Copyright ©

Section
2000

REMOVAL AND INSTALLATION OF THE ENGINE

2000

Copyright © 2009 CNH France S.A.

Printed in France
CNH Lep SM470B2000-0EN March 2009
 Copyright ©
2000-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY ......................................................................... 3
REMOVAL OF THE ENGINE ...................................................................................................................................... 3
INSTALLATION OF THE ENGINE ............................................................................................................................. 10

Lep SM470B2000-0EN Issued 03-09

 Copyright ©
2000-3
REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY

Keep away from fire.

Be sure to release hydraulic pressure before beginning work.
Caution: The air conditioner circuit is filled with high-pressure gas, so there is the danger of
gas splaying out when loosening lines.
Do not use open flames and do not allow sparks near the battery.

Be sure to stop the engine before beginning work.

Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load.
1 Removal of the engine
[1] Drain the coolant from the radiator.
(For details, see "Operator’s Manual".)
[2] Remove the engine hood.
(For details, see "Removal and Installation of Engine Hood".)
[3] Remove the pump.
(For details, see "Removal and Installation of Pump")
[4] Use a wrench (19 mm) to remove the 7 bolts (1),
and then remove the radiator cover (2).
2
1
1

TF11006-029

[5] Use a wrench (7 mm) to loosen the hose band (3)

on the radiator, and then remove the lower hose (4).
• Use caps to cover the radiator and hose to prevent
the entry of water, dust or dirt.
• Before removing the radiator hose, completely drain 4
the coolant.

3
TF11006-001

Lep SM470B2000-0EN Issued 03-09

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2000-4

[6] Use a wrench (7 mm) to loosen the hose band (5)

on the radiator, and then remove the upper hose (6).

TF11006-002

[7] Use a wrench to loosen the 2 line bolts (7), and then
remove the 2 compressor lines (8) and (9). 8
• Before removing the compressor lines, recover the
air conditioner gas.
• Always remove the low-pressure (suction side) line
(8) first.
• Attach caps or plugs to the compressor and lines to 9
prevent any entry of water, dust or dirt.
• The O-ring cannot be reused. Always replace it with
a new one.

TF11006-003

[8] Use a wrench (8 mm) to loosen the hose band (10)

on the inter cooler, and then remove the hose (11).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.

10
11

TF11006-004

Lep SM470B2000-0EN Issued 03-09

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2000-5
[9] Prepare the waste oil can (12).
• Drain the engine oil before removing the engine oil
hose.
[10]Use a wrench to remove the 2 engine oil remote
hoses (13).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them with a
parts cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
13

12

TF11006-005

[11]Use a wrench (17 mm) to loosen the nut (14), and

then remove the battery cable (15) on the negative
side.
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against
sparks.
14
15

TF11006-006

[12]Use a wrench to remove the 3 nuts (16), and then

remove the starter motor wiring (17).
16
16

17

16

TF11006-007

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2000-6
[13]Use a wrench to remove the 1 bolt (18), and then
remove the ground wiring (19).

19

18

TF11006-008

[14]Use a wrench to loosen the hose band (20), and

then remove the fuel hose (21).
• Attach caps or plugs to the engine and hose to pre-
vent any entry of water, dust or dirt.

20

21

TF11006-009

[15]Use a wrench to loosen the hose band (22), and

then remove the fuel hose (23).
• Attach caps or plugs to the engine and hose to pre-
vent any entry of water, dust or dirt.

23 22

TF11006-010

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2000-7
[16]Use a wrench to remove the 4 bolts (24), and then
remove the box cover (25).
[17]Remove the connectors (26) in the box.
• Wrap the removed connectors in plastic after tying 24
them together.

26

25

24
TF11006-011

[18]Use a wrench (7 mm) to loosen the 2 hose bands

(27), and then remove the 2 heater hoses (28).
• Attach caps or plugs to the engine and hose to pre-
vent any entry of water, dust or dirt.

27
28
TF11006-012

[19]Use a wrench to remove the 2 bolts (29).

[20]Use a wrench (7 mm) to loosen the 2 hose bands
(30), and then remove the air hose (31). 32 33
• Use caps to cover the line and hose to prevent any
entry of water, dust or dirt. 30
[21]Use a wrench (8 mm) to loosen the 2 hose bands
(32), and then remove the air hose (33).
• Use caps to cover the line and hose to prevent any
entry of water, dust or dirt.
31
30 29
32

TF11006-013

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2000-8
[22]Remove the connector (34) from the alternator.
[23]Use a wrench (10 mm) to remove the nut (35).
[24]Use a wrench to remove the bolt (36), and then 34
remove the alternator wiring (37).

