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Service Manual: Tractor

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50% found this document useful (2 votes)
194 views41 pages

Service Manual: Tractor

Uploaded by

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Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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SERVICE MANUAL

6010 / 6510 / 7510


Tractor

Part number 47969433


1st edition English
November 2016
Replaces part number 47628612

© 2016 CNH Industrial (India) Pvt.Ltd. All Rights Reserved.


SERVICE MANUAL

6010
6510
7510

47969433 28/11/2016
EN

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Contents

INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

Clutch ....................................................................................... 18
[18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

Transmission.............................................................................. 21
[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1

[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.110] Master clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

[21.120] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6

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[21.126] Gearbox external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7

[21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8

[21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9

[21.162] Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10

[21.168] Hi-Lo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.11

[21.200] Dropbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.12

Front axle system ....................................................................... 25


[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

Rear axle system........................................................................ 27


[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Power Take-Off (PTO) ................................................................. 31


[31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1

Brakes and controls .................................................................... 33


[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

Steering..................................................................................... 41

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[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

Electrical systems ....................................................................... 55


[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

Platform, cab, bodywork, and decals ............................................. 90


[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

[90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

[90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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INTRODUCTION

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Contents

INTRODUCTION

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules - Health and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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INTRODUCTION

Safety rules
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages involving personal safety. Carefully read
the safety rules contained herein and follow advised precautions to avoid potential hazards and
safeguard your safety and personal integrity. In this manual you will find this symbol together with the
following key-words:
WARNING – It gives warning about improper repair operations and deriving potential consequences
affecting the service technician’s personal safety.
DANGER – It gives specific warning about potential dangers for personal safety of the operator
or other persons directly or indirectly involved.

TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in workshops are due from non-observance of some simple and
essential prudential rule and safety precautions. The possibility that an accident might occur with any type of machines
should not be disregarded, no matter how well the machine in question was designed and built.

A wise and careful service technician is the best precautions against accidents

Careful observance of this only basic precaution would be enough to avoid many severe accidents.
NOTE: Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

SAFETY RULES

Generalities
• Carefully follow specified repair and maintenance procedures.
• Do not wear rings, wrist watches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught in moving parts. Use approved safety clothing such as
anti—slipping footwear, gloves, safety goggles, helmets, etc.
• Wear safety glasses with side guards when cleaning parts using compressed air.
• Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing.
• Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear whenever
welding. All persons standing in vicinity of the welding process should wear approved eye protection. NEVER
LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.
• Never carry out any repair on the machine if someone is sitting on the operator’s seat, except they are qualified
operators assisting in the operation to be carried out.
• Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side
of the machine when operating the fender switches.
• Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop
the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.
• All repair and maintenance operations should be carried out with greatest care and attention.
• Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all
equipment which should be raised.
• Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such
fluids are flammable.
• The fuel filling gun should always remain in contact with filler neck. Maintain this contact until the fuel stops flowing
into the tank to avoid possible sparks due to static electricity build-up. • To transfer a failed tractor, use a trailer of
a low loading platform trolley if available.
• To load and unload the machine from the transportation means, select a flat area providing a firm support to the
trailer or truck wheels. Firmly tie the machine to the truck or the trailer platform and block wheels as required by
the transporter.
• Always use lifting equipment of appropriate capacity to lift or move heavy components.

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INTRODUCTION

• Chains should always be safely fastened.


• Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening
point.
• The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil.
• Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non flammable non-toxic propri-
etary solvents.
• Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal
container.

START UP
• Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extrac-
tion.
• Never bring your body, arms, legs, feet, hands, fingers near fans or rotating belts.

ENGINE
• Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant
should be topped up only when the engine is stopped.
• Do not fill up fuel tank when the engine is running.
• Never adjust the fuel injection pump when the tractor is moving. Never lubricate the tractor when the engine is
running.

ELECTRICAL SYSTEMS
• If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (-) to
(-). Avoid short-circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During
charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery
area. Do not smoke.
• Do not charge batteries in confined spaces.
• Always disconnect the batteries before performing any type of service on the electrical system.

HYDRAULIC SYSTEMS
• Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate skin.
For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece
of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate
medical attention may result in serious infections or dermatitis.
• Always take system pressure readings using the appropriate gauges.

WHEELS AND TIRES


• Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check for
possible damage to the rims and tyres.
• Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong reading due to over- pres-
sure.
• Never cut, nor weld a rim with the inflated tire assembled.
• Never cut, nor weld a rim with the inflated tire assembled.
• Deflate the tire before removing any object caught into the tire tread.
• Never inflate tyres using flammable gases as they may originate explosions and cause injuries to bystanders.

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INTRODUCTION

Safety rules - Health and safety


Health 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 and the materials and equipment as-
sociated with them.

The precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and
procedures and the handling of materials, should be carried out with health and safety in mind.

Acid and alkalis


see Battery acids, e.g. caustic soda, sulfuric acid.
Used in batteries and cleaning materials

Irritant and corrosive to the skin, eyes, nose and throat. Causes burns.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary
protective clothing. Do not breathe mists.
Ensure access to water and soap is readily available for splashing accidents.

Adhesive and sealers


see Fire Highly Flammable, Flammable, combustible.
Generally should be stored in “ No Smoking” areas; cleanliness and tidiness in use should be observed, e.g.
disposable paper covering benches; should be dispensed from applicators where possible; containers, including
secondary containers, should be labeled.

Solvent based Adhesive/Sealers


See Solvents. Follow manufacturer’s instructions.

Water base Adhesive/ Sealers


Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use. Follow
manufacturer’s instructions

Resin based Adhesives/Sealers


e.g. epoxied and formaldehyde resin based.
Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic of harmful
chemicals through the skin. Splashes can damage the eyes
Provide adequate ventilation and avoid skin and eye contact . Follow manufacturers’ instructions.

