Documente Academic
Documente Profesional
Documente Cultură
667TA/EED -- 667TA/EBD
Every information, illustration and specification contained in the present manual is based on the most recent informa--
tion available at the time of printing.
NEW HOLLAND reserves the right, to modify the text at any time without prior communication.
NEW HOLLAND
PRINT No. 604.13.689
Edition -- May 2006
Copyright © New Holland
2 WE
MOTORI
2
Copyright © New Holland
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no--
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example:: T 1 -- 2 -- 3
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min--1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
Copyright © New Holland
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
MOTORI
Copyright © New Holland
SECTION 1
DIAGNOSTICS
INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
CNH -- EST diagnostics tool . . . . . . . . . EW--1--4
Main engine operating anomalies . . . EW--1--5
Copyright © New Holland
INDICE
Copyright © New Holland
EW--1--3
DIAGNOSTICS
DIAGNOSTICS
FOREWORD
A good diagnosis is carried out with the competence With the use of computerised tools, it is also possible
acquired from years of experience and taking part in to establish a bi--directional communication with the
repair courses. central unit with which it is possible not only to decode
When a user complains about a bad efficiency or ope-- the error codes, but also to address the image in its
rating anomalies, his indications must be kept into memory to obtain those further necessary informa--
due account, taking from them those useful informa-- tion to go back to the anomaly origin.
tion that will be used to guide our intervention. Every time an inconvenience occurs and its existence
is detected, it is necessary to proceed with the elec--
After having detected the anomaly, it is advisable to tronic unit query through one of the pointed--out ways
carry out failure search operations by decoding self-- and then proceed with the diagnostic survey through
diagnosis data of the central electronic unit of theEDC tests and measures through which an outline of ope--
(Engine Diesel Control) system. rating conditions is obtained and the real anomaly
reasons are identified.
In case the electronic unit does not provide indica--
tions, one will have to proceed with one’s experience
by adopting traditional diagnostic modes.
Copyright © New Holland
EW--1--4
DIAGNOSTICS
88201
The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating para--
meters of electronic control components (control units, sensors etc.) and the check of flow--rates, pressures and
temperatures; it is further arranged for searching inconveniences and detect data for electronically--controlled
CNH engines.
DIAGNOSTICS
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
YES
The feeding circuit or injection pump does not Check and eliminate causes of infiltration.
show air penetration NO
(to be continued)
Copyright © New Holland
EW--1--6
DIAGNOSTICS
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water tank).
NO
YES
YES
YES
YES
2 ENGINE OVERHEATS
YES
Coolant level correct Check for leaks and restore the level.
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level.
NO
(to be continued)
Copyright © New Holland
EW--1--7
DIAGNOSTICS
YES
YES
Radiator in working order Wash down thoroughly, check for fluid leaks, re--
NO place (if necessary) the part.
YES
Air filter and circuit piping both in working order Clean or replace faulty parts.
NO
YES
Openings for coolant flow to the head in working Wash down thoroughly.
order NO
YES
YES
YES
DIAGNOSTICS
Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.
YES
Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.
YES
Feeding circuit in working order Check and make (if necessary) the required re--
NO pairs.
YES
The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.
YES
YES
High pressure pump efficient Check using a diagnostic tester and replace if
NO necessary.
YES
(to be continued)
Copyright © New Holland
EW--1--9
DIAGNOSTICS
Rail pressure relief valves efficient Disconnect fuel return pipe from rail and check
NO for leaks.
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.
YES
YES
YES
YES
(to be continued)
Copyright © New Holland
EW--1--10
DIAGNOSTICS
High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO
YES
YES
High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO
DIAGNOSTICS
Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect--
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.
NO
Knock detected in pistons Check the following items: play between the pis--
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.
NO
Knock detected in the cylinder head Check the following items: operation play be--
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
YES moreover, check for broken springs, for excess--
ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.
NO
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.
Copyright © New Holland
EW--1--12
DIAGNOSTICS
8 ENGINE STOPS
YES
YES
Feeling circuit in working order Check the circuit and proceed as necessary.
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
NO arms.
YES
Pressure control valve in working order Check and replace (if necessary).
NO
(to be continued)
Copyright © New Holland
EW--1--13
DIAGNOSTICS
Oil pump and delivery pipes both in working or-- Check and replace (if necessary).
der NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.
YES
Engine oil SAE viscosity conforming to stan-- Replace the engine oil with equivalent of ad--
dards NO equate viscosity.
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.
YES
YES
DIAGNOSTICS
NOTES
Copyright © New Holland
SECTION 2
ENGINE OVERHAUL
INDEX
Coding of source engines . . . . . . . . . . EW--2--4 High pressure electronic injection
Main engines features . . . . . . . . . . . . . . EW--2--5 system (Common rail) . . . . . . . . . . . . . . EW--2--38
General engines features . . . . . . . . . . . EW--2--6 EDC 7 operation . . . . . . . . . . . . . . . . . . . EW--2--39
Supply system . . . . . . . . . . . . . . . . . . . . . EW--2--40
Assembling play -- specifications . . . EW--2--8
Supply system diagram . . . . . . . . . . . . . EW--2--41
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--14 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--42
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15 Mechanical supply pump . . . . . . . . . . . . . EW--2--43
Graphic indications and symbols . . . EW--2--16 Normal operating condition . . . . . . . . . . . EW--2--43
667TA engines . . . . . . . . . . . . . . . . . . . . . EW--2--17 Output overpressure condition . . . . . . . . EW--2--43
Description of main mechanic Drain conditions . . . . . . . . . . . . . . . . . . . . . EW--2--44
engine components . . . . . . . . . . . . . . . . EW--2--18 High--pressure pump type CP3.3 . . . . . . EW--2--44
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--18 High pressure pump--inside structure . . EW--2--46
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Working principle . . . . . . . . . . . . . . . . . . . . EW--2--47
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--2--19
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--20 Boost gauge valve . . . . . . . . . . . . . . . . . EW--2--50
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Electro--injector . . . . . . . . . . . . . . . . . . . . EW--2--51
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--22 Electro--injector . . . . . . . . . . . . . . . . . . . . . EW--2--52
EGR exhaust gas recirculation system EW--2--22 Pressure limiter for fuel return . . . . . . EW--2--53
Internal EGR acting on the Location of the main electrical
exhaust valves . . . . . . . . . . . . . . . . . . . . . . EW--2--22 components . . . . . . . . . . . . . . . . . . . . . . . EW--2--54
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--23 EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--55
Cable on engine . . . . . . . . . . . . . . . . . . . . EW--2--56
Cylinder head engines: 667TA/EBF --
Injectors connector (A) . . . . . . . . . . . . . . . EW--2--57
667TA/EBD -- 667TA/EED . . . . . . . . . . . . EW--2--24
Sensors connector (C) . . . . . . . . . . . . . . . EW--2--57
Cylinder head engines: 667TA/EEG --
Crankshaft sensor . . . . . . . . . . . . . . . . . . . EW--2--58
667TA/EEC . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25
Timing sensor . . . . . . . . . . . . . . . . . . . . . . EW--2--58
Valves and valve seats . . . . . . . . . . . . . . . EW--2--26
Supercharging air pressure --
Valves and valve seats . . . . . . . . . . . . . . . EW--2--27 temperature sensor . . . . . . . . . . . . . . . . . . EW--2--59
Valve drive jumpers . . . . . . . . . . . . . . . . . . EW--2--27 Engine oil temperature--pressure sensor EW--2--59
Engine head grinder . . . . . . . . . . . . . . . . . EW--2--27 Fuel temperature and pressure sensor . EW--2--60
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--28 Electro--injectors . . . . . . . . . . . . . . . . . . . . EW--2--61
Auxiliary component drive . . . . . . . . . . . . EW--2--29 Pre--post heating resistance
and contactor . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Engine lubrification . . . . . . . . . . . . . . . . EW--2--30 Coolant temperature sensor . . . . . . . . . . EW--2--63
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--31 Fuel temperature sensor . . . . . . . . . . . . . EW--2--64
Oil pressure regulation valve . . . . . . . . . EW--2--31 High pressure pump -- pressure regulator EW--2--65
By--pass valve . . . . . . . . . . . . . . . . . . . . . . EW--2--31 Checking the fuel system . . . . . . . . . . . EW--2--66
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32 Description of tests and checks
Oil sump engines: 667TA/EEG --667TA/ that can be performed . . . . . . . . . . . . . . EW--2--66
EEC -- 667TA/EBF -- 667TA/EED . . . . . . EW--2--33 Necessary equipment . . . . . . . . . . . . . . . . EW--2--66
Low pressure supply test . . . . . . . . . . . . . EW--2--67
Oil sump engines: 667TA/EED --
667TA/EBD . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Low--Pressure Pump . . . . . . . . . . . . . . . . EW--2--68
Test on the pressure relief valve
Engine oil vapour recirculation . . . . . . . . EW--2--35
on the rail . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Engine cooling . . . . . . . . . . . . . . . . . . . . . EW--2--36 Test on fuel backflow from the return . . . EW--2--70
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Engines overhaul at the bench . . . . . . EW--2--72
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Disassembling the engine . . . . . . . . . . . . EW--2--72
Copyright © New Holland
INDEX
Figure 1 Figure 2
114201
114199
Figure 3
114200
6 6 7 T A E D B +
Engine calibration
(power)
Compression ratio:
B = 16.5:1 > 130 kW
D = 17.5:1 ≤ 130 kW
E = 17.5:1 > 130 kW
Electronic injection
(common rail)
Intercooler
Turbocharged
67 = cylinder capacity
6 = no. of cylinders
Copyright © New Holland
EW--2--5
E 6728 cm3
G Direct injection
H (common rail)
T.A.A.
