ENGINES 0. Fun 005 1 CONTENT OF SECTIONS Section General nforation 1 Feed 2 Dury —Industsl appliations Mechanical injection Engines 3 ‘Overhaul and technical specications 4 Exuipment 5 Intaltion guidelines Safety instructions Appen PREFACE TO USER'S GUIDELINE MANUAL Section | describes the engine iustrating its features ‘and working in general | Section 2 describes the type of ful feed | Section 3 relatesto the specific duty and isvided in four sepa- rate parts |. Mechanical part, related to the engine overhaul lenited to those components with diferent characteristics based on the relating spec duty, 2. Electrica part, concerning wiring harness, electrical land electronic equipment with diferent characteristics based on the relating specific duty, 3. Maintenance planning and specific overhaul 4.Troubleshooting part dedicatedto the operators who, being entitled to provide technical assistance, shall have simple and rect instructions to identify the cause ofthe major incorwe Sections 4 and 5 illustrate the overhaul operations ofthe eng)- ne overhaul on tandandthe necessary equipmentto exeaute such operations. Inealtion general presriptions are reported within the ap pendix, Such prescriptions shall be strict followed by the operators in-charge of instalation to avoid incorrect working as well as serious falures which may reduce performance and lif ofthe engine Furthermore, the appendix reports general safety prescrip- ions tobe followed by all operators whether beingin-charge ofinstalation or maintenance, in order to avoid serious injury.FD. FEBUARY 200 ENGINES‘Where possible the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to gve a clearer and more immediate llustation of the subject being dealt with, (ee Feu 2000 SPECIAL REMARKS ‘ext page) instead of ging descriptions of some operations or arocecures. Example © | = housing for connecting rod smal end bush © 2 = housing for connecting rod beaings Tighten to torepie Tighten to torque + angular valveA FD. FEBUARY 200, Beane Graph and symbols Ty] keno! inate IEEg] Disconnection cf " 2 Refitting Exhaust Eq} Comesion es i Ce) money Sorin (ES) fare pee =o mine Stowe [D] Teron eee] Wee dtrence | [GQ] Terertotrge + rte fling tonne Bl) Pres orca FT] Regulation Fy| oh| See, Jj een 7 Warning E ange AR a ‘Angular value P ‘Visual inspection o ( ae TURBOCHARGER > Ly exaust om EERE AIR FILTER al GB must vom] VLESSS | Description “The turbocharger is composed by the folowing main parts: cone turbine, one transforming vale to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine dik wheels rotation. ‘The compressor rotor, being connected by shaft to the turbine dsk wheel, rotates as long a: this last one rotates, compressing the sucked ar through the air fiter “The above mentioned airis then cooled by the radiator and flown through the piston induction collector TURBOCHARGER, The turbocharger is equipped with a transforming vale to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector Its duty isto choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value The cooling process and the lubrication ofthe turbocharger and ofthe bearing: is made by the ol of the engine12. SECTION | ~GENERAL SFECIRCATIONS ‘fo Fenuny 200 ENGINESENGINES .Fenuary 2005, SECTION 2~ SECTION 2 INJECTION FEED SYSTEM BY MECHANICAL, ROTARY PUMP FEED PUMP PRIMING PUMP FUEL FILTER INJECTION FEED SYSTEM BY MECHANICAL, PUMP UNIT FEED PUMP FUEL FILTER ED2 SECTION 2 ~FeE0 Ep, Femua 200 ENGINESBRINE en FEMUR 20 SECTION? -FED 3 | INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP General information Fuel feed system is composed by- 1 Fuel tank (placed on the machine) D1 Fuel delivery and backflow to tank C1 Fuel pre-fiter (ravailable, ti usually placed close to the ngine on the machine frame) G1 Priming pump, assembled to the engine and driven by the camshaft Fuel fier (assembled to the engine in diferent postions according to equipment application and duty) Injector feed pipatine (Form fuel feed pump to injectors) OD Injectors | njector eed pipes ~2. Fuel exhaust pipes fom injectors ~3, Fue feed rotary purnp ~4. Connector for LDA pressure _uge pipe within suction collector ~ 5, KKSB thermal bulb ~ 6, Electro-vale ~7. Injector0, euay 200 ENGIN Figura 2 |. Fuel fiter ~2. Feed pipeline from fer to fuel pump ~3. Feed pipelne from priming pump to fiter ~. Priming pump Description of working principles Fuels sucked from the fue! takby the priming purnp. This last| _| The fuel arrives therefore tothe vahe gauging the pressures ‘one ie placed on the engine basement andis driven by the camn-| | de feed purnp. fee ‘The cstbution puner further increases this pressure and de “Throughout the fiters the felis piped tothe union ting va-| _|lversfuel throughout the delvery pipe iting to the njectors. uur chamber of the transfer pump. For applications t0 be] | the tt raving or 2 a luc drawing from the injectors is recovered and delivered equipped in cod chat areas the fel fer prowded wih] | Teel dawn heater), "Transfer pump is placed inside the eed purnp, andis bladed ty-| sits duty isto increase fuel pressure in correspondence with | {the increase of the number of revolutions,FEED PUMP VE 412 11901 rotary ype pump is driven by a gear mating the cemshalts one. w 1 = Pump dimensions = 4 lindars engine = Distrbution rotary plunger = Distribution plunger in mn, 1150 = Number of pump revolutions per minute = Leftdrection of otaton Figura O.FEBUARY 2002 Diafram 2, Locking nut 3. Pot 9, Advance converter scowone FEED 5. 7 8 Uy) 2 ¢ i O) AES Z TOU ES Li, Low (=e) hoon pun tal seen 4. Drive lever 5, Speed gauge 6. Tanster pump —_7. Drive shaft 8. Cam disk 10, Distribution plunger 11. Delivery pipe fiting 12. Hydraulic head 13. Drive plate 14, Gauge pin 15. Countractng spring,6 SECTION? FEED eo reauary 200 PRIMING PUMP “This pump has the specific duty to prime the fuel avalable in the tank and convey it to the feed purnp inet. is assembled to the engine basement and driven by the carehaf. “The picture here following shows the purnp (I) and the position that the pump dive lever assumes depending on the camshaft rotation (2) and on ite eccentricity Figura 4 qH L| ——s / |. Priming purnp ~2. CanshaftENGINES ED. FEMUARY 20s section? Fem FUEL FILTER ‘The teri assembled cose tothe fed and priming pump and hes the specie duty to provide barrier tothe impurities and separa- ‘tion of water from fuel ‘On the fiter cartridge base () there is a water dump screw, throughout which it possible to provide regular drainage: on the ‘bearing (I) for those equipment applications requiring (cold elmate area) there can beaheater assembled to (2)andatempera- ‘ure sensor (5). Figura S| oO \l TTT |. Fuel ter bearing~2. Heater ~3, Water dump screw—4. iter cartridge — 5, Temperature sensorSECTION? -FEED €,FeBunRy 200 eNGINSSECTION2 FEED | INJECTION FEED SYSTEM BY MECHANICAL PUMP UNIT | General information Fuel fed system compoted by Fil ak aed on the machine) | Go Fuel delnery and backflow o tank | Gi Fuel pre-fiter (iPavailable, iti usually placed close to the engine on the machine frame) 1 Priming pump, assembled to the purnp body 1 Ft erased to he eng in erent posites cording to esupment appation and duty) CO njector ed piptne (rom fe ed pur to nec) O injectors Figura 6 | Injector feed pipes ~2. Fuel exhaust pipes from injectors ~3, Fuel feed pump ~4. Connector for LDA pressure gauge pipe within suction collector ~5, Lubrication pipes 6, Engine stop ~ 7. Injector10 secTion2-FeeD Figura 7 Description of working principles Fuels aicked from the fuel tank by the pring purnp. This lat ‘one is placed on the engine basement andis driven by the cam shaft “Throughout the fterfs, the fuelispipedto the union fitting va- ‘cuum chamber of the transfer purnp. (For applications to be ‘equipped in cold climate areas, the fue! fer is provided with heater) “Transfer pump is placed inside the feed pump, andi bladed ty pe its duty isto increase fal pressure in correspondence with the increase of the number of revolutions fo, rouaRy 200) vanes |. Fuel filter ~2. Feed pipeline from fiter to fuel pump ~3. Feed pipeline ffom priming purnp to fer ~4. Priming purnp Fuels delivered to the pressure gauge valve within feed pump, “Timing plungers further increace the pressure and deliver fuel to the injectors throughout the delvery pipe fitings, Fuel eeding rom the injectors isrecevered and piped backto| the pump.FMR 208 | FEED PUMP “The pump is den by a gear mating the carshals ene. Direction of rotary Left Defnition of dir ofrotation “Left” means anticlockwise when looking from the drive end “The low pressure system must be bleed Ambient temperature from “40° to +120°C ‘Oi fll quantity (0.45 liters engine oil Figura 8 SECTION? -FeED12 secnow2 ~Fe=D €,FepuaRY 200 ENGINES FUEL FILTER “The iter ic assembled close tothe feed and priming purnp andhas the specific duty to provide barrier tothe impurities and separa- {ton of water fom fue. (On the fiter cartridge base (4) there isa water dump screw, throughout which it is possible to provide regular drainage; on the bearing (I) forthove equip appications requiring (cold climate ares), there canbe a heater assembled to (2) andatempera ture sensor (5), Figura 9 |. Fuel fiter bearing ~2, Heater ~3, Bleender vent screw —4. Filter cartridge — 5, Temperature sensor ~6, Water dup screwSECTICNS3 ~DUTY “INDUSTRIAL APPLICATION 0 Franny 200, ENGINES SECTION 3 DUTY - INDUSTRIAL EQUIPMENT. GENERAL INFORMATION 1D Version equipped with mechanical feed pump 1 Clearance data PART ONE = MECHANICAL COMPONENTS (OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL ROTARY FUMP Preface Engine sting operation forthe assembly on turning sand Disassembly of application cornponents Installation of application components Completion of the engine Rotary feed pump disassembly and sob prseaire Feed system bleed procedure Power take-off disassembly and assembly procedure Check and controls oO, ow) ow \oo; oo (OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL IN LINE PUMP Preface Engine sting operations forte ase on turning stan Diasserbly of application components Installation of application components ‘Completion ofthe engine Feed pump unit deasserby and assembly procedure Feed system bleed procedure lo| olo| colo loo] of Power take-off dsasserrbly and assembly procedure ‘Check and controls TIGHTENING TORQUE 19 33 35 38 38 38 39 39 4l 2 e o eoos Trae reat pear cel Pacha Pana PART WO “ELECTRICAL EQUPMENT 72 |_|. paRr THREE -TROUBLESHOOTING 8 | ELECTRICAL COMPONENT LAYAOUT (4 CYL. 7 aca. Conponen uaa ys. |PARTFOUR-MAINTENANCE PLANNING 91 Coot temper swan 76, | MANTENANCERLANNING 98 © sure 76, | Oh Recovery al SB water temperatur sensor ELISE vocertonperaiarsseor! + 8 Planning of control and periodical intervention 93 Checks not inched in maintenance planning ~ Erectromagnets assented to fed pure | | 2 Spt se Sl esteee 77 | MAINTENANCE PROCEDURES ~CHECKS ©) flier 77) | NAMB cons x TD) Pre-past hextng reskanr 768) | GD Enghe ol level check. 