Anaerobic, Cyanoacrylate and other Acrylic Adhesives


Many are irritant, sensitizing or harmful to the skin. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturers’ instructions followed.
Cyanaocrylate adhesives (super-glues) must not contact the skin or eyes. If skin or eye tissue is bonded cover
with a clean moist pad and get medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas
as vapors can cause irritation of the nose and eyes.
For two-pack systems see Resin based adhesives/sealers.

Isocyanate (Polyurethane) Adhesives/ Sealers


—see Resin based Adhesives.
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity
reactions can occur.
Any spraying should preferably be carried out in exhaust ventilated booths removing vapors’ and spray droplets
form the breathing zone. Individual’s working with spray applications should wear supplied air respirators

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INTRODUCTION

Antifreeze
- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Menthol.
Highly Flammable, Flammable, Combustible. Used in vehicle cooling systems, brake air pressure systems,
screen wash solutions.
Vapors given off from coolant antifreeze (glycol) arise only when heated.
Antifreeze may be absorbed through skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical
attention must be found immediately.

Arc welding
see Welding

Battery acids
see Acids and Alkalis.
Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently
charged batteries.

Brake and clutch fluids (Polyalkylene Glycols)


- see Fire Combustible.
Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation of
vapors hazards do not arise at ambient temperatures because of the very low vapor pressure

Brazing
See welding

Chemical materials - General


- see Legal Aspects
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake
fluids, oils and grease should always be used with caution and stored and handled with care. They may be toxic,
harmful, corrosive irritant or highly inflammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening or may reduce life expectancy.

Do’s
Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily
soiled clothing and have it cleaned.
Do carefully read and observe hazard and precaution warning given on material containers (labels) and in any
accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained
from manufacturers’.
Do organise work practices and protective clothing to avoid soling of the skin and eyes; breathing
Vapors/aerosols/dusts/fumes inadequate container labelling; fire and explosion hazards.
Do wash before job breaks; before eating, smoking, drinking or using toilet facilities when handling chemical
materials.
Do keep work areas clean, uncluttered and free of spills.
Do store according to national and local regulations.
Do keep chemical materials out of reach of children.

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INTRODUCTION

Do not’s
Do not mix chemical materials except under the manufacturers’ instructions; some chemicals can form other toxic
or harmful chemicals; give off toxic or harmful fumes; be explosive when mixed together.
Do not spray chemical materials, particular those based on solvents, in confined spaces e.g. when people are
inside a vehicle.
Do not apply heat or flame to chemical materials except under the manufacturers’ instructions. Some are highly
inflammable and some may release toxic or harmful fumes.
Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some
fumes are heavier than air and will accumulate in confined areas, pits etc.
Do not transfer chemical materials to unlabeled containers.
Do not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels will dry the skin
and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities.
Do not use emptied containers for other materials, except when they have been cleaned under supervised
conditions.
Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Clutch fluids
see Brake and Clutch Fluids.

Clutch linings and pads


see Brake and Clutch Linings and Pads.

Corrosion protection materials


see Solvents, Fire.
Highly flammable, flammable.
These materials are varied and the manufactures’ instructions should be followed. They may contain solvents,
resins, petroleum products etc. skin and eye contact should be avoided. They should only be sprayed in conditions
of adequate ventilation and not in confined spaces.

Cutting
see Welding

De-waxing
see Solvents and Fuels (Kerosene).

Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or
those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Electric shock
Electric shocks can result from the use of the faulty electrical equipment or from the misuse of equipment even in
good condition.
Ensure that electrical equipment is maintained in good condition and frequently tested.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.
Ensure that electric equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in anyway faulty. The results could be fatal.
Use reduced voltage equipment where possible in preference to electrical equipment.

In cases of electrocution:-
• switch off electricity before approaching victim
• if this is not possible, push or drag victim from source of electricity using dry non— conductive material
• Commence resuscitation if trained to do so.
• SUMMON MEDICAL ASSISTANCE

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INTRODUCTION

Exhaust fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, alde-
hydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or
general ventilator and not in confined spaces.

Gasoline (petrol) engine


There may not be adequate warning properties of odor or irritation before immediate and delayed toxic or harmful
effects arise.

Diesel engine
Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Fibre insulation
see Ducts
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical
effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the
use of gloves.

Fire
see Welding, Foams, and Legal Aspects.
Many of the materials found on or associated with the repair of vehicles are highly inflammable. Some give off toxic
or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equip-
ment or welding processes.
Ensure before using electrical or welding equipment but that there is no fire hazard present.
Have suitable fire extinguisher available when using welding or heating equipment.

First aid
Apart from meeting any legal requirements its desirable for someone in the workshop to be trained in first aid proce-
dures.
Splashes in the eye should be flushed with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Inhalation affected individuals should be removed to fresh air immediately.
If swallowed or if effects persist consult a doctor with information (label) on material used.
Do not induce vomiting (unless indicated by manufacturer)

Foams
see Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturers’ instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems or histories of allergic diseases
should not work with or near uncured materials.
The components, vapors, spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be breathed. These materials must be applied with adequate ventilation and respi-
ratory protection. Do not remove respirator immediately after spraying, wait until vapor/ mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes.
Smoking, open flames or the use of electrical equipment during foaming operations and until vapors/mists have
cleared should not be allowed. Any heat cutting of cured foams or partially cured - foams should be conducted with
extraction ventilation (see Body Section 44 Legal and Safety Aspects).

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INTRODUCTION

Fuels
see Fire, Legal Aspects, Chemicals - General, Solvents.
Used as fuels and cleaning agents.

