SERVICE MANUAL

TT4.55 / TT4.65 / TT4.75

Tractor

Part number 47969434

1st edition English
November 2016
Replaces part number 47866576

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

 SERVICE MANUAL

TT4.55 TIER 3 Engine, 2WD Tractor, TT4.55 TIER 3 Engine, 4WD Tractor,
TT4.65 NH 2WD TIER 3 ROPS, TT4.65 NH 4WD TIER 3 ROPS, TT4.75 NH 2WD
TIER 3 ROPS, TT4.75 NH 4WD TIER 3 ROPS

47969434 28/11/2016
EN

Find manuals at https://best-manuals.com

 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

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

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 [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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 SERVICE MANUAL
Engine

TT4.55 TIER 3 Engine, 2WD Tractor, TT4.55 TIER 3 Engine, 4WD Tractor,
TT4.65 NH 2WD TIER 3 ROPS, TT4.65 NH 4WD TIER 3 ROPS, TT4.75 NH 2WD
TIER 3 ROPS, TT4.75 NH 4WD TIER 3 ROPS

47969434 28/11/2016
10
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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

TT4.55 TIER 3 Engine, 2WD Tractor, TT4.55 TIER 3 Engine, 4WD Tractor,
TT4.65 NH 2WD TIER 3 ROPS, TT4.65 NH 4WD TIER 3 ROPS, TT4.75 NH 2WD
TIER 3 ROPS, TT4.75 NH 4WD TIER 3 ROPS

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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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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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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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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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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

TT4.55 ANZ --- APAC --- LA --- MEA
TT4.65 ANZ --- APAC --- LA --- MEA
TT4.75 ANZ --- APAC --- LA --- MEA

Serial number Special tool description Special tool number

1 Engine stand with support 380000301
2 Nozzle tester 380000215
3 Sling hook engine 380000216

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Serial number Special tool description Special tool number

4 Adopter for slide hammer 380000541
5 Tappet adjusting screw driver 380000232
6 Angular torquing gauge 380000304
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 - Overview DESCRIPTION AND OPERATION

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.

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

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 Engine - Engine and crankcase

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.

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.

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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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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 - 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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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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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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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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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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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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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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 Engine - Engine and crankcase

Separating the front axle from the engine

1. Loosen and remove the hose clamps and remove
the bottom hose (1) from radiator to drain the coolant.

GNIL14TR02030AA 29

2. Detach radiator upper hose (2) by removing the hose

clamp (1)

GNIL14TR02031AA 30

3. Loosen and remove the hose clamps (1). Disconnect

hose (2) from air cleaner to turbocharger. Turbocharger
to after cooler (3). Inter cooler to air intake (4).

GNIL14TR02032AA 31

4. Connect the engine to a suitable hoist.

GNIL14TR02033AA 32

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 Engine - Engine and crankcase

4. Remove the four buckle up bolts (1) coupling engine

and front axle support. Separate it from the front axle.

GNIL14TR02034AA 33

5. Remove the engine from front axle carefully. Mount

it on engine stand 380000301.

NDIL14TR00042AA 34

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 Engine - Engine and crankcase

Engine - Install
Engine Installation
Re-install the engine on the tractor by observing the following:
Re-Installation follows the removal procedure in reverse from step 10 back to step 1
Apply thread sealant at the required places
Before coupling engine and transmission housing clean and decrease the mating surfaces thoroughly and apply a
strip of sealing compound of about 2 mm diameter as shown in the figure
Due care should be taken in aligning input shaft with clutch plates and pilot bearing as to avoid damage to input
shaft and hearing
Apply the torque setting listed in tightening torque table.
Before starting all the fluid levels should be correct. Start and run the engine until oil and coolant temperature
reaches to operating temperature and check for leaks and rectify if required and recheck fluid levels.

GNIL14TR02036FA 1

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 Engine - Engine and crankcase

Engine - Disassemble
Engine Stripping
NOTE: In case, replacement of parts is not required make and identification mark to keep the parts in a numbered
rack to assemble parts back in the original order.
1. Detach muffler pipe support bracket (2) by removing
the bolts (1).

GNIL14TR02037AA 1

2. Detach the turbocharger. Refer “TURBOCHARGER

REMOVAL” process from Engine Section.
3. Loosen and remove the bolts (1) and separate the ex-
haust manifold (2).

GNIL14TR02038AA 2

4. Loosen and remove the terminal nuts (1) and discon-

nect the electrical wiring from alternator.

GNIL14TR02039AA 3

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 Engine - Engine and crankcase

5. Loosen and remove the alternator mounting bolts (1)

and remove the alternator.
Remove the alternator upper mounting bracket by re-
moving bolt (2).

GNIL14TR02040AA 4

6. Loosen and remove the bolt (1). Remove the alterna-

tor’s lower mounting bracket (2).

GNIL14TR02041AA 5

7. Loosen and remove the hose clamp (1). Disconnect

the oil cooler inlet hose (2).

GNIL14TR02042AA 6

8. Loosen and remove the worm drive clamp (1). Remove

air inlet hose (2).

GNIL14TR02043AA 7

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 Engine - Engine and crankcase

9. Loosen and remove the bolts (1). Remove the fuse box
assembly (2).

GNIL14TR02044AA 8

10. Disconnect the following:

a. Earthing connection (1) on intake manifold.

GNIL14TR02045AA 9

b. Connection to the KSB (2).

GNIL14TR02046AA 10

c. Connection to the stater motor solenoid switch (3).

GNIL14TR02047AA 11

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 Engine - Engine and crankcase

d. Connection to the water temperature sensor (4).

