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Farmall 90 Manual

Engine
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Section
Description
10 001 10
10 001 53
Chapter 1 - - Engine
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Summary of Contents for Farmall 90

  • Page 1: Table Of Contents

    SECTION 10 - - ENGINE - - CHAPTER 1 SECTION 10 - - ENGINE Chapter 1 - - Engine CONTENTS Section Description Page Specifications ..............Torques .
  • Page 2 SECTION 10 - - ENGINE - - CHAPTER 1 Section Description Page Fitting the Crankshaft Front Seal ......... Fitting the Crankshaft Front Pulley .
  • Page 3 SECTION 10 - - ENGINE - - CHAPTER 1 Section Description Page 10 414 10 Coolant Pump and Generator Drive Belts ........Adjusting Tension .

  • Page 4: Section 10 - - Engine - - Chapter

    Number of cylinders in line ....... Piston diameter model Farmall 90, Farmall 95 ..... . 104 mm (4.0944 in) Piston stroke .
  • Page 5 Cooling system ........coolant circulation Radiator on Models Farmall 90, Farmall 95 ....4 lines of vertical pipes with copper fins Fan, attached to the pulley .
  • Page 6 BOSCH pump: Farmall 90 model -- type F4CE9487M*J ....VE 4/12 F1250 L2043 (S/N 504218826) Farmall 95 model -- type F4CE9487N*J ....
  • Page 7 SECTION 10 - - ENGINE - - CHAPTER 1 CRANKCASE/CYLINDER BLOCK DATA mm (in) Crankcase ..........cast--iron monobloc with cylinder liners, crankshaft, camshaft and tappets Cylinder bore diameter .
  • Page 8 PISTON DATA Farmall 90 - - Farmall 95 Pistons ..........
  • Page 9 SECTION 10 - - ENGINE - - CHAPTER 1 mm (in) PISTON DATA (continued) PISTON DATA (continued) Farmall 90 - - Farmall 95 Piston ring groove clearance (measured vertically): Piston ring groove clearance (measured vertically): 0.100 to 0.175 (0.0039 to 0.0068) -- 1°...
  • Page 10 SECTION 10 - - ENGINE - - CHAPTER 1 ROCKER ARM - - VALVE DATA (continued) mm (in) Valve clearance for normal running (engine cold): -- inlet valve ..........0.300 to 0.050 (0.0118 to 0.0019) -- exhaust valve .
  • Page 11 SECTION 10 - - ENGINE - - CHAPTER 1 CYLINDER HEAD DATA (continued) mm (in) Inlet and exhaust valve springs: free length ......... . . 63.500 (2.4999) length under load of 329 N .

  • Page 12: Torques

    SECTION 10 - - ENGINE - - CHAPTER 1 TORQUES Tightening torque PARTS TO BE TIGHTENED PARTS TO BE TIGHTENED Thread Thread ft-lbs Flywheel casing retaining bolts ..... . M 12 x 1.75 x 100 80 ±...
  • Page 13 37 ± 4 phase 2 M 12 x 1.5 80 ± 6 59 ± 4 phase 3 M 12 x 1.5 90° ± 5° Big end cap bolts phase 1 M 10 x 1.25 30 ± 5 22 ± 4 phase 2 M 10 x 1.25...

  • Page 14: Special Tools

    SECTION 10 - - ENGINE - - CHAPTER 1 SPECIAL TOOLS WARNING X 380000664 Splining tool for fitting rear seal on crankshaft. The operations described in this section can only be carried out with ESSENTIAL tools indicated X 380000665 Tool to extract crankshaft front by an (X).

  • Page 15: Sectional Views

    SECTION 10 - - ENGINE - - CHAPTER 1 SECTIONAL VIEWS MIF1097A View of Farmall 90 tractor engines of 65 kW (88 HP) and Farmall 95 of 70 kW (95 HP)
  • Page 16 SECTION 10 - - ENGINE - - CHAPTER 1 Oil path under pressure Oil return path under gravity MIF1098A Lubrication diagram for engines mod. Farmall 90 and Farmall 95 Forced--circulation lubrication is accomplished by oil pressure control valve incorporated in the the following components: cooler assembly;...
  • Page 17 SECTION 10 - - ENGINE - - CHAPTER 1 Coolant recirculating in the engine Coolant entering the pump MIF1099A Cooling system diagram The forced circulation, closed--circuit engine cooling a centrifugal coolant pump housed at the front of system is composed of the following components: the crankcase;...
  • Page 18 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1101A Detail of cylinder head with valve seats fitted in engines mod. Farmall 90, Farmall 95 1. Exhaust manifold 4. Fitted valve seats 2. Intake manifold 5. Thermostat valve 3. Air heater...
  • Page 19 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1102A Additional counterweights 1. Retaining bolts 6. Half bearings 2. Support 7. Counter--shaft 3. Retaining bolts 8. Gear 4. Gear 9. Ring 5. Balancing weight 10. O--Ring...