I
(Boosted by intercooler)
A Machine type
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
Copyright © New Holland
EW--2--6
Bore mm 104
Stroke mm 132
Compression ratio --
667TA
Type
EEG EEC EBF EED EBD
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
FILLING
Total capacity
Ambra Mastergold HSP 1st filling: litres -- --
kg -- --
Pump setting
Start of delivery mm
Injection sequence 1 -- 5 -- 3 -- 6 -- 2 -- 4
Position of pistons
from crankcase X --
667TA
Type
EEG EEC EBF EED EBD
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Measurement dimension X --
667TA
Type
EEG EEC EBF EED EBD
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--7 0.044 to 0.106
n. 2--3--4--5--6 0.041 to 0.103
Half bearings -- crankpins 0.039 to 0.111
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
667TA
Type
EEG EEC EBF EED EBD
VALVE GEAR – CYLINDER ASSEMBLY mm
Valves:
∅4 6.970 to 6.999
α 60° ± 0.25°
∅4 6.970 to 6.999
α 45° ± 0.25°
Seat on head
for valve seat:
∅1 34.837 to 34.863
∅1 34.837 to 34.863
X 0.96 to 1.48
Valve seats --
Copyright © New Holland
EW--2--12
667TA
Type
EEG EEC EBF EED EBD
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 47.75
under a load of:
339.8 N ± 19 N H1 35.33
741 N ± 39 N H2 25.2
7.239
Copyright © New Holland
EW--2--13
667TA
Type
EEG EEC EBF EED EBD
VALVE GEAR – CYLINDER ASSEMBLY mm
∅2
Outer diameter of
tappet collar:
∅3
∅2 15.924 to 15.954
∅2 ∅3 15.960 to 15.970
Tappets --
∅1
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
nd
2 p phase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st pphase 50 ± 6 (5 ± 0.6)
2nd pphase 80 ± 6 (8 ± 0.6)
rd
3 phase 90° ± 5°
Connecting g rod cap g 1st p
p fastening phase 50 ± 5 (5 ± 0.5)
nd
2 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
TOOLS
380000158 1--6 Nm dynamometric screw driver for calibrating injector solenoid valve connector check
nut (Common Rail)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket (except engines: 667TA/EBF -- 667TA/EED)
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel (except engines: 667TA/EBF -- 667TA/EED)
380000990 Engine flywheel retaining tool (except engines: 667TA/EEG -- 667TA/EEC)
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001099 Tool for extracting electric injectors (Common Rail)
Copyright © New Holland
EW--2--16
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
Copyright © New Holland
EW--2--17
667TA ENGINES
Figure 4
114058
Figure 5
2
7 3
86605
Copyright © New Holland
EW--2--19
Drive shaft
It ismade of steel and rests on seven induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine flyw-
Inside the drive shaft are the lubricating oil ducts. heel mounting hub.
The main half bearings are made of steel with an-
The following items are force--fitted on the front tifriction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley. The penultimate main half bearings are equipped
with a shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering man-
ner on the rear shank and cannot be replaced.
Figure 6
84037
1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear --
4. Flywheel attachment hub
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cy-
chining. linder in which it is mounted.
- By a letter (on the connecting rod body) indica-
The connecting rod half bearings aremade of steel, ting the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 7
84038
Copyright © New Holland
EW--2--21
Pistons
The combustion chamber is found on the piston The following reference data are engraved on the pi-
crown. The crown is cooled by the engine oil delive- ston crown:
red by the nozzle fitted to the crankcase. 1. Spare part number and design modification
Recesses, housing spring rings, are three; the 1st number
one is made of a cast iron insert. 2. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cy-
linder liner.
3. Date of manufacture;
4. Stamping indicating 1st recess insert testing.
Figure 8
86549
Copyright © New Holland
EW--2--22
70164
114501
Copyright © New Holland
EW--2--23
Valve control
Figure 10
003198t
1. Rocker arm -- 2. Arbour -- 3. Adjusting screw -- 4. Rod -- 5. Jumper -- 6. Lock cones -- 7. Cup --
8. Spring -- 9. Tappet -- 10. Distributing shaft
Copyright © New Holland
EW--2--24
114059
114060
Copyright © New Holland
EW--2--26
70319
Valve seats have following angles: Exhaust valves 2 have a distinctive notch at the cen-
- 45° (exhaust valves) tre of the head.
- 60° (intake valves)
Figure 14
70334
Figure 15
Valve drive jumpers Jumpers must be positioned with marks (→) to-
When remounting the cylinder head, the orientation wards exhaust manifold.
of valve drive jumpers must be observed.
Figure 16
70345
1. Jumper -- 2. Rods
Engine head grinder A single thickness gasket is available as a spare
Cylinder head nominal thickness is 105 ± 0.25 mm part.
and maximum removal enabled by metal must not
exceed 0.13 mm.
Figure 17
70325
Copyright © New Holland
EW--2--28
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 18 Figure 20
114086 86488
Figure 19
86454
Figure 21
114061
1. Automatic belt stretcher -- 2. Alternator -- 3. Water pump -- 4. Poly--V belt -- 5. Drive shaft
Copyright © New Holland
EW--2--30
ENGINE LUBRIFICATION
Forced circulation lubrication is performed by the fol- gine crankcase, with oil filter adapter;
lowing components: - oil pressure control valve (1) built into the oil filter
- rotor--equipped oil pump (5), housed in the cran- adapter;
kcase front part, controlled by the straight tooth - by--pass valve (4) for clogged oil filter cut--off,
gear force--fitted on the drive shaft shank; built into the oil filter adapter;
- water / oil heat exchanger (3), housed in the en- - cartridge--type oil filter (2).
Figure 22
114087
Heat exchanger
Figure 23
114062
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5*. Oil return to filter – 6*. Oil inflow from filter -- 7. Oil filter
* Only engines: 667TA/EEG -- 667TA/EEC
Flow
107419 70483
Oil pump
Figure 26
84052
Figure 27
70150
Figure 28
84054
Figure 29
84055
Copyright © New Holland
EW--2--34
Figure 30
003202t
003203t
Copyright © New Holland
EW--2--35
Figure 31
Oil condensate
ENGINE COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components: - thermostat, used to regulate coolant flow.
- heat exchanger, used to cool the lubricating oil
(lubrificatiion see);
Figure 32
86494
Copyright © New Holland
EW--2--37
Figure 33
79458
84058
Figure 34
84059
Copyright © New Holland
EW--2--38
Extremely high injection pressures are necessary in than 152 kW, DSLA nozzles are fitted which work a
order to reduce PARTICULATE emissions. pressures up to 1450 bar.
