SECTION 10 –ENGINE – CHAPTER 3 1

SECTION 10 – ENGINE

Chapter 3 – Fuel System

CONTENTS

Section Description Page

10 200 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bosch VE Type Mechanically Controlled Fuel Injection System – Removal . . . . . . . . . . . . 8
Bosch VE Type Pump Timing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bosch VP Electronically Controlled Fuel Injection System – Removal . . . . . . . . . . . . . . . 13
Bosch VP Electronically Controlled Fuel Injection System – Timing Check . . . . . . . . . . . 14
Injection System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Injection System Testing and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10 210 Electric Lift Pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electric Lift Pump – Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10 250 Turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Turbocharger – Dissassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Turbocharger – Inspection – Reassembly– Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 202 Air Cleaner – Removal – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 216 Main Fuel Tank – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Auxiliary Fuel Tank – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 220 Foot Throttle Cable – Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hand Throttle Cable – Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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2 SECTION 10 – ENGINE – CHAPTER 3

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

FUEL SYSTEM TORQUE CHART

NVm Ft Lbs

Injector attachment bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17

Injector line nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18

Injection pump drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 23

Injection pump rear mounting bolts . . . . . . . . . . . . . . . . . . . 38 28

Injection pump-to-front adaptor plate . . . . . . . . . . . . . . . . . 38 28

Injection pump-to-gear drive bolts . . . . . . . . . . . . . . . . . . . . 67 50

Injection timing gear access cover . . . . . . . . . . . . . . . . . . . 38 28

Leak-off tube banjo fitting bolts . . . . . . . . . . . . . . . . . . . . . . 9 7

Lift pump mounting to main junction pump, nuts (3) . . . . 8 6

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 SECTION 10 –ENGINE – CHAPTER 3 3

SPECIAL TOOLS
Description CNH Tool Number
Crankshaft Timing Pin 380000172
Fuel Injection Pump Timing Pin 380000404
Injector – hand pump tester 290284

Nozzle Test Adaptor

Injector – cleaning kit 293671
Injector – splitting block 293760
Injector – Splitting socket kit 293761
Injection pump drive gear puller 295042

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4 SECTION 10 – ENGINE – CHAPTER 3

FUEL SYSTEM

1 2 3 4 5

11 10 9 8 7
BSE2374A

1
Fuel System
1. Fuel tank vent 7. Fuel injection pump
2. Main fuel tank 8. Fuel filter
3. Fuel level sender 9. Water in Fuel Sensor
4. Thermostart 10. Fuel pump
5. Injectors x6 11. Auxiliary fuel tank
6. Fuel shut off solenoid

The diesel fuel system consists of fuel tank, fuel filter Fuel Shut Off (Injection Pump)
with electric lift pump, BOSCH VE distributor type All VE type fuel injection pumps are equipped with an
fuel injection pump (Mechanically Governed), or electrically operated fuel shut off solenoid.
Bosch VP type (Electronically Governed), fuel
The fuel shut off solenoid is energised by operation
injectors, and interconnecting tubes and lines. See
of the ignition switch mounted in the instrument
Figure 1.
panel.
The fuel injection pump is pressure fed from an
With the ignition switched ‘‘OFF” a spring loaded
electric lift pump. Fuel flows from the fuel tank to the
plunger in the solenoid (held in position by the spring
sediment separator, through the electric lift pump
tension), prevents fuel flowing into the pump from the
and then through the fuel filter. From the filter the fuel
main fuel feed port.
passes to the transfer pump which is an integral part
of the fuel injection pump. With the ignition switched ‘‘ON” the magnetised
plunger is energised by an internal coil and is drawn
The transfer pump delivers fuel to the injection pump
up into the body of the solenoid. Fuel is then allowed
to supply fuel at high pressure to each injector and
to flow through the open port into the pump.
also provides extra fuel which lubricates and cools
the injection pump. On VP type pumps this function is controlled by the
electronic control unit.
This extra fuel is recirculated, via a fitting on the fuel
injection pump governor control housing to the fuel
tank, by means of the injector leak off line.
On all models excess fuel that leaks past the needle
valve of the injectors is directed back into the fuel
tank, by means of the injection leak off line.

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 SECTION 10 –ENGINE – CHAPTER 3 5

DESCRIPTION OF OPERATION
The CNH 7.5 Litre engine is fitted with either a
mechanically controlled Bosch VE Rotary fuel
injection pump.

2
or
Electronically controlled Bosch VP Rotary fuel
injection pump .
Further explanation on the operation of these pumps
is given on the following pages..