36
35

37

TF11006-014

[25]Use a wrench to remove the 4 bolts (38), and then

remove the step (39). 38

39

38

TF11006-015

[26]Install the 4 shackles (40), and then use the wire

ropes (41) and liftcrane to secure the engine main
unit.

40 40
41

TF11006-016

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2000-9
[27]Use a box wrench (30 mm) to remove the 4 bolts
(42) from the mount.
42
42

42 42

TF11006-017

[28]Use the wire ropes (41) and liftcrane to lift the

engine main unit.
[29]Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.

41
41

TF11006-018

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2000-10
2 Installation of the engine
[1] To install the engine, perform the reverse of the removal procedure.
After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and perform filling for the
air conditioner gas.
For details, see the individual explanations for each procedure.
[2] Run the engine at no-load idling and check for any water or oil leaks.
[3] Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each procedure.

Lep SM470B2000-0EN Issued 03-09

 Copyright ©

2001
Section
2001

REMOVAL AND INSTALLATION OF THE FUEL-

COOLER, ENGINE INTER-COOLER, RADIATOR AND
OIL-COOLER

Copyright © 2009 CNH France S.A.

Printed in France
CNH Lep SM470B2001-0EN March 2009
 Copyright ©
2001-2

TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF FUEL COOLER .......................................................................................... 3
REMOVAL OF FUEL COOLER .................................................................................................................................. 3
INSTALLATION THE FUEL COOLER .......................................................................................................................... 3
REMOVAL AND INSTALLATION OF INTER COOLER......................................................................................... 4
REMOVAL OF INTER COOLER ................................................................................................................................. 4
INSTALLATION OF INTER COOLER ........................................................................................................................... 4
REMOVAL AND INSTALLATION OF RADIATOR ................................................................................................. 5
REMOVAL OF RADIATOR ........................................................................................................................................ 5
INSTALLATION OF RADIATOR................................................................................................................................ 13
REMOVAL AND INSTALLATION OF OIL COOLER............................................................................................ 14
REMOVAL OF OIL COOLER ................................................................................................................................... 14
INSTALLATION OF OIL COOLER............................................................................................................................. 14

Lep SM470B2001-0EN Issued 03-09

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2001-3
REMOVAL AND INSTALLATION OF FUEL COOLER
Be sure to stop the engine before beginning work.
Caution:
As the fuel hose will be removed, strictly prohibit open flames.
1 Removal of fuel cooler
[1] Use a wrench (7 mm) to loosen the 2 hose bands
(1), and then remove the 2 hoses (2).
• Mark the fuel cooler (3) and hoses (2) so that the 2 2
connectors match at the time of assembly.
• Fuel will spill out, so place a drip pan directly below
the area.
• Attach caps or plugs to the fuel cooler and hoses to
prevent any entry of water, dust or dirt. 1 1

3
TF11006-030

[2] Use a wrench (12 mm) to remove the 4 bolts (4),

and then remove the fuel cooler (3).

4
4

3
TF11006-031

2 Installation the fuel cooler

Perform the reverse of the removal procedure.
• After connecting the hoses, carefully check for any fuel leaks.

Lep SM470B2001-0EN Issued 03-09

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2001-4
REMOVAL AND INSTALLATION OF INTER COOLER
Be sure to stop the engine before beginning work.
Caution:
As the fuel hose will be removed, strictly prohibit open flames.
1 Removal of inter cooler
[1] Remove the fuel cooler.
(For details, see "Removal and Installation of Fuel
Cooler")
[2] Use a wrench (8 mm) or flathead screwdriver to 2 2
loosen the 2 hose bands (1), and then remove the 2
hoses (2).
• Use caps to cover the inter cooler and hoses to pre-
vent the entry of water, dust or dirt. 1 1

TF11006-032

[3] Use a wrench (14 mm) to remove the 6 bolts (3),

then remove the inter cooler (4).

3 3

TF11006-033

2 Installation of inter cooler

Perform the reverse of the removal procedure.
Check for any air leaks.

Lep SM470B2001-0EN Issued 03-09

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2001-5
REMOVAL AND INSTALLATION OF RADIATOR
Do not remove the radiator cap when the radiator coolant temperature is high. Hot
Caution:
liquid could spray out.

