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87618716 12/06 Replaces 87056434 © 2006 CNH America LLC Printed In U.S.A. TC35A, TC35DA, TC40A, TC40DA, TC45A, TC45DA REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION 2 .............................. SECTION 10 - ENGINE 3 .............................................. SECTION 18 - CLUTCH 10 .............................................. SECTION 21 - TRANSMISSION 12 ....................................... SECTION 23 - DRIVELINE 14 ........................................... SECTION 25 - FWD FRONT AXLE 15 .................................... SECTION 27 - DIFFERENTIAL, REAR AXLE 18 ........................... SECTION 29 - HYDROSTATIC TRANSMISSION 19 ........................ SECTION 31 - POWER TAKE-OFF (PTO) SYSTEMS 22 .................... SECTION 33 - BRAKES 25 .............................................. SECTION 35 - HYDRAULIC SYSTEM 25 .................................. SECTION 41 - STEERING 29 ............................................ SECTION 44 - 2WD FRONT AXLE 31 .................................... SECTION 50 - CLIMATE CONTROL 31 ................................... SECTION 55 - ELECTRICAL 35 ......................................... SECTION 90 - PLATFORM 53 ........................................... The following pages are the collation of the contents pages from each section and chapter of the TC35A -- TC45DA Repair manual. Complete Repair part # 87618714. 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 TC35A -- TC45DA Tractors.

New Holland TC35DA Tractor Service Repair Manual

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Text of New Holland TC35DA Tractor Service Repair Manual

  • 87618716 12/06Replaces 87056434

    © 2006 CNH America LLCPrinted In U.S.A.

    TC35A, TC35DA, TC40A, TC40DA,TC45A, TC45DAREPAIR MANUAL

    COMPLETE CONTENTS

    SECTION 00 - GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 10 - ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 18 - CLUTCH 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 21 - TRANSMISSION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 23 - DRIVELINE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 25 - FWD FRONT AXLE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 27 - DIFFERENTIAL, REAR AXLE 18. . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 29 - HYDROSTATIC TRANSMISSION 19. . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 31 - POWER TAKE-OFF (PTO) SYSTEMS 22. . . . . . . . . . . . . . . . . . . .

    SECTION 33 - BRAKES 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 35 - HYDRAULIC SYSTEM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 41 - STEERING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 44 - 2WD FRONT AXLE 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 50 - CLIMATE CONTROL 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 55 - ELECTRICAL 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 90 - PLATFORM 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    The following pages are the collation of the contents pages from each section and

    chapter of the TC35A -- TC45DA Repair manual. Complete Repair part # 87618714.

    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 TC35A -- TC45DA Tractors.

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-1

    SECTION 00 - GENERAL INFORMATION

    Chapter 1 - General Information

    CONTENTS

    Section Description Page

    00 000 Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Technical Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Safety Precautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Safety Decals -- TC35A, TC40A, TC45A 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Instruction Decals -- TC35A, TC40A, TC45A 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Safety Decals -- TC35DA, TC40DA, TC45DA 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Instruction Decals -- TC35DA, TC40DA, TC45DA 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    International Symbols 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Specifications -- TC35A, TC40A, TC45A 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    General Dimensions -- TC35A, TC40A, TC45A 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Specifications - TC35DA, TC40DA, TC45DA 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    General Dimensions -- TC35DA, TC40DA, TC45DA 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Minimum Hardware Tightening Torques 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Special Tools 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Lubricants 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    00 400 Recommended Lubricants 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Adjustments 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Tire Inflation Pressure -- Adjustments 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    00 100 Pre-Season and Pre-Delivery Checklist 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-2

    INTRODUCTION

    This repair manual provides the technical informa-tion needed to properly service the New HollandTC35A, TC35DA, TC40A, TC40DA, TC45A andTC45DA tractors. Use this manual in conjunctionwith the operators manual for complete operation,adjustment, and maintenance information.

    On New Holland equipment, left and right aredetermined by standing behind the unit, looking inthe direction of travel.

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-3

    PRECAUTIONARY STATEMENTS

    PERSONAL SAFETY

    Throughout this manual and on machine decals, you will find precautionary statements (CAUTION,WARNING, and DANGER) followed by specific instructions. These precautions are intended for the personalsafety of you and those working with you. Please take the time to read them.

    CAUTIONThe word CAUTION is used where a safe behavioral practice according to operating and maintenanceinstructions and common safety practices will protect the operator and others from accidentinvolvement.