94 vise 70 | | C1 creck ore ten %5 HECTHCAL COMPONENT LAYAOUT 6crL |_| CL Cooling sem check %5 ERSNESRITH Pure Unt) » Lubricating tem check % Cooling liquid temperatur sensor 80, eee eta eee ee eee care em Goole Ea coe Check of water presence within fel er O Sater 5 sree 98 158 water terperaur sewer 20 | | check ordre bt ensoning %6 {2 Engine stop assembled to eed pump a1 | | Co check orbs tear and wear stats %6 O. Olpresre sich 81) | checkand setting of tapped dearace %6 O Feel fitters: co Oil motor and filter replacement 7 re-post hewing rior 82) | C foet iter repacerent %8 post heating | y O Alternator 82 2 Alternator belt replacement 98SECTION 3 ~ DUTY ~INDUSTRIAL APPLICATION FD. Fenuny 2003 avons 3 GENERAL INFORMATION ‘Version equipped with mechanical feed pump. Figure | F4BE0484 engineshavebeen designed and developed specifically for transportation by land and farming equipment in general [They are featured by 4 stroke diesel cycle having 4 cylinder boost with 2 valves per cyinder Feed is provided by rotary mechanical pump or en tine according to the equipment application, It clifers from other applications because of the provision of diferent power, power take-of for the diferent collector configuration, priming pump, oil pan and boost turbine. ‘The picture shows application designed for4 cylinders version, 2 vakes per cyinder, having fuel feed mechanical pump. Data, technical specications and performances parted shal be vald only the Setter wil flow and emply with al intaltionpresptons Furthermore, the expanders assembledby the Setter ‘must always comply with couple, power and number ‘of revolutions based on wihich the engine has been designed, “The section herein described is composed or four directories 1 drectory of mechanical overhaul prescribed in axcordance to the engine's specific duty, illustrating all necessary operations to. remove and assembly the ‘external components of the engine, including cylinder heads, gearbox ofthe timing system and ofthe font part LD electrical directory. describing the connections of the diferent components. of the pre-post heating gearbox (nly for some versions) and ofthe sensors assembled to the engine: 1 toubteshooting directory; rectory of preventive and regular” maintenance ‘operations providing instructions forthe execution ofthe ‘main operations4 NEFENGINES ED. FEBRUARY 203, SECTION 3 DUTY - INDUSTRIAL APPLICATION CLEARANCE DATA ~ 4 CYL. Data, Features and performances are valid only if the etter fully complies with al the installation prescriptions. Furthermore, te users assembled by the setter shall always be in conformance to couple, power and numberof tans FAGE04 ine 044"D6 | S4A*D6 84C*D6 Compression ratio ms ‘Max. outpat kW a 4 T 4 ca) 5 10 18 om 230 2300 2300 Max. torge Ni = wR 500 erm) = wx 500 om : vo | 1400 Toadies engine iting rem 890 850 850 Loadless engine peak om 2300 2300 2300 Hore x stoke mm Jos x 132 Displacement em 5 fy 0 SUPERCHARGING with itereooler I einai rs by Be pam, ave sige ston | Ce oil « ) = i pressure (warm engine | @©8 , | lng bar 070 | peak rpm bar 330 | coouso xm pp ein ernse exchanger, inercoler ‘Water pump contol “Through belt ‘Thermostat ~stat of opening °C sie FILLING BL tswosceas enemies 8s engine sump + filter liters 95 based on which the engine has been designedSECTION 3-DUTY INDUSTRIAL APPLICATION >, FEBRUARY 2003 ENGINES (CLEARANCE DATA - 6 CYL. Type | o1nsps sicepe | Compression ratio | 15:1 LTTE w ary) | 110 175, pm 2500 2300 ‘Mx, torque Nm 3 700 kam é 700 om_| 1400 _ Loads engine ialng mm | S 880 Loaaless engine | peak pm pm = 2500 Bore x stoke 1 THX Displacement 6729 SUPERCHARGING ith itercooter “Tabocharger type HOLSET HX35W TUTBRICATION Oil pressure (warm engine) Forced by gear pump, relief valve single action ‘oi iter idling bar 0.70 ~ peak rpm bar 350 COOLING By centrifugal pump, regulating thermal, heat | ‘eachanger intercooler Water pump control | ‘Through belt ‘Thermostat | stat ofopening °C | s22 FILLING Bf svsoacenes tne ann tiers 1s 16 ‘engine sump + titer ters based on which the engine has been designed, ‘Data, features and performances are valid only If the sete fully complies with all the installation prescriptions. Furthermore, the users assembled by the setter shall ways bein conformance to couple, power and number of turnsENGINES ED, FEBUN 2002 SECTION 3 ~DUTY -INDUGTRUAL APPLICATIONSECTION 3 ~ DUTY —INDUGTRAL APPLICATIONS rea 2000 Moron 7 PART ONE - MECHANICAL COMPONENTSED, FeBUARY 2003 SECTION 3 -DUTY -INDUSTRIAL APPLICATION.SECTION 3- DUTY = INDUSTRIAL APPUCAION EDEBIARY200 ENGINES 9 OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface Part of the operations illustrated within this section con be Periially execuied while the engine is assembled on the ‘hicle, depending on the room available lor access 10 the engine and on the equipment application as wel With rogord to the engine disassembly operations, please apply for information consulting the speciic ‘manual. All operations of engine disassembly ‘operations as well os overhaul aperatione must be executed by qualiled engineers provided withthe specific tooling and equipment required, The following information relate 10 the engine overhaul ‘operations only for what concerns thedlferent components cuslomising the engine, according lois specific duties. For speciic application exigencies, some units con be ‘ossembled lo the engine in cllerent positions Within “Gonerol overhaul” section, ell the operations of engine block overhaul hove baen contemplated. Therlore the above mentioned section isto be consideredosfollowing the part hereby described Engine setting operations for the assembly on turning stand In orderto apply the brackes to the engine block to fix it on fo the stand for the overhaul, tis necessary 10 perform the following operations: ‘On the right hond side: 1G disossemble pipes (1) rom the union (2) fing the lubrication oi filler (essembled on the opposite side: Unlock the nuls fing the pipes (1) and remove them from ihe union (2};droin the oil eventually silinsde he pips and elug hem propery in rr 6 ooidimpury shall be disassombled using acceptable tools. Werning: the oil fier contains inside opr. 1 ko. of engine ol. Provide for oil recovery ond disposal in ‘compliance wth the law ond regulations in force, disassemble lubrication il exhaust pipe from the turbo blower: Underneath the turbo - Blower loosen the lwo screws {2), loosen the screw (3) fixing the pipe throughout the slop collr (4 xing the block; finally loosen ond remove the union (5) from the block; plug the pipe ends andthe exhaust of the turbo - blower 1 Disassemble the starter; Properly hold the starier (I) and loosen the wo fing serews (2); assemble the bracke! bearing using the four screw threaded ports (3) |]On the left hand side Disassemble oilfiter (I) and bracket as wel farversions with engine oi fiter not directly assemtled on to the exchanger) Use accoptabl to! to incta i Loosen the screws (3) removing the bracket together with the fter bearing (4 and 5), Warning: the oil flter contain inside api. | hg. of engine oi Prowie tank with sufficient capacity to contain the liquid Waning: avoid contact of engine oll wth the skin: case of skin contamination rnze in running water Engine ols highly pollutant provide for disposal in compliance with the law and regulations in force, Ci Remove the oil evel rod together with guide pipe (2); (loosen the guide pipe disassembling from the block) properly pipe the screw-threaded port to avoid inlet of Foreign matters 0, FEBUARY m2 SECTION 3 -DUTY ~INDUSTRIAL APPUCATION, O Assemble the second bracket throughout the. serew-threaded ports (1), 1 Lift the engine using the rocker arm and put {Won the turning stand, Drain the ol through the cap underneath the plug. ‘Warning: avoid contact af engine oil wth the akin: in x ne om ‘ase of skin contamination, rinse in running water Engin oils highly pollutant: provide for disposal in compliance with the law and regulations in force.SECTION 3 -DUTY “INDUSTRIAL APPLICATION, ED FesUARY 2002 eGNe 1 Disassembly of application components Proceed dlzasserbiing the supercharger: 1D toosen the fixing nut (1) and remove the hibrication pipe from the supercharger Analogously carry out the sarme ‘operation on the other end of the pipe and remove ft fom the upper part ofthe heat exchanger Loosen the serew nuts fixing the supercharger on the exhaust manifold Hold up the supercharger and ar Ring remove the soket Figure 8 BF K @ Place a container under the fue! fiter and serew out the condense drain faucet underneath said fiter Carry out complete drainage of the fuel contained therein. screw out completely the faucet and, using accoplabe toa, remove the ol itr (, C1 Disconnect fuel pipelines (2 and 3) respectively from priming purnp to fiter bearng and from ths last one to the feed pur, Remove the fue fit bearing (4) from the bracket