Gasoline (petrol)
Highly flammable.
Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, e.g. through vomiting,
is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye
causes severe smarting.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentrations
of gasoline vapors must be kept. very low. High concentrations will cause eye, nose and throat irritation, nausea,
headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of conscious-
ness.
Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious
consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks. Gasoline should not
be used as a cleaning agent. It must not be siphoned by mouth.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspi-
ration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye
may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from
kerosene at elevated temperatures should be avoided (mists may arise in de-waxing). Avoid skin and eye contact
and ensure there is adequate ventilation.

Gas-oil (diesel fuel)


see Fuels (Kerosene). Combustible.
Gross or prolonged skin contact with high boiling gas oils may also 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 cylinders at pressures of
up to 2000 Ib/sq. in. (13,790 kn/m2) and great care should be taken in handling these cylinders to avoid mechanical
damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel
gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. Only trained
personnel should undertake work involving gas cylinders

Gases
see Gas Cylinders

Gas shielded welding


-see Welding.

Gas welding
-see Welding.

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INTRODUCTION

General workshop tools and equipment


It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used
where required.
Never use tools or equipment for any purpose other than that for which they were designed.
Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by over-
loading is not always immediately apparent and may result in a fatal failure he next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiseling or sand blasting equipment
Wear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials or using
spraying equipment

Glues
see Adhesives and Sealers.

High pressure air, lubrication and oil test

Equipment
see Lubricants and Greases.
Always keep high pressure equipment in good Condition and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle at the skin as the fluid may penetrate to the underlying tissue etc. and cause
serious injury.

Legal aspects
Many laws and regulations make requirements relating to health and safety in the use of materials and equipment in
workshops.

Workshops should be familiar, in detail, with associated laws and regulations. Consult local factory inspectors if in
any doubt.

Lubricants and greases


Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service
(e.g. routine service change sump oils) are more irritating and more likely to cause serious effects including skin
cancer in the event of gross and prolonged skin contact. Wash skin thoroughly after work involving oil. Proprietary
hand cleaners may be of value provided they can be removed from the skin with water. Do not use petrol, paraffin or
other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particular care
should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil.
Dry clean or launder such clothing at regular intervals. Discard oil soaked shoes.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Used oils may only be disposed of in accordance with local regulations.
There are publications describing the problems and advising on precautionary measures.

Noise insulation materials


See Foams, Fibre Insulation.

Paints
see Solvents and Chemical Materials - General.
Highly Flammable, Flammable.

ONE PACK.
Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should only be
carried out with adequate ventilation.

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INTRODUCTION

TWO PACK.
Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturer’s instructions
should be followed and the section of page 5 on resin based adhesives, isocyanate containing Adhesives and Foams
should be consulted.
Spraying should preferably be carried out in exhausted ventilated booths removing vapor and spray mists from the
breathing zone. Individuals working in booths should wear respiratory protection. Those doing small scale repair work
in the open shop should wear supplied air respirators.

PAINT THINNERS -see Solvents.

PETROL -see Fuels (Gasoline).


Pressurised Equipment -see High Pressure Air, Lubrication and Oil Test Equipment.

Resistance Welding
see Welding

Sealers
see Adhesives and Sealers.

Solder
see Welding.
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (nor-
mally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is
used. Oxy - acetylene flames should not be used, as they are much hotter and will cause lead fumes to be evolved.
Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of
these should be avoided.
Removal of excess solder should be undertaken with care, to ensure that fine lead dust is not produced, Which can
give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filing should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid indigestion of lead or inhalation of solder dust
from clothing.

Solvent
see Chemical Materials -General
Fuels (Kerosene), Fire.
e.g. Acetone, white spirit, toluene, xylene, trichlorethane.
Used in cleaning materials, de-waxing, paints, plastics, resins, thinners etc.
Highly Inflammable, Flammable.
Skin contact will decrease the skin and may result in. -irritation and dematitis following repeated or prolonged contact.
Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness,
headaches and in the worst circumstances, unconsciousness.
Repeated or prolonged exposures to excessive but lower concentrations of vapors or mists, for which there might
not be adequate warning indications, can cause more serious toxic or harmful effects. Aspiration into the lungs (e.g.
through vomiting) is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly
sealed. Do not use in confined spaces.
When the spraying material contains solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal
respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.

Sound Insulation
see Fibre Insulation, Foams.

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INTRODUCTION

Spot Welding
-see Welding.

Suspended loads
There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or raised
load, e.g. jacked up vehicle, suspended engine, etc.
Always ensure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the
job, in good condition and regularly maintained.
Never improvise lifting tackle.

Underseal
see Corrosion Protection

Welding
see Fire, Electric Shock, Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Arc Welding
and Gas Welding.

Resistance welding
This process may cause particles of molten metal to be emitted at high velocity and the eyes and skin must be pro-
tected.

Arc welding
This process emits a high level of ultraviolet radiation which may cause eye and skin burns to the welder and to other
persons nearby. Gasshielded welding processes are particularly hazardous in this respect. Personal protection must
be worn, and screens used to shield other people.
Metal spatter will also occur and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded and from any applied coatings
or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation should
always be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary,
particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In
extreme cases where adequate ventilation cannot be provided, supplied air respirators may be necessary.

Gas welding
Oxy-acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of
these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright and eye protection should be used, but the ultra-violet emission is much less than that from arc
welding and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be evolved from the metals in the brazing rod, and a severe hazard may arise if brazing
rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert
advice may be required.
Special precaution must be taken before any welding or cutting takes place on vessel which have contained com-
bustible materials, e.g. boiling or steaming out of fuel tanks.