    DANGERThe word DANGER denotes a forbidden practice in connection with a serious hazard.

    WARNINGThe word WARNING denotes a potential or hidden hazard which has a potential for serious injury. Itis used to warn operators and others to exercise every appropriate means to avoid a surpriseinvolvement with machinery.

    FAILURE TO FOLLOW THE CAUTION, WARNING, AND DANGER INSTRUCTIONS MAY RESULT INSERIOUS BODILY INJURY OR DEATH.

    MACHINE SAFETY

    The precautionary statement (IMPORTANT) is followed by specific instructions. This statement is intended formachine safety.

    IMPORTANT: The word IMPORTANT is used to inform the reader of something he needs to know to preventminor machine damage if a certain procedure is not followed.

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-4

    TECHNICAL INFORMATION

    HARDWARE

    GENERALThe TC35A, TC35DA, TC40A, TC40DA, TC45A andTC45DA tractors have been built using metrichardware.

    NOTE: Be sure to use the hardware specified whenusing tapped holes, as trying to install a metric bolt inan inch thread, or an inch bolt in a metric thread, willdamage the thread.

    Certain hardware must be tightened to specifictorque specifications. If specific torque specificationsare not noted, tighten the hardware to the standardtorque chart specification listed in this manual.

    PLATINGHardware used on New Holland balers is plated withzinc chromate (gold color). Gold colored hardwarehas different torquing requirements from unplated orzinc plated (silver color) hardware because of thedifference in the coefficient of friction of the platingmaterial. The torque charts in this manual list thecorrect specifications for gold, silver, and unplatedbolts.

    NUT TIGHTENINGWhenever possible, the nut should be tightened, notthe head of the bolt. When tightening using the bolthead, the clamp load can be lost because some ofthe torque applied twists the bolt instead oftensioning (stretching) it. The tension on the bolt iswhat holds the joint together.

    Approximately 90% of the torque applied duringassembly goes to overcoming friction between theparts. The other 10% is used to tension (stretch) thebolt. After assembly, the frictional forces disappear,which is the basis for the saying If it does not failduring assembly, it will not fail in service. The boltmay later fail due to other factors, but not from beingover tightened.

    LOCKNUTSMost locknuts are coated with a special lubricant thatis dry to the touch. Anytime a locknut is used, a lowerthan normal torque is required. Refer to the torquecharts in this manual for specific values.

    JAM NUTSWhen using a jam nut to lock a regular nut, the jamnut should be installed first and tightened to one halfthe recommended torque, then held in place whileinstalling a regular nut to the recommended torque.

    THREAD LUBRICATIONThe addition of antiseize compound, Molykote, oil,graphite, or any other lubricant to a bolt decreasesthe friction between it and a nut. This makes itnecessary to reduce the recommended torque toprevent over tensioning of the bolt. When using thetorque charts in this manual, decrease the value by20% whenever a lubricant is used.

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-5

    SAFETY PRECAUTIONSA careful operator is the best operator. Mostaccidents can be avoided by observing certainprecautions. To help prevent accidents, read andtake the following precautions before operating thistractor. Equipment should be operated only by thosewho are responsible and instructed to do so.

    THE TRACTOR

    1. Read the Operators Manual carefully beforeusing the tractor. Lack of operating knowledgecan lead to accidents.

    2. Use an approved roll bar and seat belt for safeoperation. Overturning a tractor without a roll barcan result in death or injury. If your tractor is notequipped with a roll bar and seat belt, see yourNew Holland Dealer.

    3. Always use the seat belt. The only instance whenthe seat belt should not be used is if the roll barhas been removed from the tractor or foldingROPS is in down position.

    4. If a front end loader is to be installed, always usea FOPS (Falling Object Protective Structure)canopy to avoid injury from falling objects.

    5. Use the handholds and step plates when gettingon and off the tractor to prevent falls. Keep stepsand platform cleared of mud and debris.

    6. Do not permit anyone but the operator to ride onthe tractor. There is no safe place for extra riders.

    7. Keep all safety decals clean of dirt and grime,and replace all missing, illegible, or damagedsafety decals. See the list of decals in the Decalsection of this manual.

    SERVICING THE TRACTOR

    1. The cooling system operates under pressurewhich is controlled by the radiator cap. It isdangerous to remove the cap while the system ishot. Always turn the cap slowly to the first stopand allow pressure to escape before removingthe cap entirely.

    2. Keep any type of open flame away from thetractor and do not smoke while refueling. Wait forthe engine to cool before refueling.