  • Page 20: Troubleshooting

    SECTION 10 - - ENGINE - - CHAPTER 1 TROUBLESHOOTING Problems Possible Causes Solutions Engine does not start. 1. Batteries partially discharged. Check and recharge batteries. Re- place if necessary. 2. Battery terminal connections cor- Clean, inspect and tighten terminal roded or loose.
  • Page 21 SECTION 10 - - ENGINE - - CHAPTER 1 TROUBLESHOOTING (continued) Problems Possible Causes Solutions Engine overheating. 1. Coolant pump malfunction. Overhaul pump and replace if neces- sary. 2. Thermostat faulty. Replace the thermostat. 3. Radiator inefficient. Remove internal deposits by flushing. Check for leaks and repair.
  • Page 22 SECTION 10 - - ENGINE - - CHAPTER 1 TROUBLESHOOTING (continued) Problems Possible Causes Solutions 8. Fuel supply pump damaged. Replace fuel supply pump. 9. Incorrect valve -- rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 10.
  • Page 23 SECTION 10 - - ENGINE - - CHAPTER 1 TROUBLESHOOTING (continued) Problems Possible Causes Solutions Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to val- black or dark grey smoke. pump too high. ues specified in calibration tables. 2.

  • Page 24: Overhaul

    SECTION 10 - - ENGINE - - CHAPTER 1 OVERHAUL Op 10 001 10 ENGINE Removal DANGER Lift and handle all heavy parts using suitable lift- ing equipment. Make sure that assemblies or parts are sup- ported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted.
  • Page 25 SECTION 10 - - ENGINE - - CHAPTER 1 5. Disconnect the electrical connection (1) of hood. 6. Detach the gas struts (1) from the hood. 7. Remove the four hood hinge bolts (1) and lift the hood clear.
  • Page 26 SECTION 10 - - ENGINE - - CHAPTER 1 8. Remove the three retaining bolts (1) and the guard (2) on the right--left hand side of the fan. 9. Unscrew the nut (1) from the weight retaining pin. Remove the weights from the front support. 10.
  • Page 27 SECTION 10 - - ENGINE - - CHAPTER 1 11. Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle. 25039 12. Remove the circlip (2) and move the rear sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive.
  • Page 28 SECTION 10 - - ENGINE - - CHAPTER 1 14. Remove the retaining bolts (1) of the suction pipe (2) of the lift pump. 15. Disconnect the delivery and return lines from the hydraulic lift pump. 16. Detach the cab heating pipes (1) and (2).
  • Page 29 SECTION 10 - - ENGINE - - CHAPTER 1 17. Detach the cab air--conditioning pipes (1) and (2). 18. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1). 19.
  • Page 30 SECTION 10 - - ENGINE - - CHAPTER 1 20. Remove the electrical connection from the brake fluid reservoir and take the brake fluid reservoir (1) from the bracket. 21. Disconnect the steering oil delivery and return hoses (1) and (2). 22.
  • Page 31 SECTION 10 - - ENGINE - - CHAPTER 1 23. Remove the fusebox (1) from the hood support. 24. Remove the electrical connections of tempera- ture sender (1) and oil switch (2). 25. Remove the retaining retaining clips (1) and de- tach the flexible cables governing the hand throttle and pedal throttle.
  • Page 32 SECTION 10 - - ENGINE - - CHAPTER 1 27. Disconnect the electrical connection (1) between the cab and the engine. 28. Disconnect the electrical connections from alter- nator (1) and starter motor (2). 29. Disconnect the electrical connections of dryer fil- ter sensor (1) and water in fuel sensor (2).
  • Page 33 SECTION 10 - - ENGINE - - CHAPTER 1 30. Remove the electrical connection (1) and air filter clogging sensor (2). 31. Remove the two retaining bolts and the support together with relays protecting system (1). 32. Loosen the corresponding retaining clamps and extract the pipes (1), (2) and (3).
  • Page 34 SECTION 10 - - ENGINE - - CHAPTER 1 33. Hitch the engine to the hoist with the chains an- choring it to the attachments on the engine. 34. Position a fixed stand under the over drive clutch housing near the engine attachment flanging and apply the hand brake.
  • Page 35 SECTION 10 - - ENGINE - - CHAPTER 1 36. Extract the differential lock pedal retaining pin from the drive shaft (1), remove the pedal and footboard (2). 25043 37. Unscrew the nuts (1) and the bolts securing the engine to the transmission. Access is through the two slots in the cab floor.
  • Page 36 SECTION 10 - - ENGINE - - CHAPTER 1 39. Separate the engine from the transmission with the tool 380000569. 40. Remove the spacer located between the engine and the transmission. 41. Insert the fixed under the ballast support and se- cure the front wheels with wooden blocks.
  • Page 37 SECTION 10 - - ENGINE - - CHAPTER 1 42. Loosen the corresponding retaining clamp (1) and extract the pipes. And remove the bracket (2). 43. Disconnect the delivery and return lines (1) to the power steering cylinders. 44. Remove the hood support (1).
  • Page 38 SECTION 10 - - ENGINE - - CHAPTER 1 45. Loosen the retaining clamp and extract the pipe (1) joining the coolant pump to the bottom of the radiator. 46. Position a fixed stand (3) under the support of the groove (1) of the front axle drive placing a wood- en plug (2) between the parts (3) and (1).
  • Page 39 SECTION 10 - - ENGINE - - CHAPTER 1 48. Remove the four bolts (2) fastening the front axle support (1) to the engine (3). 49. Insert the hooks of the lifting chains (1) in the eye- lets shown in the figure, afterwards tensioning the chains with the hoist.