The common rail system makes it possible to inject Description of system
fuel at pressures of up to 1450 -- 1600 bar, while the
injection precision obtained by electronic control of The injection system is composed of an electrical
the system serves to optimise operation of the en- part and a hydraulic part.
gine while limiting emissions and fuel consumption. Electrical system
For engines more powerful than 152 kW, the CRIN2 The electronic control unit monitors engine control
injectors have DLLA nozzles that work up to a pres- parameters by means of the various sensors on the
sure of 1600 bar, whilst for engines less powerful engine.
Figure 36
107851
SUPPLY SYSTEM
Figure 37
High pressure
Low pressure
Fuel outlet
108607
1. Electro--injector -- 2. Common rail -- 3. Pressure limiting device for fuel return -- 4. Common rail pressure
relief valve -- 5. Pre--filter mounted on the frame -- 6. High--pressure pump --
7. Mechanical vane pump -- 8. Fuel filter
The common rail system has a special pump that The low--pressure circuit is composed of the follo-
continually keeps the fuel at high pressure, irrespec- wing pipes:
tive of the phase and the cylinder that must receive
the injection and it accumulates it in a duct common - fuel pipe from fuel tank to prefilter;
to all the electro--injectors.
At the electro--injector inlet there is therefore always - pipes supplying the mechanical supply pump
fuel at the injection pressure calculated by the elec- through the heat exchanger of the control unit,
tronic control unit. the manual priming pump and the pre--filter;
When the solenoid valve of an electro--injector is
energized by the electronic control unit, fuel taken di- - pipes supplying the high pressure pump via the
rectly from the rail is injected into the relevant cylin- fuel filter.
der.
The fuel system is composed of a low--pressure cir- The fuel system is completed by the fuel outlet circuit
cuit and a high--pressure circuit. from the common rail, injectors and high--pressure
The high--pressure circuit is composed of the follo- pump cooling circuit.
wing pipes:
- pipe connecting the high--pressure pump outlet
to the common rail;
- pipes supplying the electro--injectors from the
common rail.
Copyright © New Holland
EW--2--41
OUTLET
108608
1. High pressure pump -- 2. Relief valve on the high--pressure pump, 5 bar -- 3. Adjuster valve fitted on the
fuel return from the electro--injectors, 1.3 -- 2 bar -- 4. Over--pressure valve of the Common Rail -- 5. Com-
mon Rail -- 6. Pressure sensor -- 7. Electro--injector -- 8. Return pipe -- 9. Heat exchanger of the
control unit -- 10. Mechanical priming pump -- 11. Prefilter fitted on chassis -- 12. Fuel tank --
13. Mechanical fuel supply pump -- 14. Fuel filter -- 15. Pressure regulator -- 16. Backflow pipe from high--
pressure pump -- 17. By--pass valve -- 18. By--pass valve.
The pressure regulator, upstream from the high-- The relief valve (3) housed on the cylinder head, fit-
pressure pump, controls the flow of fuel needed in the ted on the electro--injector return, governs the flow of
low--pressure system. Then the high--pressure pump fuel returning from the electro--injectors at a pressure
correctly supplies the common rail. This solution, of 1,3 ÷ 2 bars.
pressurizing only the necessary fuel, improves ener- In parallel with the mechanical supply pump there are
gy efficiency and limits the heating of the fuel in the two by--pass valves.
system. The by--pass valve 18 makes it possible to have the
The relief valve (2) fitted on the high pressure pump fuel flow back from the mechanical pump outlet to its
serves the purpose of maintaining the pressure at the inlet, when the pressure at the fuel filter inlet exceeds
pressure regulator inlet at a constant level of five bars the permissible limit. The by--pass valve 17 makes it
regardless of the efficiency of the fuel filter and the possible to fill the supply system via the manual pri-
upstream system. ming pump (10).
Relief valve (2) operates to increase fuel flow in the
high pressure pump cooling circuit through pipe (16)
carrying fluid into and out of pipe (8).
Copyright © New Holland
EW--2--42
Fuel filter
It is placed on engine cylinder block in the circuit bet- Heater is activated if the fuel temperature is ≤ 0 °C
ween supply pump and high--pressure pump (CP3). and is heated till it reaches 5 °C. Fuel temperature,
signalled by the related sensor to EDC control unit 7,
The following are placed on the support: fuel tempe- allows a very accurate computation of fuel flow--rate
rature sensors and heater resistance. to be injected into the cylinders.
Figure 39
003206t
1. Fuel filter support -- 2. Heater connector -- 3. Electric fuel heater -- 4. Fuel filter -- 5. Fuel temperature
sensor -- A. High--pressure pump outlet fitting -- B. Fuel exhaust inlet fitting from Common Rail and cylinder
head (injectors) -- C. Exhaust fitting from high--pressure pump -- D. Inlet fitting from supply pump --
E. Fuel exhaust outlet fitting to tank.
Copyright © New Holland
EW--2--43
Figure 40
001237t
Output overpressure condition The current pressure, overcoming the elastic resi-
The by--pass valve (1) triggers when an overpressu- stance of spring (1), communicates outlet with inlet
re is generated as output (B). through duct (2).
Figure 41
001238t
Copyright © New Holland
EW--2--44
Drain conditions
The by--pass valve (2) triggers when, with turned--off Under this situation, the by--pass valve (2) is opened,
engine, the supply system has to be filled in through due to the inlet pressure, and the fuel flows to outlet
the priming pump. (B).
Figure 42
001239t
High--pressure pump type CP3.3 On the read high--pressure pump side, the mechani-
Pump with 3 radial pumping elements controlled cal supply pump is assembled, controlled by the
through distribution gear, it does not need to be pha- high--pressure pump shaft.
sed--up.
Figure 43
001250t
1. Fuel outlet fitting to rail -- 2. High--pressure pump -- 3. Pressure regulator -- 4. Fuel inlet fitting
from filter -- 5. Fuel outlet fitting to filter support -- 6. Fuel inlet fitting from control unit heat exchanger --
7. Fuel outlet fitting from mechanical pump to filter -- 8. Mechanical supply pump.
IMPORTANT -- The high pressure pump unit -- feeding pump is not subject to overhaul , therefore it must not
be disassembled neither the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Copyright © New Holland
EW--2--45
Figure 44
001967t
1. Mechanical supply pump -- 2. Fuel return from high--pressure pump -- 3. Delivery valve to Common Rail --
4. Single pumping element -- 5. By--pass valves on supply pump -- 6. Pump shaft -- 7. Fuel inlet from filter --
8. 5--bar limiting valve -- 9. Pressure regulator.
Copyright © New Holland
EW--2--46
Figure 45
Sec. B-B
Sec. C-C
70498
1. Cylinder. – 2. Three--lobe element. – 3. Cap intake valve. – 4. Ball delivery valve. – 5. Piston. – 6-- Pump
shaft. – 7. Low--pressure fuel inlet. – 8. Pumping elements supplying fuel ducts
Every pumping unit is composed of: with but is only translated in a circular movement
along a wider radius, with the resulting alternate
- a piston (5) actuated by a three--lobe element (2)
actuation of the three pumping elements;
floating on the pump shaft (6). The element (2),
being floating on a misaligned part of the shaft - cap intake valve (3);
(6), when the shaft rotates, does not rotate there- - ball delivery valve (4).
Copyright © New Holland
EW--2--47
Working principle
Figure 46
Sec. B-B
1. Rail delivery outlet -- 2. Rail delivery valve -- 3. Pumping element -- 4. Pump shaft -- 5. Pumping element
supply duct -- 6. Pressure regulator supply duct -- 7. Pressure regulator
The pumping element (3) is orientated towards the PWM command received by the engine control mod-
pump’s camshaft (4). During the intake phase, the ule, stops the fuel flow to the pumping element.
pumping element is fed through the feeding line (5). During compression phase of the pumping element,
The quantity of fuel to flow to the pumping element the fuel achieves the level of pressure determining
is determined by the pressure regulating gauge (7). the opening of the by--pass valve to common rail (2),
The pressure regulating gauge, according to the feeding it through the exhaust unit (I).