    3. Keep the tractor and equipment, particularlybrakes and steering, maintained in a reliable and

    satisfactory condition to ensure your safety andcomply with legal requirements.

    4. Keep open flame or cold weather starting aidsaway from the battery to prevent fires orexplosions. Use jumper cables according toinstructions to prevent sparks which could causeexplosion.

    5. Stop the engine before performing any serviceon the tractor.

    6. Escaping hydraulic/diesel fluid under pressurecan penetrate the skin causing serious injury. Iffluid is injected into the skin, obtain medicalattention immediately or gangrene may result.

    • DO NOT use your hand to check for leaks.Use a piece of cardboard or paper to searchfor leaks.

    • Stop the engine and relieve pressure beforeconnecting or disconnecting lines.

    • Tighten all connections before starting theengine or pressurizing lines.

    7. Do not modify or permit anyone else to modify oralter this tractor or any of its components orfunctions without first consulting a New HollandDealer.

    8. The fuel oil in the injection system is under highpressure and can penetrate the skin. Unqualifiedpersons should not remove or attempt to adjusta pump, injector, nozzle, or any other part of thefuel injection system. Failure to follow theseinstructions can result in serious injury.

    9. Continuous long-term contact with used engineoil may cause skin cancer. Avoid prolongedcontact with used engine oil. Wash skin promptlywith soap and water.

    10. Some components of your tractor, such asgaskets and friction surfaces (brake linings,clutch linings, etc.) may contain asbestos.Breathing asbestos dust is dangerous to yourhealth. You are advised to have any mainte-nance or repair on such components carried outby an authorized New Holland Dealer. However,if service operations are to be undertaken onparts that contain asbestos, the essentialprecautions listed below must be observed:

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-6

    • Work out of doors or in a well ventilated area.

    • Dust found on the tractor or produced duringwork on the tractor should be removed byextraction, not by blowing.

    • Dust waste should be dampened, placed ina sealed container, and marked to ensuresafe disposal.

    • If any cutting, drilling, etc. is attempted onmaterials containing asbestos, the itemshould be dampened and only hand tools orlow speed power tools used.

    OPERATING THE TRACTOR

    1. Before starting the tractor, apply the parkingbrake, place the PTO lever in the OFF position,the lift control lever in the down position, theremote control valve levers in the neutralposition, and the transmission in neutral.

    2. Always sit in the tractor seat when starting theengine or operating controls. Do not start theengine or operate controls while standing besidethe tractor.

    3. Do not bypass the neutral start switches. Consultyour New Holland Dealer if your neutral startcontrols malfunction. Use jumper cables only inthe recommended manner. Improper use canresult in tractor runaway.

    4. Avoid accidental contact with the gear shift leverwhile the engine is running, as this can causeunexpected tractor movement.

    5. Before getting off the tractor, disengage the PTO,turn the engine off, and apply the parking brake.Never get off the tractor while it is in motion.

    6. Do not park the tractor on a steep incline.

    7. Do not operate the tractor engine in an enclosedbuilding without adequate ventilation. Exhaustfumes can cause death or illness.

    8. If the power steering or engine ceases operating,stop the tractor immediately.

    9. Pull only from the drawbar or the lower linkdrawbar in the down position. Use only a drawbarpin that locks in place. Pulling from the tractorrear axle or any point above the axle may causethe tractor to upset.

    10. 1If the front end of the tractor tends to rise whenheavy implements are attached to the three-point hitch, install front end or front wheelweights. Do not operate the tractor with a lightfront end.

    11. Always set the hydraulic selector lever in positioncontrol when attaching or transporting equip-ment. Ensure hydraulic couplers are properlymounted and will disconnect safely in case ofaccidental detachment of implement.

    12. Do not leave equipment in the raised position.

    13. Use the flasher/turn signal lights and SMV signswhen traveling on public roads both day andnight (unless prohibited by law).

    14. When operating at night, adjust lights to preventblinding oncoming drivers.

    DRIVING THE TRACTOR

    1. Watch where you are going, especially at rowends, on roads, around trees and low hangingobstacles.

    2. To avoid upsets, drive the tractor with care and ata safe speed. Use extra caution when operatingover rough ground, when crossing ditches orslopes, and when turning corners.

    3. To provide two-wheel braking, lock tractor brakepedals together when transporting on roads.

    4. Do not coast or free wheel down hills. Use thesame gear when going downhill as is used whengoing uphill.

    5. Any towed vehicle with a total weight exceedingthat of the towing tractor should be equipped withbrakes for safe operation.