  • Page 40: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 Installation CAUTION 15. The installation phase described here requires the presence of two or three workers to use the Always use appropriate tools to align fixing movable tool for dismantling tractors 380000569 holes.
  • Page 41 SECTION 10 - - ENGINE - - CHAPTER 1 31. Refit the silencer together with the exhaust pipe. 44. Working on the left--hand side of the engine, install the lift pump draw pipe and tighten the re- 32. Secure the silencer to the exhaust manifold with taining bolts.

  • Page 42: Disassembly

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 001 53 Disassembly CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the engine as described in operation 10 001 10, proceed as follows.
  • Page 43 SECTION 10 - - ENGINE - - CHAPTER 1 7. Remove the intake manifold (2). 8. Disconnect the engine oil vapor recovery pipe from the blow--by (3). 9. Remove the tappet covers (1). 10. Remove the pipes with the quick--fit coupling (6) and (8).
  • Page 44 SECTION 10 - - ENGINE - - CHAPTER 1 20. Detach the fuel pipe assembly (1) from the injec- tors. 21. Remove the fuel outlet pipe (2) from the injectors removing the screw (3) and the seal (4). MIF1108A 22. Remove the screws (2) and the turbine (1). 23.
  • Page 45 SECTION 10 - - ENGINE - - CHAPTER 1 28. Lock the flywheel to stop it turning, remove the fixing screws (1) from the pulley (2). MIF1111A Removing the Crankshaft Front Seal (Op. 29. to 33.) 29. Apply tool 380000665 (4) on the front shank (2) of the crankshaft.
  • Page 46 SECTION 10 - - ENGINE - - CHAPTER 1 34. Turn the engine over, take out the screws (2) and remove the oil sump (1). MIF1117A 35. Take out the bolts (2) and remove the oil pump (1). NOTE: The oil pump (1) cannot be overhauled. It must be replaced if there is any irregular operation.
  • Page 47 SECTION 10 - - ENGINE - - CHAPTER 1 37. Before removing the injection pump, do the tim- ing and lock the engine flywheel with cylinder no. 1 at T.D.C. as shown on page 100, using tools 380000988 and 380000732. Then loosen the bolt (2), remove the “L”...
  • Page 48 SECTION 10 - - ENGINE - - CHAPTER 1 40. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). 41. Extract the engine flywheel (1) so it can be slung with the lift and put it away in a specific container. MIF1116A Removing the Crankshaft Rear Seal (Op.
  • Page 49 SECTION 10 - - ENGINE - - CHAPTER 1 47. Take out the screws (1) and remove the gears (3) and (4) from the camshaft (2). MIF1118A 48. Take out the bolts (1) and remove the hydraulic pump drive gear (2). MIF1119A 49.
  • Page 50 SECTION 10 - - ENGINE - - CHAPTER 1 50. Extract the injectors (2) with tool 380000671 (1). MIF0934A 51. Take out the screws (1) fixing the head to the crankcase. MIF1120A 52. After fitting the brackets (1) and (2) hook the met- al cables and detach the cylinder head from the crankcase with the hoist.
  • Page 51 SECTION 10 - - ENGINE - - CHAPTER 1 53. Valves are removed with tool 380000302 (1), ap- plying pressure on the cap (3) so that, by com- pressing the springs (4), it is possible to remove the cotters (2). Then remove the cap (3) and springs (4).
  • Page 52 SECTION 10 - - ENGINE - - CHAPTER 1 55. Remove the thermostat valve (2) from the gover- nor body (1) taking out the screws (3). MIF1124A 56. Take out the screws (1) securing the connecting rod caps (2) and remove them. 57.
  • Page 53 SECTION 10 - - ENGINE - - CHAPTER 1 59. The piston pin (1) retaining rings (2) should be re- moved using a marking tool (3). MIF0951A 60. Take out the screws (1) and remove the main bearing caps (2). MIF1126A 61.
  • Page 54 SECTION 10 - - ENGINE - - CHAPTER 1 62. Using tool 380000362 (1) and a hoist, remove the crankshaft (2) from the crankcase. MIF1127A 63. Remove the main half bearings (1). 64. Take out the screws (2) and remove the oil nozzles (3).
  • Page 55 SECTION 10 - - ENGINE - - CHAPTER 1 66. Carefully extract the camshaft (1) from the crank- case. MIF1129A 67. Extract the tappets (1) from the crankcase. MIF0945A 68. To remove and renew the front and rear bushings (1) of the camshaft, use the drift 380000667 (2) and grip 380000668 (3).

