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SECTION 00 – GENERAL INFORMATION

00-20

RECOMMENDED LUBRICANTS AND COOLANTS (North America Only)

New Holland (North America)

LUBRICATION

Adequate lubrication and maintenance on a regular schedule is vital to maintaining your equipment. To ensure
long service and efficient operation, follow the lubrication and maintenance schedules outlined in this manual.
The use of proper fuels, oils, grease and filters, as well as keeping the systems clean, will also extend machine
and component life.

IMPORTANT: Always use genuine New Holland replacement parts, oils and filters to ensure proper operation,
filtration of engine and hydraulic systems. See your New Holland dealer for additional oil quantities.

RECOMMENDED LUBRICANTS AND COOLANTS

Lubricant

Location Used

Type and Description

Part Number

Quart or
Liter

Gallon
or Tube

Oil

Engine and Pivot Points
without Grease Fittings,
Chains

SAE 30 API CF–2SJ

9613286

1Qt.

SAE 30 API CF–2SJ

9613289

2.5 Gal.

SAE 30 API CF–2SJ

9613366*

4 L

5W–30 API SG/CD

9673589DS

1 Qt.

5W–30 API SG/CD

9624590*

4 L

10W–30 API SG/CD

9613313

1 Qt.

10W–30 API SG/CD

9613314

2.5 Gal.

10W–30 API SG/CD

9673508DS

5 Gal.

10W–30 API SG/CD

9613358*

1 L

10W–30 API SG/CD

9613359*

4 L

15W–40 API CF–4

9613290

1 Qt.

15W–40 API CF–4

9673730DS

1 Gal.

15W–40 API CF–4

9613303

2.5 Gal.

15W–40 API CF–4

9613292

5 Gal.

15W–40 API CF–4

9613350*

1 L

15W–40 API CF–4

9613351*

4 L

Coolant

Engine

ESE–M97B18–D, Ethylene Glycol New Hol-
land Spec. Coolant Concentrate

FGCC2701DS

1 Gal.

Propylene Glycol Concentrate

FGCC2711DS

1 Gal.

Hydraulic Oil

Hydraulic System,
Hydrostatic System
Front Axle Oil

134D – ESN–M2C134–D
New Holland Spec. Hydraulic oil

9624450

2.5 Gal.

134D – ESN–M2C134–D

9624451

5 Gal.

134D – ESN–M2C134–D

9613367*

4 L

134D – ESN–M2C134–D

9624785*

10 L

Hydraulic Oil

Optional, Multi-Seasonal
Use, Recommended for
Low Temperatures

F200

86523625DS

1 Qt.

F200

86523626DS

5 Gal.

F200

86509446*

20 L

Gear Oil

Gearboxes

80W90 EP Gear Oil API GL5

9613295

1 Qt.

80W90 EP Gear Oil API GL5

9613294

2.5 Gal.

80W90 EP Gear Oil API GL5

9613375*

5 L

85W140 EP Gear Oil API GL5

9613297

1 Qt.

85W140 EP Gear Oil API GL5

9613296

2.5 Gal.

85W140 EP Gear Oil API GL5

9613376*

4 L

Grease

All Grease Fittings

Lithium base EP high temperature

9861804DS

Tube

Lithium base EP high temperature

9861804CDS*

Tube

Brake Fluid

Mineral Based Oil

1QM6C34A or
86541699DS

1 Qt.

* NOTE: Canada Part Numbers ONLY.

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Summary of Contents for TV145

Page 1: ...peration 87049449 21 1 Transmissions Drivelines 87049449 21 2 Transmissions Auxiliary Pump Drive 87049449 21 3 Transmissions Splitter Box Removal Disassembly and Assembly 87049449 21 4 Transmissions Auxiliary Hydraulic Pump 87049449 21 5 Transmissions Hydrostatic Drive 87049449 21 6 Transmissions Hydrostatic Motor Pump and Control Cables 87049449 21 7 Engine End Axle 87049449 25 1 Cab End Axle 870...

Page 2: ...0 1 Electrical System 87038780 55 1 Accessories 87038781 88 1 Cab General Information 87038781 90 1 Cab Removal and Installation 87038781 90 2 Cab Exterior 87038781 90 3 Cab Interior 87038781 90 4 Cab Control Consoles 87038781 90 5 Description Book Number Section Number Chapter Number Find manuals at https best manuals com ...

Page 3: ... 2003 1 Issued 9 03 TV145 Tractor Repair Manual Table of Contents Description Section Number Chapter Number General Information 00 Engine 7 5L 10 1 Engine Fuel System 10 2 Find manuals at https best manuals com ...