    6. If the tractor becomes stuck or the tires becomefrozen to the ground, back up the tractor toprevent upset.

    7. Always check overhead clearance, especiallywhen transporting the tractor.

    8. When operating at night, adjust lights to preventblinding oncoming drivers.

    OPERATING THE PTO

    1. When operating PTO driven equipment, shut offthe engine and wait until the PTO stops beforegetting off the tractor and disconnecting theequipment.

    2. Do not wear loose clothing when operating thepower take-off or when near rotating equipment.

    3. When operating stationary PTO driven equip-ment, always place all gear shift levers in neutralposition.

    Apply the tractor parking brake, and block therear wheels front and back.

  • SECTION 00 - GENERAL INFORMATION - CHAPTER 1

    00-7

    4. To avoid injury, do not clean, adjust, unclog, orservice PTO driven equipment when the tractorengine is running.

    5. Ensure the PTO master shield is installed at alltimes. Always replace the PTO shield cap whenthe PTO is not in use.

    DIESEL FUEL

    1. UNDER NO CIRCUMSTANCES should gaso-line, alcohol, or blended fuels be added to dieselfuel. These combinations can create anincreased fire or explosive hazard. Such blendsare more explosive than pure gasoline in aclosed container such as a fuel tank. DO NOTUSE THESE BLENDS.

    2. Never remove the fuel cap or refuel with theengine running or hot.

    3. Do not smoke while refueling or when standingnear fuel.

    4. Maintain control of the fuel filler pipe nozzle whenfilling the tank.

    5. Do not fill the fuel tank to capacity. Allow room forexpansion.

    6. Wipe up spilled fuel immediately.

    7. Always tighten the fuel tank cap securely.

    8. If the original fuel tank cap is lost, replace it witha New Holland approved cap. A non-approved,proprietary cap may not be safe.

    9. Keep equipment clean and properly maintained.

    10. Do not drive equipment near open fires.

    11. Never use fuel for cleaning purposes.

    12. Arrange fuel purchases so that winter grade fuelsare not held over and used in the spring.

    SAFETY FRAME (ROPS)Your New Holland tractor is equipped with a safetyframe. It must be maintained in a serviceablecondition. Be careful when driving through doorwaysor working in confined spaces with low headroom.

    UNDER NO CIRCUMSTANCES should you:

    • modify, drill, or alter the safety frame in any way.Doing so may render you liable to legalprosecution.

    • attempt to straighten or weld any part of the mainframe or retaining brackets which have suffereddamage. Doing so may weaken the structure andendanger your safety.

    • secure any parts on the main frame or attachyour safety frame with anything other than thespecial high tensile bolts and nuts specified.

    • attach chains or ropes to the main frame forpulling purposes.

    • take unnecessary risks even though your safetyframe affords you the maximum protectionpossible.

    WHEN YOU SEE THIS SYMBOL

    IT MEANS:

    ATTENTION!

    BECOME ALERT!

    YOUR SAFETY IS INVOLVED!

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-1

    SECTION 10 - ENGINE

    Chapter 1 - Engine

    CONTENTS

    Section Description Page

    Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Metric Bolt Torque Specifications 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Special Tools 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Compression Test and Tools 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Description of Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Troubleshooting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Head and Valve Train Components 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Block Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Separating the Tractor at the Clutch Housing/Engine -- 12x12 Transmission 25. . . . . . .

    Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Separating the Tractor at the HST Housing/Engine -- HST Transmission 29. . . . . . . . . .

    Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Separating the Tractor at the HST Engine Frame 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Attaching the 12x12 Transmission to the Engine 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Attaching the HST to the Engine 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Overhaul 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Engine 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Injector and Glow Plug 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Oil Pressure Switch 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Temperature Sending Switch and Alternator 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fan, Water Pump and External Oil Tube 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Air Inlet Manifold 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rocker Arm Shaft and Support Bracket 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 101 Cylinder Head 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-2

    Section Description Page

    Valve Tappet 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Shutoff Solenoid 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Engine Timing Gear Cover, Timing Gears, and Cam Shaft 57. . . . . . . . . . . . . . . . . . . . . .