Copyright © New Holland
EW--2--48
Figure 47 shows the fuel runs at low pressure inside The pressure gauge (5) determines the quantity of
the pump; the following elements are clearly visible: fuel to feed the pumping elements: the fuel in excess
the main feeding line to the pumping elements (4); flows through the exhaust gallery (9).
the feeding lines to the pumping elements (1--3--6),
The limiting valve to 5 bar, in addition to recovering
the duct lines run for the pump lubrication (2), the
fuel exhaust as a collector has also function to keep
pressure gauge (5), the flow limiting valve to 5 bar (8)
the pressure constant to 5 bar limit at gauge entry.
and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the
feeding and recovery lines.
Figure 47
1. Pumping element inlet -- 2. Pump lubricating ducts -- 3. Pumping element inlet -- 4. Main pumping ele-
ments supplying duct -- 5. Pressure regulator -- 6. Pumping element inlet -- 7. Regulator exhaust duct --
8. 5--bar limiting valve -- 9. Fuel exhaust from regulator inlet.
1. Fuel exhaust flue -- 2. Fuel exhaust gallery -- 3 Fuel exhaust flowing from pump with connector to high
pressure pipe for common rail
Copyright © New Holland
EW--2--49
Operation
The cylinder is filled through the cap intake valve only The pumping element piston goes back towards the
if the supply pressure is suitable to open the delivery bottom dead center and the remaining fuel is decom-
valves set on the pumping elements (about 2 bars). pressed.
The amount of fuel supplying the high--pressure When the pumping element chamber pressure be-
pump is metered by the pressure regulator, placed comes less than the supply pressure, the intake
on the low--pressure system; the pressure regulator valve is again opened and the cycle is repeated.
is controlled by the EDC7 control unit through a PWM
signal. The delivery valves must always be free in their
movements, free from impurities and oxidation.
When fuel is sent to a pumping element, the related
piston is moving downwards (suction stroke). When The rail delivery pressure is modulated between 250
the piston stroke is reversed, the intake valve closes and 1600 bars by the electronic control unit, through
and the remaining fuel in the pumping element the pressure regulator solenoid valve.
chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail. The pump is lubricated and cooled by the fuel.
The thereby--generated pressure makes the exhaust The radialjet pump disconnection – reconnection
valve open and the compressed fuel reaches the time on the engine is highly reduced in comparison
high--pressure circuit. with traditional injection pumps, because it does not
require setting.
The pumping element compresses the fuel till the top
dead center (delivery stroke) is reached. Afterwards, If the pipe between fuel filter and high--pressure
the pressure decreases till the exhaust valve is clo- pump is to be removed--refitted, be sure that hands
sed. and components are absolutely clean.
RAIL
Figure 49
108609
The rail volume is comparatively small to allow a abled by a calibrated hole being set downstream of
quick pressurisation at startup, at idle and in case of the high--pressure pump.
high flow--rates.
A fuel pressure sensor (1) is screwed to the rail. The
It anyway has enough volume as to minimise system signal sent by this sensor to the electronic control unit
spikes and the use of plenum chambers caused by is a feed--back information, depending on which the
injectors openings and closings and by the high-- rail pressure value is checked and, if necessary, cor-
pressure pump operation. This function is further en- rected.
Copyright © New Holland
EW--2--50
Figure 50
70502
1. Body – 2. Small piston – 3. Stop – 4. Spring – 5. Direct tank discharge – 6. Seat on rail
A Normally, the tapered piston end keeps closed B If the 1750 bar fuel pressure is exceeded in rail,
the discharge towards the tank. the small piston is displaced and the excess
pressure is discharged into the tank.
Copyright © New Holland
EW--2--51
15
70506
Injection end
70505
When coil (4) is de--energised, shutter (6) goes back
to its closing position, in order to re--create such a
force balance as to make plunger (2) go back to its
1. Pressure rod – 2. Plunger – 3. Nozzle – 4. Coil – closing position and end the injection.
5. Pilot valve – 6. Ball shutter – 7. Control area –
8. Pressure chamber – 9. Control volume –
10. Control duct – 11. Supply duct – 12. Control IMPORTANT -- The injector cannot be overhauled
fuel outlet – 13. Electric connection – 14. Spring – and therefore it must not be disassembled.
15. High--pressure fuel inlet.
Copyright © New Holland
EW--2--52
Electro--injector
The injectors are BOSCH CRIN 1 and CRIN 2, fitted
according to the power developed by the engine.
Figure 53
108610
1. Jet
Copyright © New Holland
EW--2--53
It is housed on the rear of the cylinder head, and ad- sure to the return fuel, the fuel vapours formation in-
justs the pressure of fuel returning from injectors at side injectors is avoided, optimising fuel spraying and
a pressure 1.3 and 2 bars. By guaranteeing this pres- combustion.
Figure 54
70507
Figure 55
108641
The engines are fully driven by the electronic engine The electrical and electronic components of the en-
control module, which is assembled directly to the gine are listed here following:
engine by means of a heat exchanger enabling its 1. Coolant temperature sensor.
cooling, utilising rubber buffers to reduce vibration
2. Electro--injector.
originated by the engine.
3. RAIL pressure sensor.
Through the engine control module it is possible to
4. Air temperature/pressure sensor.
verify the correct working of the engine. (See part
three of the hereby user’s guide specifically dedi- 5. Starter motor.
cated to diagnostic). 6. Timing sensor.
7. Solenoid valve for pressure regulator.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre--post heating.
Copyright © New Holland
EW--2--55
EDC7 ECU
Figure 56
01525t
A -- Connector to injectors; B -- Connector to chassis (Provide reference of the vehicle to which the engine
is assembled); C -- Connector to sensors
Copyright © New Holland
EW--2--56
Cable on engine
All the components described below refer to the en-
gine cable in question, therefore the connections to
the pins are a preliminary version, in other words at
the approval stage.
Figure 57
114296
1. Injectors for cylinders 1--2 -- 2 Injectors for cylinders 3--4 -- 3. Injectors for cylinders 5--6 -- 4. Engine rpm
sensor -- 5. Timing sensor -- 6. Engine oil pressure and temperature sensor -- 7. Fuel temperature sensor --
8. Coolant temperature sensor -- 9. Air temperature and pressure sensor -- 10. Rail temperature and pres-
sure sensor -- 11. Pressure regulator -- 12. Connector C EDC control unit (signal) -- 13. Connector A EDC
control unit (power).
Copyright © New Holland
EW--2--57
Crankshaft sensor
This is an inductive sensor located at the front left on the crankshaft.
hand side of the engine. The crankshaft sensor pro- The crankshaft sensor is connected to the control
duces signals obtained from a magnetic flux field unit on pins 19C -- 23C. The sensor impedance is
closing through the openings in a phonic wheel fitted ∼900 Ω.
Figure 58
50319
Crankshaft sensor
Figure 59
50320
Timing sensor
3 2 1
50288
50342
ECU pin
Ref
Ref. Description
Camshaft sensor Timing sensor
1 Signal 19C 10C
2 Signal 23C 9C
3 Schield
Copyright © New Holland
EW--2--59
Engine oil temperature--pressure sensor The sensor is supplied with 5 Volts. The signal de-
This component is analogous to the air temperature-- tected is transmitted to the EDC control unit which,
pressure sensor. in turn, controls the relative device on the instrument
The engine oil temperature--pressure sensor is in- panel (gauge + low pressure warning light).
stalled on the engine oil filter support in a vertical The oil temperature is not displayed on any gauges
position. -- this value is used exclusively by the control unit.
This sensor measures the engine oil temperature
and pressure.
The sensor is connected to the control unit on pins Pin 24C -- 28C Temperature
24C -- 28C -- 32C -- 27C. Pin 32C -- 27C Pressure
Figure 60
50324 50344
Wiring diagram
ECU Pin
Ref
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power unit 32C 34C
4 Signal (pressure) 27C 34C
Copyright © New Holland
EW--2--60
Mounted on one end of the rail, this sensor measures of the electrical injection command.
the internal fuel pressure and informs the control unit This sensor is connected to the control unit on pins
of the value (feedback). 12C -- 14C-- 13C.
The injection pressure value is used as a pressure The power supply is 5 Volt.
control feedback signal and to determine the duration
Figure 61
0051065t
Electro--injectors
Figure 62
50343
Figure 63
50349
Copyright © New Holland
EW--2--62
The pre--post heating resistance is located on the in- heating operations. This resistance is powered by a
take manifold. contactor on the left hand side of the chassis.