3
The fuel system is fitted with a fuel
sedimenter/primary filter with an electric lift pump

All engines are fitted with Thermostart(1) to aid

engine starting in cold weather conditions.
Boost and Temperature Sensor (2) is fitted to 175
and 190 Models

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6 SECTION 10 – ENGINE – CHAPTER 3

Fuel Sedimenter/Primary Filter

The sedimenter/primary filter, Figure 5 is positioned
on the right hand side of the engine. The fuel enters
the sedimenter/filter and flows into the head, to be
directed down, and around the edges of the sediment
separator cone.
The larger particles of dirt and water (which are
heavier than fuel oil), are separated out and sink to
the collecting bowl (2) which can be removed and
cleaned. The clean fuel is then drawn back through
the filter to the top of the unit by the electric lift pump
and on to the secondary fuel filter. A sensor (3)
indicates if any water is present.
5
Electric Lift Pump
An electric fuel lift pump (1) is fitted to all models.
Located in the head of the sedimenter, Figure 6, the
pump draws fuel from the tank, via the
sedimenter/filter and passes fuel under pressure to
the secondary filter and onto the fuel injection pump.

6
Power Boost
175 and 190 Models with Power Command
transmissions are equipped with an electronically
controlled power boost facility that automatically
increases engine power in certain conditions.
Engine Power Boost may be activated in the high
road gears(16,17, and 18) and only if Auto Shift is
selected, or when using the P.T.O. providing certain
criteria are met.
The Power Boost function electronically changes the
characteristics of the engine power curve which is
programmed into the vehicle and engine control
modules.
7
During P.T.O. operations a warning light (1), on the
instrument panel will illuminate when Power Boost is
activated.

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 SECTION 10 –ENGINE – CHAPTER 3 7

Constant Engine Speed Control

175 and 190 Tractors

The Constant Revolutions Per Minute (CRPM)
function permits a fixed engine speed to be
programmed into the tractors electronic control
module. With CRPM engaged, the control module
will monitor engine speed and make adjustments to
compensate for load variations, thereby maintaining
a constant erpm. This is activated by momentarily
depressing the upper part of the CRPM switch (1)
and de–activating in the same manner.

9
High RPM Switch Priority
With the tractor in CRPM mode it is possible to adjust
speed setting by using the control switch on the
instument panel (3). This increases or decreases
speed in 10 rpm increments. Holding the switch
down will permit the speed to ramp up at 100
rpm/second, providing there is no load on the engine.

10

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8 SECTION 10 – ENGINE – CHAPTER 3

FUEL SYSTEM

Bosch VE Type Fuel Injection

Pump–(Mechanically Governed) Removal
(Op. 10 2)
NOTE: Ensure that the areas around the injection
pump, injectors and front cover access plate are
clean.
1. With reference to Figure 1, disconnect and
remove the following items from the injection
pump,
1. Injector Pipes x 6
2. Boost Control Pipe
3. Leak Off Return 1
4. Throttle Cable Lever
5. Fuel Inlet Pipe
6. Return to Tank Outlet Pipe
2. Remove the fan drive belt guard, (1), the drive
belt, (2), and the injection pump gear access
plate and belt tensioner assembly, (3), from the
front cover plate.
3. To aid reassembly turn the engine over,
clockwise (when viewed from the front), so that
the engine cover pointer aligns with the 0° TDC
mark on the front pulley, with No.1 cylinder on the
compression stroke. This can be verified with the
cover plate removed, the pump retaining bolts
only align in this position, Figure 3. 2

4. Remove the pump gear nut.

NOTE: If the pump is only being removed to replace
the sealing ‘O’ ring or for another reason which does
not involve rotating the pump shaft or the engine, the
pump can be locked into position by removing the
spacer plate and tightening the screw. The pump can
then be replaced without having to use the special
timing tool. Before locking the pump rotate gear
anti–clockwise to remove gear backlash.

3
5. Using a suitable manufactured puller, or Tool
No.295042, as detailed under ‘Special Tools’,
remove the gear. Figure 4.
6. Withdraw the pump mounting bolts and remove
the pump from the front cover. Cap all openings
to prevent dirt ingress.

Inspection
The pump should not be tampered with in any way.
If the pump operation is suspect it should be taken to
an approved BOSCH agent for testing and repair.

TA6010020
4

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 SECTION 10 –ENGINE – CHAPTER 3 9

Fuel Injection Pump Timing and Installation

The pump timing should be checked prior to installing
the pump to the engine using the following
procedure:
1. Mount the pump into a vice and ensure the pump
is in the unlocked condition, i.e, the spacer, is
between the screw head and the pump body,
Figure 5.
2. Rotate the pump so that the shaft keyway groove
aligns with the injector outlet, marked ‘B’, for
No.1 cylinder. This positions the pump into the
No.1 firing position.
TA6010021
3. Remove the centre bolt from the rear of the pump
and install special tool No.297195, and a dial 5
test indicator, 291754. Pre–load the gauge
approximately 2mm.
4. Set the dial gauge to zero. Rotate the pump
clockwise (when viewed from the shaft end) until
the dial gauge indicates the plunger has moved
0.9mm( +/– 0.06mm). Remove the spacer from
the screw head located on the pump body and
tighten the screw, (1), to lock the pump shaft in
position.
5. Remove the D.T.I. gauge and special tool and
install and tighten the rear centre bolt and
washer. Figure 6.

6
6. 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.

7
7. Insert the crankshaft timing pin 297672 into the
side of the block.