    Timing Gear Cover Removal 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Timing Gears and Cam Shaft 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 102 Oil Sump 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Oil Suction Pipe and Strainer 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 110 Balancer Assembly 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 105 Connecting Rods, Bearings, and Pistons, Rings 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 103 Flywheel 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 103 Backplate and Oil Seal 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Crankshaft -- Main Bearings 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 101 Cylinder Head 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Disassembly 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection and Repair 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Valve Seats 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Valves 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Valve Guides 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Valve Springs 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rocker Arms 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Push Rods 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Head 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Assembly 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Block 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Pistons 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Disassembly and Inspection 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Piston Rings 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Connecting Rods 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-3

    Section Description Page

    Connecting Rod Bearing 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Clearance Check 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Connecting Rod Bearing 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Clearance Check 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Pistons, Rings, and Connecting Rod 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Assembly 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 103 Crankshaft -- Main Bearing and Thrust Washer 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal and Inspection 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Crankshaft 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Bearing (Bushing) 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Replacement 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Main Bearing 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Assembly 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Port Block 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Timing Gear 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Camshaft 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Disassembly 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Assembly 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 103 Flywheel 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 102 Timing Gear Housing 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 102 Front Oil Seal and Steering Pump Seal 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Replacement 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 103 Crankshaft and Bearing Holder 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rear Oil Seal and Backplate 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Flywheel 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 105 Pistons and Connecting Rods 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 110 Balancer Assembly 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Balancer Shims 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Oil Suction Pipe and Suction Strainer 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-4

    Section Description Page

    Oil Sump 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Camshaft and Camshaft Gear 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Idler Gear, Oil Pump, and Injection Timing 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Timing Gear Cover 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Crankshaft Pulley 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Injection Pump 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Hydraulic Oil Pump 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Power Steering Pump 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 101 Head Gasket Selection 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Selection Chart 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Head 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 106 Valve Clearance 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Adjustment 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Valve Cover 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Water Pump and Cooling Fan 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    External Oil Tube 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Assembly 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Glow Plug and Connector 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Injector 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 218 Fuel Piping 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Alternator and Temperature Sender Switch 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Exhaust Manifold 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-5

    Section Description Page

    10 304 Description of Operation -- Engine Lubrication System 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 206 Oil Filter 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Construction and Function 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Maintenance 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 304 Oil Pump 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation and Adjustment 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Engine Oil Pressure 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Check 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Oil Pressure Relief Valve 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Oil Consumption 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 400 Description of Operation -- Cooling System 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Maintenance 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Coolant 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Radiator Cap 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 402 Thermostat 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 402 Water Pump 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 414 Cooling Fan 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Overhaul -- Cooling System 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 406 Radiator 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection and Repair 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 402 Water Pump 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection and Repair 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    10 402 Thermostat 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Removal 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Inspection and Repair 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cab Heater 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Installation 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-6

    SPECIFICATIONS

    GENERAL TC35A, TC35DA TC40A, TC40DA TC45A, TC45DA

    Engine Model N843L N844 N844L

    Number of Cylinders 3 4 4

    Bore x Stroke 3.31 x 3.94 in.(84 x 100 mm)

    3.31 x 3.54 in.(84 x 90 mm)

    3.31 x 3.94 in.(84 x 100 mm)

    Displacement 101.4 cu. in.(1622 cc)

    121.7 cu. in.(1995 cc)

    135.2 cu. in.(2216 cc)

    Compression Ratio 22.5:1 22.5:1 22.5:1

    Rated Speed (rpm) 2600 2600 2600

    Muffler Horizontal

    Firing Order 1-2-3 1-3-4-2 1-3-4-2

    Low Idle Speed 1050 rpm 1050 rpm 1050 rpm

    Maximum No-Load Speed 2840 rpm 2840 rpm 2840 rpm

    Cylinder Arrangement In-Line Vertical In-Line Vertical In-Line Vertical

    Valve Arrangement Overhead Overhead Overhead

    Compression Pressureat 200 rpm (cylinder speed)

    427 ± 50 psi(29.4 ± 1.8 bar)

    427 ± 50 psi(29.4 ± 1.8 bar)

    427 ± 50 psi(29.4 ± 1.8 bar)

    Variation between cylinders

    CYLINDER BLOCK N843L N844 N844L

    Bore

    Standard 3.3071-3.3078 in.(84.0 mm)

    3.3071-3.3078 in.(84.0 mm)

    3.3071-3.3078 in.(84.0 mm)

    Maximum 3.3543 in.(85.2 mm)

    3.3543 in.(85.2 mm)

    3.3543 in.(85.2 mm)

    Head Surface Warp

    Standard .002 in.(.05 mm)

    .002 in.(.05 mm)

    .002 in.(.05 mm)

    Maximum .005 in.(.12 mm)

    .005 in.(.12 mm)

    .005 in.(.12 mm)

    * If bore size exceeds 3.3543 in. (85.2 mm) replace with long block.