Be sure to release hydraulic pressure before beginning work.

Be sure to stop the engine before beginning work.
Caution:
Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load.
1 Removal of radiator
[1] Open the engine hood.
[2] Drain the hydraulic oil from the hydraulic oil tank.
(See Operator’s Manual for details of this procedure).
[3] Use a wrench (19 mm) to remove the 5 bolts (1),
and then remove the under cover (2).

1
2

TM13006-001

[4] To make it easier to drain the coolant, remove the

radiator cap (3).

TM13006-002

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2001-6
[5] Install the drain hose (4), and then prepare the drain
tank (5).
[6] Loosen the drain plug (6), and then drain the cool-
ant.

6 4

TM13006-003

[7] Use a wrench (19 mm) to remove the 7 bolts (7),

and then remove the radiator cover (8).
8
7
7

TM13006-004

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2001-7
[8] Remove the connector (9).
[9] Use a wrench to remove the bolt (10).
[10]Use a wrench (8 mm) to remove the 3 sleeve nuts 12
(11), and then remove the hoses (12). 9 10
• Use caps to cover the line and fan motor to prevent
any entry of water, dust or dirt.
11

12

11 12 TM13006-005

[11]Use a wrench (7 mm) to loosen the hose band (13)

on the radiator, and then remove the lower hose
(14).
• Use caps to cover the hose and radiator to prevent
any entry of water, dust or dirt.
14

13
TM13006-006

[12]Use a wrench (7 mm) to loosen the hose band (15)

on the radiator, and then remove the upper hose
(16).
• Use caps to cover the hose and radiator to prevent
any entry of water, dust or dirt. 16

15

TM13006-007

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2001-8
[13]Use a wrench (7 mm) to loosen the hose bands (17)
of the oil cooler. Use a box wrench to remove the 2 21 20
bolts (18), and then remove the oil cooler pipe (19).
• Use caps to cover the oil cooler and hose to prevent
any entry of water, dust or dirt. 19
[14]Use a wrench (7 mm) to loosen the oil cooler hose
bands (20), and then remove the hose (21). 18
• Use caps to cover the line and hose to prevent any
entry of water, dust or dirt.
17

TM13006-008

[15]Remove the connector (22) from the sensor.

[16]Use a wrench to remove the 2 bolts (23), and then
remove the oil cooler pipe (24).
• Use caps to cover the oil cooler and line to prevent
any entry of water, dust or dirt.

22
23

24

TM13006-012

[17]Use a wrench (7 mm) to loosen the 2 hose bands

(25), and then remove the 2 hoses (26).
28 27 27 28
• Fuel will spill out, so place a drip pan directly below
the area.
• Mark the fuel cooler and hoses so that the connec-
tors match at the time of assembly.
• Use caps to cover the fuel cooler and hoses to pre-
vent any entry of water, dust or dirt.
[18]Use a wrench (8 mm) to loosen the 2 hose bands 25
26
(27), and then remove the 2 hoses (28). 26
25
• Use caps to cover the inter cooler and hoses to pre-
vent any entry of water, dust or dirt.

TM13006-009

[19]Close the drain plug (29), loosen the hose band

(30), and then remove the hose (31).

29

30

31 TM13006-010

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2001-9
[20]Loosen the hose band (33), and then remove the
hose (32) from the radiator cap. 32
• Attach caps or plugs to the hose to prevent any 33
entry of water, dust or dirt.

TM13006-011

[21]Use a wrench to loosen the nut (34). Use a wrench

to remove the bolt (35), and then remove the engine
hood opener cable (36).

34 36 35

TM13006-013

[22]Use a wrench to remove the 4 bolts (37), and then

remove the frame (38).
37

38

37

TM13006-014

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2001-10
[23]Install the 2 shackles (39) to the top of the radiator
cover, and then use the wire rope (40) and liftcrane
to secure the radiator and oil cooler assembly.

40

39

39

TM13006-015

[24]Use a wrench (19 mm) to remove the 2 bolts (41).

41

TM13006-016

[25]Use a wrench (19 mm) to remove the 4 bolts (42),

and then remove the 2 radiator stays (43).
43 42 43 42

TM13006-017

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2001-11
[26]Use a wrench to remove the 4 bolts (44).

44 44

TM13006-018

[27]Use a box wrench to remove the 4 bolts (45).