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10 SECTION 10 – ENGINE – CHAPTER 3

8. 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’.

9
9. To help locate this notch in the crankshaft it is
advisable to note where the TDC indicator on the
pulley is positioned. If the ‘O’ is close to the timing
pin on the block then the crankshaft timing pin is
close to the notch in the crankshaft.
IMPORTANT: Do not attempt to rotate the
crankshaft when timing pin is fully inserted as
damage will occur.

10
10. 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.

11
11. Ensure the engine is set to TDC and assemble
the ‘LOCKED’ pre–timed fuel injection pump with
a new ‘O’ ring, aligning the mark on pump flange
to the timing mark on the front cover. Torque
pump retaining bolts to 24Nm
(18 lbf ft). Position the pump gear retaining nut
onto the pump shaft and initially tighten to a
torque of 20Nm (15lbf.ft.), while holding the gear
counter clockwise to remove gear
backlash.Tighten the pump flange screws.
‘UNLOCK’ the pump by releasing the locking
screw and installing the spacer between the
pump body and screw head. The pump gear
retaining nut can now be fully tightened to a
torque value of 92Nm, (68lbf.ft). 12

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 SECTION 10 –ENGINE – CHAPTER 3 11

12. Thoroughly clean the mating surfaces between

the cover and plate using a suitable solvent
cleaner and carefully apply a thin bead,
approximately 2mm, of the recommended
flexible gasket sealant, see specifications, to the
access plate. Assemble the plate to the cover
and tighten the retaining bolts to a torque of
24Nm (18lbf.ft).
13. The remainder of installation is the reverse of
removal.

13

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12 SECTION 10 – ENGINE – CHAPTER 3

ELECTRONICALLY CONTROLLED FUEL INJECTION PUMP

Engine speed
sensor on
Injection Pump

Fuel rack
Position Sensor

Fuel
temperature
sensor

Engine speed
sensor on
Front Pulley

Boost Pressure
Engine and temperature
sensor
Thermostart
Coolant
Temperature
Sensor

Injection Pump
Electronic
Control Unit

Hand Throttle Vehicle Electronic

and Idle Switch Control Unit

Constant RPM Switch Inc/Dec Engine Rear PTO Shaft

Speed Switch Twist Sensor

14
Electronically Controlled Bosch VP Pump Fuel Injection System

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 SECTION 10 –ENGINE – CHAPTER 3 13

Bosch VP Fuel injection Pump – (Electronically

Controlled) Removal (OP.10 2)
NOTE: Ensure that the areas around the injection
pump, injectors and front cover access plate are
clean.
1. Making sure that the ignition key is in the “OFF”
position or disconnect the battery. Disconnect
the electrical connectors.
2. Undo the six injector pipes and the inlet pipe.

15
3. Remove the injection pump timing cover.
NOTE: If the pump is only being removed to replace
the sealing ‘O’ ring or for another reason which does
not involve rotating the pump shaft or the engine, the
pump can be locked into position by removing the
spacer plate and tightening the screw,Fig17. The
pump can then be replaced without having to use the
special timing tool.Before locking the pump rotate
gear anti–clockwise to remove gear backlash.

16
4. Remove the injection pump mounting bolts and
and remove the pump from the front cover. Cap
all openings to prevent dirt ingress.

Inspection
The pump should not be tampered with in any way.
If the pump operation is suspect it should be taken to
an approved BOSCH agent for testing and repair.

17

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14 SECTION 10 – ENGINE – CHAPTER 3

INJECTION PUMP 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
Engine”.
1. Remove engine drive belts.

18
1. Remove injection pump timing cover.

19
2. Using 29mm socket (1–1/8 inch) socket rotate
crankshaft to top dead centre (TDC) with number
1 cylinder firing. This is indicated by the ‘V‘ cut
into the notch of the sensor wheel which should
align with the sensor (See fig.20).

20
3. When engine is at TDC the hole in the injection
pump drive flange aligns with the pump timing
plate.

21

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 SECTION 10 –ENGINE – CHAPTER 3 15

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.

22
5. insert the crankshaft timing pin 297672 into the
side of the block.

23
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’.

24
7. To help locate this notch in the crankshaft there
is a ‘V‘ cut into the sensor wheel groove on the
damper . When this groove is close to the sensor
then the notch should be within range of the
timing pin.
IMPORTANT: Do not attempt to rotate the
crankshaft when timing pin is fully inserted as
damage will occur.

25

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16 SECTION 10 – ENGINE – CHAPTER 3

8. 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.

26
9. Check that the injection pump timing pin Tool No
380000404 will screw into the pump hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
10. If the pin (1) engages in the pump timing plate
(Figure 27) when the crankshaft is at TDC the
pump timing is correct.

