service repair manual

1. 87693277 6/07
Replaces 87515329
© 2007 CNH America LLC
Printed In U.S.A.
TS100A, TS110A, TS115A, TS125A,
TS130A AND TS135A REPAIR
AND
T6010, T6020, T6030,
T6050, T6070 REPAIR
SECTION 00 - GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 01 - SEPARATING THE TRACTOR 3. . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 18 - CLUTCH 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 21 - TRANSMISSION SYSTEMS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 23 - DRIVE LINES 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 25 - MECHANICAL FRONT AXLE 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 27 - MECHANICAL REAR WHEEL DRIVE 34. . . . . . . . . . . . . . . . . . . .
SECTION 31 - POWER TAKE-OFF 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 33 - BRAKING SYSTEM 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 35 - HYDRAULIC SYSTEMS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 41 - STEERING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 44 - FRONT AXLE AND WHEELS 69. . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 50 - AUXILIARY UNITS 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 55 - ELECTRICAL SYSTEM 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following pages are the collation of the contents pages from each section and
chapter of the TS100A, TS110A, TS115A, TS125A, TS130A, TS135A and T6010, T6020,
T6030, T6050, T6070 Repair manual. Complete Repair part # 87693272.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the TSA Series and T6000 Series
Tractors.

2. 2
Some sections of this Repair Manual have been revised to include the New T6000 Delta and
Plus Series Models T6010, T6020, T6030, T6050, and T6070.
Please note the following to locate new T6000 Tractor Model Repair information:
For complete engine repair information for the new T6000 Series Tractors use Engine
Repair Manual # 87661796.
Most all repairs can be carried out by following the Tractor’s systems and specific product
configurations in the repair manual. Example; 16 x16 Transmission, Air Conditioning and
TSA Standard Series Closed Center Hydraulic System.
“TSA Standard” Repair Information also applies to the New T6000 Delta Series Models.
Where specific T6000 Tractor Models are not identified use the following TSA to T6000 cross
reference:
T6000 Tractor Models Use TSA tractor Model
T6010 TS100A
T6020 TS110A
T6030 TS115A
T6050 TS125A
T6070 TS135A

3. 87693279 6/07© 2007 CNH America LLC
Printed In U.S.A.
INFORMATION
With the introduction of the T6000 Series Tractors, controller identifications codes have changed. Also, the
location of the diagnostic connector has changed. The updated Repair Manual # 87693272 does not contain
the new controller ID’s or the new location of the diagnostic connector. This page shows the T6000 Series
controller identification codes and the diagnostic connector location.
NOTE: Please insert a copy of this page in the front of each Repair Manual Volume for your reference.
Models covered are:
T6000 DELTA TRACTORS
T6020, T6030, T6050
T6000 PLUS SERIES TRACTORS
T6010, T6020, T6030, T6050, T6070
CONTROLLER IDENTIFICATION CODES
The controller identifiers change with the introduction of the T6000 range of tractors, eg., Controller DA for
TS-A will become Controller DR for T6000 range. This is required to be remembered throughout this Repair
Manual. See table below:
Identifier Identifier Controller Function(s)
TS-A T6000
DA DR 24x24 Transmission, Electronic Draft Control, Rear PTO,
Differential Lock, Four Wheel Drive
DB DS 16x16 Transmission, Electronic Draft Control, Rear PTO,
Differential Lock, Four Wheel Drive
DD DU (Options) Front PTO, Front Hitch, Front Axle Suspension,
Electronic Hydraulic Remotes
EDC7 EDC16 Engine Control (Engine Side)
HA HJ Enhanced Analogue Digital Instrument Cluster (ADIC)
HB HK Basic ADIC
GA 12x12 PTO Controller -- Rear PTO, Differential Lock, Four Wheel
Drive
JA Keypad