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-7

    CYLINDER HEAD N843L N844 N844L

    Head Warp

    Standard 0.002 in. less than(0.05 mm)

    0.002 in.(0.05 mm)

    0.002 in.(0.05 mm)

    Maximum 0.005 in.(0.12 mm)

    0.005 in.(0.12 mm)

    0.005 in.(0.12 mm)

    Valve Seat Width

    Standard 0.067-0.082 in.(1.7-2.1 mm)

    0.067-0.082 in.(1.7-2.1 mm)

    0.067-0.082 in.(1.7-2.1 mm)

    Maximum 0.098 in.(2.5 mm)

    0.098 in.(2.5 mm)

    0.098 in.(2.5 mm)

    Valve Seat Sink

    Standard (Recess) 0.0334-0.0453 in.(0.85-1.15 mm)

    0.0334-0.0453 in.(0.85-1.15 mm)

    0.0334-0.0453 in.(0.85-1.15 mm)

    Maximum 0.071 in.(1.8 mm)

    0.071 in.(1.8 mm)

    0.071 in.(1.8 mm)

    Valve Angle 45° 45° 45°

    PISTON N843L N844 N844L

    Diameter

    Standard 3.30503-3.30562 in.(83.948-83.963 mm)

    3.30503-3.30562 in.(83.948-83.963 mm)

    3.30503-3.30562 in.(83.948-83.963 mm)

    MInimum 3.2953 in.(83.7 mm)

    3.2953 in.(83.7 mm)

    3.2953 in.(83.7 mm)

    Bore Clearance

    Standard 0.0014-0.0028 in.(0.038-0.072 mm)

    0.0014-0.0028 in.(0.038-0.072 mm)

    0.0014-0.0028 in.(0.038-0.072 mm)

    Maximum 0.010 in.(0.25 mm)

    0.010 in.(0.25 mm)

    0.010 in.(0.25 mm)

    Piston Pin Bore

    Standard 1.102-1.1023 in.(27.996-28.000 mm)

    1.102-1.1023 in.(27.996-28.000 mm)

    1.102-1.1023 in.(27.996-28.000 mm)

    Maximum 1.102 in.(27.98 mm)

    1.102 in.(27.98 mm)

    1.102 in.(27.98 mm)

    Piston Pin Clearance

    Standard --0.000393 +0 .0002 in.(--0.001 + 0.007 mm)

    --0.000393 +0 .0002 in.(--0.001 + 0.007 mm)

    --0.000393 +0 .0002 in.(--0.001 + 0.007 mm)

    Maximum 0.0008 in.(0.02 mm)

    0.0008 in.(0.02 mm)

    0.0008 in.(0.02 mm)

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-24

    MODEL N843L - TC35A, TC35DA10044349 10044350

    4

    MODEL N844 and N844L - TC40A, TC40DA, TC45A, TC45DA10044351

    10044352

    5

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-25

    SEPARATING THE TRACTOR AT THECLUTCH HOUSING/ENGINE - 12X12TRANSMISSION

    Removal

    1. Remove the negative (-) battery cable, 1, and thepositive (+) battery cable, 2, from the battery.

    2. Drain all of the hydraulic fluid from the transmis-sion and the differential into a suitable container.

    3. Disconnect the headlight wire harness plug andremove the hood from the tractor.

    4. Remove the seat, and the seat base assemblyfrom the tractor.

    5. Remove the light bars from the fenders and theROPS.

    30997558

    21

    6

    6. If equipped, remove the remote loader controlvalve, 1, and the connecting hydraulic tubes fromthe right fender.

    7. Remove the left and right fenders from thetractor.

    30997555

    1

    7

    8. Remove the left, 1, and right, 2, rear hood sidepanels.

    9. Disconnect and remove the throttle cable fromthe foot throttle control pedal, located on the rightdeck.

    10. Remove the left and the right deck from the trac-tor.

    11. Disconnect the throttle cable from the dashmounted throttle control lever.

    10000864

    21

    8

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-26

    12. Loosen and remove the two instrument panel re-taining screws, 1. Remove the instrument panel,2, from the dash housing. Disconnect the wiringconnector from the instrument panel.