27
11. If pump timing is incorrect and timing pin cannot
be screwed into pump, remove pump and reset.
12. Remove spacer (4) and tighten locknut
(3).Remove the pump mounting bolts and
remove pump from front cover.
13. Unlock the pump by loosening locknut (3)install
timing pin 380000404 (1) into pump by adjusting
nut (2).
14. Lock pump by tightening nut (3).Check again to
make sure timing pin can be removed and
installed freely. Refit pump to cover and initially
tighten shaft nut to 20Nm. while holding the gear
counter clockwise to remove gear backlash.
15. The pump gear retaining nut can now be fully 28
tightened to 92Nm.and all pump bolts fully
tightened.
16. Unlock pump by loosening nut (3) 3 turns and
replace spacer (4) and tighten to 12.5 Nm.
IMPORTANT: Ensure both timing pins are removed
from their locations before engine is rotated.
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.

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 SECTION 10 –ENGINE – CHAPTER 3 17

Injection System Bleeding

It may be necessary after injection pump removal,
replacement of injector high pressure lines or after
running out of fuel, to purge the system of air to allow
the engine to start.
If the engine fails to start after several turns, after one
of the above situations has occurred, bleed the
system using the following procedure:
1. Ensure the tractor has adequate fuel and the
battery is fully charged. 1
2. ‘Crack’ open the nuts of the high pressure lines
to each of the injectors. Crank the engine on the
starter motor to expel the air. If possible, i.e, with
the aid of an assistant, tighten the injector nuts
as the engine begins to fire.
WARNING
Wear suitable eye and skin protective clothing. Fuel
may be expelled under high pressure.

29

Injector Removal
1. Ensure the areas around the injectors and fuel
pump are clean prior to disassembly.
2. Remove the injector high pressure lines,
carefully pull the leak off tubes from the injectors,
remove the two retaining bolts of each injector
and withdraw the injectors from the cylinder
head.
NOTE: Each injector should have a cork seal under
the retaining flange, remove the seal from either the
cylinder head or injector and discard. New seals
should always be installed on reassembly. 30

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18 SECTION 10 – ENGINE – CHAPTER 3

Injector Testing and Overhaul

WARNING
The spray from a fuel injector tester can pierce hu-
man skin with fatal results. When an injector is spray-
ing, the nozzle holder should be turned away from
the operator and any other persons.

During the Nozzle Opening Pressure and Spray

Pattern Tests, collect the spray in a container partly
filled with rags to absorb the spray.
When conducting the Nozzle Seat Leakage Test,
release the injector tester pump pressure before
touching the nozzle tip with a sheet of blotting paper.

31
WARNING
The spray is flammable make sure no open flames
are in the area of the tester and do not generate ex-
cessive vapour.

1. Fill the injector tester, Tool No.290284, with a

calibrating type fuel oil and leave the filler cap
loose to prevent a vacuum forming during
testing.
2. Prime the tester until oil is emitted from the tester
line, then connect the injector.
3. Make sure the knob on the right-hand side of the
tester is screwed in to prevent the gauge being
over-pressurized if the injector nozzle is blocked.
4. Pump the tester and check the nozzle is free to
open. Open the pressure gauge valve and begin
injector testing. If the nozzle is blocked or the
needle jammed, disassemble the injector.

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 SECTION 10 –ENGINE – CHAPTER 3 19

5. Nozzle Opening Pressure Setting - Slowly pump

the injector tester and observe the pressure at
which the needle valve lifts and fuel is injected
from the nozzle tip. The minimum acceptable
opening pressure is 240 bar (3480 lbf/in2). If the
opening presure is below 240 bar, reset to
270–278 bar (3915–4031 lbf/in2).
6. Spray Pattern - Pump the tester rapidly (80 to 90
strokes per/min.) and observe the spray pattern
from the holes. An atomized spray free from
distortion and irregular streaks of fuel should be
observed. The tester is not regarded as providing
a suitable test for atomization under working
conditions, but gives an indication of the working
32
of the nozzle.
7. Nozzle Seat Leakage - Wipe the nozzle tip dry
and apply a pressure 10 bar (145 lbf/in2) below
the opening pressure. The nozzle tip and bottom
face must remain essentially dry and there must
be no tendency for blobs of fuel to collect or drip.
A slight dampness can be ignored. If there is any
leakage from the nozzle seat, the nozzle
assembly must be cleaned or replaced.
8. Nozzle Back Leakage - Apply a pressure 10 bar
(145 lbf/in2) below the opening pressure, then
release the handle and time the pressure drop.
The pressure should drop 100–150bar in 5–45
seconds. If below 5 seconds, the nozzle
assembly must be replaced. If above 45
seconds, check for carbon on the valve and/or
blocked back leak drillings.
NOTE: If the injectors meet the tests carried out then
refit the injectors to the engine.

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20 SECTION 10 – ENGINE – CHAPTER 3

Disassembly
1. Place the injector in a holding fixture, Tool
No.293760, with the nozzle uppermost. Do not
clamp the injector body in a vice. Use socket tool,
295008, (kit 293761), to loosen the nozzle
retaining nut.
2. Remove the nozzle retaining nut, complete with
the nozzle body, needle valve and the dowelled
adaptor plate.
3. Remove the injector body from the holding
fixture, invert and carefully remove the spring
seat, spring and adjustment shims. To avoid
TA6010117
damage, place all dismantled components in
suitable baths of clean fuel oil. 33
NOTE: To prevent corrosion of injector components
after cleaning, rinse in clean fuel oil and place in a
suitable bath of clean fuel oil.