White spirit
See solvents

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SERVICE MANUAL
Engine

6010
6510
7510

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Contents

Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

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Engine - 10

Engine and crankcase - 001

6010
6510
7510

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Contents

Engine - 10

Engine and crankcase - 001

TECHNICAL DATA

Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA

Engine
Overview DESCRIPTION AND OPERATION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE

Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overhaul CYLINDER BLOCK OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

DIAGNOSTIC

Engine
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

(*) See content for specific models

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Engine - Engine and crankcase

Engine - General specification


Table 1

GENERAL SPECIFICATIONS
Make IVECO
4 stroke, diesel, naturally aspirated, direct
Type
injection, water cooled
Power 55/60/65/75 Hp
No of Cylinders 3
Bore 104 mm
Stroke 115 mm
Cubic Capacity 2931 cm³
Compression Ratio 18:1
Firing Order 1–2–3
Idle Speed 650 ± 50 RPM
Maximum no Load Speed 2550 ± 50 RPM
Rated Speed 2300 RPM
Engine block
Cylinder liner seat diameter in engine block 106.850 - 106.900 mm
Cylinder sleeve O.D 106.94 - 106.97 mm
Interference between liners and seats in block 0.04 - 0.12 mm
Liner O.D oversize 0.2 mm
Cylinder liner inner diameter 104.00 - 104.024 mm
Maximum ovality and taper due to wear 0.12 mm
Liner inner diameter oversize 0.4 - 0.8 mm
Camshaft bush seat diameters
Front 54.780 - 54.805 mm
Intermediate 54.280‐‐ - 54.305 mm
Rear 53.780 - 53.805 mm
Tappet seat bore diameter 15.000 - 15.018 mm
Tappet oversize 0.1–0.2 - 0.3 mm
Main bearing seat bore diameter 84.200 - 84.230 mm
Cylinder head
Valve guide seat bore diameter in head 13.950 - 13.983 mm
Valve guide oversize 0.2 mm
Valve stand-in 0.7 - 1.0 mm
Maximum stand‐in permitted 1.3 mm
Injector standout 0.05 - 0.7 mm
Max. standout permitted 1.0 mm
Original cylinder head height 92 mm
Maximum head dressing allowed 0.5 mm
Compression pressure 28 bar
Engine cracking speed 250 RPM
Exhaust valves
Valve head diameter 40.75 - 41.25 mm
Valve stem diameter 7.975 - 7.990 mm
Face angle 45 30’ ± 7’ °
Tappet clearance 0.30 ± 0.05 mm
Cam lift 6.127 mm
Valve lift 10.445 mm
Intake valves
Valve head diameter 45.300 - 45.500 mm
Valve stem diameter 7.985 - 8.000 mm
Face angle 60 30´ ± 7´ °
Tappet clearance (cold) 0.30 ± 0.05 mm
Cam lift 5.889 mm

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Engine - Engine and crankcase

Valve lift 10.445 mm


Tiner - Internal Exhaust Gas Recirculation(EGR)
Intake opening (After BDC, during exhaust stroke) 3°
Intake valve closing (Before TDC, during Exhaust stroke) 61 °
‘Tiner’ cam lobe lift 1.076 mm
Intake valve lift (tiner) 1.908 mm
Valve springs
Number per valve 1 mm
Free length 44.6 mm
Length loaded at 26.1 - 28.9 kg 34 mm
Length loaded at 51.2 - 56.5 kg 23.8 mm
Valve timing
Intake opening (before top dead centre) 15 °
Intake closing (after bottom dead centre) 45 °
Exhaust opening (before bottom dead centre) 56 °
Exhaust closing (after top dead centre) 26 °
Valve inserts
Valve guide OD 13.933 - 14.016 mm
Valve guide oversize 0.2 mm
Valve guide interference fit in housing cylinder head 0.005 - 0.050 mm
Valve guide fitted ID after reaming 8.023 - 8.043 mm
0.023 - 0.058 mm (for intake valve)
Valve stem clearance in guide
0.033 - 0.068 mm (for exhaust valve)
Maximum wear clearance . 0.13 mm
Maximum valve stem eccentricity over one revolution with stylus on
0.03 mm
sealing face

Crank gear
Crankshaft- Bearings
Main journal diameter 79.791 - 79.810 mm
Main journal undersize 0.254‐‐0.508‐‐0.762‐‐1.016 mm
Main bearing wall thickness 2.168 - 2.178 mm
Main bearing undersize 0.254‐‐0.508‐‐0.762‐‐1.016 mm
Main journal clearance in bearings 0.034 - 0.103 mm
maximum wear clearance 0.180 mm
Crank pin diameter 63.725 - 63.744 mm
Crank pin undersize 0.254‐‐0.508‐‐0.762‐‐1.016 mm
Big end bearing wall thickness 1.805 - 1.815 mm
Big end bearing undersize 0.254‐‐0.508‐‐0.762‐‐1.016 mm
Crank pin clearance in big end bearing 0.033 - 0.087 mm
maximum wear clearance 0.180 mm
Crankshaft thrust washer thickness 3.378 - 3.429 mm
Thrust washer oversize 0.127‐‐0.254‐‐0.508 mm
Width of main bearing housing over thrust washers 31.766 - 31.918 mm
Length of corresponding main journal 32.000 - 32.100 mm
Crankshaft end float 0.082 - 0.334 mm
maximum wear end float 0.40 mm
Maximum main journal and crank pin ovality or taper after grinding 0.01 mm
Maximum main journal and crankpin ovality or taper due to wear or 0.05 mm
taper due to wear
Maximum main journal misalignment
Crankshaft resting on end journals 0.10 mm
Maximum misalignment of crank pins relative to main journals(in 0.25 mm
either direction)
Tolerance from outer crankpin edge to crank‐shaft center line ±0.10 mm

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Engine - Engine and crankcase