    10035024

    2

    11

    9

    13. Drive the roll pin, 1, from the lower shuttle shiftshaft, 2. Remove the retaining ring, 3, and the rollpin, 4, from the lower main shift shaft, 5. Loosenand remove the retaining bolts, 6, securing themain shift bracket, 7, and the shuttle shift brack-et, 8, to the steering column, 9. Remove the shiftshaft assemblies by feeding the control leversdown through the dash housing.

    14. Remove the dash housing from the firewall. Dis-connect the wiring connectors from the dashswitches.

    15. Disconnect the main wiring harness connector.

    9

    4

    10996566

    3

    52

    1

    86

    7 6

    10

    16. Remove the firewall support bracket, 1, from thefirewall, 2, and the clutch housing, 3.

    2

    1

    20000908

    3

    11

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-27

    17. Remove the hydraulic system inlet tube, 1, fromthe hydraulic pump, 2.

    18. Remove the hydraulic system pressure tube, 3,from the hydraulic pump, 2, and the divertervalve.

    30997557

    2

    3

    1

    12

    19. Disconnect the wires, 1, on the starter, 2, and re-move the starter from the tractor.

    30997565

    2

    1

    13

    20. If equipped with FWD, remove the roll pins, 1,from the front and rear of the FWD driveshaft, 2,and remove the driveshaft from the tractor.

    NOTE: Draining the engine oil and removal of the oilfilter is necessary on the TC35A tractor to gain ac-cess to several of the buckle-up bolts.

    21. Drain the engine oil into a suitable container andremove the oil filter.

    2

    1

    200009041

    14

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-28

    22. Remove the fuel supply, 1, and return, 2, linesfrom the fuel filter, 3.

    23. Drain the fuel tank into a suitable container.

    10000865

    2

    1

    15

    24. Attach a chain sling, 1, to the two hoist eyes, 2and 3, on the engine.

    10000867

    1

    2

    3

    16

    25. Attach a suitable hoist, 1, to the chain sling, 2.

    NOTE: The hoist is used for supporting the engineand axle assembly, not for lifting.

    26. Roll a floor jack under the tractor from the rear ofthe tractor, and place under the clutch housing.Raise the jack enough to support the drive train.

    10000868

    1

    2

    17

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-29

    27. Remove the buckle-up bolts, 1, that secure theengine, 2, to the clutch housing, 3.

    NOTE: The hoist and/or the floor jack may need to beraised or lowered to allow the separation of the en-gine from the clutch housing.

    28. Carefully roll the drive train away from the en-gine, using the floor jack for support.

    220000905

    3

    1

    1

    18

    SEPARATING THE TRACTOR AT THE HSTHOUSING/ENGINE-HST TRANSMISSION

    Removal

    1. Remove the negative (-) battery cable, 1, and thepositive (+) battery cable, 2, from the battery.

    2. Drain all of the hydraulic fluid from the transmis-sion, differential, and the oil cooler into a suitablecontainer.

    3. Disconnect the headlight wire harness plug andremove the hood from the tractor.

    4. Remove the seat, and the seat track assemblyfrom the tractor deck.

    10998231

    1

    2

    19

    5. Remove the control lever grips, 1, from the con-trol levers on both sides of the tractor.

    6. Remove the left, 2, and the right, 3, control podsfrom the fenders.

    7. Remove the light bars from the fenders and theROPS.

    8. Disconnect and remove the control levers fromthe tractor deck and the connecting linkage.

    10997819/20

    3

    1

    1

    1

    2

    20

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-30

    9. If equipped, remove the remote, loader controlvalve, 1, from the right fender, and the cup holder/tool box, 2, from the left fender.

    10. Remove the left and right fenders from thetractor.

    10998371/8229

    1

    2

    21

    11. Disconnect and remove the differential lock ped-al, 1.

    10998223

    1

    22

    12. If equipped, disconnect and remove the fulltime2WD lever, 1.

    13. Disconnect and remove the parking brake han-dle, 2.

    10998312

    1

    2

    23

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-31

    14. Remove the left, 1, and right, 2, rear hood sidepanels.

    15. Remove the floor mat from the tractor deck.

    10000864

    21

    24

    16. Drive the roll pin or clip, 1, from the HPL speedcontrol shaft, 2, and remove the control shaftfrom the HPL shaft, 3.

    17. Remove the deck from the tractor.

    2

    1

    19998697

    3

    25

    18. Loosen and remove the two instrument panel re-taining screws, 1. Remove the instrument panel,2, from the dash housing, 3. Disconnect the wir-ing connector from the instrument panel.