TA6010118
34
Inspection and Repair
1. Clean the injector body by soaking in a carbon
solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and
pressure face, making sure the holes in the
injector nozzle are thoroughly clean with no signs
of corrosion or pitting.
2. Clean the spring and spring seat using a brass
wire brush and check for scoring, pitting or
corrosion.
3. Clean the dowelled adaptor plate using a brass
wire brush. Inspect the plate for loose or bent
dowels, a damaged pressure face or corrosion. TA6010113
35
4. Clean the needle valve and body by soaking in a
carbon solvent and brushing with a brass wire
brush. Using the tools included in the Injector
Nozzle Cleaning Kit, Tool No.293671, clean the
nozzle as follows:
NOTE: If the needle valve is in any way damaged or
blued, it must be discarded and a new matched
needle valve and nozzle body assembly obtained. It
is not possible to grind or lap the three special angles
on the valve point.

36

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 SECTION 10 –ENGINE – CHAPTER 3 21

A. Clean the spray holes with a nozzle cleaning wire

held in a pin vise so that it protrudes for only 1.5
mm (0.06 in.), thereby giving maximum resis-
tance to bending. Insert the wire into each hole,
pushing and rotating gently until each hole is
cleared.

37
B. Clean the needle valve seat using the valve seat
scraper by rotating and pushing the tool onto the
valve seating.
C. Clean the fuel port using the fuel port scraper. In-
sert the scraper into the port, press hard against
the side of the cavity and rotate to clear all carbon
deposits from this area.

38
5. Use a Reverse Flush Nozzle Adaptor on the
injector tester and reverse flush the nozzle to
remove the carbon loosened during cleaning,
Step 4.
6. After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end
of a polishing stick and rotate in the nozzle.

39
7. Clean the top of the needle valve using a needle
valve scraper.
8. Clean the nozzle retaining nut using a brass wire
brush and check to see that the threads are not
damaged and are free from carbon deposits.

40

604.55.111.00 – 06 – 2002
22 SECTION 10 – ENGINE – CHAPTER 3

Re–assembly
1. Make sure all parts are absolutely clean and
undamaged prior to re–assembly. Rinse all parts
in clean fuel oil and assemble the components
while still wet.
2. Place the shims, spring and spring seat into the
injector body bore. Place the injector body into
the holding fixture.
3. Assemble the needle valve into the nozzle body
and then position the dowelled adaptor plate onto
the nozzle body. Insert this assembly into the
nozzle retaining nut.
TA6010113
41
4. Carefully assemble the dowelled adaptor plate
and the nozzle retaining nut assembly onto the
injector body, tighten the retaining nut to 45 Nm
(33 ft. lbs) torque.
To set the nozzle opening pressure, connect the
injector to the test rig as described in ‘‘Testing’’ and
add or subtract shims from the spring until the
specified initial setting opening pressure of between
270–278 bar (3915–4031 lbf.in2) is achieved.

42
Injector Installation
The installation is the reverse of the removal
procedure noting the following points.
1. Install a new cork seal to the underside of the
retaining flange.
2. Tighten the retaining bolts to a torque of 23Nm,
(17lbf.ft).
3. It may be necessary to bleed the fuel system of
air in order to start the engine. Refer to, ‘Injection
System Bleeding’.

43

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 23

Electric Lift Pump – Removal

1. The electric lift pump, (1), is located in the head
of the sedimenter/primary filter assembly.
2. Disconnect the electrical connection. Rotate the
head retaining ring anti–clockwise and lift off the
pump assembly.

44
Electric Lift Pump Testing
NOTE: The electric pump is a sealed unit and failure
of it will require a new pump to be installed.
1. If when the key start is switched on the pump
cannot be heard running gently tap the pump unit
with a soft hammer, if it starts operating this
indicates that the pump is sticking and will need
replacing.
2. If the pump cannot be heard operating after the
above operation, disconnect the electrical
connector and check for +12V at the harness
side. If votage is present and the connector
terminals look good the pump is faulty and will
need replacement. 45
3. If there is no voltage, check Fuse 8 in the fuse
box, if this is okay inspect the harness for
damage, repair/replace wiring as required.
4. If the pump can be heard running with voltage
applied check the pump output. Arrange the
outlet from the filter assembly to run into an
empty container, allow the pump to run for a
minute and measure the quantity of fuel
delivered.
NOTE: Ensure that the filters are clean and that there
are no other obstructions in the fuel system from the
tank up to the filters.

The pump should deliver a minimum of 1.5L/min. 46

Replace the pump if the output is less than specified.