Maximum crankshaft flange run‐out with gauge, over 108 mm 0.025 mm


(4.25”) diameter (total gauge reading)
Maximum flywheel seat eccentricity relative to main journals (total 0.04 mm
gauge reading)
Connecting rods
Small end bore diameter 41.846 - 41.884 mm
Small end bushing outer diameter 41.979 - 42.017 mm
Bushing interference fit in small end 0.095 - 0.171 mm
Small end bushing fitted I.D . 38.004 - 38.014 mm
Big end bore diameter 67.407 - 67.422 mm
Maximum connecting rod axis misalignment at 125 mm ± 0.07 mm
Maximum connecting rod weight difference over a complete set 25 g
from the same engine
Pistons
Piston diameter: measured at 12 mm from base of skirt and right 103.852 - 103.870 mm
angles to pin
Piston clearance in liner 0.130 - 0.172 mm
max. wear clearance 0.30 mm
Piston oversize range 0.6 mm
Piston stand‐out with respect to head at T.D.C 0.430 - 0.840 mm
Piston pin diameter 37.983 - 37.99 mm
Piston pin seat bore in piston 38.000 - 38.006 mm
Piston pin clearance in piston 0.010 - 0.023 mm
Piston pin clearance in small end bushing 0.014 - 0.031 mm
maximum wear clearance 0.06 mm
Maximum weight difference between pistons on same engine 20 g
Piston ring clearance in groove
• Top 0.090 - 0.122 mm
• 2nd 0.060 - 0.092 mm
• 3rd 0.040 - 0.080 mm
Maximum wear clearance
• Top 0.50 mm
• 2nd and 3rd . 0.20 mm
Piston ring gap
• Top 0.30 - 0.45 mm
• 2nd 0.60 - 0.85 mm
• 3rd 0.30 - 0.55 mm
Maximum wear gap 1.20 mm

Valve gear
Valve timing gears
Timing gear backlash 0.160 mm
Idler gear jack shaft diameter 36.975 - 37.000 mm
Idler gear bushing fitted I.D. after reaming 37.050 - 37.075 mm
Jack shaft journal clearance in bushing 0.050 - 0.100 mm
Max. wear clearance 0.15 mm
Bushing interference fit in idler gear 0.063 - 0.140 mm
Lift and power steering pump drive gear shaft
Diameter 36.975 - 37.000 mm
Bushing fitted I.D. after reaming 37.050 - 37.075 mm
Shaft clearance in bushing 0.050 - 0.100 mm
Bushing interference fit in housing 0.063 - 0.140 mm
Pump drive gear thrust washer thickness 1.45 - 1.50 mm

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Engine - Engine and crankcase

Camshaft
Camshaft bushing O.D.
• Front 54.875 - 54.930 mm
• Intermediate 54.375 - 54.430 mm
• Rear 53.875 - 53.930 mm
Bushing interference fit in housing 0.070 - 0.150 mm
Camshaft bushing fitted I.D after reaming:
‐ Front 51.080 - 51.130 mm
‐ Intermediate 50.580 - 50.630 mm
‐ Rear 50.080 - 50.130 mm
Camshaft journal diameter:
‐ Front 50.970 - 51.000 mm
‐Intermediate 50.470 - 50.500 mm
‐ Rear 49.970 - 50.000 mm
Camshaft journal clearance in bushing 0.080 - 0.160 mm
Maximum wear clearance 0.20 mm
Camshaft end float (thrust plate to associated seat in camshaft) 0.070 - 0.220 mm
Tappets
Tappet O.D 14.950 - 14.970 mm
Tappet clearance in housing on engine block 0.030 - 0.068 mm
Maximum wear clearance 0.15 mm
Tappet oversize 0.1‐‐0.2‐‐0.3 mm
Rocker bore diameter 18.016 - 18.034 mm
Rocker shaft diameter 17.982 - 18.000 mm
Rocker shaft clearance in bracket 0.016 - 0.052 mm
maximum wear clearance 0.15 mm
Rocker spacer spring length:
‐ Free 59.5 mm
under load 4.7 - 5.3 kg 44 mm
Valves, guides and springs
Valve head diameter inlet 45.300 - 45.500 mm
Exhaust 40.75 - 41.25 mm
Valve stem diameter Inlet- 7.985 - 8.000 mm
Exhaust 7.975 - 7.990 mm
Valve face angle: inlet 60 o 30’±7 ’ °
Exhaust 45 o 30±77’ °
Tappet clearance 0.45 °
Engine inlet 0.30±0.05 mm
Exhaust (cold) 0.30±0.05 mm
Cam lift: inlet 5.889 mm
exhaust 6.127 mm
Valve lift: inlet 10.445 mm
Exhaust 10.868 mm

Lubrication system
Oil pump Gear, crankshaft driven
Oil pump drive ratio 1.27:1
Oil pressure Rated – 3 - 4.5 bar
Peak torque – 2.5 - 3.5 bar
Relief valve crack‐off setting . 3.6 bar
Assembly. clearance between shaft and bushing oil pump drive 0.016 - 0.070 mm
Shaft clearance in driven gear 0.016 - 0.054 mm
Gear backlash 0.100 mm
Gear radial clearance in pump housing 0.015 - 0.067 mm
Drive and driven gear width 15.973 - 16.000 mm

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Engine - Engine and crankcase

Gear housing depth in pump body 16.016 - 16.080 mm


Drive and driven gear end float 0.016 - 0.107 mm
Relief valve spring length:
‐ Free 35.9 mm
‐ AT load 134.55±6.73 N 29 mm
‐ AT load 245.70±12.3 N 23.2 mm
Oil filter Mesh on suction and cartridge on delivery