4. CONTROLLER FUNCTIONS
Electronic Module
Model/Type 24x24 16x16 24x24
16x16
12x12 24x24
16x16
Function DA(DR) DB(DS) DD(DU) GA EDC7
(EDC16)
Rear PTO n n n
Differential Lock n n n
Four Wheel Drive n n n
Engine Control (vehicle side) n n
Auto Headland Turn
Sequence (HTS)
n n
Electronic Draft Control n n
Front Suspension n
Front PTO n
Front Lift n
Electro-Hydraulic Remotes n
Transmission 24x24 n
Transmission 16x16 n
Engine Control (engine side) n
The controller type is identified by a code which is
attached to each module. The code, for example,
’DB/DS’ identifies it as the module used on a tractor
with a 16x16 transmission controlling those
functions highlighted in the table above.
All the modules on the tractor are linked by the CAN
harness and this also links in the instrument cluster,
gear display (16x16 only) and diagnostic connector.
Refer to the system diagrams in Section 55,
Chapter 1 of this repair manual for full controller
details and inter connectivity.
DIAGNOSTIC CONNECTORS
(ADDITIONAL “C” PILLAR LOCATION)
A single diagnostic port, 2, located behind the trim
under the transmission control levers, or on the right
hand “C” pillar, 1, to interrogate all of the controllers
is incorporated into the wiring harness. With the aid
of special service tool 380000843, the port can be
used to gain access to the on-board H-menu
diagnostics, see Section 55, Chapter 1 of this
Repair Manual for full details, to download software
or to connect in more specialized diagnostic
equipment such as the E.S.T. (Electronic Service
Tool).
C277

5. SECTION 00 -- GENERAL -- CHAPTER 1 1
SECTION 00 -- GENERAL
Chapter 1 -- General Information
CONTENT
Section Description Page
00 000 General Instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautionary Statements 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ecology and the Environment 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Identification 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
International Symbols 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications -- Plus/Deluxe Models 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Dimensions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications -- Standard Models 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Dimensions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Hardware Tightening Torques 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. 2 SECTION 00 -- GENERAL -- CHAPTER 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by authorised
workshops. All instructions should be carefully observed and special equipment where indicated should be used.
Anyone who carries out service operations described without carefully observing these instructions will be
directly responsible for any damage caused.
NOTES FOR EQUIPMENT
Equipment shown in this manual is:
-- designed expressly for use on these tractors;
-- necessary to make a reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working life.
NOTICES
The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat
oriented to the normal direction of movement of the tractor.

7. SECTION 00 -- GENERAL -- CHAPTER 1 3
PRECAUTIONARY
STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”,
“WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal
safety of you and those working with you. Please take the time to read them.
DANGER
This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or
serious injury. The color associated with Danger is RED.
WARNING
This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury. The color associated with Warning is ORANGE.
CAUTION
This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is
YELLOW.
FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for
machine safety.
IMPORTANT: IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to
know to prevent minor machine damage if a certain procedure is not followed.
INFORMATION
NOTE: NOTE: Instructions used to identify and present supplementary information.

8. 4 SECTION 00 -- GENERAL -- CHAPTER 1
IMPORTANT WARNINGS
The machine is designed and produced exclusively
for agricultural use.
All other use will be considered to be contrary to the
use specified by CNH AMERICA LLC, who cannot be
held liable for damage to property or the machine, or
for personal injuries which may result.
Persons who risk improper use will therefore assume
the responsibility for any consequences arising from
such use.
Compliance with the instructions for use,
maintenance and repairs described in this manual,
are the essential preconditions for use specified by
CNH AMERICA LLC.
The machine must only be used, serviced or repaired
by personnel trained in the relevant working methods
and safety regulations and who have been
authorized to work on the machine.
The user must also observe the rules concerning
general safety and accident prevention, including the
Highway Code when driving on public highways.
Any arbitrary modifications made to this machine will
release CNH AMERICA LLC from any liability
resulting from damage or injury.
CNH AMERICA LLC and all its distribution
organizations, inclusive of, but not restrict to,
national, regional or local distributors, cannot be held
liable for damage resulting from the malfunction of
parts and/or components not approved by CNH
AMERICA LLC.
Under no circumstances will a guarantee be issued
for products made or sold by CNH AMERICA LLC
that are damaged as a result of the malfunction of
parts and/or components not approved by CNH
AMERICA LLC.
TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in
workshops are due from non-observance of some
essential rules and safety precautions.
The possibility that an accident might occur with any
type of machines should not be disregarded, no
matter how well the machine in question was
designed and built.
A wise and careful service technician is the best
precautions against accidents.
Careful observance of this basic precaution would be
enough to avoid many severe accidents.
DANGER
Never carry out any cleaning, lubrication or
maintenance operations when the engine is running.