45

45

TM13006-019

[28]Use the wire rope (40) and liftcrane to lift the radia-
tor and oil cooler assembly.
[29]Thoroughly check that the location is safe before
lowering the radiator and oil cooler assembly on
wood planks, etc.

40

TM13006-020

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2001-12
[30]Use a wrench to remove the 8 bolts (47), and then
remove the fan assemblies (48).

47 47

48 48

47
47
TM13006-021

[31]Use a wrench to remove the 10 bolts (49), and then

remove the shroud assembly (50).
50 49

49 49

TM13006-022

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2001-13
[32]Use a wrench (14 mm) to remove the 4 bolts (51),
the 8 washers (52) and the 4 rubber cushions (53).
• Be careful not to drop the bottom side washers.
51 52 53 52

51

51

TM13006-023

[33]Lift the radiator (55) until the fixtures (54) at the bot-
tom of the radiator become disconnected.
[34]Thoroughly check that the location is safe before
lowering the radiator on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (54).

55
54

TM13006-025

2 Installation of radiator
To install, perform the reverse of the removal procedure.
For details on the method for coolant filling, see the Operator’s Manual.
Coolant capacity is 38 L.
Finally, check that the level of coolant is correct.

Lep SM470B2001-0EN Issued 03-09

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2001-14
REMOVAL AND INSTALLATION OF OIL COOLER
Caution: Keep away from fire

Be sure to stop the engine before beginning work.

Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load.
1 Removal of oil cooler
[1] Remove the radiator and oil cooler assembly and
also the fan assembly and shroud assembly.
See "Removal and Installation of Radiator" for
details of this procedure. 1 2 3 2
[2] Use a wrench (17 mm) to remove the 4 bolts (1) and 1
8 washers (2), and then remove the rubbers cush-
ions (3) and remove the oil cooler.
• Be careful not to drop the bottom side washers.
[3] Thoroughly check that the location is safe before
lowering the oil cooler on wood planks, etc.

TM13006-024

2 Installation of oil cooler

Perform the reverse of the removal procedure.

Lep SM470B2001-0EN Issued 03-09

 Copyright ©

Section
2004

2004
REMOVAL AND INSTALLATION OF THE
TURBO CHARGER

Copyright © 2009 CNH France S.A.

Printed in France
CNH Lep SM470B2004-0EN March 2009
 Copyright ©
2004-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF TURBO CHARGER .................................................................................... 3
REMOVAL OF TURBO CHARGER.............................................................................................................................. 3
INSTALLATION OF TURBO CHARGER ....................................................................................................................... 5
Tightening torque .............................................................................................................................................. 5

Lep SM470B2004-0EN Issued 03-09

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2004-3
REMOVAL AND INSTALLATION OF TURBO CHARGER
The turbo charger is extremely hot just after stopping the engine.
Caution:
Wait for them to sufficiently cool before beginning work.

Caution: Be sure to stop the engine before beginning work.

1 Removal of turbo charger

The engine oil line and coolant line will be removed, so either drain the engine oil and coolant beforehand or use
stoppers on the ends of the lines to prevent leaking.
[1] Remove the muffler.
[2] Use a wrench (7 mm) to loosen the 2 hose bands
(1), and then remove the intercooler hose (2). 3 4
• Use caps to cover the turbo charger and the hose to
prevent any entry of water, dust or dirt.
[3] Use a wrench (7 mm) to loosen the hose band (3),
and then remove the intake hose (4).
• Use caps to cover the turbo charger and the hose to 1
prevent any entry of water, dust or dirt.
2
1

TF11006-024

[4] Use a wrench (14 mm) to remove the eyebolt (5),

and then remove the oil feed pipe (6).
• Use caps and plugs to cover the turbo charger and 6
oil feed pipe to prevent any entry of water, dust or
dirt. 5
• When removing the oil feed pipe, be very careful not
to damage or lose the packing.

TF11006-025

[5] Use a wrench (10 mm) to remove the 2 bolts (7),

and then remove the oil return pipe (8).
• Use caps and plugs to cover the turbo charger and
oil return pipe to prevent any entry of water, dust or
dirt. 7 8

TF11006-026

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2004-4
[6] Use a wrench (14 mm) to remove the 4 nuts (9), and
then remove the turbo charger (10).

10
TF11006-027

[7] Use a wrench (13 mm) to remove the 8 nuts (11),

and then remove the line (12) from the turbo charger
main unit.