604.55.111.00 – 06 – 2002
24 SECTION 10 – ENGINE – CHAPTER 3

Turbocharger – Removal
With reference to Figure 47.
1. Lift the engine hood.
2. Remove the exhaust muffler.
3. Disconnect the air cleaner to turbocharger tube
(1) and the turbocharger to exhaust tube(3).
4. Disconnect the oil supply (4) and return (5) tubes
from the turbocharger (2). Cap all tube openings
to prevent dirt ingress.
NOTE: Before removing and cleaning the unit look
for signs of oil and/or gas leakage, also wheel dam-
age which may not be evident after cleaning.
5. Remove the turbocharger (2) and gasket (5) 47
from the exhaust manifold. Cover the exhaust
manifold opening to prevent dirt ingress.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 25

Turbocharger – Disassembly
1
NOTE: Figure 48 details the only components that
are serviced for the turbocharger.
Before the removal of the end housings the end of
each shaft should be rotated with slight pressure in
both the axial and radial direction. No sign of contact
should be present between the wheels and the
housings. If any contact is present, unless another
cause such as dirt build up is found, then the
bearings may be worn. If the bearings are worn the
entire centre housing rotating assembly should be
replaced.
6010074
The cause of bearing failure should be established
as they seldom fail during normal operation of a well 48
maintained engined. For example engine oil/filter
requires replacement.
The centre housing and rotating assembly, item 1
Figure 48, has been balanced during manufacture
under precision conditons. The assembly should not
be disassembled in any way and is only serviced as
an assembly.
If it has been determined that a major component of
the turbocharger needs replacing, use the following
procedure to disassemble:
6. Clean the exterior of the turbocharger with a non
caustic cleaning solvent.
7. Scribe a mark on the components of the
turbocharger to facilitate reassembly.
8. Remove the four bolts from the turbine housing
and the six bolts from the compressor housing.
Remove the clamp plates and carefully separate
the end housings from the centre housing
rotating assembly.

Cleaning
Before cleaning inspect all parts for burning, rubbing
or impact damage that may not be evident after
cleaning. Clean all parts in a non caustic solution,
using a soft bristle brush, a plastic blade scraper and
dry compressed air to remove residue.
• DO NOT – use abrasive cleaning methods which
might damage or destroy machined surfaces.
• DO NOT – immerse the centre housing and ro-
tating assembly in solvent.
• DO NOT – blow under the compressor wheel
with compressed air.
• DO NOT – permit wheel/shaft assembly to spin
when blowing off solvent and residue.

604.55.111.00 – 06 – 2002
26 SECTION 10 – ENGINE – CHAPTER 3

Inspection
Inspect the housings for the following defects:
• Wheel rub damage in the contour area that can-
not be polished out with 80 grit silicon carbide ab-
rasive cloth (compressor housing) or 60grit (tur-
bine housing).
• Nicks, dents or distortion that could prevent
proper sealing between the housings and the
centre housing rotating assembly.
A housing should be replaced if any of the above
defects are found.
6010074
Centre Housing and Rotating Assembly
49
(CHRA)
NOTE: If there is any compressor or turbine wheel
blade damage, the CHRA must be replaced. Operat-
ing a turbocharger with damaged blades will result in
further damage to component parts or the engine.
Blades cannot be straightened in service.

Reassembly
1. It is recommended that the following parts are
replaced after removal:
• The compressor housing clamp plates and bolts
• The turbine housing bolts
2. Ensure all parts to be reassembled are
completely clean. If new components are being
used transfer the scribe marks from the old
components to ensure correct assembly.
3. Assemble the outer housings to the centre
housing assembly, taking extreme care not to
damage the turbine blades. Ensure all scribe
marks align and install the new clamp plates and
bolts. Coat the bolts in a suitable non–seize
compound and tighten to a torque of 22Nm
(16.3lbf.ft) for the turbine housing and 11Nm
(8.1lbf.ft) for the compressor housing
4. Rotate the turbine by hand ensuring that it
rotates freely without rubbing.

Turbocharger – Installation
1. Prior to installation fill the turbocharger centre
housing with new clean oil, and rotate the main
shaft to lubricate the bearings.
2. Installation of the turbocharger, reference Figure
50, follows the removal procedure in reverse.
Install a new manifold gasket and tighten
retaining nuts, to 41–47Nm (30–35 lbf ft).