  • Page 56: Engine Assembly On The Bench

    SECTION 10 - - ENGINE - - CHAPTER 1 NOTE: After disassembling the engine, thoroughly clean the parts. Pages (56--83) show the assembly operations that require extra attention in order to assemble parts correctly. The torque settings are shown on pages 12 and IMPORTANT: When partially or fully disassembling the engine, all seals must be replaced.

  • Page 57: Fitting The Tappets

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Tappets (Disassembly operation 67.) Lubricate the tappets (1) and fit them in their seats in the crankcase. MIF1131A Fitting the Camshaft (Disassembly operation 65. to 66.) Lubricate the bushings supporting the camshaft and mount the camshaft (1) taking care that, dur- ing this process, the bushings or the supporting seats do not get damaged.

  • Page 58: Fitting The Oil Nozzles

    SECTION 10 - - ENGINE - - CHAPTER 1 Check that the end float of the camshaft (1) comes within the tolerance range prescribed on page 10. MIF1133A Fitting the Oil Nozzles (Disassembly operation 64.) Fit the nozzles (2) and tighten the retaining bolts (1).
  • Page 59 SECTION 10 - - ENGINE - - CHAPTER 1 Check that the toothing of the grooved bushing (1), splined onto the crankshaft (2) is neither damaged nor worn; if it is, remove it with the a suitable extractor (3). When fitting the new grooved bushing it must be heated for 60 minutes in an oven at a constant temperature of 160 °C (320 °F) and spline it onto the crankshaft.
  • Page 60 2 phase with a torque wrench to the torque given on page 13. MIF0965A phase with tool 380000304 (1) positioned as in the figure, further tighten the screws (2) with an angle of 90° ± 5°. MIF0966A...

  • Page 61: Fitting The Connecting Rod -- Piston Assembly

    SECTION 10 - - ENGINE - - CHAPTER 1 Remove the support caps. The clearance between the main bearings and the relevant journals is measured by comparing the width of the calibrated wire (2), at the point of greatest crushing, with the graduation of the scale on the case (1) containing the calibrated wire.
  • Page 62 SECTION 10 - - ENGINE - - CHAPTER 1 1. Using the pin (3) connect the piston (2) to the connecting rod (4) so that the reference arrow (1) for fitting the piston (2) in the cylinder liner is fac- ing as described in point 2.

  • Page 63: Fitting The Piston Connecting Rod Assemblies In The Cylinder Liners

    SECTION 10 - - ENGINE - - CHAPTER 1 4. Fit the half bearings (1) on the connecting rod and cap. NOTE: If the crankpins of the crankshaft are under- sized it is necessary to replace the big end bearings of the same undersize class made.

  • Page 64: Big End Cap Assembly

    SECTION 10 - - ENGINE - - CHAPTER 1 To measure the clearance proceed as follows: Carefully clean the parts and remove all traces of oil; Position a length of calibrated wire (2) on the crankshaft journals (1); Fit the connecting rod caps (3) with the relevant half bearings (4).

  • Page 65: Fitting The Thermostat Valve

    SECTION 10 - - ENGINE - - CHAPTER 1 3. Remove the cap and determine the clearance by comparing the width of the calibrated wire (2) against the graduated scale printed on the pack- et (1) containing the wire. MIF1078A 4.