fixed to the engine head “To disconnect fuel pipelines (2 and 3, picture 8), in /'\\ ow pressure from the relating pipe fitings, i is Necessary to press the locking fastener (I) at shown in picture B. After having disconnected the pipeline, reet the locking fastener (|) in lock postion as’ shown i, Ficture A, to avoid any possible deformation of the fastener itself DD Disconnect the LDA pipe (1) fom the head and from the feed pump Pipe the ends ofthe pipelines as well as the feed pump and the engine head,0 FeaunRv 200 SECTION 3 ~DUTY ~INDUSTRIAL APPUCATION C1 Disconnect the pipeines (1) and (2) that provide feed and fuel recovery betvieen pump and injectors screw fut the nut fang the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws Sing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (1.6, and 7, Figure |); pipe the pipeline ends, Disassemble the injectors and remove them from their slot: remove the gnekets, |. Rear bracket fing screw (on suction collector plate) ~ 2. Fuel recovery pipeline to pump ~3. Rotary feed pump ~4 ‘Connection nut to pumping elements =5. Injector ~ 6, Bracket fixing screvé to injection pump side 7. Front bracket fing screw (on suction collector plate) Di Loosen the two fixing serews and disassemble priming pump,SECTION 3 -DUTY ~INDUSTRIAL APPLICATION D.Feauney 200 DD Remove tappet caps Loosen the four fing screws (I) and it the caps (2): remove the gaskets i In the picture, the front cap has already been (On the central cap there is a blow-by valve forthe Lrication oil vapours. ‘All the gaskets shall ays be replaced during assemby = Da Disassemble rocker arm bearings: loosen the two fing screws (2)andremove the completerockerarmbeanng, withdraw tappet rods. Repeat the operation fora the remaining rocker arm bears. Dr Disassemble water temperature transriter (I) C1 Disassemble suction and exhaust manifolds: loosen the 8 screws (I) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since firing the pipe brackets to the Injectors) from the exhaust manifold sie; loosen the eight (2) fixing screws; remove the gaskets Dr Loosen the screw (I) on the altemator belt tensioning banger and by loosening the lock nut, loosen the screw as well (3) in. order to sack the bett (4) unt enabling ‘withdrawal ofthe driven and guide pulleys. Disassemble alternator bet tensioning hanger (5)e | Disassemble thermostat unit; loosen the three fixing screws (I) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and she thermostat (5) Assemble the bracketin the orginal postion fixing it wth ‘he screws ofthe thermostat unt. Figure 19) |e Property hold the alternator (I) separating it fromm its bearing by loosening the screw (2) remove screw nut and washer: 1D Loosen the screws (2) and withdraw the altemator beating (I) ep. 2000 SECTION 3 -DUTY ~INDUSTRIAL APPLICATION TD Loosen the screws (4) and diassemble the ol! pressurekerperature sensor (3) (fed) Th Loosen the screws (I) and disassemble the ol iterheat exchanger bearng (2), interlayer plate (6) and relating paket, Dy Disassemble oil evel sensor (5) (whether provided). Dr Disassemble injection pump (See specific procedure) and the power take-off undem D From the front, disassemble transmission pulley (I). CD Loocen the four serews (2) and dzasserble the pulley (0) from the bearing undemeath Proceed slsassembiing the bearing,SECTION3 -DUTY “INDUSTRIAL APPLICATION, Eo. FERUARY 2002 ENGINES a 1 Disassemble cyinder head, loozen the crews I) and (2) fing thecyfinder head (3) hhook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block, Figure 24 oF @) Gi Use the 380000988 too! (2) to operate on the thywheol cover box (I) in order to block flywheel rotation (3). (Utlise starter holding down studs and fing screw ruts). | Loosen the flywheel fixing screws (4) to engine drive shat Ci Loosen the screws (1) and withdraw water pump (2) 1D) Loosen the screws (3) and disassemble the pulley (4. Remove the engine drive shat fing rng rom the front over. Use the to! 220000065 (4) opera onthe Honk tang 2) of the engine crve sha, Throughout the tool guide ports drilthe intemal holding rng (I) using © 35 fren dil for Simm depth. Fix the tool tthe ring tignening the 6 srewe special provided Proceed withdrawing the ing (1) tering the screw ©0, FeaunRy 2a SECTION 3 DUTY ~INDUSTRIA APPLICATION. Use acceptable tools (8) (4) and withdraw the extemal holding ting (2 trom the front cover () i Loosen the screws (I) and remove the font cover (2). R “Take note of the screw (I) assembly poston, since the screws have diferent length Cr Lcosen the screws (1) and remove oil pump (2. C._Screw out the opposite screws (I) from the ports where ‘the withdrawal pins shall be introduced (see pecture folowing) Loosen remaining flywheel fing screws (3) to the engine drive shat (4). Rerove the tywheel block tool (2)SECTION 3 ~DUTY “INDUSTRIAL APPLICATION eo Feauny 200 INGNES 17 1D) Screw up two medium length screws in the ports (4) t0 sling the flywheel with a hoist. “Throughout two guide pins (2) previously screwed up into the engine dive shaft ports (3) control the engine | flywheel withdrawal by means of a hoist IWS Remove the fyvhee cover box fing ringusing the tool “HOOIOE62 (3) to operate on the Back tang (8) ofthe engine drive shat Throughout the tool guide ports ei theintemalholdngring using @ 35 erm cl fora Siren epth Fax the too! 380000663 (3). to the ring (1) tightening the 6 screws specially provided (4). Proceed with craving the rng) tightening the screw @ Use accopable too (8) (4 and witha the extemal holding rng ofthe yhoo cover box. a Qa 1 Loosen the screws (2) and remove the fywheel cover box (1) “Take note of the screw (|) assembly position since the screws have diffrent length, Tum the engine upside-down, 1D Loosen the screws (2) disassemble the plate (3) and remove the oll pan (1. iN “The shapeand dimensions ofthe pan and ofthe rose pipe may vary according to the engine application, ‘The relating lustrations provide general guidelines ‘of the operation to be performed. The procedures described are applicable anyway.18 exanes |) igure’3s Loosen the screws (1) and disassemble the ail suction rose pipe (3). Cr Loosen the screws (2) and remove the stifling plate @ 1 Loosen the screws (I) and disassemble the gear fromthe camshaft (2) ED, Fenun 2009 SECTION 3 -DUTY ~INDUSTRUAL APPLICATION. Ch Loosen the screws (2) and disassemble the timing gearbox (1), J. Tike note ofthe screw (2) assembly position, since WX, the screws have different length.SECTION 3 ~DUTY “INDUSTRIAL APPLICATION 0, runny 28 Installation of application components DXAGRAM SHOWING SEALING LOCTITE 5205 'AFPLICATION WITHIN GEARBOX AREAS Ch Accurately clean the timing gearbox (I) and the engine block Its necessary and essential to clean the surface to bee sealed in order to achieve excellent tight seal, Apply sealing LOCTITE 5205 on the boxin order to forma kerbstone ofa few mm. Diameter: It must be uniform (no crumb), with no air ister, ‘thinner or irregular zones, ‘Any eventual imperfection shall be correct as soon a possible, ‘Avoid using material n excess to seal the joint Too ‘much sealing matenal would drop out on both sides fof the joint and obstruct hibricant paseages. ‘After having completed seal application, the joints must be immediately assembled (10-20 minutes time), DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX | Reassemble to box (1) to the engine block ID Tiehten the fing screws in the same positon as found ‘ut during disassembly and fix the screws to the locking couples sted here below, folowing the order as shown, in the picture screws ra 65+ ONm | Sacws 8 peri | acws 0 22 StNm | [| Before assembly. ahvays check thatthe threads ofthe portsand ofthe serewshaveno evidence of tear and ‘wear nor drt 0 With a penmarkerrmarkthe tooth (I) ofthe driving gear assembled to the engine drive shaft with (2) (+) timing Screw up two pins to facltate operation of engine “dive shat rotation.1 Ovientengine dive shaft (4) and camshaft (2) taking care ‘that in phase of assembly ofthe driving gear (2) to the camshaf, the notches marked on the gears (I and 3) shal match, Cr Tighten the screws (1) sing the gearto the camshaft (3) and lock them to the prescribes couple. Figure 43 DIAGRAM SHOWING SEALING LOCTITE 5205 ‘APPLICATION. FD FEBUARY 2001 SECTION 3 -DUTY ~INOUSTRIAL APPLICATION. fa asa osmcs sare 7 Apply sealing LOCTITE 5205 on the box in orderto. women eee soa etary te mlb et Ee eee eae aren a DIAGRAM SHOWING SCREW TIGHTENING TO FX FLYWHEEL COVER BOX. C1 Reassemible the box (I) to the engine block, tighten the fang screws in the same postion as found out during dtassemby and foc the screws t0 the locking couples led here below, following the order as shown inthe picture, Screws M12 75 + 95Nm Screws M10 44 = 53Nm enveer meer srer emer 7 EeSECTION 3 ~DUTY “INDUSTRIAL APFUCATION a ic Dr Apply to engine drive shaft rear tang (6), the detail (5) fof tho tool 380000866, fi tighoning tho serows.(@) and keey the new holding ring on (3) Place detail (1) on detail (5), tighten the screw nut 2) Lunt complete assembly of the fixing ring (3) into the Aywheel cover box (7). Figure 46 [ea , Fuse ona mNGINS 21 Screw up two hooks or trail rings in the fywheel (1) ‘threaded ports (4) for handling Usingahoist handle the wheel to place tin ts housing inside the fywheel cover box. Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (I) properly placing inside the fyhee! cover box. In case of engine coupling with mechanical gears in /\,) presence of fiction, very surface status of the (E> fywhee and eventually workitoutto maintain rated engine fywheel thickness, which is 49,6 + 0,13. mm, Check the conditions of the rim tooth (2). Whether ‘tooth break or excessive wear is detected, disasserrble ‘the rim from the engine fywheel using a common willow and replace with a new one, previously heated to 150° C degrees for 15° +20; seconds; beveling must bbe made towards engine flywheel direction, Di Tighten the screws (4) fxing the engine fhwhee (3) to the engine shait, Use 380000088 10) (2) to ‘the fywheel cover box (I) to block engine rotation,Tighten the engine fywheel (I) fing screws (2) in two | phases | Cd Istphasetightening by means of dynamometric wrench ‘to couple 30 + 40 Nm Dr 2nd phase, 6 ++ 5* angle dwell [AQ] Angle ave shall always be performed using ‘acceptable tool Before assembly always check thatthe threads ofthe portsandof the screwshaveno evidence of tear and ‘wear nor dirt | Figures | Assemble oil pump (1) DF Tighten fixing crews (2) andlockthemto theprescribed couple. ep Feu 2a SECTION 3 -DUTY “INDUSTRIAL APPUCATION (D Aseemble the water pur (1). Tighten the screws (2) and lock them to the prescribed 1 Femove the fixing ring (2) from the front cover (1), sccurately lean the plug surfacesorta scence Sana facta | Figure 56 easy —, I] 7 a— | z Se, | a i ! 2 7) ; a4 Li i : = [Accurately clean the contact surface of engine blockand ply sealing OCTITE 5205 cn it x rer to form 3 Uniform and continuous kerbstone with no crumb, G Assemble the front cover(2)tothe blockandtighten the sere (1) fang ther to the prescribed couple Apply on engine drive zhaft front tang (6) the deta (4) ‘ofthe toot 160000866, fi it with the serews (5) and key the new holding ring on ® (7) Place the detail (2) on the detail (4), screw-up the ‘threaded nut until carrying out the complete assembly of the holding ring (7) %0 the front cover Aczemible the plate (I), the rose pipe 2), tighten the fing screws (3) and fic them tothe prescribed couple.24 ENGINES Figure 58 D Provide fornew gasket replacement (I) ofthe cil pan (2). pictures ilustrating the pan and ofthe rose pipe may not correspond to the ones of your model However the procedures described are applicable anyway. Cd Assemnbe cil pan (1), apply the plate over it (2) Tighten the screws (2) and lock thern to the prescribed couple. ED, FeBUNRY on8 eee A ee wear nor dirt SECTION 3 -DUTY INDUSTRIAL APPLICATION. [2 Asiemble the pulley (I) to the engine drive shaft, and the distance rng (3). [A Tiehten the xing screw (2) andlockthemto the 68 + 7 Nim couple C) Asemble the folowing elements to the block: new gasket (I) heat exchanger (2). new gasket (3), ol er Bearing), Tien the screws (5) and lock them to the preserbed couple Before assembly aways checkthat the threads oftheSECTION 3 DUTY “INDUSTRIAL APPUCATION Fauna oma GINS 25: Lubricate the fixing rng (2) using engine oil and place it on the oil flter (3). 1D Manually start the oil ltr (3) on the bearing union (I) Until counter-borng, further screw up the oil iter (3) by 314 tur, 1D Appl, GF needed) new fing rng on the oll ‘emperature/pressure sensor (4) and assemble it to the beating (I) tightening the fxing screws ta the prescribed couple In some applications, the bearing ofthe exchanger ‘\\] shall be assembled to a screw threaded union [5 connected to the fiter on the opposite side of the engine, throughout two pipelines (see picture 2) D1 Place a new faxing ring on the block housing (6) Figure 63 &) ® Before assembly, aways check thatthe threads ofthe portsandof the screws have no evidence oftearand wear nor dirt 1 Reassemble the alternator (I) OD Tighten the screw (2) and lock i to the prescribed couple. Cr Pace the gasket (1) over the block, “The choice of the gaskets thickness shall be made in consideration ofthe cylinder protrusion measured with respect to the block’ upper surface. 1D Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. Tighten the screws (2) and lock them to the prescribed couple. Verify thatthe engine block stand is lean Donotgrease the gasket Its recommended tokeep the gusket inside packaging unt assembly to the cylinder head Gasket assembly shall be made following the 0.1 mm the screw rust be replaced Ep. Feaunny aoa GING 27 | Aiur the sk between rockerarmsandvalesusing socket ‘wrench (I), point wrench (3) and feer gauge 2). Correct working slack = "Tucion valves 030 + 005 rm = exhaust valves 055 + 005 mm aN In order carry out a quicker adustment of the working slack between rocker arms and valves, proceed a: folowing Rotate the engine drive shaf. balance the valves of ‘jlinder | and adjust the vahes identifed by star _ymbol, a incicated in the following table Gfindern [2 3s Te Suction © T-[-[- Exhaust =bet* t= Rotate the engine civ shaft of 360 deg, balance the valves of einer 4 and adjust the valves identified by star symbol, a5 dicated i the following table: Gylindern® [Ts a Suction ~[+[. [= Exhaust =[=l=Ts28 ENGINES Assemble injectors after having replaced the sealing ase (1). J |] Daring aserby oF njectors, very that te jetor /\| sphere is correctly postioned onthe head hous, aareree fA (2) D1 Assemiie cylinder covers (2) with the respective gaskets; C1 Fit the seal nods and tighten the screws fixing them to the prescribed couple. ep Fenny 2000 SECTION 3 -DUTY “INDUSTRIAL APPLICATION. [A | Always replace the gaskets using new ones, ZY, cheartettventsottne ing srensther sabe po otdene of wo ovat Sapa Seal nods shall have no visible deformation In such case provide for replacement with new nods. DP Gt ree Eee Ie Ee © 1 Assemble thermostat unit (2) including thermostat (5) and gasket (4), Di Tehten the screws to the prescribed couple, “The serews (I) have been have been utilised to fx the bracket (3) Disassemble the bracket and reassemble components from | to 5 as shown inthe picture. “The gasket must be new.SECTION3 -DUTY ~INDUGTRIA APPUCATION ro Feuney 200 1D Assemble the driving belt (4) tighten the screw (1) ‘without locking in orderto tt sie within thebracket hole (5). Adjust belt tensioning by tightening the screw (3). After ‘having set correct tensioning blockthe checknut (2)and the screw (I) Dr Assemble the pulley fan bearing tightening the screws to the preserbed couple. 1 Assemble the altemator tensioning bracket Assemble the tivo pulleys (3) and fcthem tightening the screws (2) ofthe bearnig. Assemble the tranrizsion pulley (1), Incase the same belt priory removed is assembled agan, proceed examinng it carefully to check there (KDr Apply on the surface joining the suction manifold plate (i) a aufcient coat of Loctite 5999 and provide, fing, the screws to the prescribed couple, C1 Irth pipe (6) ofthe suction manifold plate (1) has been removed reassemble it after having ft anew gasket (5). Tighten the serews (7) to the prescribed couple. For the versions provided with heater also assemble ‘components (3) and (4), FD, FEBUARY a3 SECTION 3-DUTY ~INDUSTRIAL APPLICATION Abo assemble the brackets (I) fxing the fuel pipelines ‘© the injectors: use the same screws ‘manifold plate ac shown in the picture @) fang the Cr Assemble priming pump (I) providing new gasket and ‘iiten the screws (2) to the prescribed couple. Cr Also assemble feed pump (see specific procedure) and the power take-off underneath Pump assembly requires. specific procedure as reported at the end of the hereby sectionep. Frauany 208 SECTION 3 DUTY “INDUSTRIAL APPUCATION | Rear bracket fing screw (on suction collector plate) ~2 Fuel recovery pipeline to purnp ~3. Rotary feed pump —4 Connection nut to purnping elements ~5, Injector ~ 6. Braet fing sre to injection purnp side 7, Front bracket fing screw (on suction collector plate) ite Peureias Se8 O Ficthe LDA pipeline (I) to the engine head and to the feed pure, le the pipes (I) and (2) providing ful feed and 5 between pump and injectors ip the long nuts and Uphten the screws fing the injectors ied the fuel recovery manifold othe pipes to throughout the brackets previously assem32 ENGINES FD. FEBUARY 008 SECTION 3 -DUTY —INDUSTRIAL APPUCATION Gh Assemble the fu! fit bearing (4) to the bracket xed ‘to the engine head Ca Connect the fue pipelines (2 and 3) respectively from priming pump to iter bearing and rom this lst one to feed pump. C1 Using acceptable tools assemble tue! titer (I). “The fter shal be prior filed with fuel to fcitate {ee system bleed operations WN “To connect fuel ppelines (2 and 3, Figure 87) in ow pressure from the relating connection unions it is necessary to press the locking fastener (I) as shown inpicure 8 ‘After having connected the pipeline, reset the fastener (I) into block postion as shown i picture a Proceed assembling the turbocharger: D1 Hold the turbocharger and place it on the exhaust ‘manifold after having interposed the gasket, 1D Screw up the fixing nuts of the turbocharger to the ‘edraust manifold tightening them to the prescribed couple, D1 Tighter the lubrication pipe fxng ring. Operate in the same way on the other end of the pipe. Connect it to ‘the upper part ofthe heat exchanger “To complete engine assembly itis necessary to remove it from the turning stand C1 Using acceptable tools hold the engine and loosen the screws fixing the brackets tothe turing stand C1 Disassemble the brackets from the engine after having roperly put it on a wooden bearing.SECTION 3 DUTY — INDUSTRIAL APPUCATION. . Fesuagy zon ENGINES 33 Completion of the engine Figure 90 ‘On the ight hond side: reassemble the pipes (1) from the union (2) 10 the lubrication al iter (placed on he opposite side) ighien the pie rings (1) and connec them to the union rectly placed on shell be assembled In some coses, the il fir (3) the heot exchonger:in this cos sing accopabletocs. Q Reossomble the lubrication cil exhoust pipeline (1) rom the turbocharger: from underneath the turbocharger lighten the two screws (2); tighten the serew (3) lxing ‘the pipolino o the block throughout the fixing collar (4) to the block; finaly ighten he union (5) fo the block.34 ENGINES 0, Feauay 2003 SECTION 3 -DUTY INDUSTRIAL APPLICATION. 