50

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 27

3. Replace the washers and re–connect the oil feed

tube (4) banjo bolt Figure 51, and torque to
30–40Nm (22–30 lbf ft).
4. The oil feed tube connector, to oil filter head
assembly, if disturbed, should be refitted. Apply
sealer to connector ‘‘See Specifications’’ and
torque to, 11–16Nm (8–12lbf.ft).
5. Apply sealer, ‘‘See Specifications”, assemble
the oil feed tube to the oil filter head connector
Figure 51, and tighten to, 18–20Nm
(13–15 lbf.ft).
6. Place a suitable receptacle below the oil outlet
port and, WITH THE SHUT–OFF SOLENOID
WIRE DISCONNECTED AT THE FUEL 51
INJECTION PUMP OR HARNESS
DISCONNECTED FROM ELECTRONIC
INJECTION PUMP, crank the engine until oil
flows from the outlet port.
7. Reconnect the oil outlet tube (5) Figure 51,
using a new gasket and tighten the retaining bolts
at the turbocharger to 20–25Nm (15–18 lbf ft).
8. Tighten the oil return tube to cylinder block
connector clamps to 2–3Nm (20–30lb.in.).
9. If disturbed, oil return tube to block connector, ,
should have sealer applied, ‘‘See Specifications”
and torqued to 34–47Nm (25–35lbf.ft).
10. Reconnect the air inlet (1), and outlet (3) tubes,
with the hose clamps, and torque to
1.7–2.3Nm (15–20 lb.in) for the inlet and 6–7Nm
(50–65 lb.in) for the outlet, Figure 51.
11. Reconnect the fuel shut–off solenoid wire.
12. Check the engine oil level and add oil if required.
Idle the engine and check all tubes and gaskets
for leaks.
13. Run the engine at rated speed and listen for
sounds of metallic contact from the turbocharger.
If any noise is apparent, stop the engine
immediately and correct the cause.
NOTE: After the unit has obtained operating tem-
perature, the rotating assembly should coast freely
to a stop after the engine is stopped. If the rotating
assembly jerks to a sudden stop, the cause should
be corrected immediately.

604.55.111.00 – 06 – 2002
28 SECTION 10 – ENGINE – CHAPTER 3

Air Intake Components

Air is directed through the duct (1) and via a large

hose (2) into the air cleaner assembly (3). The air is
then sent through to the tubocharger (5) and then into
the charge air cooler pipe (4).

52

Air Cleaner
NOTE: It is not necessary to remove the complete air 1
cleaner body, as described below, to service the air
cleaner elements.

Removal
1. To remove the air cleaner body from the vehicle,
raise the engine hood. Slacken and remove the
hose clamps on the aspirator tube to muffler, inlet
manifold and turbocharger connection.
2. Remove the air cleaner attaching bolts from the
engine hood frame and remove the air cleaner
2
body from the vehicle.
53
Disassembly (Mechanically Governed Engines)
1. Unscrew the wing nut and extract the outer 1 3
element as the nut is unscrewed.

54

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 29

Disassembly (Electronically Governed

Engines)
1. Unlatch the three retaining clips (1) and lift off the
air cleaner assembly cover. Supporting the outer
element carefully extract it from the assembly
housing ensuring the inner element remains in
place.
IMPORTANT: The inner safety element, Figure 56,
should not be removed or disturbed unless it is
damaged or contaminated with dirt by a faulty outer
element .

55
2. If required extract the inner element, Figure 36.

Inspection and Repair

1. Clean and examine the outer casing and repair
or seal any damaged seams.

Outer Element
1. If dust is present inside the the outer element it
must be renewed. If satisfactory clean the
element by tapping both ends on the palm of the
hand. Do not tap the element against a hard
surface as it will be damaged or distorted.

56

57
2. Alternatively, compressed air, not exceeding
2 bar (30 lbf in2) may be used. Insert the air line
nozzle inside the element and blow the dust from
the inside through the element to the outside.
Blow loose particles from the outside of the
element by holding the nozzle at least 150 mm (6
in.) from the element, Figure 58.
WARNING
Wear eye protection and a face mask when carrying
out this operation.

TA6010077
58

604.55.111.00 – 06 – 2002
30 SECTION 10 – ENGINE – CHAPTER 3

If the filter element is undamaged wash the element

every 300 hrs, or after five dry cleanings.
IMPORTANT: Never use oil, petrol, or solvent. Use
only water but not hotter than the hand can stand,
otherwise the element may be damaged.
3. Seal the small hole at the closed end of the filter
with a strip of adhesive tape and place the filter
open end up in a deep flat bottomed container or
tub. Add a small amount of non–sudsing washing
powder (automatic washing machine type) to the
inside of the filter element.
Add warm water 35° C (100° F) to the inside of TA6010078
the element until the level in the container is just 59
below the open end of the element. Allow the
element to soak for at least 15 minutes (but never
more than 24 hours) in the cleaning solution.

4. After soaking gently agitate the element being

careful not to allow dirty cleaning solution from
the container to splash into the inside of the
element.
5. Rinse the element in clean cold water allowing
water to flow from the inside through the element
until the water comes through clear. If using a
hose do not use a pressured flow a slow trickle
is sufficient. Ensure water is allowed to flow
through the entire element.
6. Remove the adhesive tape and shake excess
water from the filter element and allow to dry
naturally. The element will need 24–48 hours to TA6010079
dry thoroughly. Install a new element at this stage 60
retaining the washed element for the next
service.
IMPORTANT: Do not attempt to dry the element with
compressed air or install before thoroughly dry as it
may rupture. It is recommended that a new element
is installed at this service and the washed element
allowed to dry and retained for installation at the next
service.
7. After drying thoroughly, examine the paper
pleats carefully, this can be done by inserting a
lamp into the middle of the element and
observing the element surface. An even, fine
pattern of light indicates the element is clean,
undamaged and suitable for further service. If
this is not the case discard the element.
8. Every 600 hours the element must be renewed.