11

12
TF11006-028

Lep SM470B2004-0EN Issued 03-09

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2004-5
2 Installation of turbo charger
To install, perform the reverse of the removal procedure. During installation, replace each gasket and the packing
with new ones.
Make sure to check the engine oil and coolant levels and resupply as necessary.
Each of the installation tightening torque values are indicated below.
Check carefully for exhaust leaks, water leaks, and oil leaks.
1 Tightening torque
Unit: Nm

1 Oil feed pipe 34.3 Nm

2 Exhaust manifold -
4 3 3 Turbo charger assembly 40 Nm
2 Bolt 50 Nm
4 Exhaust adapter
Nut 40 Nm
5 Oil return pipe 43.8 Nm

3
2

4
TF11006-092

Lep SM470B2004-0EN Issued 03-09

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2004-6
NOTES
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Lep SM470B2004-0EN Issued 03-09

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Section
2005

REMOVAL AND INSTALLATION OF THE

EGR COOLER AND EGR VALVE

2005

Copyright © 2009 CNH France S.A.

Printed in France
CNH Lep SM470B2005-0EN March 2009
 Copyright ©
2005-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE ............................................................. 3
REMOVAL OF EGR COOLER AND EGR VALVE ........................................................................................................ 3
INSTALLATION OF EGR COOLER AND EGR VALVE ................................................................................................. 5
Tightening torque for each section .................................................................................................................... 5

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2005-3
REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE
The EGR cooler and EGR valve are extremely hot just after stopping the engine.
Caution:
Wait for them to sufficiently cool before beginning work.

Be sure to stop the engine before beginning work.

Caution:
Be sure to drain coolant before beginning work.
1 Removal of EGR cooler and EGR valve
[1] Use a wrench (12 mm) to remove the 6 bolts (1).

1
TF11006-069

[2] Use pliers to loosen the 4 hose bands (2), and then
remove the 4 hoses (3). 2
• Use caps and plugs to cover the line hoses to pre-
3
vent any entry of water, dust or dirt.
3

3
2 TF11006-070

[3] Use a wrench (12 mm) to remove the 7 bolts (4),

and then remove the EGR duct C (5).

4
4

5
TF11006-071

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2005-4
[4] Use a wrench (12 mm) to remove the bolts (6), and
then remove the EGR cooler (7). 6
7

TF11006-072

[5] Remove the connector (8).

8

TF11006-073

[6] Use a wrench (12 mm) to remove the 2 bolts (9).

Use a wrench (12 mm) to remove the 4 bolts (10),
and then remove the EGR valve (11). 10
Use a wrench (12 mm) to remove the 2 bolts (12),
and then remove the EGR duct B (13). 11

9
12 13 TF11006-074

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2005-5
2 Installation of EGR cooler and EGR valve
To install, perform the reverse of the removal procedure. During installation, replace gaskets with new ones.
Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening torque values are
indicated below.
Check carefully for exhaust leaks and water leaks.
1 Tightening torque for each section
Unit: Nm

21. 6

50
50

21. 6

43. 8
50

50
50 50 TF11006-075

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 Copyright ©
2005-6
NOTES
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Lep SM470B2005-0EN Issued 03-09

 Copyright ©

Section
2006

REMOVAL AND INSTALLATION OF THE

ENGINE HOOD

2006

Copyright © 2009 CNH France S.A.

Printed in France
CNH Lep SM470B2006-0EN March 2009
 Copyright ©
2006-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF ENGINE HOOD........................................................................................... 3
REMOVAL ............................................................................................................................................................. 3
INSTALLATION ....................................................................................................................................................... 4

Lep SM470B2006-0EN Issued 03-09

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2006-3
REMOVAL AND INSTALLATION OF ENGINE HOOD

Be sure to stop the engine before beginning work.

Do not perform this operation in strong wind.
Caution:
Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load.
1 Removal
[1] Pull the engine hood lock release lever (2) to
release the lock.
1

2
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[2] Open the engine hood, and then remove the Mat-
suba pin (3) and the flat washer (4).

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[3] Pull out the lock arm (6) from the engine hood (1).
6

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Lep SM470B2006-0EN Issued 03-09

 Copyright ©
2006-4
[4] After closing the engine hood, use a wrench (19
mm) to remove the 9 bolts (7) from the engine hood.

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[5] After closing the engine hood, use a wrench (19

mm) to remove the 9 bolts (7) from the engine hood.

5 1

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2 Installation
To install, perform the reverse of the removal procedure.

Lep SM470B2006-0EN Issued 03-09