    19. Disconnect the throttle cable from the throttlecontrol lever.

    20. Remove the dash housing from the firewall. Dis-connect the wiring connectors from the dashswitches.

    21. Disconnect the two main wiring harnessconnectors.

    10034980

    1

    2

    1

    3

    26

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-32

    22. Remove the firewall support bracket, 1, from thefirewall, 2, and the HST housing, 3.

    10000863

    23

    1

    27

    23. Remove the hydraulic system inlet tube, 1, fromthe hydraulic pump, 2.

    24. Remove the hydraulic system pressure tube, 3,from the hydraulic pump, 2, and the divertervalve.

    30997557

    1

    3

    2

    28

    25. Remove the HST oil cooler tube, 1, and the HSTpressure tube, 2, from the tractor.

    30996397

    1

    2

    29

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-33

    26. Disconnect the wires, 1, on the starter, 2, and re-move the starter from the tractor.

    30997565

    2

    1

    30

    27. If equipped, disconnect the Sensitrack linkage,1, from the control arm, 2, at the Sensitrackclutch, 3.

    30996381

    3

    21

    31

    28. Remove the two FWD, driveshaft, front and rear,retaining bolts, (one roll pin on standard FWDaxle), and remove the driveshaft from the tractor.

    30996382

    1

    32

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    NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

    https://www.aservicemanualpdf.com/downloads/new-holland-tc35a-tc35da-tc40a-tc40da-tc45a-tc45da-tractor-service-repair-manual

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-34

    29. Use a floor jack, 1, to raise the front of the tractorand place wood blocks, 2, between the axle, 3,and the frame, 4. Lower the jack.

    10000866

    1 4

    3

    2

    33

    30. Remove the cotter pin, 1, and the castle nut, 2,from the support bar, 3, at the rear mountingbracket, 4.

    31. Use a brass drift and a hammer to drive the sup-port bar, 3, stud out of the mounting bracket, 4.

    NOTE: Draining the engine oil and removal of the oilfilter is necessary on the TC35DA tractor to gain ac-cess to several of the buckle-up bolts.

    32. Drain the engine oil into a suitable container andremove the oil filter.

    20000902

    31

    4 2

    34

    33. Remove the fuel supply, 1, and return, 2, linesfrom the fuel filter, 3.

    34. Drain the fuel tank into a suitable container.

    10000865

    3

    1

    2

    35

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-35

    35. Attach a chain sling, 1, to the two hoist eyes, 2and 3, on the engine.

    10000867

    1

    2

    3

    36

    36. Attach a suitable hoist, 1, to the chain sling, 2.

    NOTE: The hoist is used for supporting the engineand axle assembly, not for lifting.

    10000868

    1

    2

    37

    37. Roll a floor jack under the tractor from the rear ofthe tractor, and place under the HST housing.Raise the jack enough to support the drive train.

    38. Remove the buckle-up bolts that secure the en-gine to the HST housing.

    NOTE: The hoist and/or the floor jack may need to beraised or lowered to allow the separation of the en-gine from the HST housing.

    10000869

    38

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-36

    39. Carefully roll the drive train away from the en-gine, using the floor jack for support.

    SEPARATING THE TRACTOR AT THEENGINE/FRAME

    1. Use jack stands under the frame rails to supportthe front frame/engine assembly.

    WARNINGMake sure the front frame/engine assembly is se-curely supported before removing the chainsling from the engine.

    2. Remove the chain sling from the two hoist eyeson the engine.

    10000870

    39

    3. Drain the hydraulic fluid from the power steeringreservoir, 1, into a suitable container. Removethe reservoir, 1, from the firewall, 2.

    4. Remove the power steering lines, 3, from thepower steering control motor, 4, the frame, 5, andthe power steering pump, 6.

    20002368

    21

    34

    56

    40

  • SECTION 10 -- ENGINE -- CHAPTER 1

    10-37

    5. Remove the air cleaner assembly, 1, from thefirewall, 2.

    20002366

    1

    2

    41

    6. Remove the muffler guard, 1, from the tractor.

    30996394

    1

    32

    42

    7. Remove the muffler, 1, and the exhaust pipe, 2,from the tractor.

    8. Drain the coolant from the radiator into a suitablecontainer.

    9. Remove the top and the bottom radiator hoses.

    10. Remove the radiator and the oil cooler (ifequipped) from the tractor.

    20002367

    2

    1

    43