The resistance serves to heat the air in pre / post The resistance impedance is approximately 0.5 Ω.
Figure 64
003215t
Resistance
Figure 65
002371t
A. Control contactor
The control contactor is connected to the control unit The contactor is tripped with water and/or fuel tem-
B connector. perature below 5 °C.
The contactor impedance is approximately 15 Ω.
WARNING -- Do not use flammable liquids or gases to help starting the engine.
These substances could easily catch fire once in contact with the resistance, causing very dangerous situa-
tions.
Copyright © New Holland
EW--2--63
This is a variable resistance sensor able to read the an instrument panel gauge, if present.
coolant temperature in order to provide the control This sensor is connected to the control unit on pins
unit with an indication of the thermal status of the en- 15C -- 26C.
gine. The impedance of the coolant temperature sensor at
The same signal is utilized by the control unit to drive 20 °C is approximately 2.50 Ω.
Figure 66
107471
Copyright © New Holland
EW--2--64
This sensor is identical to the coolant temperature The fuel temperature sensor is connected to the con-
sensor. trol unit on pins 35C -- 18C.
This sensor detects the fuel temperature to provide The sensor impedance at 20 °C is approximately
the control unit with a parameter defining the thermal 2.50 Ω.
status of the fuel.
Figure 67
0051140t
Figure 68
107799 107798
Connector
ECU Pin
Ref
Ref. Description
Coolant Fuel
1 Ground 15C 35C
2 Temperature signal 26C 18C
Copyright © New Holland
EW--2--65
Figure 69
000912t
A. Pressure regulator
The quantity of fuel supplied to the high pressure Delivery pressure to the rail is modulated between
pump is metered by the pressure regulator on the low 250 and 1450 bar by the electronic control unit by
pressure system; the pressure regulator is managed controlling the pressure regulator solenoid valve.
by the EDC7 control unit. - This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on
pins 9A -- 10A.
- The solenoid valve impedance is approximately
3.2 Ω..
Copyright © New Holland
EW--2--66
This section analyses the tests for correctly trouble- tion system correlated with error codes 8.x saved in
shooting and checking the fuel circuit and the com- the control unit, or not accompanied by any error
mon rail injection system. The stated procedure can code and the user notices a drop in performance. The
be used in the event of trouble with the engine injec- following table gives descriptions of error codes 8.x.
Error Description
8.1 -- Negative deviation of the fuel pressure (actual pressure higher than the objective pressure).
-- Positive deviation of the fuel pressure (actual pressure lower than the objective pressure).
-- Drop in fuel pressure with vehicle in motion (lack of diesel).
-- Drop in fuel pressure with vehicle in motion: downhill with throttle pedal released (lack of die-
sel).
-- Drop in fuel pressure with the engine idling (lack of diesel).
8.2 -- Fuel pressure sensor on rail.
8.4 -- Backflow valve control (opening the pressure relief valve DBV).
8.5 -- Fuel pressure in the rail too high.
-- Fuel pressure in the rail too low.
Figure 70
108599
1. Pressure gauge 1 (0 -- 15bar) and standard couplings -- 2. Pressure gauge 2 and standard couplings --
3. 2--litre container -- 4. Pressure gauge pipes -- 5. Graduated container of 100ml -- 6. Plug for rail --
7. Closed Voss coupling.
Copyright © New Holland
EW--2--67
Figure 71
108600
108601
Copyright © New Holland
EW--2--68
Low--Pressure Pump
The function of the gear pump is to supply the high-- Under normal operating conditions, the flow of fuel in-
pressure pump CP3.3. It is driven by the shaft of the side the pump is as shown in the figure.
high--pressure pump and is fitted on its rear portion.
Figure 73
108602
On completing the fuel supply system and with the - On pressure gauge M1 it must be between 6 and
battery charged to 24.7V, the engine must start within 9 bar:
the 20 seconds of activation of the starter motor, -- if lower than 6 bar: replace the pump,
drawing fuel from the external container placed at -- if higher than 9 bar: replace the diesel filter.
most 1 metre lower than the engine. If the pump is not
- On pressure gauge M2 it must be greater than 5
able to draw up fuel in the stated time and therefore
bar:
start the engine, replace it.
-- if lower, replace the diesel filter,
-- if the trouble persists, check the seals of the
After starting the engine, check the pressure at 1500 couplings of the fuel filter support and of the
rpm: high--pressure pump inlet.
Copyright © New Holland
EW--2--69
108603
Disconnect recirculation pipe (1) from the pressure tive even though a great amount of diesel flows out.
relief valve and plug with the Voss fitting in the ap- Whereas, if the valve seeps diesel without fault code
propriate set. No diesel must come out of the valve 8.4, then replace it.
at any engine speed. If the diagnosis system signals
fault code 8.4 ”Engine -- backflow valve control”, it With the overpressure sensor disconnected or with
means that the EDC control unit has recognised that a bundle of defective cables fault code 8.2 is gener-
the valve has opened after a significant change in the ated and the rail pressure is set to 710bar (measur-
pressure of the rail (greater than 1700bar). Since its able with the diagnosis instrument). Therefore the
opening is to be considered a consequence of the ab- trouble is to be found in the wiring and it is not necess-
normal increase in pressure, the valve is NOT defec- ary to replace the component.
IMPORTANT -- The experience acquired to date shows that the defectiveness is RARELY due to the sensor.
Copyright © New Holland
EW--2--70
Permits establishing the operating status of the injec- quantity of fuel injected per cycle. In its turn, this is
tors. The engine speed and power are controlled converted into microseconds of injector opening ac-
through the injectors. The power required by the cording to the rail pressure.
user, through the accelerator, is converted into the
Figure 75
108604
Figure 76
108605
Copyright © New Holland
EW--2--71
Figure 77
108606
Make sure first of all that the engine idling speed is flowing out in one minute from the coupling on the cyl-
as set in the factory. Check the quantities of fuel recir- inder head by means of a graduated container. Once
culation from the cylinder head. The conditions for you have ensured that recirculation exceeds 80ml
measuring the quantities of injector return fuel are: per minute, plug the rail outlet of one injector (4) at a
time, using the rail plugs in the set. The defective in-
- engine idling and without air compressor or air
jector is the one whose exclusion caused a signifi-
conditioner working;
cant reduction in recirculation. In addition, remember
- engine at temperature (> 50 °C). that when changing an injector it is necessary to
change the duct. After identifying the injectors / ducts
The quantity that flows out must be no greater than
with a high recirculation, check that the tightness of
80ml of diesel in one minute. Excessive recirculation
the ducts is as designed (50Nm ± 5) and tighten them
(more than 80ml of diesel a minute) could be caused
if they are loose and then check the recirculation va-
by:
lues again. If on the other hand the tightness is cor-
- incorrect coupling between one or more injectors rect, remove the pipe and check that the spherical
and the related ”needles”; end towards the injector is not out of shape; replace
it if it is and then check the recirculation value again.
- problem of internal leakage of the injector.
If the duct is not out of shape either, then replace the
To identify the defective injector, follow the method injector and duct because there must be a leak inside
described hereunder. Measure the quantity of fuel the injector. Check the recirculation value again.
Copyright © New Holland
EW--2--72
Figure 78
86500
Figure 79
70126
70128
IMPORTANTE -- Press clamp (1), as shown in Fi- Remove the screws (2) and remove the oil pipe (3)
gure B, to disconnect the low p ressure fuel pipes from the supercharger pipe (1) and from the engine
(2 -- 3 -- 4, Figure 78) from the corresponding con- block.
nections. After disconnecting the pipe, reset the Remove the starter (5) from the flywheel housing (4).
clamp (1) in locking position (Figure A) to prevent Apply brackets 380000995 to engine block and use
distortions. them to secure the engine to the revolving stand
380000978.
Copyright © New Holland
EW--2--73
Figure 82
70129
1. Injector connections -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil
temperature and pressure sensor -- 5. Output shaft sensor -- 6. Injector -- 7. Air temperature/pressure sen-
sor -- 8. Timing sensor -- 9. Fuel heater and fuel temperature sensor -- 10. Pressure limiter -- 11. EDC7 ECU
91576
Figure 84 Figure 86
74170 70132
Disconnect pipe (2) from fuel return pressure limiter Loosen tappet adjustment fastening nuts (1) and un-
(1), as shown in Figure 79. screw the adjusters. Remove the screws (2), remove
Remove the nut, loosen the retaining collar and dis- the rocker assembly (3), consisting of: bracket (6),
connect the oil vapour pipe (5). Remove bolts (3) and rockers (4), shafts (5) and remove jumpers (7) from
take off the blow--by filter (4). valves. Remove rods (8).