  • Page 66: Fitting The Cylinder Head

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Cylinder Head (Disassembly operations 51. to 54.) 1. Lubricate the valve stem and insert into the rele- vant valve--guides according to the position marked during disassembly. 2. Fit the seals (1). MIF1137A 3.
  • Page 67 SECTION 10 - - ENGINE - - CHAPTER 1 6. Using the dial gauge 380000364 (1) fitted with its base 380000228 (2), check the protrusion of the pistons (3) at T.D.C. from the cylinder block face is within the tolerance limits prescribed on page 9. MIF1080A 7.

  • Page 68: Fitting The Injectors

    SECTION 10 - - ENGINE - - CHAPTER 1 10. Before inserting the control rods, check that the spherical seat (1) of contact with the rocker arm adjuster screw and the spherical end (2) of con- tact with the tappet show no sign of wear; if there are, then change them.

  • Page 69: Fitting The Rocker Arm Assembly

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Rocker Arm Assembly (Disassembly operation 49.) 1. Check that the spindle (2) / rocker arm (1) cou- pling surfaces are neither too worn nor damaged. Main spindle- -rocker arm data (mm) MIF1012A 2.
  • Page 70 SECTION 10 - - ENGINE - - CHAPTER 1 2. Direct the crankshaft (3) and camshaft (4) so that when mounting the driven gear (1) on the cam- shaft, the marks stamped on the gears (1 and 2) coincide. MIF0978A 3.
  • Page 71 90° for all the screws stage additional tightening to an angle of 90° for 140 and 180 mm (5.5118 and 7.0866 in) long bolts only. A = fan side 6. Adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3).

  • Page 72: Fitting The Injection Pump

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Injection Pump (Disassembly operations 38.) 1. Before fitting the injection pump, check that the engine flywheel is still locked and in time with cyl- inder no. 1 at T.D.C. (as described in opera- tion 37.), using tools...

  • Page 73: Fitting The Additional Counterweights

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Additional Counterweights (Disassembly operations 36.) 1. After taking the first cylinder to the top dead cen- ter and doing the timing of the gear of the timing system as described above, do the timing of the additional counterweights, making the marks (A) stamped on the gears coincide as shown in the figure.

  • Page 74: Fitting The Hydraulic Pump Drive Gear

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Hydraulic Pump Drive Gear (Disassembly operation 48.) 1. Insert the gear driving the hydraulic pumps (2) into the seat. 2. Tighten the bolts (1). MIF1144A Fitting the Timing Gear Casing (Disassembly operation 46.) 1.

  • Page 75: Fitting The Crankshaft Rear Seal

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Crankshaft Rear Seal (Disassembly operations 42. to 45.) 1. Fit part (6) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (1) and spline the new seal (2) onto it.

  • Page 76: Fitting The Oil Pump

    SECTION 10 - - ENGINE - - CHAPTER 1 4. Spline the flywheel (1) onto the crankshaft, tight- ening the screws (2) by hand. 5. Lock the flywheel appropriately before tightening the relevant screws to torque. MIF1115A 6. Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page 13: phase, tightening...

  • Page 77: Fitting The Oil Sump

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Oil Sump (Disassembly operation 34.) 1. Place the new seal on the crankcase. 2. Fit the oil sump (1). 3. Insert the screws (3) and tighten them to the torque prescribed on page 12.

  • Page 78: Fitting The Cooling System Union

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Cooling System Union (Assembly operation 27.) 1. Position the cooling system fitting so that the pins (3 and 4) are against the crankcase. 2. Tighten the screws (1 and 2). MIF1005A Fitting the Coolant Pump (Assembly operation 26.)

  • Page 79: Fitting The Fan--Alternator Pulley

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Fan- -alternator Pulley (Disassembly operation 25.) 1. Fit the coolant temperature sensor (1) screwing it down with a torque wrench. 2. Fit the fan pulley support (2) with the screws (3), tightening them to the torque given on page 12.

  • Page 80: Fitting The Auxiliary Member Drive Belt

    SECTION 10 - - ENGINE - - CHAPTER 1 6. Fit the fan pulley (2) on the support (1) with the screws (3), tightening them to torque. MIF1153A 7. Fit the tightener (1), tightening the bolts (2) and the tightener nut as directed on page 112. MIF1154A Fitting the Auxiliary Member Drive Belt (Disassembly operation 24.)

  • Page 81: Fitting The Exhaust Manifold -- Turbine

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Exhaust Manifold - - Turbine (Disassembly operations 22. and 23.) 1. Mount the exhaust manifold (4) and tighten the screws (3) to the torque prescribed on page 12. 2. Fit the turbine (1) with the screws (2). MIF1156A Fitting the Injector Feed Pipes (Assembly operations 20.