9. SECTION 00 -- GENERAL -- CHAPTER 1 5
SAFETY RULES
Generalities
• Carefully follow specified repair and
maintenance procedures.
• Do not wear rings, wristwatches, jewels,
unbuttoned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get caught on moving parts. Use
approved safety clothing such as anti--slipping
footwear, gloves, safety goggles, helmets, etc.
• Wear safety glasses with side guards when
cleaning parts using compressed air.
• Damaged or frayed wires and chains are
unreliable. Do not use them for lifting or towing.
• Wear suitable protection such as approved eye
protection, helmets, special clothing, gloves and
footwear whenever welding. All persons
standing in the vicinity of the welding process
should wear approved eye protection. NEVER
LOOK AT THE WELDING ARC IF YOUR EYES
ARE NOT SUITABLY PROTECTED.
• Never carry out any repair on the machine if
someone is sitting on the operator’s seat, except
if they are qualified operators assisting in the
operation to be carried out.
• Never operate the machine or use attachments
from a place other than sitting at the operator’s
seat or at the side of the machine when operating
the fender switches.
• Never carry out any operation on the machine
when the engine is running, except when
specifically indicated. Stop the engine and
ensure that all pressure is relieved from hydraulic
circuits before removing caps, covers, valves,
etc.
• All repair and maintenance operations should be
carried out with the greatest care and attention.
• Disconnect the batteries and label all controls to
warn that the tractor is being serviced. Block the
machine and all equipment which should be
raised.
• Never check or fill fuel tanks or batteries, nor use
starting liquid if you are smoking or near open
flames as such fluids are flammable.
• The fuel filling gun should always remain in
contact with the filler neck. Maintain this contact
until the fuel stops flowing into the tank to avoid
possible sparks due to static electricity build--up.
• To transfer a failed tractor, use a trailer or a low
loading platform trolley if available.
• To load and unload the machine from the
transportation means, select a flat area providing
a firm support to the trailer or truck wheels. Firmly
tie the machine to the truck or trailer platform and
block wheels as required by the transporter.
• Always use lifting equipment of appropriate
capacity to lift or move heavy components.
• Chains should always be safely fastened.
Ensure that fastening device is strong enough to
hold the load foreseen. No persons should stand
near the fastening point.
• The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of
water or oil.
• Never use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non--flammable
non--toxic proprietary solvents.
• Do not pile up grease or oil soaked rags, as they
constitute a great fire hazard. Always place them
into a metal container.

10. 6 SECTION 00 -- GENERAL -- CHAPTER 1
START UP
• Never run the engine in confined spaces which
are not equipped with adequate ventilation for
exhaust gas extraction.
• Never bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
• Always loosen the radiator cap very slowly
before removing it to allow pressure in the
system to dissipate. Coolant should be topped up
only when the engine is stopped.
• Do not fill up fuel tank when the engine is running.
• Never adjust the fuel injection pump when the
tractor is moving.
• Never lubricate the tractor when the engine is
running.
ELECTRICAL SYSTEMS
• If it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+)
to (+) and (--) to (--). Avoid short--circuiting the
terminals. GAS RELEASED FROM BATTERIES
IS HIGHLY FLAMMABLE. During charging,
leave the battery compartment uncovered to
improve ventilation. Avoid sparks or flames near
the battery area. Do no smoke.
• Do not charge batteries in confined spaces.
• Always disconnect the batteries before
performing any type of service on the electrical
system.
HYDRAULIC SYSTEMS
• Some fluid coming out from a very small port can
be almost invisible and be strong enough to
penetrate the skin. For this reason, NEVER USE
YOUR HANDS TO CHECK FOR LEAKS, but use
a piece of cardboard or a piece of wood for this
purpose. If any fluid is injected into the skin, seek
medical aid immediately. Lack of immediate
medical attention may result in serious infections
or dermatitis.
• Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
• Check that the tyres are correctly inflated at the
pressure specified by the manufacturer.
Periodically check for possible damage to the
rims and tyres.
• Stay at the tyre side when inflating.
• Check the pressure only when the tractor is
unloaded and tyres are cold to avoid wrong
readings due to over--pressure.
• Never cut, nor weld a rim with the inflated tyre
assembled.
• To remove the wheels, block both front and rear
tractor wheels. Raise the tractor and install safe
and stable supports under the tractor in
accordance with regulations in force.
• Deflate the tyre before removing any object
caught into the tyre tread.
• Never inflate tyres using flammable gases as
they may originate explosions and cause injuries
to bystanders.
REMOVAL AND INSTALLATION
• Lift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that
parts are supported by appropriate slings and
hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.