Remove nuts and remove the tappet cover including
the gasket.
Figure 85
Figure 87
86501
manifolds (4).
Figure 88 Figure 90
86504
Figure 91 (Demonstration)
Figure 89
70137
Figure 92
70511
Figure 93 Figure 96
114168
Release on the drive belt tensioner (2) and extract the
belt (3) from the belt pulleys from the water pump 70142
ones and from the belt rebound pulleys. Remove the screws (1) and disconnect the ECU (2)
Disassemble the belt tensioner (2). including the heat exchanger.
Loosen the screws fixing the alternator (1) to the sup-
port and disassemble it.
Figure 94 Figure 97
70145
108549
Use tool 380000985 to remove the oil filter (1). Remove the nut (1) and disconnect the timing sensor
Except 667TA/EEG--/EEC engines (2).
Remove bolts (2) and disconnect the alternator Remove the nuts (3) and disconnect the high pressu-
mount (3). re pump (4) including the feed pump (5).
Figure 95
Figure 98
70141
70146
Remove the screws (4) and disconnect the oil tempe-
rature/pressure sensor (3). Remove the screws (1)
and then remove: heat exchanger/oil filter support Fit tool 380000990 (2) to the flywheel housing (1) to
(2), intermediate plate (6) and relevant gaskets. stop flywheel (3) rotation. Loosen the screws (4).
Remove the oil level sensor (5).
Copyright © New Holland
EW--2--77
108548
00904t
Remove the screws (3) and disassemble the damp- Using the specific tie rod (3) of the tool 99363204 and
ing flywheel (2) and the pulley (1). the ancillary lever (4), remove the external holding
Figure 100 ring (2) from the front cover (1).
Figure 103
70149
108549
Remove the screws (1) and disconnect the water Remove the screws (1) and take out the front cover
pump (2). Remove the screw (3) and the roller (4). (2).
Remove the screw (3) and disconnect the engine
speed sensor (4). IMPORTANT -- Note the installation position of
bolts (1) because they are of different lengths.
Figure 101
Figure 104
00900t
74775
70152
Screw two pins (2) of adequate length into drive shaft 86516
holes (3).
Take out engine flywheel (1) so that it can be harnes- Remove the screws (1 and 4) and disassemble the
sed by means of a hoist and placed into its own con- oil suction tube (5). Remove the screws (2) and dis-
tainer. assemble the stiffening plate (3).
Figure 107
70153
70158
Figure 115
70156
70157 70160
The penultimate bed cap (1) and its respective sup-
Remove screws (2) and take off timing gear case (1). port have half bearing (2) provided with shoulder.
IMPORTANT -- Take note of themounting position
of lower and upper half bearings; in fact, if they ha-
IMPORTANT -- Take note of themounting position ve to be used again, they must be mounted in the
of screws (2), due to the different size of the latter. same position they had prior to being taken off.
Copyright © New Holland
EW--2--80
70164
84086
Remove drive shaft (2) from crankcase by means of Carefully remove distributing shaft (1) from the engi-
tool 380000992 (1) and a hoist. ne crankcase.
Figure 118
70162
70163
REPAIR OPERATIONS Checking the eccentric lift and the pin align-
CYLINDER UNIT ment
Checks and measurements Place the shaft on back centres and check, bymeans
Figure 122 of a centesimal comparator placed on themiddle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.582 mm (for ex-
haust eccentrics) and 6.045 mm (for intake eccen-
trics). If different values are found, replace the shaft.
Figure 124
70166
After the engine has been dismantled, clean the cran-
kcase--cylinder cluster thoroughly. Use proper rings
to move the cylinder cluster. Check the crankcase ca-
refully for cracks. Check the condition of working
caps. They must be replaced if they arerusty or their
sealing properties are in doubt. Inspect the cylinder
liner surfaces; they must not show traces of seizing,
scoring, out--of--roundness, taper and excessive
wear. The check of cylinder liner inner diameter (in or- 70171
der to measure the amount of out--of--roundness, ta-
per and wear) is carried out by means of bore gauge
(1) equipped with a comparator previously reset on Check the diameter of distributing shaft support pins
the ring gauge (2) of the cylinder liner diameter. (2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
70167
Measurements must be taken for each single cylin-
der, at three different heights of the liner and on two 70172
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on The distributing shaft bushings (2) must be force--fit-
the latter plane and during the first measurement. ted into their respective seats.
When detecting out--of--roundness, taper or wear, the The inner surfaces must show no traces of seizing or
cylinder liners must be bored and refaced. Cylinder li- wear.
ner reconditioning must be performed with regard to Use bore gauge (3) to measure the diameter of front
the spare piston diameter increased by 0.5 mm of the and rear bushings (2) and of distributing shaft inter-
rated value, and to the prescribed assembling play. mediate seats (1).
Measurements must be taken on two axes perpendi-
cular to each other.
Copyright © New Holland
EW--2--82
Figure 126
sec. A--A
107268
84088
Verify that the head supporting plane on the cylinder
cluster does not show deformations. This check can
be carried out by taking off dowels (4) by means of a
gauged rule (2) and thickness gauge (3). After detec-
ting the deformed areas, flatten the supporting surfa-
ce by means of a grinder. The flatness error must not
be greater than 0.075 mm.
80585
IMPORTANT -- In case of reconditioning, all the li- IMPORTANT -- Crankcase flattening may be car-
nersmust bemachined to the same increase (0.5 ried out only after making sure, when the repair
mm). work has been completed, that the protrusion of
the piston fromthe cylinder liner is not greater than
Check the main bearing seats as follows: the specified value.
- mount the bed caps on the supports without bea- Check the condition of cylinder cluster working caps
rings; (1); they must be replaced if they are rusty or their
- tighten the fastening screws to the specified tor- sealing properties are in doubt.
que; After flattening, restore the cylinder liner countersink,
as shown in Figure 127.
- check, by means of an adequate internal compa-
rator, that the seat diameter is the same as the
specified value. TIMING SYSTEM
If a greater value is found, replace the crankcase. Distributing shaft
Figure 129
84089
The shaft support pin and eccentric surfaces must be of seizing and scoring, it is advisable to replace the
perfectly smooth; if, on the contrary, they show traces shaft and its respective bushings.
Copyright © New Holland
EW--2--84
70176
When replacing bush (1) use drift 380000991 (2) and Figure 133
handle 380000999 (3) to remove and refit.
70164
Figure 134
70238
86507
MAIN FEATURES OF TAPPETS AND THEIR Place distributing shaft (3) retaining plate (1) with the
RESPECTIVE SEATS ON THE CRANKCASE slotted hole facing the crankcase upper side and the
stamping facing the operator, then fasten screws (2)
to the specified torque.
Copyright © New Holland
EW--2--85
70179
It must result of 0,23 ÷ 0,13 mm. If traces of excessive seizing, scoring or out--of--
roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to grin-
Figure 136 ding pins (2), measure the journals by means of a mi-
crometer (1) so as to determine the amount (diame-
ter) by which the pins have to be reduced.
Figure 138
70514
Figure 139
84091
Figure 140
84275
Copyright © New Holland
EW--2--87
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 141 Figure 143
84092
Figure 145
70185
Clean thoroughly the main half bearings (1) provided Fasten pre--lubricated screws (1) by tightening them
with lubrication holes, then fit them to their seats. in three subsequent phases.
The penultimate main half bearing (1) is provided with - 1st phase with a torque wrench at 50 ± 6 Nm.
shoulder half rings.
- 2nd phase with a torque wrench at 80 ± 6 Nm.
Copyright © New Holland
EW--2--88
70188
Figure 147
CONNECTING ROD--PISTON ASSEMBLY
Figure 149
70189
32613
32615
Taking piston rings (1) off piston (2) by means of pliers
380000986 (3). Measuring the piston diameter (1) by means of a mi-
crometer (2) to determine the assembling play.