Page 4: ...Precautionary Statements 3 Safety Precautions 3 General Considerations 5 Tractor Identification 12 Engine Identification 15 Service Techniques 17 Minimum Hardware Tightening Torques 18 Standard Torque Data 20 Recommended Lubricants and Coolants 22 Recommended Sealants 24 Find manuals at https best manuals com ...

Page 5: ...cific troubleshooting special tools and specifications Any reference in this manual to right left rear front top or bottom is as viewed from the operator s seat looking toward the engine All data and illustrations in this manual are subject to variations in build specification This information was correct at the time of issue but New Holland policy is one of continuous improvement and the right to...

Page 6: ...NS Practically all service work involves the need to drive the tractor The operator s manual supplied with each tractor contains detailed safety precautions relating to driving operating and servicing that tractor These precautions are as applicable to the service technician as they are to the operator and should be read understood and practiced by all personnel Prior to undertaking any maintenanc...

Page 7: ...a compressed air line often exceeds 100 PSI 690 kPa It is perfectly safe if used correctly Any misuse may cause injury Never use compressed air to blow dust filing and dirt away from your work area unless the correct type of nozzle is fitted Compressed air is not a cleaning agent it will only move dust from one place to another Look around before using an air hose as bystanders may get grit into t...

Page 8: ...e engine if at all possible before performing any service Place a warning sign on tractors which due to service or overhaul would be dangerous to start Disconnect the battery leads if leaving such a unit unattended Do not attempt to start the engine while standing beside the tractor or attempt to bypass the safety start switch Avoid prolonged running of the engine in a closed building or in an are...

Page 9: ...AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health This section lists alphabetically some of these hazardous operations materials and equipment associated with them The precautions necessary to avoid these hazards are identified The list is not inclusive all operations procedures and handling of materials s...

Page 10: ...charging are explosive Never use an open flame or allow sparks near charging or recently charged batteries CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling North America Only BRAKE AND CLUTCH LININGS AND P...

Page 11: ...rly those based on solvents in confined spaces i e when people are inside a vehicle Do not apply heat or flame to chemical materials except under the manufacturer s instructions Some are highly flammable and some may release toxic or harmful fumes Do not leave containers open Escaping fumes can build up to toxic harmful or explosive concentra tions Some fumes are heavier than air and will accumula...

Page 12: ...or welding equipment be sure there is no fire hazard present Have a suitable fire extinguisher available when using welding or heating equipment FIRST AID Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in first aid procedures Splashes in the eye should be flushed with clean water for at least ten minutes Soiled skin should be washed with soap an...

Page 13: ...ures should be avoided mists may arise in dewaxing Avoid skin and eye contact be sure there is adequate ventilation Diesel Fuel Gas Oil See Fuels Kerosene CAUTION Combustible Gross or prolonged skin contact with high boiling gas oils may cause serious skin disorders including skin cancer GAS CYLINDERS SEE FIRE Gases such as oxygen acetylene carbon dioxide argon and propane are normally stored in c...

Page 14: ...ubricants or for any application where major skin contact is likely to occur Used oils may only be disposed of in accordance with local regulations Refer to the Recommended Lubricants and Coolants Charts for the recommended lubricants NOISE INSULATION MATERIAL SEE FOAMS FIBRE INSULATION PAINTS SEE SOLVENTS AND CHEMICAL MATERIALS GENERAL CAUTION Highly flammable Paints can contain harmful or toxic ...

Page 15: ...on data is also needed to aid in identifying the tractor if it is ever stolen VEHICLE IDENTIFICATION PLATE The vehicle identification plate 1 is located on the lower left front corner of the cab MA03D028 1 1 Record the Model Number and Product Identification Number for future quick reference 50014893 2 ENGINE IDENTIFICATION The engine serial number is stamped on a flat boss area on the right side ...

Page 16: ...e Germany 36202 01323 15194 Serial number 0400876405 Supplier order number PES6A95D410RS2835 Alphanumeric produc tion designation PE Inline injection pump with camshaft S Flange mounted 6 Number of cylinders A Size pump A 8670 and 8770 P 8870 and 8970 95 Plunger diameter in 1 10 mm 915 mm D Pump model D is the latest version of A size pumps 410 Number code for location of feed pump and governor R ...

Page 17: ...mber and starter information are on the plate 1 on the starter housing 7 REAR AXLE IDENTIFICATION The serial number 1 is stamped on the left side of the PTO boss on the rear axle housing 8 CAB IDENTIFICATION The serial number is on the certification plate 1 on the rear crossbar 9 ...