11. SECTION 10 -- ENGINE -- CHAPTER 1 15
DESCRIPTION OF OPERATION
COOLING
The forced circulation, closed--circuit engine cooling system is composed of the following components:
-- Expansion tank: its location, shape and size may change depending on the engine version.
-- Radiator, whose job is to dissipate the heat taken by the coolant from the engine. This component, too, is
a feature of the version as regards both positioning and engine.
-- Viscostatic fan, with the task of increasing the radiator’s dissipating capacity: this, too, belongs to the specific
engine version.
-- A lubricating oil cooler: this, too, belongs to the specific engine version.
-- A centrifugal coolant pump housed at the front of the crankcase.
-- A thermostat governing coolant circulation.
-- The circuit may also extend to the compressor if the version includes it.
80369
A = TO THE RADIATOR
B = FROM THE RADIATOR
8
COOLING SYSTEM DIAGRAM

12. 16 SECTION 10 -- ENGINE -- CHAPTER 1
LUBRICATION
Forced--circulation lubrication is accomplished by the oil pump, housed at the front of the crankcase.
The lubricating oil is sent from the oil sump to the crankshaft, camshaft and valve control.
Lubrication also includes the cooler, turbo--blower and compressor for the compressed air system if there is one.
All these components often change according to use and will therefore be covered under the specific heading.
80370
Pressurized oil
Oil under gravity
9

13. SECTION 10 -- ENGINE -- CHAPTER 1 17
LUBRICATION SYSTEM COMPONENTS
80371
10
1. Crankshaft – 2. Balancing weight – 3. Oil sump with suction rose – 4. Suction rose in oil sump –
5. Oil pump – 6. Relief valve.

14. 18 SECTION 10 -- ENGINE -- CHAPTER 1
ENGINE OVERHAUL
INTRODUCTION
Removal
To remove engine from tractor see Section 01
“Separating the Tractor.”
DISASSEMBLY
Some of the operations described in this section can
be carried out directly with the engine fitted on the
vehicle, depending on access to the engine bay and
on the version.
CAUTION
The operations for removing the engine, as those for
overhaul, must be performed by skilled personnel us-
ing specific tools.
Fuel System/Preparing Engine to Mount on
Rotating Stand
To be able to fit the brackets 380001298 (for fixing the
engine to the overhaul stand, 380000301) to the
crankcase, it is necessary to work from the left--hand
side of the engine:
1. Remove the fuel filters (6) from the mounting
(1);
2. Disconnect the electrical connection (2) from
the mounting (1) and the one to the heater
(again located on the filter mounting);
3. Disconnect the fuel pipes (3 -- 4 -- 5) from the
mounting (1);
4. Remove the bracket supporting the mounting
(1) from the crankcase.
CAUTION
To disconnect the fuel pipes (3 – 4 – 5, Figure 11)
from the relevant fittings, you need to press the clip
(1) as shown in Figure 12, B.
After disconnecting the piping, put the clip (1) back in
its locking position (Figure 12, A) to prevent it getting
buckled.
80372
11
5. Disconnect the high--pressure fuel pipe (7, Fig-
ure 1) from the rail choke tube and from the
high--pressure pump (8) and remove it from the
crankcase by taking out the bracket.
6. Disconnect the pipe 9 from the high--pressure
pump (8).
CAUTION
Depending on the high pressure in the piping from
the high--pressure pump to the rail and from here to
the electro--injectors, never:
-- disconnect the pipes with the engine running,
-- reuse disconnected pipes.
80628
12

15. SECTION 10 -- ENGINE -- CHAPTER 1 19
7. Remove the oil filler pipe (3).
8. Unscrew the fixing screws (1) and remove the
starter motor (2) from its seat.
80374
13
9. Working from the right--hand side of the engine,
disconnect the lubricating pipe (1) from the top
of the cooler to the turbo--blower (2).
10. Remove the thermostat body (3) together with
the seal.
80373
14
11. Fit brackets 380001298 into the holes (1) and
(2) in the crankcase on both sides and, using
these brackets, secure the engine to the rotat-
ing stand 380000301. Drain off the engine oil by
removing the plug from the sump.
80401
15