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 31

Inner Element
1. The inner element should not be disturbed
unless damaged, or contaminated by dirt
through failure of the outer element. The
elementand should therefore only be replaced
and not cleaned when contaminated.
2. If the inner element is okay leave assembled in
the cleaner body, and change only annually, or
every 1200 hours whichever occurs first.
Re–Assembly
1. Clean the inside of the air cleaner casing with a
damp, lint–free cloth and install the inner and
outer element. Ensure that the rubber sealing
rings on the ends are secure and undamaged.
2. Refitting of the filter body to the vehicle, is the
reverse procedure to disassembly.

61
Main Fuel Tank – Removal and Installation 3
On units less the cab suspension it is necessary to
raise the cab approximately 4 inches in order to
remove the main fuel tank. Remove the floor mat and
remove both front mounting bolts and loosen the two
rear mounting bolts. Attach cab lifting tool
no.297268. Using a suitable lifting hoist, carefully
raise the cab.
NOTE: It is recommended that the fuel tanks are
drained prior to removal from the tractor. Drainage
points are provided on both main and auxiliary tanks. 1
2
TA6010080
62
1. Disconnect the battery.
2. Drain the fuel tank into a suitably sized fuel
container.
3. Remove the rear left hand wheel.
4. Disconnect the wiring from the sender, located at
the top, front of the tank, disconnect the fuel
pump return line, the top crossover tube, if fitted,
and the vent tube from the rear of the tank.
5. Loosen the strap tensioning bolt, (1), to release
the strap, remove the two bolts (2) & (3) and
remove the left hand foot step, Figure 61.
2 1
TA6010082
63

604.55.111.00 – 06 – 2002
32 SECTION 10 – ENGINE – CHAPTER 3

TA6010134
64
6. Remove the nut from the rear strap, and position
the strap out of the way, if an auxiliary tank is
fitted disconnect the lower crossover tube 3
connector. 2
7. With the aid of an assistant or trolley jack remove
the tank from the tractor.
8. Installation is the reverse of the removal. 1

TA6010083
65
Auxiliary Fuel Tank Removal and Installation
1. Disconnect the battery.
2. Place a suitable container under the drain plug
and drain the fuel. Slacken the worm drive clip on
the connector tube, (1), Figure 66. Loosen the
strap tensioning bolt (2) and release the strap.
Remove the right hand foot step, removing bolts
(1) and (2) Figure 65. Disconnect the remaining
fuel lines and remove the tank from the tractor.
3. Installation is the reverse of the removal.

66
Crankcase Ventilation
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.
1. To remove breather undo hoses and remove
bolts from mounting bracket.
2. To remove and change filters unlatch the clips
remove cap and seal (1) and replace filters (2)
and (3).

67

604.55.111.00 – 06 – 2002
 SECTION 10 –ENGINE – CHAPTER 3 33

Foot Throttle Cable Replacement and

Adjustment (Mechanically Governed Engines)
A single cable directly from the foot pedal operates
the fuel pump lever.
1. Raise the engine hood.
2. Slacken the cable adjusting nuts and remove the
clip retaining the cable to the fuel injection pump
lever.
3. Remove the right hand instrument console lower
panel and remove the clip retaining the cable to
the foot throttle linkage (2), Figure 68.
4. Remove the cable from the engine side. TA6010084
5. Installation is the reverse of removal. 68

Adjustment
1. Adjust the cable at the injection pump, Figure
68, to remove all slack at the idle position.
Depress the pedal fully and ensure that full
throttle is achieved. If not achieved adjust the
stop bolt, (1) Figure 69, on the pedal to allow
further movement. If full throttle is achieved too
early in the pedal movement again adjust the
pedal stop to coincide with injection pump full
throttle. 6010085

69
Hand Throttle Cable Replacement and
Adjustment
A single cable from the hand lever attaches to a pivot
plate at the foot pedal assembly. This actuates the
injection pump, via the foot throttle cable.

70
1. Remove the transmisson lever console lower
panel, Figure 70. Remove the clip retaining the
cable to the lever, (1) Figure 71, and slacken the 1
outer cable adjusting nuts(2 and (3) Figure 71,
and slide the cable from the bracket.
2. Remove the right hand instrument console lower
2
panel and remove the clip retaining the cable to
the pivot plate (1) Figure 72.
3. Remove the cable from the tractor.
3
4. Installation is the reverse of removal.

6010086
71
Adjustment

604.55.111.00 – 06 – 2002
34 SECTION 10 – ENGINE – CHAPTER 3

1. Ensure that the foot throttle cable is correctly

adjusted as described above. Adjust the hand
throttle cable, using the two outer cable nuts, to
remove all slack from the cable when in the idle
position. Ensure that there is a slight clearance
between the hand throttle pivot plate and the foot
throttle assembly.

6010085
72

604.55.111.00 – 06 – 2002