1 Reassemblethe starter; properiyholdthestarter(I)and_ | [On the lefthand side: tugiten the fixing screws (2) to the prescribed couple, Assemble ol fiter (I) together with bracket (for the ‘arsions with engine ol fiter not directly assembled to ‘the exchanger); tighten the screws (3) assembling the bracket (4) nchudingfiter bearing (5) Use acceptable tols to install the ol iter Assemble cillevel odtogether with guide pipe 2). Fllup engine of TD testa the engine on the archine (for instalation ‘operations please apply to specie isue).SECTION 3 -DUTY “INDUSTRIAL APPLICATION Rotary feed pump disassembly e assembly procedure “This procedure prescribes that: C1 The fuel pipelines (rom pumping elements to Injectors bleeding recovery pipes rominjectors ‘to pump, LDA pipeine and feed provided by ppoiming purmp) sal all be cssesernbled 1D Electrical connection to feed pump shall be disconnected, Oi Accelerator cable shall be disconnected, Incase feed pump replacement is necessary, this shall be supplied pre-set aeady as spare part. (On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while itis sil assembled to the engine and dsazcemble only afterwards ‘The following procedure analyses this second hypothesis since its the more complex. Figure 95 1 Rotate with caution the fee following its own rotation seve to annul the gar sacks and tthe same time keep the (~) pin presied unt when thi ast one isting into the port ofthe camshaft gear This way the PMS. shall be determined within Ni. ojinder FD, Fea 208 None 35 (Cr Dizacsemble the starter from the fywheel box (1) and | so the 880000988 tool (2) orotate the fywhoel. bea rotation shall be cared outwith Cauton Thepmchargedby exes shea aes may get damaged36 ENGINES Partially loosen the lateral screw (2) locking the pump shaft and remove the sip washer (2). Absolutely keep ‘the sip washer (it isrecommended to fit with stripe ‘or wire to the purp). Tighten the lateral sere (I) blocking rotation of the pump shat. CD From tiring side, remove the cover (2) loosening the screws (I) inorder to have access to the union fixing rst @) to the pump crving gear Loosen the fxingnut (3)and remove the relating washer: ep Fes 2008 ‘SECTION 3 -DUTY INDUSTRIAL APPUCATION. Fromm the pump side, loosen the focng nuts (|) without removing them in order to enable moving the pump backward using 380000079 extractor. 1D Assemble to 380000879 extractor throughout the two threaded ports (4, Figure 97) and withdraw the gear ‘fom the pump shaft Dr Property hold the feed pump and loosen completely the ‘ing nuts, DD Withdraw the pump from the studs, together with the ket ‘When assembling the eed pumptothe engine itisnecessary to meet the PMS, requirements forthe NI. cylinder C1 Use the 380000088 too! (2) on the flywheel box () to carry out flywheel rotation and operate using the pin 3s previously described. Al Hold the pump driving gearto avoid interference or crawling during timing gear rotation.SECTION “DUTY ~INDUSTRIN. APPLICATION Cr Assemble the pump pre-setin its housing onthe engine, fitting the shaf into the gear port (not provided with wrench) Gi Tighten the fixing nuts (1) locking the pump fange inthe slot centre JA The ese removed crng pump desesemtly shall ZN) not be tied again 1 Aways use ongnal pare pats Gy On the timing side, throughout the specially appointed port, ft the washer and screw up the fixing nut (3) tothe pump shaft Lock the nut to the 90-95 Nin couple. ro Femunky om D1 Partially loosen the screw (2) locking the pump shaft rotation and fit the sip washer (1). Tighten the screw fixing above said washer: this way the feed pump shaft is free to rotate 1D Assemble the cover (2,Figure 101) inching gasket and tighten the screws (1, Figure 101). Oath pin outwards setting the camshaft gear fee. Dr Disassernble the $00000868 tool locking fywheel rotation; place the starter in its housing, Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). 1D Connect electrical connections to electro-magnets on ‘the hydraulic head and on KKSE, Incase pump removalhas been carried out while the A nrcerecrmalmtomearatog tee38 ENGINES ep. Feauy 2002 SECTION 3 -DUTY “INDUSTRIAL APPLICATION, Feed system bleed procedure In case any operation hasbeen executedon the components ofthe feed circuit ti necessary to execute bleeding of ai ‘within the system, Cy Loosen the bieeder vent screw (3) on the fuel ster (1) and keep working on the bleed lever of the priming pump (2) Da Continue executing this operation unti when ful drains ‘fom the bleeder vent screw. Tighten the tieeder vent screw () Power take-off disassembly and assembly procedure, Figure’ (04 Where designed, there isa power take-off able to transmit motion to different aunilary parts, Disassembly of such mechanism shall be executed as allowing Cr Loosen the two screws (3)and atterhaving removedthe cover (I) with a specially provided extractor withdraw the power take-off 2). The two gaskets (4) shall be replaced in phase of reassemble Ci Vary out the assembly fitting the power take-off ints hauting, providing nev gasket and checking the sprocket gearmeshing (Assemble cover and gasket and tighten the serewstothe preserbed couple, ‘Checks and controls “he following tests shall be made after engine assembly 10 the vehicle Preventively check that the liquid levels have been correctly restored, IS) sete erase ni a vin ern (Gay Sa RAE ae Sg i en ei “be ake ord ‘thermostat opening, then check that [There is no water bleeding from the manifolds connecting engine cooing. circut pipelines and cabin irternal heating, eventually providing to further tighten the locking rings. i Garetuly check the fuel connection pipes to the respective unions, 1 There's no cil leakage fromthe lubrication circuit ofthe ‘various pipelines connecting cover and. Di Cylinder head, oil pan and bearing, oll fiter and heat cerchanger az well as relating housings There is no fuel leakage from fuel pipelines. DD There sno blow-by from pneumatic pipes (provided). DD Verify correct working of the lighting leds of the dushboard containing the tools as well as of the equipment that was disconnected during engine connection, Cr Check and blow by with care the engine cooling stern, carrying out frequent drainageSECTION 3- DUTY ~ INDUSTRIAL APPLICATION ED TeBuARY 203 ENGINES 39 OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL IN LINE PUMP. |Preface | | Port ofthe operations illustrated within this section con be [portly execvied while the engine is assembled on the |fehicle, depending on the room evlale lor aczes othe bngine and on tho equipment application os wel TA] With regard fo the engine disassembly operations, please apply for inlormation coneuling the speciic manual. All operations of engine disassembly ‘operations os well os overhaul operations must be ‘executed by qualified engineers provided wih the | specific fooling ond equipment required The following information relate to the engine overhaul operations anlyforwhatcancernsthe diferent components customising the engine, eccording oil specific duis. For speci opplication exigances, some unis con be ‘essembled lo the engine in eileen! positions Within "Generel overhau!" section, all the operations of tengine block overhoul have been contemplated. Therelore The above mentioned section isto be considered asfollowing the port heceby described Engine setting operations for the assembly on turning stand Figure 105 eZ In order to apply the brackots tothe engine biook io fix it on to the stond for the overhaul, itis ‘necessary lo perform the following operations: (On the right hand side 1D disossemble pipes (1) from the union (2) fing the lubrication ol filler fossembled on the oppesi sd): unlock the nuts fring the pines (1) and remove them fromthe union (2) drain he ofl eventually sil inside he pipes and pug hem propery inorder io vadimpuriy For some versions, the oil fier (3) is directly ‘orsembled on fo the heat exchanger: in such cose i ‘shall bo disassembled using acceptable tools. Warning: the ol filer contain inside apex 1 kg. of ‘engine oil. Provide for cil recovery and disposal in ‘compliance with the law and regulotions in force D disossemble lubricotion oll exhoust pipe trom the turbo blower: Underneath the trbo- blower loosen the Iwo scress {2), loosen the screw (3) fixing the pipe throughout the siop collor (4 xing he bloc; finaly loosen and remove ‘the union (5) rom he block; plug he pipe ends ond he ‘ephous! ol the turbo: blower 1 Disossomble the siarter; Properly hold the starer (1) ond loosen the two fixing screws (2)ED. FERUARY 2002 SECTION 3 - DUTY ~INDUSTRIAL APPLICATION. (On the left hand sie: D1 Disassemble oil fiter (I) and bracket aswel (forversions. with engine ol iter not directly assembled on to the exchanger) Use acceptable tools to remove the ol iter Loosen the screws (3) removing the bracket (4) ‘together with the flter bearing (5). Manteo Reresemn see oe WN ts ee es liquid. \Warning:avoid contact of engine cl wth the skin: in case of sk contamination rinse in running water Engine oll is highly pollutant: provide for cisposal in compliance with the law and regulations in force 1D Remove the oil level rod together with guide pipe (2); (loosen the guide pipe disassembling from the block); properly pipe the serewthreaded port to avoid inlet of foreign matters, Figure 110 o 1D Assemble the second bracket throughout the ‘crew-threaded ports (I). C1 Litthe engine using acceptable tools and put it on the {turning stand, Drain the oi through the cap undemeath the plug ‘Waring: avoid contact of engine cil with the skin: in case of skin contamination, rinse in running water, Engine ols highly pollutant: provide for disposal in ‘compliance with the law and regulations in force.