Page 18: ...oosely connect each end and make sure the hose takes up the designed position before tightening the connection Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing After hose replacement to a moving component check that the hose does not foul by moving the component through the complete range of travel Be sure any hose which has been installed is not kin...

Page 19: ...26 35 3 8 5 16 115 13 149 17 178 20 229 26 250 28 324 37 125 14 176 20 5 16 1 4 55 6 2 72 8 1 86 9 7 112 13 121 14 157 18 61 6 9 86 9 8 1 4 MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS NEWTON METERS FOR NORMAL ASSEMBLY APPLICATIONS INCH HARDWARE AND LOCKNUTS NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR B GR C NOMINAL SIZE or W ZnCr or W ZnCr or W ZnCr w GR5 w GR8 SIZE PLATED PL...

Page 20: ...671 195 265 M24 303 411 392 531 478 648 619 839 662 897 855 1160 338 458 NOTE Torque values shown with are inch pounds IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5 6 AND UP MANUFACTURER S IDENTIFICATION PROPERTY CLASS HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER S IDENTIFICATION MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS NEWTON METERS FOR NORMAL ASSEMBLY APPLICATIONS M...

Page 21: ... 1 1 16 12 1 3 16 12 1 5 16 12 1 5 8 12 1 7 8 12 2 1 2 12 9 12 21 35 53 77 90 110 140 160 225 12 15 24 40 53 82 100 120 150 175 240 12 16 29 47 72 104 122 149 190 217 305 16 20 33 54 79 111 136 163 204 237 325 6 10 15 25 35 60 70 80 95 120 250 10 15 20 30 40 70 80 90 115 140 300 8 14 20 34 47 81 95 108 129 163 339 14 20 27 41 54 95 109 122 158 190 407 TUBE NUTS FOR 37 FLARED FITTINGS O RING BOSS P...

Page 22: ...ITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fittings 1 and lubricate the O ring 2 with light oil Make sure both surfaces are aligned properly Torque the fitting to specified torque listed throughout the repair manual IMPORTANT If the fitting surfaces are not properly cleaned the O ring will not seal properly If the fitting surfaces are not properly aligned the ...

Page 23: ... 9613314 2 5 Gal 10W 30 API SG CD 9673508DS 5 Gal 10W 30 API SG CD 9613358 1 L 10W 30 API SG CD 9613359 4 L 15W 40 API CF 4 9613290 1 Qt 15W 40 API CF 4 9673730DS 1 Gal 15W 40 API CF 4 9613303 2 5 Gal 15W 40 API CF 4 9613292 5 Gal 15W 40 API CF 4 9613350 1 L 15W 40 API CF 4 9613351 4 L Coolant Engine ESE M97B18 D Ethylene Glycol New Hol land Spec Coolant Concentrate FGCC2701DS 1 Gal Propylene Glyc...

Page 24: ...e and Description Part Number Oil Engine and Pivot Points without Grease Fittings Chains SAE 30 Ambra Super 30 5W 30 API SG CD Ambra Super Gold 5W 30 10W 30 API SG CD Ambra Super Gold 10W 30 15W 40 API CF 4 Ambra Super Gold 15W 40 Coolant Engine ESE M97B18 D Ethylene Glycol New Holland Spec Coolant Concentrate Ambra Agriflu 50 mix Propylene Glycol Concentrate Hydraulic Oil Hydraulic System Hydrost...

Page 25: ...RTV Gasket Non corrosive Black L59875 10 2 oz cartridge Ultra Blue RTV Gasket Non corrosive Black 518 Gasket Eliminaor L51831DS Mating Machined Surfaces Flexible Red RECOMMENDED SEALANTS All Markets Except North America SEALANTS Description Part Number Typical Applications Strength Color Thread Lock 82995773 2995773 242 Small screw hardware Medium Blue 82995772 2995772 262 Nuts Bolts High Red Thre...

Page 26: ...ming Check 25 Engine Disassembly and Overhaul Cylinder Head Valves and Related parts 28 Hydraulic Tappets Adjustment 38 Front Cover and Timing Gears 40 Oil Pan 44 Flywheel 45 Rear cover plate 46 Oil pump 47 Oil Pressure Relief Valve 49 Camshaft tappets and camshaft bearings 50 Pistons and Cylinder Block 53 Crankshaft 62 Crankshaft Front Seal Installation 66 Engine compression test 67 Cooling Syste...

Page 27: ... 12 volt Crankcase Capacity with filter 19 0 Litres 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 ...

Page 28: ... 0 023 0 069mm 0 0009 0 0027 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 VALVE INSERTS Insert Oversize Exhau...

Page 29: ...eeth 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 1...

Page 30: ...2 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 Compressio...

Page 31: ...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 ...