  • Page 82: Fitting The Pipes Between The Fuel Supply And Injection Pumps Pre-Heating System And Tappet Cover

    SECTION 10 - - ENGINE - - CHAPTER 1 Fitting the Pipes Between the Fuel Supply and Injection Pumps, Pre- -heating System and Tappet Cover (Disassembly operations 7. to 16.) 1. Fit the fuel filter mounting (9). 2. Fit the control unit for the heater (10). 3.

  • Page 83: Crankshaft Front Seal

    3. Fit the wiring (1). 4. Fit the fan unit to the fan pulley. 5. Add engine oil through the filler plug. 6. Install the hood as described in opera- tion 90 100 22. MIF1103A Op 10 102 70 CRANKSHAFT FRONT SEAL...
  • Page 84 SECTION 10 - - ENGINE - - CHAPTER 1 3. Remove the engine radiator (1), as indicated in operation 10 406 10. 4. Loosen the pivot screws (2) and lock screws (1) of the tightener (3). 5. Loosen the bolt (2) tensioning the belt (1) and re- move the belt.
  • Page 85 SECTION 10 - - ENGINE - - CHAPTER 1 6. Remove the six retaining bolts (1), the pulley (2) governing the accessory assemblies and the fan--alternator--coolant pump pulley (3). 7. Apply tool 380000665 (4) on the front shank (2) of the crankshaft. 8.

  • Page 86: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 Installation To fit the front seal on the crankshaft, proceed as fol- lows: 1. Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it.
  • Page 87 SECTION 10 - - ENGINE - - CHAPTER 1 2. Remove the eight screws (1) fixing the engine fly- wheel (2). 3. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). Slightly extract the engine flywheel (1) so it can be slung and then and put down in a specific wooden container with the hoist.

  • Page 88: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 8. To assemble and install, proceed as follows: Installation CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. To fit the front seal on the crankshaft, proceed as fol- lows: 1.

  • Page 89: Valve-Rocker Arm Clearance

    Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the hood (1) as described in opera- tion 90 100 22. 2. Disconnect the battery negative lead.
  • Page 90 SECTION 10 - - ENGINE - - CHAPTER 1 3. Remove the clamp (2) and extract the pipe (1) connecting the intake manifold (3) to the air filter. 4. Remove the plastic retaining clamps, from the cab heater water delivery--return pipes (2) and those of the electric cables (1), moving the pipes and cables on the compressor as described in the figure.
  • Page 91 SECTION 10 - - ENGINE - - CHAPTER 1 6. Remove the two retaining bolts (3) and the cen- tral tappet inspection cover (2) together with the engine vapor intake pipe (1) and the cover base seal. 7. Remove the retaining bolt and the rear tappet in- spection cover (1) together with the cover base seal.

  • Page 92: Installation

    5. Insert the intake manifold--air filter connecting pipe on the intake manifold and insert the retain- ing clamp. 6. Install the hood as described in opera- tion 90 100 22. 7. Reconnect the battery negative lead.

  • Page 93: Engine Injector

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 218 30 ENGINE INJECTOR Removal CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. CAUTION Always use appropriate tools to align fixing holes.

  • Page 94: Installation

    7. Fit the three rear retaining bolts of the exhaust si- lencer. 8. Install the hood as described in opera- tion 90 100 22. 9. Lower the hood and reconnect the battery nega- tive cable.

  • Page 95: Bosch Injection Pump

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 246 14 BOSCH INJECTION PUMP Removal CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
  • Page 96 SECTION 10 - - ENGINE - - CHAPTER 1 4. Disconnect the engine stop electromagnet wire (1). 5. Remove the quick couplers (1) on the filter and (2) on the injection pump, remove the injec- tion pump supply pipe. Remove the pipe (3) coming from the tank. CAUTION Make the vehicle safe and put the gear into neutral.
  • Page 97 SECTION 10 - - ENGINE - - CHAPTER 1 7. Remove the fittings of the pipes (2) connecting the injection pump--injectors, the pipe (1) con- nected to the thermostarter device and the elec- trical connection of the engine stop device (3). MIF1163A 8.
  • Page 98 SECTION 10 - - ENGINE - - CHAPTER 1 10. Remove the retaining bolts (1) and the three brackets (2) retaining the pipes, inserted on the injection pump/injector connection line. 11. Remove the fittings (1) of the injector diesel deliv- ery pipes and the fittings (2) of the injection pump diesel return pipe, then detach the pipes.

  • Page 99: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 14. Remove the three nuts (2) (3) (5) securing the in- jection pump (1) to the engine flywheel casing (4) and extract it from its housing. MIF0922A Installation To refit the injection pump, proceed as follows: CAUTION Always use appropriate tools to align fixing holes.