Cooling system
Water pump Centrifugal, vane
60 / 55 Hp 65 Hp 75 Hp
Water pump drive ratio 1.04 1.18 1.38
Shaft interference fit in impeller 0.017 - 0.059 mm
Shaft interference fit in fan hub 0.024 - 0.058 mm
Face sealing bushing interference fit in impeller 0.012 - 0.058 mm
Thermostat type Wax
Opening temperature 79±2 °C
Close off temperature 94 °C
Valve travel when fully open 7.5 mm
Radiator Vertical tube and Aluminium fins
Fan Suction, steel, 6 blades
Water temperature gauge Three colored sectors
Temperature range for each sector:
‐ white sector 0 - 40 °C
‐ green sector 40 - 112 °C
‐ red sector 112 - 120 °C

Fuel system
Fuel feed pump Double diaphragm
Operation Engine driven
Minimum fuel flow at 1600 RPM shaft speed 100 L/hour
Drive shaft eccentricity 3 mm
Fuel pump drive Shaft journal dia 31.975 - 32.000 mm
Bushing fitted I.D. after reaming 32.050 - 32.075 mm
Shaft clearance in bushing 0.050 - 0.100 mm
Bushing interference fit in housing 0.063 - 0.140 mm
Inner washer thickness 1.45 - 1.50 mm
Outer washer thickness 2.93 - 3.00 mm
Injection pump Distributor, integral governor and advance device
‐ BOSCH
55 Hp 60 Hp 65 Hp
0460423063 (with ( 0460423072) 0460423073 With
LDA) With KSB KSB
0460423079 (0460423076) (0460423077)
(without LDA) Without KSB Without KSB
75 Hp
(0460423075)
With KSB
(0460423078)
Without KSB
Firing order : 1‐2‐3
Injectors: 55 / 60 / 65 Hp 75 Hp
Make BOSCH BOSCH
Nozzle holder F002 C70 567 (KBAL 86 P 163) F002 C70 567 (KBAL
86 P 163 )
Nozzle. F002 C40 750 (DSLA 142 P 5565 ) F002 C40 738 ( DSLA
145 P 5544)

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Engine - Engine and crankcase

Number of spray orifices 6 6


Spray orifice diameter 0.176 mm 0.193 mm
Pressure setting 260 - 268 Kg/cm² 260 - 268 Kg/cm²
Delivery pipes
Type 5801439057
pipe dimensions 6X1.6X530
55 hp‐0.45±0.05 mm plunger lift @ TDC (without LDA)
Pump timing, cylinder no. 1 in compression stroke 55 hp‐ 0.6±0.05 mm plunger lift @ TDC (with LDA)
(delivery connection of cylinder no. 1: marked with 60 hp‐ 1±0.05 mm plunger lift @ TDC
letter “A” 65 hp‐ 1±0.05 mm plunger lift @ TDC
75 hp‐ 1.2±0.05 mm plunger lift @ TDC

Engine - Torque
TIGHTENING TORQUES
Description Thread size Torque (Nm) Angle
Cap screw, cylinder head (C1) M12 X 1.25 40 130±5 + 140±5 °
Cap screw, main bearing caps (C2) M14 X 1.25 80 90 °
Cap screw, timing cover and case (C3) M12 X 1.25 40
Cap screw, connecting rod caps (C4) M11 X 1.25 40 60 °
Cap screw, flywheel (C5) M12 X 1.25 40 60 °
Cap screw, rocker shaft bracket (C6) M8X1.25 25
Nut, crankshaft pulley hub (C7) M30 X 1.5 300
Cap screw, fan and alternator drive pulley(C8) M12 X 1.25 49
Nut, injection pump shaft gear (C9) M12 X 1.25 64
Nuts, injection pump to support (C10) M12 X 1.25 23
Retaining screws, additional weights (C11) M12 X 1.25 110

Engine - Sealing
SEALANTS
Operation Description Sealant Specification
Adopter for Oil Filter (S1) LOCTITE® 270
Adopter for Tachometer Cable (S2) LOCTITE® 243™
Flywheel Housing to Engine Block (S3) LOCTITE® 510™
Timing Gear case Studs (S4) LOCTITE® 270
Timing Gear cover Dowel pin(S5) LOCTITE® 270
Starter Motor to Flywheel Housing (S6) LOCTITE® 510™
Allen Plug in Cylinder Head Thermostat Housing (S7) LOCTITE® 243™
Cylinder Head Exhaust Manifold Studs (S8) LOCTITE® 270
Oil Sump to Engine Block (S9) LOCTITE® 5900®
Silencer mounting Studs on Exhaust Manifold(S10) LOCTITE® NICKEL ANTI-SEIZE 77164
Flywheel Bolt (S11) LOCTITE® 243™

Engine - Special tools


Serial number Special tool description Special tool number
1 Engine stand with support 380000301
2 Nozzle tester 380000215
3 Sling hook engine 380000216
4 Adopter for slide hammer 380000541
5 Tappet adjusting screw driver 380000232
6 Angular torquing gauge 380000304

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Engine - Engine and crankcase

Serial number Special tool description Special tool number


7 Remover, filters 380200593
8 Engine oil pressure gauge with adapter 380200591
9 Remover, fuel injection pump nut 380200594
10 Wrench to remove solenoid switch 380200595
11 Compression gauge 380200596
12 Dummy injector (turbo engine) 380200334

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Engine - Engine and crankcase

Engine - Overview DESCRIPTION AND OPERATION


6510 APAC
7510 APAC

The engine is a 3 cylinder engine with Turbo Charger and a inter‐cooler. This engine features cross flow cylinder
heads, with the inlet and exhaust manifolds on opposite sides of the cylinder head. The fuel and air combustion
process, takes place in the specially designed bowel in the crown of the pistons

CYLINDER HEAD ASSEMBLY


The cylinder head consists of valves and springs, 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. The intake and exhaust manifolds are bolted
to the head; the intake manifold is mounted on the right side of the engine, with the diesel injectors mounted outside
the rocker cover. The exhaust manifold is mounted on the left side of the engine. Water outlet connections and
thermostat being attached to the front of the cylinder block directly behind the radiator Valve guides are inserted into
the cylinder head, and replaceable. Special replaceable cast alloy valve seats are pressed into each valve port during
manufacturing. No oversize valve seats on guides are available. All valves are fitted with positive value rotators; 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 3 replaceable bushes. 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 integral on rear of cam
shaft, and drives the engine oil lubrication pump mounted forward of the flywheel.