GNIL14TR02048AA 12

4. Loosen and remove the bolt (1) and remove fuel sedi-
mentary device (2).

GNIL14TR02049AA 13

5. Loosen the nut (1) ,and disconnect fuel high pressure

line from FIP.

GNIL14TR02050AA 14

6. Loosen the nuts of fuel high line (1) and remove the
high pressure line.

GNIL14TR02051AA 15

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 Engine - Engine and crankcase

7. Loosen and remove the bolts (1) and disconnect turbo

boost pipe (2) from intake manifold.

GNIL14TR02052AA 16

8. Loosen and remove the bolt (1). Disconnect the fuel

pipe connecting the primary fuel filter to feed pump at
the filter end.

GNIL14TR02053AA 17

9. Loosen and remove the bolt (2) and disconnect the

other end of the pipe (3) at the feed pump end.

GNIL14TR02054AA 18

10. Loosen and remove the bolt (1). Remove fuel pipe
connecting primary fuel filter to secondary fuel filter
(2).

GNIL14TR02055AA 19

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 Engine - Engine and crankcase

11. Loosen and remove the bolt (1) and remove the fuel
pipe connecting secondary fuel to FIP (2).

GNIL14TR02056AA 20

12. Disconnect and remove the fuel over flow line (1) con-
necting FIP to the injectors.

GNIL14TR02057AA 21

13. Remove the secondary fuel filter assembly (2).

GNIL14TR02058AA 22

14. Loosen and remove the bolts (1). Remove secondary

fuel filter head (2).

GNIL14TR02059AA 23

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 Engine - Engine and crankcase

15. Loosen and remove the bolts (1). Remove secondary

fuel filter mounting (2).

GNIL14TR02060AA 24

16. Remove the primary fuel filter assembly (1).

GNIL14TR02061AA 25

17. Loosen and remove the bolts (1). Remove primary

fuel filter head (2).

GNIL14TR02062AA 26

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 Engine - Engine and crankcase

Engine - Overhaul CYLINDER BLOCK OVERHAUL

1. Remove the engine (please refer engine removal
and installation section).
2. Remove the Cylinder head and timing cover with
gears from the Engine (please refer the Engine disas-
sembly section).
3. Dismantle the Block (please refer engine disassem-
bly Section).

NDIL14TR00135AA 1

4. Repair and inspection of cylinder bore :-

– Cylinder block plugs and senders, require changing if
leaking and rusty, and must be replaced. Clean the old
sealant of the block, and fit new plugs with sealer.
– Check the seating surface of the cylinder head for un-
evenness by means of a calibrated ruler and a feeler
gauge. Surface-grind the sealing surface by means of
a grinding machine, removing as little material as pos-
sible after determination of the unevenness.
NOTE: Pull out the center ring pin, only if sealing surface
must be surface ground.

NDIL14TR00136AA 2

– Check the cylinder bore for scuffing or rings around

the ring frame area. Irregularities can be felt by run-
ning a finger over the surface. To check out-of-round-
ness, wear, or taper, use a telescopic gauge or dial bore
gauge.

NDIL14TR00137AB 3

– After removal of the old sleeves, the parent bore must

be thoroughly cleaned both in the top recess off the
sleeve flange and in the parent bore itself.
– A check must be made to ensure that the whole areas
of contact with the sleeves in the cylinder block are free
from burrs, corrosion or damage. Remove any burrs
present.
– Check engine block bore ovality and if necessary re-
store to 106.850 - 106.9 mm.
– Check if cylinder liner outer diameter is 107.020 -
107.050 mm.
NOTE: The cylinder liners are delivered as spare parts with
an over dimension outer diameter of 0.2 mm. NDIL14TR00138AB 4

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 Engine - Engine and crankcase

– Ensure that the sleeve is thoroughly clean before fit-

ting. If cleaning fluid is used to wash the sleeve, it is
important that the sleeve be thoroughly dried and well
oiled before fitting.
Throughout the whole operation, extreme cleanliness
is essential as the entry of the smallest particle or other
foreign matter is sufficient to cause local distortion of
the sleeve bore. Lubricate the outside diameter of the
sleeves with clean oil using spray. The use of brush is
not recommended.
5. Inspect the dynamic balancer (Please refer the En-
gine disassembly section).
6. Repair and inspection of Connecting Rods, Bear-
ings, Pistons and rings.
h. Clean the piston, and connecting rod assembly, in a
suitable solvent and inspect for damage to ring lands,
skirts, or pin bosses.
i. Check connecting rod components for damage, and
place in the test mandrel to check for distortion, and
ensure that any distortion, is within specifications.

Removal of sleeves
NOTE: Engines are supplied with initially no sleeves, however for engine overhauling; new sleeves have to be fitted.
1. Press or draw the sleeves out through the top of the
cylinder block ensuring no damage is done to the parent
bores (cast iron production sleeves are an interference
fit and it should be removed with a heavy duty press).
NOTE: For sleeve removal and Installation, do not heat
sleeves, use a press.

Installation of new sleeves

1. Preparation for fitting new sleeves:-
– After removal of the old sleeves, the parent bore must
be thoroughly cleaned both in the top recess off the
sleeve flange and in the parent bore itself.
– A check must be made to ensure that the whole areas
of contact with the sleeves in the cylinder block are free
from burrs, corrosion or damage. Remove any burrs
present.
– Check engine block bore ovality and if necessary re-
store to 106.85 - 106.90 mm.
– Check if cylinder liner outer diameter is 107.02 -
107.05 mm.
NOTE: The cylinder liners are delivered as spare parts with
an over dimension outer diameter of 0.2 mm.

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