Figure 151
IMPORTANT -- The diameter must be measured
49.5 mm far from the piston skirt base.
Figure 153
32614
The piston rings (2) retaining the piston pin (1) are re-
moved by means of a mark scraper (3). 70192
The play between the piston and the cylinder liner can
also be measured by means of a thickness gauge (1)
as shown in the figure.
Figure 154
X = 0,6 ± 0,15
114088
32620
18857
Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 2nd and 3rd slot and the re-
spective seats on piston (2).
Conditions for correct pin/piston matching
Figure 156
Figure 159
32619
41104
Y Year of manufacture
D Day of manufacture
H Weight class
70194
Connecting rods
Figure 161
114314
61695
61696
Check connecting rod flexion (5) by comparing two
Check the centrelines of connecting rods (1) are par- points C and D of pin (3) on the vertical plane of the
allel using proper device (5) as follows: connecting rod axis.
- mount connecting rod (1) on tool (5) spindle, then Place comparator (2) vertical support (1) so that the
secure it by means of screw (4); comparator rests on pin (3) at point C.
Swing the connecting rod to and fro, looking for the hi-
- place spindle (3) on V--shaped block squares by ghest position of the pin; under such condition, set
putting connecting rod (1) on stop bar (2). comparator (2) to zero.
Move the spindle with connecting rod (5) and repeat
the highest point check on opposite side (D) of pin (3).
Checking the torsion The difference between points C and D must not be
greater than 0.08 mm.
Figure 164 Mounting the connecting rod--piston assembly
Connecting rod--piston coupling
Figure 166
86550
61694 The following reference data are engraved on the pi-
Check connecting rod torsion (5) by comparing two ston crown:
points (A and B) of pin (3) on the horizontal plane of 1. Spare part number and design modification num-
the connecting rod axis. ber;
Place comparator (2) support (1) so that the compara- 2. Inscription (facing the crankcase front side) indi-
tor is preloaded by ∼ 0,5 mm on pin (3) at point A, then cating the mounting sign of the piston in the cylin-
set comparator (2) to zero. Move spindle (4) with con- der liner.
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A 3. Date of manufacture;
and B must not be greater than 0.08 mm. 4. Stamping indicating 1st recess insert testing.
Copyright © New Holland
EW--2--93
Figure 170
86551
70201
70204
70202 - Tighten screws (1) (previously lubricated with en-
SCHEME FOR MOUNTING THE CONNECTING gine oil) to the specified torque by means of a tor-
ROD----PISTON ASSEMBLY INTO THE TUNNEL que wrench (2);
- the piston ring apertures are offset to each other
by 120°; Figure 175
- all the connecting rod/piston assemblies weigh
the same; α
- the writing stamped on the piston crown faces the
crankcase front side, or the notch obtained on the
piston skirt corresponds to the position of oil noz-
zles.
Figure 176
70203
70207
If the measured play is different from the specified 70209
one, replace half bearings and repeat the check. SCHEME FOR SEALANT LOCTITE 5205
Once the specified play has been obtained, lubricate APPLICATION AREA
the connecting rod half bearings and mount them de-
finitely by tightening the connecting rod cap fastening Clean thoroughly distribution gearbox case (1) and
screws as described. the engine crankcase.
Cleaning the surface to be sealed is necessary and
IMPORTANT -- Prior to mounting the connecting unavoidable in order to ensure optimum seal.
rod cap fastening screws definitely, verify that the Apply sealant Loctite 5205 on the case so as to make
diameter of the same (as measured at the middle a bead with a diameter of a few millimetres. The bead
of the thread length) is not smaller than 0.1 mm of must be smooth (no lumps) and free from air bubbles,
the diameter measured at about 10 mm from the thin areas or gaps.
screw end. Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
Check manually that connecting rods (1) run axially both sides of the joint and obstruct lubricant flowing
on the drive shaft pins, and that the end play of the passages.
same (as measured by means of a thickness gauge After completing sealant application, the joints must
(2)) is 0.10 to 0.33 mm. be mounted immediately (within 10 -- 20 minutes).
Figure 180
Checking piston protrusion
Figure 178
70210
SCHEME FOR REAR GEARBOX CASE
FASTENING SCREW TIGHTENING SEQUENCE
70208 Reconnect box (1) to engine block. Screw securing
After the connecting rod--piston assemblies have be- screws in the position found out on dismounting and
en mounted, check, by means of comparator lock screws at tightening torques below indicated ac-
380001004 (1) equipped with base 380001000 (2), cording to the order shown in figure.
the protrusion of pistons (3) at the top dead centre re- Screws M12 65 ÷ 89 Nm
lative to the crankcase upper plane. Screws M8 20 ÷ 28 Nm
Screws M10 42 ÷ 52 Nm
It must result of 0.28 -- 0.52 mm.
Copyright © New Holland
EW--2--96
70211
70214
Mark, with a felt--tip pen, the tooth of drive gear (1)
mounted on drive shaft (2), the side surface of which SCHEME FOR SEALANT LOCTITE 5205
bears a stamped notch (→) for timing. APPLICATION AREA
Clean thoroughly the attaching surfaces of flywheel ca-
Figure 182 se (1) and distribution gearbox case.
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant Loctite 5205 on the case (1) so as to ma-
ke a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from air
bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing pas-
sages.
After completing sealant application, the joints must be
mounted immediately (within 10 -- 20 minutes).
70212
Turn drive shaft (4) and distributing shaft (2) in such Figure 185
a direction that whenmounting driven gear (1) on the
distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Figure 183
70216
70152
Screw down two pins (2) of adequate length into the
70216
shaft holes (3), then remove the engine flywheel (1)
by means of suitable harnesses and a hoist.
Apply part (5) of tool 380000983 on drive shaft rear
Figure 189
shank (6), secure it by means of screws (4) and for-
ce--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
ENGINE FLYWHEEL
Figure 187
70218
Apply tool 380000990 (2, except for 667TA/EEG --
667TA/EEC engines) to the flywheel cover case (1)
to stop engine flywheel (3) rotation.
Tighten screws (4) fastening engine flywheel (3) to
the drive shaft.
Figure 190
114066
Check the condition of ring gear (2) teeth. If breaks or Tighten engine flywheel (2) fastening screws (1) in
excessive tooth wear is found, remove the ring gear two separate phases:
from the engine flywheel (1, Figure 187) by using a - 1st phase: tighten to a torque of 30 ± 4 Nm by
normal beater, then mount the new gear ring after means of a torque wrench;
previously heating it to 150 °C for 15′ to 20′; the coun- - 2nd phase: angle--tighten to 60° ± 5°.
tersink made on the gear ring inner diameter must fa-
ce the engine flywheel. IMPORTANT -- Angle tightening is carried out by
means of tool 380000304.
Copyright © New Holland
EW--2--98
70220 70223
Mount oil pump (1). Take seal ring (2) off front cover (1), clean thoroughly
Screw down fastening screws (2) and tighten them to the attaching surface and apply sealant Loctite 5205
the specified torque. onto the same.
Figure 192
Figure 195
70221 70224
Apply a new seal ring (2) onto water pump (1). Clean thoroughly the surface of front cover (2) atta-
ching base, then mount front cover.
Fasten screws (1) and tighten them to the specified
torque.
Figure 196
Figure 193
70225
Mount plate (3) and strainer (5), then screw down fa- Figure 201
stening screws (1--2--4) and tighten them to the speci-
fied torque.
Figure 198
74775
Fit the oil sump (1) and apply the plate (3) to it.
Tighten the screws (2) to the specified torque.
86505
Mount oil sump (1) and apply plate (3) on the same. Figure 202
Fasten screws (2) and tighten them to the specified
torque.
Figure 199
70363
70230 70232
Mount a new seal ring on rpm sensor (3). Lubricate the sealing ring (2) with engine oil and set
Fit rpm sensor (3) in front cover (1) and tighten screw it on the oil filter (3).
(2) for securing at prescribed torque. Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3)
by 3/4 turn (except for 667TA/EEG -- 667TA/EEC en-
gines).
Apply a new sealing ring on the oil temperature/pres-
sure sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
Fit a new sealing ring (6) in the engine block seat.
Figure 206
Figure 204
70234
70231
114170
Reconnect alternator (1) and tighten the bolts to the
specified torque.