Cylinder block assembly


The cylinder block is an alloy cast iron with deep cylinder skirts & water jackets for cooling the cylinders. The cylinder
bores are machined integral with the cylinder block, during the manufacturing process. Cylinders are inline and vertical
and numbered from 1 to 3 from front of the engine to the rear. The oil sump, which is attached to the bottom of the
cylinder block, is the reservoir for the engine oil lubrication system. A cast iron engine front cover and front plate is
attached to the front of the engine and covers all of the timing gear assembly.

CRANKSHAFT ASSEMBLY
The crankshaft is supported in the cylinder block by 4 main bearings. The crankshaft is manufactured from steel with
machined finished crank webs, End thrust is controlled by a thrust bearing. A dynamic balancer is fitted and driven by
crankshaft to ensure smooth running operation. Front and rear crankshaft oil sealing is affected by one piece seals
that are designed for long and durable service life.

CONNECTING RODS
The “Wedge” shaped at the small end of the connecting rod has been designed to reduce the reciprocating weight at
the piston end. The connecting rods have a heavy beam construction and are assembled as a matched set to each
engine. They are attached to the crankshaft, by means of insert type bearings. 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.

PISTONS
Pistons are constructed of an aluminium silicon alloy with notch type combustion chamber being recessed in to the
piston crowns.
Each piston has two compression rings and one oil control ring, to reduce the friction and increase positive seating.
All rings are located above the piston pin.

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Engine - Engine and crankcase

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. The intake manifold is connected through hose to air
cleaner.

NDIL14TR00001FA 1

Timing gears
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
drives the idler gear, which is attached to the front of cylinder block. The idler gear then drives the camshaft and the
injection pump via meshing helical gears

The camshaft gear is bolted to the front of the shaft and is keyed to maintain position of the gear on the camshaft.

LUBRICATION SYSTEM
Lubrication of the engine, Figure 7 & 8 is maintained by a gear type oil pump mounted in the rear of the engine block.,
forward of the flywheel on the left hand side viewing from rear side of the engine. The oil pump is driven from the rear
of the camshaft and drains oil from the engine oil sump through a tube and screen assembly

A spring loaded relief valve is integral with the oil filter and prevents over pressurization of the system. A spin on type
oil filter is mounted externally to its support housing on the left hand side of the engine. Oil flows from the filter to the
main oil gallery, which runs the length of the cylinder block, which also intersects the camshaft follower chamber.

The main gallery also supplies oil to the crankshaft main bearings, connecting rods both big and small ends and timing
gear bushes. The underside of the pistons and pins are lubricated by oil pressure jets.

Timing gears are lubricated by splashed oil from the cam follower chamber and the pressure lubricated camshaft drive
gear bushing.

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Engine - Engine and crankcase

An intermittent flow of oil is directed to the value rocker arm shaft assembly via a drilled passage in the cylinder block.
This is located vertically above No. 3 camshaft bearing and aligns to a hole in the cylinder head. The rotation of the
camshaft allows a controlled intermediate flow of lubrication.

GNIL14TR02062EA 2

COOLING SYSTEM
The function of the water pump mounted at the front of the engine, is to maintain a continuous flow of water around
the cooling system. This is essential to ensure engine temperature and performance within the recommended range,
during vehicle operation.
The Water pump is driven by a ‘V’ belt by the crankshaft pulley, when the engine is running.

The cooling system for the new generation of engines is of recirculating by‐pass type with full length water jackets for
the bottom tank of the radiator by the water pump, which passes the coolant to the cylinder block. This coolant then
flows through cored passages to cool the cylinder walls.

Passages in the cylinder head gasket allow coolant to flow from the cylinder block, into the cylinder head cored pas-
sages also conduct the coolant to the fuel injector nozzle locations before re‐entering the water pump below the
thermostat

The thermostat is located in the top of the water pump body, and controls the flow of the water as required by tem-
perature changes.

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Engine - Engine and crankcase

GNIL14TR02063FA 3

NOTE: A faulty thermostat may cause the engine to operate at too high (hot) or low (cold) operating temperature. If
not replaced this could result in a damaged engine or impaired engine performance. When the thermostat is closed
a recirculating by‐pass is provided to allow the coolant to recirculate from the head to the block in order to aid a faster
warm‐up. Once the engine has reached its normal operating temperature, the thermostat will open and allow water to
be drawn through the radiator by the pump action. Cooled water then returns to the engine system. Cooling occurs
as the coolant passes down through the radiator cores, which are exposed to the air as it is drawn through the radiator
by the fan.
NOTE: Do not operate an engine without a thermostat. The cooling system incorporates a drain plug, on the left hand
side of the cylinder block. The cap on the radiator is a system pressure cap and should not be removed unless refilling
the system from empty.
The engine cooling fan is mounted on a pump pulley which is belt driven from the crankshaft.

