ENGINE – CHAPTER 2

3. To remove the impeller/shaft assembly, place the

pump body impeller side down. Support the
pump in a manner to allow the impeller diameter
to drop clear of the pump, as it is pressed out
from the pump body, Figure 17.
NOTE: Apply pressure to the outer bearing race,
and shaft simultaneously to remove, using the cor-
rect tool. Do not press the centre shaft only, as the
shaft may move, leaving the outer bearing case in the
pump body.

TA6010097
17
4. With the impeller/shaft assembly removed from
the pump, place the impeller on supports, and
press out the shaft assembly from the impeller,
Figure 18. Remove and discard the seal from
the bearing and shaft assembly.

TA6010098
18
Inspection and Repair
1. Check the bearing shaft assembly for signs of
wear or leaks, and if evident, the assembly must
be replaced with new parts.
2. The impeller should be checked for worn or
damaged vanes and must be replaced if not to an
acceptable standard.
3. Clean and check the pump body for signs of
cracks, erosion or leaks. If any of these faults are
in evidence and likely to cause pump failure at a
later date, the pump body must be repaired or
replaced with a new one.
TA6010104
19
Re–Assembly A
1. To install the bearing into the pump cover, place
the cover rear face down onto suitable blocks to
allow the shaft to protrude through. Install the
bearing with the longer stepped end of the shaft
in the body, and using a sleeve that contacts the
bearing outer race only, press the bearing into
the body. Once installed in the body the bearing
case end face must be flush with the pump front
face to within 0.000–0.006 in (0.00–0.076mm),
Reference ‘‘A”, Figure 20.

TA6010099
20

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 2 79

2. With the water pump placed front face down and

the shaft supported, place the seal assembly on
the end of the shaft, with its smallest diameter
uppermost. To insert the seal assembly place
Tool No 295007 over the seal and press, until the
lip on the seal body seats on the pump body,
Figure 21.

TA6010100
21
3. With the water pump rear face up, and the shaft
supported, place the impeller over the shaft and
press the impeller into the water pump body.
Installed correctly the face of the impeller fins to
the operating face of the water pump cover
should be, 0.25–0.88mm (0.010–0.035 in),
Reference ‘‘A” Figure 22.
4. With the pump rear face down and the shaft
supported, press the pulley onto the shaft
ensuring that the pulley front face to the rear face
of the cover is, 77.85–78.10mm (3.065–3.075
in), Reference ‘‘A”, Figure 23.
5. Install the cover assembly, with a new O–ring TA6010101
fitted, onto the pump body, tightening the six 22
retaining bolts to a torque of 17–26 Nm (12–19
lbf.ft)
6. 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. If not disassemble and recheck the
relevant dimensions.

Installation
1. Installation of the water pump to the engine is the
reverse of disassembly, but observing the
following requirements.
Clean the block face, and fit a new O–ring between TA6010102
the pump and block face, (1) Figure 15, 23
Place the water pump onto the block and install and
torque the four pump bolts to
61–68N m (45–50 lbs ft).
Ensure the fan belt tensioner pulley rotates freely,
and the swinging arm of the tensioner returns to rest
freely. Gently lever the arm up to enable the fan belt
to be seated in the grooves on the pulleys. Refit the
fan blade assembly.
After installation of the radiator, refill the cooling
system as previously described, and run the engine
checking for leaks. TA6010103

24

604.55.111.00 – 06 – 2002
80 SECTION 10 – ENGINE – CHAPTER 2

NOTES

604.55.111.00 – 06 – 2002