Reconnect automatic tensioner (4) and tighten bolt
(3) to the specified torque. 70319
Turn the automatic belt tensioner (4) to fit the belt (2) Intake (1) and exhaust (2) valves have heads with the
on pulleys and guide rollers. same diameter.
Figure 208 The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
70145
Refit the high pressure pump (5) including the feed
pump (6) and tighten the nuts (3) to the specified tor- Figure 211
que. Fit the support (4) with a new sealing ring, the ti-
ming sensor (2) with a new sealing ring and tighten
the relevant fastening nut (1) to the specified torque.
Figure 209
70321
70322
Figure 213
Figure 215
70323
70326
VALVE GUIDE
18625
Figure 220
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns.
Reface, if necessary, the valve seats by means of
grinder 380000975, by removing as less material as
possible.
Figure 218
INTAKE EXHAUST
79457
18882
Use a bore gauge to measure the valve guide inner
Use a micrometer (2) to measure valve stem (1), diameter, which must be equal to the value shown in
which must be equal to 7.96 to 7.98. the figure.
Copyright © New Holland
EW--2--104
VALVES SEATS
Valve seat reconditioning -- replacement
Figure 221
70330
Figure 222
INTAKE EXHAUST
107283
Figure 223
EXHAUST INTAKE
70332
If the valve seats cannot be restored by simply recon- Heat the cylinder head to 80 to 100 °C, then mount
ditioning them, they can be replaced with spare parts. the new valve seats (previously cooled) onto the
By using the same tool (1, Figure 221) and taking ca- head by means of a suitable beater.
re not to indent the cylinder head, remove as much Recondition the valve seats by means of tool
material as possible from the valve seats until the lat- 380000975, according to the values shown in
ter can be taken off the cylinder head by means of a Figure 222.
punch.
VALVE SPRINGS
Figure 225
Figure 224
50676
70334
70335
Lubricate the valve stem (1) and insert into the re-
spective valve guide according to the position marked Verify that the cylinder head attaching plane and the
upon disassembling. crankcase attaching plane are both clean.
Mount seal rings (2 and 3) onto the valve guide. Do not spoil the cylinder head gasket.
IMPORTANT -- Seal rings (2) for aspiration valves Arrange gasket (1) for cylinder head with writing
are yellow: seal rings (3) for exhaust valves are “TOP” (1) towards head.
green. The arrow shows where gasket shim is inserted.
Figure 227
Figure 229
70336
77032 Mount cylinder head (1), screw screws (2) and tigh-
ten them in three successive steps, following order
and modalities indicated in next figure.
Position spring (4) and upper collar (3) on the cylinder
head: use tool 380000987 (1) to compress spring (4) IMPORTANT -- Angle tightening is carried out by
and link the parts to the valve by means of lock cones means of tool 380001001 (3).
(2).
Copyright © New Holland
EW--2--107
70476
• screw 12x1,75x150 ( ) 55 ± 5 Nm
- 2nd phase: angle tightening: 90° ± 5° Fit injectors (1) on the cylinder head seats, directed
- 3rd phase: angle tightening: 90° ± 5° so that the fuel inlet hole (2) is facing the fuel manifold
seat (3) side.
A = Front side
Figure 233
Fitting injectors
Figure 231
70338 70133
Use tool 380001099 (1) to fit the injector (2) into its
Fit a new sealing ring (2) lubricated with vaseline and seat.
a new sealing washer (3) on injector (1). Screw injector fastening screws without tightening
them.
Copyright © New Holland
EW--2--108
32655
Rocker control rods shall not be distorted; the ball
seats in touch with the rocker adjusting screw and
70341 with tappets (arrows) shall not show seizing or wear;
otherwise replace them. Intake and exhaust valve
Fit a new sealing ring (3) lubricated with vaseline on control rods are identical and are therefore interchan-
the fuel manifold (2) and fit it into the cylinder head geable.
seat so that the positioning ball (5) is coinciding with
the relevant housing (4).
Rocker arm assembly
Figure 237
IMPORTANT -- Disassembled fuel manifolds (2)
must not be used again, but however replaced with
other new ones.
70343
PARTS MAKING UP THE ROCKER ARM
Figure 235 ASSEMBLY:
1. Screws -- 2. Support -- 3. Arbour -- 4. Rocker arm
Figure 238
70342
70345 70520
Fit the rods (2). Adjust clearance between rockers and valves using
Position jumpers (1) on valves with marks (→) facing setscrew wrench (1), box wrench (3) and feeler gau-
the exhaust manifold. ge (2).
Working clearance shall be as follows:
-- intake valves: 0,25 ± 0,05 mm
-- exhaust valves: 0,51 ± 0,05 mm
70346
74762
Connect new fuel pipes (1) to rail (3) and injector ma-
nifolds (2).
IMPORTANT -- When removed, pipes (1) shall al-
ways be replaced.
Figure 245
s
114067
Connect the fuel pipe (3) to the rail (2) following the pro-
Figure 243
cedure shown in the following figure.
Figure 246
70126
Press the clamp (1) in arrow direction (Figure B) and
74761 connect the pipe to the rail (2, Figure 245), reset the
Fit the rail (2) and tighten the screws (1) to the speci- clamp to the initial locking position “A”.
fied torque, connect the ground cable (3) to the intake
manifold (4) and tighten the fastening nut (5) to the IMPORTANT -- Check proper fuel pipe connec-
specified torque. tion.
Copyright © New Holland
EW--2--111
72501
72511
Fit the tappet cover (1) and tighten the nuts (2) to the
specified torque.
70353
Fit the wiring support (2) and tighten the screws (1)
to the specified torque. Figure 252
Figure 249
114068
114069 70126
Connect the air duct (2) to the turbosupercharger (3) Press the clamp (1) in arrow direction (Figure B) and
and lock it by clamp (1). connect the pipe.
Reset the clamp to the initial locking position A.
Figure 254
6
2 5
4
3
74170
Figure 256
70129
1. Connections for electro--injectors -- 2. Engine cooling liquid temperature sensor -- 3. Fuel pressure sensor
-- 4. Engine oil temperature and pressure sensor -- 5. Drive shaft sensor -- 6. Electro--injector -- 7. Air tempe-
rature and pressure sensor -- 8. Distribution phase sensor -- 9. Fuel heater and fuel temperature sensor --
10. Pressure regulator -- 11. Control unit
Re--attach engine cable by connecting electro--injec- Apply rocker lever 380000216 to engine lifting hooks,
tors (6) wiring connectors (1); (7) air pressure/tempe- hook the rocker lever to hoist and detach engine from
rature sensor; (3) rail pressure sensor; (11) control rotating stand. Disassemble brackets 380000995.
unit; (10) high--pressure pump sensor; (8) distribution
phase sensor; (2) engine cooling liquid temperature
sensor on thermostat; (5) engine revolutions sensor.
Copyright © New Holland
EW--2--114
70125
70128
Screw manually the fuel filter to the support (1), screw
Complete engine refitting as follows: the filter by 3/4 turn, connect the pipes (2--3--4) to the
Form the right side: relevant support connections (1) as shown in the fol-
lowing figure.
Refit the starter (5) to the flywheel housing (4) and
tighten the fastening nuts to the specified torque.
Fit the oil pipe (3) with a new sealing ring into the engi-
ne block and secure it to the turbosupercharger (1) by
the screws (2) tightened to the specified torque.
70362 70126
Refit the bracket (2) including the fuel filter support (1) Press the clamp (1) as shown in figure B.
to the engine block, tighten the screws (3) to the spe- After disconnecting the pipe, reset the clamp (1) to
cified torque. the initial locking position A, to prevent deformations.
When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.
Copyright © New Holland
SECTION 3
INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--3--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--6
ISKRA 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--3--5
Copyright © New Holland
INDICE
Copyright © New Holland
EW--3--3
STARTER MOTOR
Quick diagnosis
Bosch 24 V -- 4 kW
6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
Figura 1 Figura 3
84262 84267
Figura 2 Figura 4
84268 84269
ISKRA 24 V -- 4 kW
Fork mesh type, driven by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
Figura 5 Figura 6
114183 114184
ALTERNATOR
Quick diagnosis
Figura 7 Figura 9
84270 84271
Figura 8 Figura 10
84272 84274