16. 20 SECTION 10 -- ENGINE -- CHAPTER 1
80375
16
REMOVING COMPONENTS OF THE APPLICATION
1. Connection for electro--injectors -- 2. Engine coolant temperature sensor --
3. Fuel pressure sensor cable -- 4. Engine oil pressure and temperature sensor -- 5. Crankshaft sensor --
6. Electro--injector -- 7. Air pressure temperature sensor -- 8. Timing system phase sensor --
9. Fuel temperature sensor -- 10. Pressure regulator wiring -- 11. EDC7C control unit
Electrical Connections
12. Disconnect the engine cable from the connec-
tors: (1) electro-injector wiring (6); (7) air
pressure/temperature sensor; (3) fuel pressure
sensor; (11) EDC control unit; (10 high-pres-
sure pump sensor; (8) timing system phase
sensor; (2) engine coolant temperature sensor
on thermostat; (5) crankshaft speed sensor.

17. SECTION 10 -- ENGINE -- CHAPTER 1 21
Fuel Rail
13. Take off the clamps fastening it to the crankcase
and remove it completely.
14. Disconnect the fuel pipes (5) from the rail (2)
and from the manifolds (6) for the electro--injec-
tors.
CAUTION
When locking the fittings (4) securing the pipes (6) to
the rail (2), using an appropriate wrench, you must
prevent the flow limiters, if fitted, (3) from turning.
15. Remove the screws (1) and detach the rail (2).
80376
17
Cylinder Head
16. Disconnect the piping from the fuel return pres-
sure limiter (1).
17. Undo the nuts (2) and take off the tappet cover
(3).
80377
18
18. Remove the nuts (7) and disconnect the electric
cables from the electro--injectors (8).
19. Take out the screws (1) and remove the elec-
tro--injector wiring mounting (2) together with its
seal.
20. Take out the screws (5), remove the air temper-
ature/pressure sensor (6).
21. Remove the nuts (3) and extract the fuel man-
ifolds (4).
CAUTION
Once removed, the fuel manifolds (4) must not be re-
used; they must be replaced with new ones.
80591
19

18. 22 SECTION 10 -- ENGINE -- CHAPTER 1
22. Loosen the tappet adjuster fixing nuts (1) and
unscrew the adjusters.
23. Take out the screws (2), remove the rocker--arm
assembly (3) comprising the mounting (6),
rocker arms (4) and spindles (5) then remove
the bridges (7) from the valves.
24. Remove the rods (8).
80640
20
25. Take out the screws securing the electro--injec-
tors and, using tool 380001099 (1), extract the
electro--injectors (2) from the cylinder head.
80686
21
26. Working on the tightener (1), extract the belt
(12) from the pulleys of the alternator, coolant
pump and snub pulleys.
27. Unscrew the bolt (2) and remove the tightener;
28. Remove the snub pulley (6), unscrew the bolts
(7) and remove the pulley (8) from the mounting
beneath.
29. Unscrew the bolts (10) and remove the tighten-
er mounting.
30. Unscrew the bolts (11) and remove the mount-
ing (9) from the crankcase.
31. Unscrew the bolts (3) and remove the coolant
pump (4).
32. Unscrew the bolt and remove the engine speed
sensor (5)
80378
22

19. SECTION 10 -- ENGINE -- CHAPTER 1 23
Proceed to remove the turbocharger:
33. Unscrew the ring nut (1) and remove the lu-
brication piping of the turbo--blower.
34. Unscrew the nuts (2) securing the turbo--blower
on the exhaust manifold (4).
35. Support the turbo--blower (5) and, lifting it, re-
move the seal.
36. Unscrew the retaining nuts (3) and remove the
exhaust manifold (4).
80315
23
37. From the opposite side, unscrew the bolts se-
curing the intake manifold (1) and remove it to-
gether with the air heater (2) for cold starts.
80379
24
38. Hook up the brackets, 380001073 (1) with a
suitable sling and, using a hoist, remove the cyl-
inder head (2) from the crankcase.
80687
25