  • Page 100: Timing

    SECTION 10 - - ENGINE - - CHAPTER 1 12. Reconnect the pipe installed between the fuel fil- ter and the fuel pump and reinsert the quick cou- plers. 13. Fit the pipe supplying the injection pump, con- necting the quick couplers on the filter and on the injection pump.
  • Page 101 SECTION 10 - - ENGINE - - CHAPTER 1 4. Remove the retaining bolts (2) and the priming pump (1) from the crankcase (3). MIF1174A 5. Check through the opening accommodating the priming pump that the camshaft (1) has the refer- ence marks (2) indicating cylinder No.
  • Page 102 SECTION 10 - - ENGINE - - CHAPTER 1 7. Loosen the screw (1) blocking rotation of the pump spindle and insert the spacer (2). 8. Tighten the screw (1), locking part (2) so that the spindle of the fuel pump can turn freely. MIF1176A 9.

  • Page 103: Fuel Circuit Air Bleeding

    SECTION 10 - - ENGINE - - CHAPTER 1 Fuel Circuit Air Bleeding 1. Loosen the injector delivery unions (1). 2. Make the engine turn with the starter motor. 3. After having checked that there are no air bubbles, tighten the unions (1). MIF1167A Op 10 402 10 COOLANT PUMP...

  • Page 104: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 4. Detach the fitting of the return pipe for the cool- ant from the cab heater radiator connected to the underside of the coolant pump and drain off the engine coolant. 5.

  • Page 105: Thermostat Valve

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 402 30 THERMOSTAT VALVE Removal WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1.

  • Page 106: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 6. Take out the bolts (1) retaining the thermostat valve body (2). 7. Remove the thermostat valve body (2), seal (3) and thermostat valve (4). Installation To refit the thermostat valve, proceed as follows: CAUTION Always use appropriate tools to align fixing holes.

  • Page 107: Engine Radiator

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 406 10 ENGINE RADIATOR Removal DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are sup- ported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted.
  • Page 108 SECTION 10 - - ENGINE - - CHAPTER 1 5. Loosen the corresponding retaining clamp (1) and extract the pipes. And remove the bracket (2). 6. Loosen the corresponding retaining clamps and extract the pipes (1), (2) and (3), remove the bracket (4).
  • Page 109 SECTION 10 - - ENGINE - - CHAPTER 1 8. Take out the two lower retaining bolts (2) and re- move the air filter (1). 9. Remove the clamp (1) and extract the radiator coolant compensation reservoir (2). 10. Remove the radiator of air cooler (1) and bracket (3).
  • Page 110 SECTION 10 - - ENGINE - - CHAPTER 1 12. Take out the two radiator retaining bolts (2) installed under the front axle support (1), remov- ing the bolts, washers and lower rubber blocks. 13. Remove the radiator (1). 14. Remove the rubber blocks (1), washers and up- per rubber blocks (2).

  • Page 111: Installation

    SECTION 10 - - ENGINE - - CHAPTER 1 Installation To install proceed as follows: CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Respect the tightening torques prescribed on page 12. 2. Fit the upper rubber blocks (2), washers and the rubber block at the base of the radiator.

  • Page 112: Coolant Pump And Generator Drive Belts

    SECTION 10 - - ENGINE - - CHAPTER 1 Op 10 414 10 COOLANT PUMP AND GENERATOR DRIVE BELTS Adjusting Tension CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
  • Page 113 SECTION 10 - - ENGINE - - CHAPTER 1 6. Using a torque wrench, tighten the M 10 nut (5) to a torque of 55 Nm (41 ft-lbs). 7. Check the tension of the Polyvee belt in the posi- tion (1), shown in the figure 246 below, using the CLAVIS frequency meter 380001268, bearing in mind that the data measured must remain within the following tolerances:...

  • Page 114: Checks, Measurements And Repairs

    SECTION 10 - - ENGINE - - CHAPTER 1 CHECKS, MEASUREMENTS AND REPAIRS CYLINDER BLOCK, LINERS WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Checks and Measurements After disassembling the engine, thoroughly clean the crankcase assembly.
  • Page 115 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1032A TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL SHAPE Cilindricity ORIENTATION Perpendicularity POSITION Location tighten the retaining bolts to the prescribed torque; NOTE: If regrinding, all the liners must have the same oversize 0.5 mm (0.0196 in).
  • Page 116 SECTION 10 - - ENGINE - - CHAPTER 1 Check that the head mating surface, on the cylinder block, has no deformation. This check can be made, after taking out the grub screws (2), with a calibrated rule (1) and feeler gauge (4).