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Engine - Engine and crankcase

Engine - Remove
Preliminary instructions
In the following procedures and illustrations the engine
is shown removed from the tractor. However there are
certain operations that can performed with the engine
still in the tractor, or separated at the connection to the
front axle support, or separated from the transmission
housing.
The engine overhaul procedure initially describes the
assembly process for rebuilding an engine using all new
components. Following this section are defined head-
ings, which describe detailed repair specifications and
procedures, where components are suitable for re-use.
See Engine - General specification (10.001), to en-
sure components are serviceable.
Where overhaul of components is required without en-
gine being removed from the tractor refer to the follow-
ing headings, and the relevant paragraphs, in the main
overhaul procedure

Operations or repairs that can be performed with the engine still in the tractor.
1. Cylinder head and associated inlet and exhaust components.
2. Fuel injection pump and related parts.
3. Water pump, thermostat, and associated components.
4. Front timing cover/timing gear removal
5. Front pulley

Operations or repairs that are performed with the engine separated from the front axle
1. Oil pan removal for access to oil pan gasket, crankshaft, bearing shells, piston removal and oil pump.

Operations or repairs that are performed with the engine separated from the transmission housing, and with
oil pan removed
1. Crankshaft rear oil seal and carrier removal. Dismantle the engine by referring to the removal procedure.
Refer to the specification section wherever necessary.

NOTE: All gaskets, seals and ’O’ rings must be replaced while reassembling. Where new sealant is to be applied
refer to "Engine Specifications".

Engine removal
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
Failure to comply could result in death or serious injury.
W0208A

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Engine - Engine and crankcase

1. Remove front ballast weights (1), if fitted.

GNIL14TR02001AA 1

2. Pull the lock (1) out, and open the front hood.

GNIL14TR02002AA 2

3. To maintain the hood in the raised position, a gas strut


(1) is provided underside the hood.

GNIL14TR02003AA 3

4. Disconnect the negative terminal (1) of the battery fol-


lowed by the positive terminal.

GNIL14TR02004AA 4

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Engine - Engine and crankcase

5. Disconnect the electric coupler (1) of head lamp har-


ness located near hood gas strut.

GNIL14TR02706AA 5

6. Loosen the lower nut of gas strut (1).

GNIL14TR02006AA 6

7. Loosen and remove the two lower nuts (1) and the two
upper bolts (2) of front hood mounting bracket and re-
move the front hood.

GNIL14TR02007AA 7

8. Drain the coolant and disconnect the radiator hoses.


Disconnect the intercooler and oil cooler hoses.
9. Loosen and remove the four bolts below the LH side
footboard (1) for the removal of foot ladder (2).

GNIL14TR02009AA 8

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Engine - Engine and crankcase

10. Disconnect the wiring harness coupler. (1) (Main to


Instrument Cluster)

GNIL14TR02010AA 9

11. Disconnect Wiring harness coupler (Main to rear) (1).

GNIL14TR02011AA 10

12. Loosen and remove the four bolts (two from each side)
and remove the support bar (2).

GNIL14TR02012AA 11

13. Loosen the hose clamp and disconnect the hose con-
necting Fuel Injection Pump (FIP) to fuel tank (1).

GNIL14TR02013AA 12

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Engine - Engine and crankcase

14. Remove split pin (1) and disconnect accelerator rod


from FIP lever (2).

GNIL14TR02014AA 13

15. Loosen worm drive clamp of fuel suction flexible pipe


(1) and disconnect the flexible pipe, connecting pre-
filter to water separator (2).

GNIL14TR02015AA 14

16. Loosen worm drive clamp of fuel suction flexible pipe


(1) and disconnect the hose (2) connecting water sep-
arator to feed pump.

GNIL14TR02016AA 15

17. Loosen and remove the two bolts (1) from the bracket.
Remove the side panel with bracket, mounted on ra-
diator (2).

GNIL14TR02017AA 16

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Engine - Engine and crankcase

18. Disconnect the power steering pipe connecting steer-


ing pipes with steering cylinder ( both ends) (1) & (2).

GNIL14TR02018AA 17

19. Loosen pipe clamp (1) holding the power steering


pipes.

GNIL14TR02019AA 18

20. Loosen and remove the two bolts (1) and detach
power steering delivery pipe from power steering
pump (2).

GNIL14TR02020AA 19

21. Detach power steering pipe (1), connecting power


steering motor and power steering pump.

GNIL14TR02021AA 20

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Engine - Engine and crankcase

22. Loosen and remove the hollow nuts (1) ,from both
ends, and disconnect the hydraulic delivery pipe from
hydraulic pump.

GNIL14TR02022AA 21

23. Loosen hose clamp (1). Remove the hydraulic suction


hose (2) connecting hydraulic pipe to hydraulic filter.

GNIL14TR02023AA 22

24. Loosen the 4 bolts (1) and remove shield (2) on LH


side. Similarly remove the shield on RH side.
25. In case of Four-Wheel Drive (4WD), remove the pro-
peller shaft and the shields. Refer drive lines section
for removal details.
26. Remove the exhaust pipes referring to the “exhaus
pipe removal” process
27. Cut the plastic clamp and take out complete center
wiring to front side
28. remove wiring connections of alternator, sensor, WT
relay, OPS, FIP and starter solenoid.
GNIL14TR02024AA 23

29. Loosen and remove the two clamp bolts (1) and re-
move muffler pipe (2).

GNIL14TR02025AA 24

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Engine - Engine and crankcase

30. Loosen and remove the bolts (1). Remove the heat
shield (2).

GNIL14TR02026AA 25

31. Loosen and remove the “U” clamp bolts (1). Remove
the muffler U -pipe (2).

GNIL14TR02027AA 26

32. Separate the Four-Wheel Drive (4WD) shaft from the


front axle (if fitted). See Dropbox drive shaft - Re-
move (21.200).
33. Use wedge (1) between the axle and front axle support
to prevent articulation.
34. Support front axle with a movable jack and rail and
immovable screw jack below engine frame.

GNIL14TR02028AA 27

35. Remove the twelve buckle up bolts (1) between en-


gine & master clutch housing. Pull the engine away
using moving rail jack.

GNIL14TR02029AA 28

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