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21. 24 SECTION 10 -- ENGINE -- CHAPTER 1
Crankcase -- External Components
39. Remove the oil filter (1).
40. Unscrew the retaining bolts and remove the al-
ternator (2).
80380
26
41. Unscrew the retaining bolts (1) and remove the
pipe fitting (2).
80326
27
42. Disconnect the connector (1) from the oil pres-
sure--temperature sensor.
43. Unscrew the bolts (2) and remove the oil pres-
sure--temperature sensor (3).
44. Unscrew the bolts (4) and remove the oil filter
mounting (5) from the crankcase together with
its seals.
45. Remove the cooler from its seat.
80400
28

22. SECTION 10 -- ENGINE -- CHAPTER 1 25
46. Remove the nuts (1) and detach the high--pres-
sure pump (2) together with the feed pump (3).
80381
29
Crank Shaft Seals
47. Install the engine turning / locking tool,
380000988, (1) and 380000732, (2).
48. Loosen the screws fixing the flywheel to the
crankshaft.
2
30
49. Unscrew the bolts (1), remove the pulley (2),
spacer (3) and pulley (4).
50. The engine flywheel locking tool can help with
disassembly of the damper flywheel (2) fitted on
the pulley (4).
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31

23. 26 SECTION 10 -- ENGINE -- CHAPTER 1
51. Extract the front cover shaft seal.
52. Apply tool 380000665 (4) on the front tang (2)
of the crankshaft.
53. Perforate the inner seal (1) with a drill bit
(∅ 3.5 mm (0.1378 in.)) through the tool’s guide
holes, for a depth of 5 mm (0.1969 in.).
54. Secure the tool to the seal by screwing down the
6 screws supplied. Extract the seal (1) by
screwing down the screw (3).
80595
32
55. Use a suitable hooked device (3) with the aid
of the lever (4) extract the outer seal (2) from the
front cover (1).
80596
33
56. Take out the screws (1) and remove the oil
pump (2).
CAUTION
Note down the assembly position of the screws (1) as
they have different lengths.
80330
34

24. SECTION 10 -- ENGINE -- CHAPTER 1 27
57. Remove two opposing screws (1) where the ex-
traction pins are to go in (see figure 36).
58. Unscrew the remaining screws securing the fly-
wheel (3) from the crankshaft (2).
59. Remove the tool locking the flywheel (4).
35
60. Screw two screws of suitable length into the
holes (4) to sling the flywheel with a lift.
61. Using the two guide pins (2) previously screwed
into the holes of the crankshaft (3), guide the ex-
traction of the engine flywheel (1) with the aid of
a lift.
80356
36
62. Extract the seal, applying tool 380000663 (3)
onto the rear tang (5) of the crankshaft.
63. Perforate the inner seal with a drill bit
(∅ 3.5 mm (0.1378 in.)) through the tool’s guide
holes, for a depth of 5 mm (0.1969 in.).
64. Secure the tool 380000663 (3) to the seal (1) by
screwing down the 6 screws supplied (4).
Extract the seal (1) by screwing down the screw
(2).
65. Using an appropriate hooked device and a le-
ver, extract the outer seal from the timing box.
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37

25. 28 SECTION 10 -- ENGINE -- CHAPTER 1
Sump
66. Turn the engine over.
Take out the screws (2) and remove the oil
sump (1).
67. Disconnect the high--pressure pump phase
sensor.
68. Unscrew the bolts (3) and remove the timing
gear box (4) from the crankcase.
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38
Rotating Counter Weights
69. Take out the screws (1) and remove the gear (3)
from the camshaft (2).
80397
39
70. Using the pin (1), lock the additional counter-
weights (2) at the T.D.C.
71. Unscrew the retaining bolts (3) and remove the
additional counterweights (2).
80332
40

26. SECTION 10 -- ENGINE -- CHAPTER 1 29
80637
41
ROTATING COUNTERWEIGHT COMPONENTS
1. Retaining bolts -- 2. Mounting -- 3. Retaining bolts -- 4. Gear -- 5. Balancing weight -- 6. O--ring -- 7. Ring --
8. Gear -- 9. Counter--shaft -- 10. Half bearings
Crankshaft
72. Take out the screws (1) securing the connecting
rod caps (2) and remove them.
73. Extract the pistons together with the connecting
rods from the top of the crankcase.
CAUTION
Keep the half bearings in their respective housings
since, if they are used, they must be mounted in the
position found upon disassembly.
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42