  • Page 117: Crankshaft

    SECTION 10 - - ENGINE - - CHAPTER 1 CRANKSHAFT CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Clean all parts carefully. If even slight cracks are found, replace the crankshaft.
  • Page 118 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1158A Measured on a radius greater than 45.5 mm (1.7913 in). ↗ 0.50 between adjacent main journals. MAIN CRANKSHAFT TOLERANCES TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL Circularity SHAPE SHAPE Cilindricity Parallelism Perpendicularity ORIENTATION...

  • Page 119: Connecting Rods

    SECTION 10 - - ENGINE - - CHAPTER 1 CONNECTING RODS CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Main data (mm) of the connecting rod, piston pin bushing and half bearings Inside diameter to be measured after installing in the small end and regrinding with a reamer.

  • Page 120: Checking Connecting Rods

    SECTION 10 - - ENGINE - - CHAPTER 1 Checking Connecting Rods Check the parallelism of the connecting rod (2) axes using instrument 380001003 (4) as follows. Fit the connecting rod (2) on the self--centering spindle (3) of tool 380001003 (4) and lock it with the screw (5).

  • Page 121: Checking Bending

    SECTION 10 - - ENGINE - - CHAPTER 1 Checking Bending Check the bend of the connecting rod (3) by compar- ing two points (C and D) of the pin (4) on the vertical plane of the connecting rod axis. Position the vertical support (2) of the dial gauge (1) so that this rests on the pin (4) at point C as shown in the figure.

  • Page 122: Measuring The Piston Diameter

    SECTION 10 - - ENGINE - - CHAPTER 1 CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Clean all parts carefully before proceeding with the operations described below.

  • Page 123: Conditions For Correct Pin-Piston Coupling

    SECTION 10 - - ENGINE - - CHAPTER 1 Conditions for Correct Pin- -piston Coupling Lubricate the pin (1) and the piston pin boss seat with engine oil; the pin must go into the piston with a light pressure of the fingers and must not drop out. MIF1038A Piston Rings Using a micrometer (1) check that the thickness of...

  • Page 124: Valves And Camshaft

    SECTION 10 - - ENGINE - - CHAPTER 1 Measuring the clearance X of the V- -ring Due to the special shape of the first seal with a trape- zoidal cross--section, the clearance between the groove and the ring should be measured as follows; Make the piston (1) protrude from the crankcase so that the ring (3) at issue comes approximately half- way out of the cylinder liner (2).
  • Page 125 SECTION 10 - - ENGINE - - CHAPTER 1 Decarbonizing, Checking and Grinding Valves Remove all carbon deposits from the valves (2) using a wire brush (1). Check that the valves show no signs of seizure, cracking or burning. If necessary, grind the bevels on the valve heads us- ing a grinding machine, removing as little material as possible.
  • Page 126 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1052A Dimensions (mm) of valve seats MIF1051A Dimensions (mm) of valve seat housings If the valve seats cannot be reconditioned by just re- Heat the cylinder head to 80 to 100 °C (176 to grinding, they can be replaced with the ones supplied 212 °F) and, using a suitable drift, insert the new as spare parts.

  • Page 127: Tappets

    SECTION 10 - - ENGINE - - CHAPTER 1 After regrinding, with the base 380000364 (2) and dial gauge 380000228 (1), check that the valve re- cessing (3) in relation to the top face of the cylinder head comes within the tolerance prescribed on page 9.

  • Page 128: Camshaft

    SECTION 10 - - ENGINE - - CHAPTER 1 Camshaft MIF1056A Camshaft data The data given refer to the normal pin diameter (dimensions in mm) The support journal surfaces on the shaft and cams must be finely honed; if there are signs of seizing or scoring, replace the shaft and relative bushings.

  • Page 129: Cylinder Head

    -reactive sealant on their sealing surface. Using a pump, introduce water heated to ∼ 90 °C (∼ 194 °F) at a pressure of 2 to 3 bar (29 to If you find any leakage from the cylinder head, it must 43.5 psi).

  • Page 130: Low Oil Pressure Indicator

    SECTION 10 - - ENGINE - - CHAPTER 1 LOW OIL PRESSURE INDICATOR Functional Checks The device is composed of the control switch (1, fig. 280), engine oil pressure gauge (2, fig. 281). This indicator light (1) indicates the engine oil pres- sure is too low.

  • Page 131: Cooling System

    SECTION 10 - - ENGINE - - CHAPTER 1 COOLING SYSTEM Clean all parts carefully before proceeding with the operations described below. The cooling system is supplied with a permanent coolant mixture consisting of water and “Fleetguard Compleat” antifreeze (up to 50% in volume). This mixture prevents freezing down to the following tem- peratures: Degrees °C (°F)
  • Page 132 SECTION 10 - - ENGINE - - CHAPTER 1...

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