‘SECTION 3- DUTY ~ INDUSTRIAL APPUCATION, | Disassembly of application components Figure 117 Proceed disassembling the superchorger: [D loosen the fixing nut (1) and remove the lubrication pipe from the superchorgec Anclogously carry ou! the some ‘operation on the other and of the pipe ond remove it from the upper part ofthe heot exchangec D1 Loosen the fixing screw (3) ond remove the exaust lubrication pipe from the superchargec [1 Loosen the screw nuts fixing the supercharger on the chavs! monial C1 Hold up the supercharger and ater iting it remove the gasket 1D Ploce 0 container under the fuel filer and screw out the condense drain faucsl underneath said flier Carry out complete droinage of the {vel contoined therein screw out completly th faucot and use acceptable tools to disassemble oll fiers (), Disconnect {vel pipelines (2 ond 3) respectively from priming pump tiller bearing and from this lost one 10 the feed pump. Gi Remove the {vel filler bearing from the bracket fixed 10 the engine head. FFEBIAReoD2 ENoIes 41 Figuie 113 {1} low pressure from the relating pipe litings, itis Fu] To disconnect ful pipelines (2 ond 3, picture 8) in Disconnect the LDA pipe (1) Irom the heod and from Necessary to press the locking fastener (1) os shown in picture B. Aller hoving disconnected the pipeline, reset the locking fastener {1) in lock postion os’ shown in Picture A, to avoid ony possible deformation of the fastener ill. the feed pump. Pipe the ends ofthe pipelines as wall as the feed pump and the engine head.,FeauaRy2o0a SECTION 3 -DUTY INDUSTRIAL APPUCATION. D1 Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw fut the nuts fixing the pipes to the pumping elements loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors {and loosen the serene fixing the fuel recovery pipeline Figure 116 D1 Loosen the screws (I, Figure 116) and (1, Fgure 117) holding the fing brackets of such pipelines; pipe the pipeline enc. Figure 118) | 2 Disconnect kibrication pipes (1) from feed pump. D1 Disassemble the injectors and remove ther from thei dot: remove the gaskets,SECTION 3 -DUTY ~NOUSTRIAL APPUCATION .FenunRy 200 evans 43 Remove tappet caps: Loosen the fixing Screws (1) and lit the caps (2); remove the gaskets. A] On the central cap there is a blow-by valve forthe /\\| lubrication oil vapours. SI A the gaskets shall avays be replaced during assembly, Dr Disassemble suction and exhaust manifolds: loosen the screws (I) fing the suction manifold plate to the cylinder head (Some of them have already been screwed-out since fixing the Injectors); from the exhaust manifold side loosen the ‘eight Q) feng screws; remove the gaskets pipe brackets to the Figure (21 Cr Disassemble rocker arm bearings loosen the two fixing screws (2) and remove the complete rocker armbearing: ‘withdraw tappet rods. Repeat the operation forall the remaining rocker arm bearings ) Disacsemble water temperature transmitter (I) | Unloose the screws fixing the altemator’s protection to the support and remove f 1 Workon the drive belttensor (I) and extractthe belt (3) from the belt pulleys, from the water pump ones and from the bet rebound pulleys. 1D Disassemble the bett tensor Unloose the screw fixing the alternator to the upper bracket.44 acne ED, FEBUAR 208 SECTION 3 -DUTY ~ INDUSTRIAL. APPLICATION, Figo 23 as 1 Disassemble thermostat nit; loosen the three fixing screws (I) and Gsasserise the thermostat unit (2) together withthe bracket (3); remove the gasket (4) and | the thermostat 6). | Assemble thebracketinthe orinapostionfxingitwith | the screws ofthe thermostat nt Figure 124 f=.) Gi Property hold the alternator () separating it from its beating by loosening the screw (2): remove screw rast and washer: D1 Loosen the screws (2) and withdraw the alternator bearing (1). Figure 126 Loosen the screws (4) and disassemble the il pressure/temperature sensor 3) (fitted) | Loosen the screws (|) and disassemble the ol fitersheat ‘exchanger bearing (2), interlayer plate (6) and relating atkets 1D Disassemibie oil level sensor (5) (whether provided), 1 Disassemble injection pump (see specific procedure) | and the power take-off undemeath, Figure 127 | | 0 Okassentie cinder head bosen the scree) and(2) feng the nderhead 3) | Roak'he beaches wth meta ropes ae trough host where eynder head for the lockSECTION 3 ~DUTY ~ INDUSTRIAL APPLICATION Dy Use the 280000888 too! (2) to operate on the fywrhea! cover box (1) order to block fwheel rotation (3. (Uillse starter holding down studs and fixing screw ut). Loosen the Mywheel fing screws (4) to engine drive shaft Figure 129 aS Di Unloose the screws (3) and disassemble the damping ‘iywheel (2) andthe pulley (1), err rare 7 esessas eee tego eed ZN seri fo. rrauary 20 euch 45 Figure 130 | Remove the screws (1) and disconnect the water pump a Remove the screw (3) and the roller (4) Oy Remove the screw (5) and disconnect the engine speed sensor (6) Figure 131 em @ = C1 Remove the engine driveshaft fing ring from the front, ‘over Use the tool 380000665 (4) to operate on the rent tang (2) of the engne dive shat, Throughout the tool guide ports, dilthe internal holding rng (I) using © 35 ‘mn drill for a Simm depth. Fix the tool to the ring tightening the 6 screws specialy provided, FRoced when he (tng the wreED. FeBUARY 008 SECTION 3 DUTY ~INDUSTRIAL APPLICATION. C1 Use acceptable tools (3) (4) and withdraw the extemal holding ring (2) ftom the trent cover () Dr Loosen the screws (I) and remove the front cover (2). “Take note of the screw (I) assembly position, since A th the screws have dflerent lengt Loosen the screws (1) and remove oil pur (2). Figure 135) | S:rew outshe opposite screws (I) from the ports where the withdrawal pins shall be Iroduced (see picture following), CD Loosen remaining fywhesl fing screws (3) to the engine drive shaft (4). Remove the fywheel block too! (2)SECTION -DUTY ~INDUSTRIAL APPUCATION ep Fenny 2a ENGIN 47 Figure 136 1D Screw up wo medium length screws in the ports (4) to sing the Mwheel with a hot. “Throughout two guide pins (2) previously screwed up into the engine drive shat ports (3) control the engine Aywheel wihdraval by means of & hoist Remove the fywheel cover box fing rng using the too! 380000663 (3) to operate onthe back tag (5) ofthe engine drive shaft. Throughout the tool guide ports, dil the internal holding ring usng @ 3,5 mm drilfora Smm depth G1 Fix the toot 380000669 (3) othe tng (I) tightening the 6 screws specially provided (4). Gi Proceed with drawing the ring (1) tightening the screw @. 1 Use acceptable tools (3) () and withdraw the external holding ring of the tlywheol cover box Cr Loosen the screws (2) and remove the fywheel cover box (1) “Take note of the screw () assembly position, since the screws have ferent length Tum the engine upside-down, i Loosen the screws (2), disassemble the plate (3) and Al “The shape and dimensions ofthe pan and ofthe rose [a remove the of pan (1, pipe ray vary according to the engine application. “The relating illustrations provide general guidelines lof the operation to be performed. The procedures described are applicable anywayIC Loosen the screws (|) and disassemble the oil suction rose pipe (3). IC Loosen the screws (2) and remove the stifening plate a Figure (41 oF D1 Loosen the screws (I) and disassemble the gear fromthe camhaft [Loosen the screws (2) and disassemble the timing gearbox (I) J | Take note of the screw (2) assembly position, since Z| the sevens have dierent lengthSECTION3 -DUTY “INDUSTRIAL APFUCATION Installation of application components Figure 143 DIAGRAM SHOWING SEALING LOCTITE 5205 "APPLICATION WITHIN GEARBOX AREAS CD Accurately clean the timing gearbox (I) and the engine bbeck Itis necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal ‘Apply sealing LOCTITE 5205 cn the boxin orderto forma kerbstone ofa few rm. Diameter Itmust be uniform (no crumbs), with no air bisters, ‘thinner or irregular zones. 1X Any eventual imperfection shal be correct as soon a: possible, ‘Avoid using material in excess to seal the joint Too ‘much sealing material would drop out on bath sides (ofthe joint and obstruct hibricant passages, After having competed seal aplication, the joints must be immediately assembled (10-20 minutes time). enone; 49 DIAGRAM SHOWING SCREW TIGHTENING TO FX REAR GEARBOX IC Reassemble to box (I) to the engine block ICD Tighten the fing screws in the same position as found cout during disassembly and fix the screws to the locking couples sted here below. folowing the order as shown in the picture. Screws M2 65 = 89 Nm Screws Me 20 + 28Nm [Screws M10 42 + 52Nm portsandof the screws haveno evidence of tearand [| Before assembly akvays check thatthe threads ofthe 7N\ ‘wear nor dit | Figure 145) (=e (2) With pen marker mark the tooth (1) ofthe diving gear assembled to the engine drive shat with (2) (-») tring notch Screw up two pins to faciitate operation of engine chive shaft rotation,C1 Orient engine dive shat (4) and camshaft (2) takingcare that n phase of assembly of the drive, gear (2) 10 the camshaf, the notches marked on the gears (I and 3) shall mate Figure 147, Tighten the screws (1) fixing the gearto the camshaft (3) and lock them to the prescribed couple. i ey Na DIAGRAM SHOWING SEALING LOCTITE 5205, AFPLICATION, 0. Feu 2008 SECTION3 - DUTY “INDUSTRIAL APPLICATION. Its necessary and essential to clean the surface to be sealed in order to achieve excellent tight sel ‘Apply sealing LOCTITE 5205 onthe boxin oderto forma kerbatone ofa few mm. Diameter must be tuniform (no crumbs), with ne air blisters, thinner or irregular zones, Any eventual imperfection shall be correct as soon 2s possible. ‘Avoid using material in excess to seal the jai, Too ‘much sealing material would drop out on both sides Of the joint and obstruct lubricant passages. ‘After having completed seal application, the joints must be enmediately azzernblec! (10-20 minutes tine). DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX 1D Reasserble the box (I) to the engine Bock, tighten the fing screws inthe same postion as found out during disassembly and fix the screws to the locking couples liked neve below, fllowng the order as shown nthe paure Screws M12 Screws M10 75 + 95Nm 44-2 53Nm Before assembly always check thatthe threads ofthe portsandof the screwshaveno evidence oftearandSECTION -DUTY “INDUSTRIAL APPLICATION. eo.FEURy 208 ecines 51 Figure 152 G Screw up two hooks or tall rings in the