Page 32: ...PIN 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 ...

Page 33: ...efer 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 Gask...

Page 34: ...ADIATOR 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 ...

Page 35: ...o 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...

Page 36: ...ply to any operation not previously listed INCH SERIES Nm lbf ft 1 4 20 11 8 1 4 28 11 8 5 16 18 19 14 5 16 24 23 17 3 4 16 31 23 3 4 24 45 33 7 16 14 65 48 7 16 20 75 55 1 2 13 88 65 1 2 20 102 75 9 16 18 122 90 5 6 18 187 138 CYLINDER BLOCK PLUGS 1 4 27 NPT 11 8 1 4 18 NPT 29 8 22 3 4 18 NPT 38 28 3 4 14 NPT 27 20 ...

Page 37: ... 502 Valve spring compressor 380000302 Water pump impeller seal installer 380000321 FNH04672 4672 Injector hand pump tester 380000215 FNH01721 Injector Adaptor Set FNH01728 Injector cleaning kit 380000254 Injector splitting block 380000308 Injector Splitting socket kit 380000309 Injection pump drive gear puller 380000322 FT6212B Adjustable bridge puller 380000329 FNH09539 9539 Shaft protector 3800...

Page 38: ...ve guide bores 5 Blown head gasket 5 Check head flatness and fit new gasket 6 Incorrect fuel delivery 6 Check injectors and pump 7 Low cylinder compression 7 Renew piston rings or re bore re sleeve as necessary Oil pressure warning light fails to operate 1 Bulb burnt out 1 Renew bulb light fails to operate 2 Warning Light pressure switch faulty 2 Renew pressure switch 3 Warning light circuit fault...

Page 39: ...rod or main bearing clearance 6 Install new bearing inserts and or 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 bore clearance 9 Re bore re sleeve block and fit new pistons 10 Excessive piston ring clearance 10 Fit new pistons and rings 11 Broke...

Page 40: ...ck 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 installed 11 Renew cylinder head gasket 12 Hot spot due to rust and scale or clogged water jackets 12 Reverse flush entire cooling system 13 Obstruction to radiator air flow 13 Remove the obstruction 14 Exten...

Page 41: ...nkshaft if necessary Excessive oil consumption 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...

Page 42: ...nlet and exhaust manifolds on opposite sides of the cylinder head The fuel and air combustion process takes place in the specially designed bowl in the crown of the pistons CYLINDER BLOCK ASSEMBLY The cylinder block is an alloy cast iron with deep cylinder skirts and water jackets for cooling the cylinders The cylinder bores are machined integral with the cylinder block during the manufacturing pr...

Page 43: ...able 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 2 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 Camsh...

Page 44: ...ion 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 trans...

Page 45: ...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 3 ...

Page 46: ...ngs 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 ...

Page 47: ...396 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 or Mechanically controlled depending on model 10 11 ...

Page 48: ... 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 ...

Page 49: ...ponents on the en gine Refer to Chapter 1 Separating and Removing Engine NOTE All gaskets seals and O rings must be re placed during re assembly Where new sealant is to be applied refer to Engine Specifications For concerns relating to the fuel system refer to the fuel system Chapter in this manual On engines fitted with the electronically controlled fuel injection pump refer to the Engine Fault C...

Page 50: ...rive 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 Refe...

Page 51: ...ed then pump timing CAN NOT be accurately set 17 5 Insert the crankshaft timing pin 380000172 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 ro...

Page 52: ... 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 t...

Page 53: ...nd 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 compo nents 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...

Page 54: ...jector lines 1 and leak off lines 2 from the fuel injectors and injection pump Cap all exposed openings 2 1 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 ...

Page 55: ...bly 31 NOTE Leave bolts in the rocker shaft supports dur ing 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 bl...

Page 56: ...02 FNH02136 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 1 2 34 35 Inlet and Exhaust Valves 1 Inlet Valve 2 Spring 3 Spring Retainer 4 Retainer Key 5 Retainer Key 6 Spring Retainer 7 Spring 8 Exhaust Valve ...

Page 57: ...able 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 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 i...

Page 58: ...ed in dry ice prior to installation Valve Seat Specifications Figure 39 1 Valve seat angle Intake 30 0 30 30 Exhaust 45 0 45 30 2 Valve seat width Intake 0 078 0 098 in 1 9 2 4mm Exhaust 0 072 0 092 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 NOTE Valve inserts of 0 010 in 0 25mm and 0 020 in 0 5mm oversize on diamet...

Page 59: ...alves and a 45 grinding wheel for intake valves TA6010016 41 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 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 4...

Page 60: ...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 are not to specification replace with new parts 6 5 TA60...

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