fhwhee! (1) ‘threaded ports (4) for handling D1 Usrigahoist handle te fywhee to place itinitshousing inside the fywhnee! cover box. ofthe too 380000666. thi ignoring the screws (a)and || 2 Seer eee “han puis, lee fn i key the new holding ang on t (3), engine flywheel (1) properly placing inside the fywheel 1 Prace detail (1) on detail (5), tighten the serew nut (2) cover box Until complete assembly of the fang ring (3) into the Aywiheel cover box (7) oH Di Apply to engine drive shaft rear tang (6), the deta (5) Figure 151 Fr In case of engine coupling with mechanical gears in ZN) presence of fiction, verify surface status of the [= ywheel and eventually workit outto maintain rated engine flywheel thickness, which is 49,6 + 0,13 mm, | check: the candions of the im tooth (2). Whether toa rea or acenie wear acoced dswemble the rim from the engine fywhee usinga cornmonvillow and replace with a new one, previously heated 10 150°C degrees for I5' + 20: seconds; beveling rust bbe made towards engine flywheel direction, Tighten the screws (4) fing the engine tywheel (3) to the engine shaft, Use 380000908 tool (2) to eperato on. the Sjwheel caver box (I) to block engine fywheel retation,52. ENGINES 0, Feauney 2003 Figure 156 Ea een te ene Bye! (1) fg ere) 9 | IO pop tothe ater p ()anew ing re OI stphacetghtening by means of dnamometrc wrench 40 couple 30 + 40 Nin Faure 157, 1D 2nd phase, 60° + SP angle dell 7 Anele dwell shal avays be performed using, AA accotabie toi Before assembiy alvayscheckthat te threads ofthe portsandofthescrewshveno.adence fear at Sear nor Dy Assemble the water pump (1). Dr Tighten the screws (2) and lock themto the prescribed couple, Figure (55 | Fate 158) Assemble ol pump (1). O Tytenbinesrere@andtakthentetepreciied | JC) famove the fing ng For the font comr (I, accurately clean the plug surface.Figure 159 C Accurately clean the contact surface ofengine blockand apply sealing LOCTITE $205 on it in orcer to form a Uriform and continuous kerbstone with no crumbs ‘Assemble the front cover (2)to theblockandtighten the screws (|) fxing ther to the prescribed couple €.Fousey 2003 |) Flgire 161 INGINES 53, B 7 a OE [= 1D Apply on engine drive shaft front tang (6) the detail (4) ‘ofthe too! ABO000606, cit with the serowes (6) andl Key the new holding ring on it (7). CO Place the detail (2) on the detail (), screw-up the ‘headed nut unti carrying out the complete assernbly of the holding ring (7) to the front cover Dh Assemble the plate (1), the rose pipe (2), tighten the fixing screws (3) and fx them to the prescribed couple54 ENGINES |. Provide for new gosket replacement) ofthe ol pan (2). ‘The pictures ilustrating the pan and ofthe rose pipe ‘may not correspond to the ones of your model. However the procedures described are applicable anyway. C1 Assemble oi pan (1), apply the plate ove it (2). Tighten the screws (2) and lock them to the prescribed couple, Before assembly always check thatthe threads ofthe portsandofthe screwshaveno evidence of tearand DFA 2000 SECTION 3 - DUTY “INDUSTRIAL APPLICATION. DD Assemble the pulley (I) and the dumping fywheel (2) to ‘the dewving shaft Tighten the fxing screws (3) and clamp them to the couple 68 = 7 Nm. Figure 166 O. Fita new seating ring on the speed sensor (3) (i ted). D1 Fit the speed senzor (3) on the front cover (I) and sighten the screw (2) to the specied torque (ited). | Fue 167 i Assemble the following elements to the blode new gasket (I), heat exchanger (2), new gasket (3), ol flter bearing 4). “Tiehten the screws (5) and lock them to the prescribed couple. A Before assembly aways check thatthe threads ofthe portsand ofthe srewshaveno evidence oftearand ‘wear nor ditN13 -OUTY ~INDUSTRAL APPLICATION Figure 168 Ci Lubricate the fing rng (2) using engine oil and place it fon the ol iter (3) Manual start the ol iter) on the bearing union (1) Until counter-borng, further screw up the ol fer (3) by 34 turn. Cl Apply. (iF needed) new fing ring on the oll ‘emperature/pressure sensor (4) and assemble itto the beating (I) tightening the xing screws to the prescribed couple. Gh Tiehten the screw (5) and lock it to the prescribed couple In some applications the bearing of the exchanger all be assembled to a screw threaded union connected to the fiter on the opposite side of the “engine, throughout twa pipelines (zee Figure 105), 1D Prace a new fing rng on the block housing (6) DD Assemble the alternator bearing (I) enauring that the pins (3 and 4) are against the engine block. Tighten the screws (2) and lock therm to the prescribed couple. ep Femuany om mNGNES 55 Before assem. abvayscheck that the threads ofthe ports and ofthe screws havena evidence oftearand ‘wear nor drt. Oy Reassemble the alternator (I). Tighten the serew (2) and lock it to the prescribed couple. Figure I71 Ret the atemator (I) 1 Tighten the screw (2) to the specified torqueDr Refit the automatic bet tensioner (2) Cr Tighten the screw (3) tothe specified torque, Turn the automatic belt tensioner (2) to ft the belt (I) | on pulleys and puide rollers, DD Assemble alternator saety suard In case the sare belt priory removed i azerbled again, proceed examining it carefully to check there [Dd Place the gasket (I) over the block The choice ofthe gaskets thickness shall be made in consideration ofthe cyinder protrusion measured with respect to the block’ upper surface. AN Verify thatthe engine block stand is clean, Do not grease the gasket isrecommmended tokeep the gasket inside packaging until assembly to the cylinder head Gasket assembly shall be made following. the direction of wording printed on the gasket itseif so ‘that this willbe readable as indicated in the pictur. ep. 208 Figure 174 Dr Flace the head (3) over the block and insert screws (I) and (2), J. | Hfthe vals have been removed fom the head. itis ZN | necessary to assemble them before asserting the SEM ead felon the engine Block Fear 175 (<= FS 189 00 49 19 50 Bo 10 ne 200 Dy Lubricate cylinder head bots and install to head. D1 Eotts must be torqued using stitching pattern starting vith the centre bolts and moiing out, Bolts to be torqued n stages: all bots torqued to snug torque, then 50 degrees rotation forall bolts. Then a further 90 cegrees for the M2 x 140.and M12 x 180, MI2x70 50Nm +90 deg’s Mi2x 140 40'Nm + [80 deg’ MI2x 180 701Nm + 180 degSECTION 3 -DUTY “INDUSTRIAL APPUCATION Figure 176 f l € ROCKER ARM UNIT COMPONENTS: |. Esti ing ~2, Spacer=3, Rocker arms~ 4 Support. Gi Carry outthe assembly ofthe rockerarms after previous check of the components Gy @ s.975 18.963, SHAFT AND ROCKER ARM BASIC DATA (Chedkthe coupling surfaces ofbearingand shaft:no evidence cof excessive wear shall be detected or damages, Replace if necessary. FD FESUARY 008 BNGNES 57 a a) ROCKER ARM ADJUSTMENT SCREW unscrewed, check adjustment quota Tighten the serew-threaded nut (I) to the 1025 ~075 Nm couple. Figure 179. 7 | a] Before executing assembly, check the Rocker Arm ding rods these shall not be deformed, the spherical ends in Contact with the Rocker Armadjustmert screw and withthe ‘appet (arrows) shall not present evidence of scare oF wearin case of detection proceed replacing therm “The rods diving the suction and exhaust valves are idertcal and therefore mterchangeasle58 ENGNES ED. FeBUARY 2003 SECTION 3 -DUTY INDUSTRIAL APPLICATION C1 insert the tappet driving rods and the Rocker Arm unit Before using the fing screws again, measure them twice a indicated nthe picture, checking DI and D2 dameters: if D1 -02<01 mmthe screw can be utilized again; if D1 —D2> 0,1 mn the serew must be replaced: ‘Adjust the slack between rockerarmsand ales using socket ‘wrerch (1), point wrench (3) and feeter gauge (2). Coneet working slack ie suction valves 030 005 mm exhaust vals 055 + O05 mem, In order carry out a quicker adjustment of the working. slack’ between rocker arms and valves proceed a: folowing: Rotate the engine dive shaft, balance the vahes of ‘finder | and adjust the valves identified by star symbol, as indicated in the following table: Gham [iL] 2>s [4.3.6 Sudion ~L* *p-[- Exhoust Cs es Rotate the engine driveshaft of 360 deg, balance the valves ofeyiinder 6 andadjus the valves identiied by star symbol, as indicated inthe following table: Giern [7] 2ps paps ye Suction =[-[*[- © 1 Tighten the screws (2) to the prescribed couple and | |f Exhaust =e bebe be assemble water temperature sensor (I)SECTIONN3 -DUTY “INDUSTRIAL APPLICATION 1 Asparlehieors ater hee oped the sang asket During assembly of injectors, verify that the injector sphere is correctly postioned on the head housing. Cr Assembie clndercovers (2) with the respective gaskets; Fite seat nds and tighten the screws (1) fing therm ‘0 the prescribed couph Ep. Feaunny 2002 | fia) ENGINES 59 ‘Always replace the gaskets using new ones ‘Check the threads ofthe fing crews there shallbe no evidence of wear or dirt deport. ‘Seal nods shall have no visible deformation In such case provide for replacernent with new nods. 1 Assemble exhaust manifold () providing new gaskets ®. Figure 186 Ey cD Gy Assemble thermostat unt (2) including thermostat (5) and gasket (4). Di Tighten the serews to the prescribed couple, AN “The screws (I) have been have been utilised to fix the bracket (3). Disassemble the bracket and reassemble Components from | to Sas shown in the picture ‘The gasket (4) must be new.60 ENGINES Figure 187 Do Appty on the surface joining the suction manifold plate (I) the gasket (3) and provide. Fring the screws (2) to the prescribed couple 1D Ifthe pipe (7) of the suction manifold plate (I) has been removed, reassemble after having ft anew gasket (6) [Tighten the screws (8) to the prescribed couple. For the versions provided with heater, also asserrHle components (4) and (5) Faure 188 | (Se) Dh Ako assemble the brackets (I) firing the fuel pipeines 4o the injectors: use the same screws (2) focng the manifold plate as shown in the picture. Dr Aso assemble feed pump (see specie procedure) and ‘he power take-off underneath. Fee Purp womb requires specie procedure ae | reported at the end ofthe hereby section 1D Assemble the pipes (I) and (2) providing fuel feed and covery between pump and injectors Screw up the locking nuts and tighten the screws fing the fuel recovery manifoldSECTION - DUTY ~INDUSTRI APPLICATION .Feauney 200 ENGINES 61 Figure 192 to the injectors throughout the brackets bled (eng screw |, Fgure 190 and 2, Cr Fix the LDA pipeline (1) to the engine head and to the feed purnp,6 eNcines | Ch Assemble the fuel fter bearing (4) to the bracket fed LT tothe engine head (Connect the fuel pipelines (2 and 3) respectively from priming pump to fiter bearing and from this last one to feed pump. 1 Use acceptable tools to instal uel iter (0 “The fiter shall be priory filed with fuel to faciitate feed system bleed operations “To connect ful pipelines (2and 3,Figure 194) in low pressure from the relating connection unions # is necessary to press the locking fastener (I) as shown in picture B. ‘After having connected the pipeline, reset the fastener (I) into block position as shown in picture A ep Fen 2am SECTION 3 -DUTY ~ INDUSTRIAL APPUCATION, Proceed assembling the turbocharger Hold the turbocharger and place it on the exhaust manifold afer having interposed the gasket. Screw up the fixing nuts (2) ofthe turbocharger to the ferhaust manifold tightening them to the prescribed couple, Da Tighten the lubrication pipe fone ring, Operate inthe same way on the other end of the pipe. Connect it to the upper part of the heat exchanger Assemble the turbocharger lubrication exhaust pipe by tightening the screws (3); connect the endo the engine block. “To complete engine assembly itis necessary to remove it fromthe turning stand. Use acceptable tools to hold the engine and loosen the| soraws fixing the brackets to the turing stan Disascemble the brackets from the engine after having properly put it on a wooden bearing,SECTION 3- DUTY ~ INDUSTRIAL APRICAION ep, FERUARY 2002 ENGINES 63 ‘Completion of the engine Figure 197 cian (@) NE z (On the right hond side: reassemble the pipes (1) from the union (2) to the Lubrication oil fier (laced onthe opposite side: lighien the pipe rings (1) and connec them to the union TT. | i some cazes, he oie (3) is ret placed on eer |G Reossemble he lubrication oll exhous pipeline (1 from th trbochorge: om underneath the fubocharger the two screws (2); ighton the screw (3) fixing te piplin fo the och oughout th ing ol tothe bloc; finaly ighlen the union (5) 1 the blockFigure 199 [CReassembete starter;properyholdthestarterIjand | tighten the fang screw! 2) to the presenbed couple D Femunny a SECTION 3 -DUTY ~INDUSTRIAL APPUCATION [On the left hand sider LD Assemble oil fiter (I) together with bracket (for the Sersions with engine ol Bter not directly assembled to the exchanger); tighten the screws (3) assembing the tracket (4) including fiter bearing (5) Use acceptable tools to install fiter: Assemble cilleve rod together with guide pipe (2). Fllup engine of 1D histal the engine on the machine (for instalation cperations please apply to speci issue)SECTION 3 ~DUTY INDUSTRIAL APPLICATION Feed pump unit assembly and disassembly procedure “This procedure prescribes that: Ci The fel pipeines (rom purping elements to sectors bleedng recovery pes Fomnjectors | 46 pump, LOA pipeline and feed provided by | priming pulp) shal allbe dzsscerbled 1 Electrical connection to feed pump shal be | dsconnected Cr Accelerator cable shall be disconnected In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part, ‘On the other hand, incase the pump shal be disassembled and reaceerrbled later on without being repaired # wil be Necessary to pr-setit while i is stil assembled tothe engine and deaseemble only aRerwards ‘The following procedure analyses this second hypothesis since itis the more complex, Disassemble the starter from the flywheel box (1) and tse the 380000888 tool (2) 10 rotate the fywheot. eo Feauney 202 eNones 65 1D Disassemble hexagon (1) shaped cap for the speed ‘gauge box andthe pin (2) underneath, C1 Verify, checking throug the hole of the box, that the reference index of the gauge unit is dsphyed66 ENN: Figure 204 2 Rotate with caution the flywheel following its own ih mean ‘time keep the (—) pin pressed until when this last one. Cetra ae emer oo Pera ose vaeera 7 sects alin rie cin are oe SECTION 3 -DUTY INDUSTRIAL AFPUCATION, [Cr Pugh the previously removed pin into the gauge housing following the direction indicate in the fgure. “he pin (2) shall be pluged until end of stroke to bindthe index and lock rotation of the pumps camshaft Assemble hexagon shaped cap (1).SECTION 3 ~DUTY ~INDUSTRIAL APPUCATION Fp. Feauney na ENGINES 67 From timing side, remove the cover (2) lootening the screws (I) in orderto have access to the union fing nut (@)10 the pump driving gear DD Loosen the fixing nut (3) and removethe relating washer D From the pump side, loosen the fing nuts (1) without removing them in order to enable moving the purnp backwards using 380000878 extractor D1 Assemble the 360000979 extractor throughout the two ‘threaded ports (4, Figure 206) and withdraw the gear from the pump shaft C1 Hots the toed pump using acceptable tools and unserow completely the fxng nuts | Withdraw the pump ffom the holding studs together with the gasket. bn these conditionsthe pump is pre-set and can be assembled to the engine further WwW ‘When assembling the fed pump tothe engine itisnecessary to meet the PMS, requirements for the NI cylinder Use the 3180000968 100! (2) onthe twwhol box () to-carry aut fywhee! ratation and operate using the pin as previously described. ] Hold the pump drivin gear to avoid interference or crawling. during timing gear rotation. Hola the feed pump using acceptable tools and assemble it (pre set pump) to the engine in ts housing: insert the camshaft capule into the port ofthe purnps driving gear {not provided with key) Di Tighten the fixing nuts (1) centering and locking the pump’ Mange within the sot. “The gasket removed during purnp disassembly shall not be utilised again ‘Always use orignal spare parts,eb. FeBUARY 2a iss) On the tiring side, throughout the specialy appointed port ft the washer and screw up the foing nut (3) to the ump shaft, Lock the nut to the 90-95 Nm couple. Remove the hexagon shaped cap (I) from the speed rexagen shaped cap Pe gauge box and withdraw lockng pin (2) from the camshaft 1 Tun the locking pin (2) upsidedown and place i in its housing: this operation enables free rotation of the pumps camshaft. Cl Assemble the hexagon shaped cap (I) to the speed gauge box SECTION 3 “DUTY ~INDUSTRIAL APRUCATION, Cr Assemble the cover (2, Figure 210) including gasket and tighten the screws (I, Figure 210) Palle pin outwards setting the camehaft gear free Femove the 360000906 too! locking flywhee! rotation place the starter in its housing Connect all pipelines (fom pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline (1) and feed provided by priming pump and libration pipsines) ‘Connect electrical switch devices to engine stop. In case pump removal hasbeen caried out while the engine was assembled, connect acceleration cableSECTION 3~ DUTY ~ INDUSTRIAL APPUCATION ED Feswnyz002 ENGINES 69 Feed system bleed procedure Figure 219 ony operation hos been exsculed on he componenis ioe cir, it is necessary 10 execule bleeding of air within the syste, Loosen the bleeder vent screws (1) on the Ive! filer supports Switch starter revolution on, activating the priming pump and driving fuel delivery tothe files. (. Continve excuting this operation until when fuel drains from the Bleeder ven screws, then tighlen the screws. | Power take-off disassembly and assembly procedure Figuie214 | ie] Ey ‘Where designed, there is © power toke-of able fo rans motion to diferent ously parks Dicossombly of such mochonism shall be exscvied os following Loosen the io screws (8) and aflerhoving removed he cover (1) wth e specially provided exroctr, withdraw ‘he power ioke-ot (2) 1 The two goskets (4) shell be replaced in phase of reassemble TD Vory out the assembly fing the power toke-off in is housing, providing new gaskel ond checking the sprocket ‘gear meshing [Assemble cover ond gasket and tighten the screws othe prescribed couse. (Checks and controls The following tests sholl be made after engine cossombly fo the vehicle. Preventively check that the liquid lovels hove been correcily restored. Slart the engine, let it run af revolution regimen slighily higher than idling ond wait that the cooling liquid’ tempercture reaches the value enabling thermostat opening, then check that [There is no water bleeding from the manifolds connecting engine cooling circuit pipelines ond cabin inleral heating, eventvolly providing 1 further ighien the locking rings A Corefully check the fuel connection pipes to the respective unions. (2) There is no oil leakage from the lubrication circuit of the vorious pipelines connecting cover ond. 1D Ghlinder head, oil pan ond beoring, ol fitter ond heat ‘exchanger os well a¢ reeling housings. (There is no fuel leckoge from fvel pipelines. |) There is no blowby from pneumatic pipes lif provided), Di Verify correct working of the lighting leds of the doshboord containing the tools as well as of the ‘equipment thot wos disconnected during engine disconnection. A Check and blow by with care the engine cooling system, corying out frequent droinage70 eNeaINes 0, FepunRy 09 SECTION 3 ~DUTY ~INDUSTRIAL APPLICATION.‘SECTION 3 -DUTY ~INDUSTRIA. APPLICATION eo. reauney 200 Moros 71 TIGHTENING TORQUE (FOR 4 AND 6 CYL) ‘COMPONENT TORQUE z = hin ign ‘Cooling Nozzles (MEX125xI0) - Bas 15 #03 ‘Main bearing cap Tat sage 3086 50#06 Ind stag B26 80406 3rd stage 90 25° Rear gear housing assembly (8x1 25x40) Med 24204 (Max! 25x25) Med D4 204 (10x15) 4985 49205 (Oi pump (MBI 25330) axl 08 #01 Front cover assembly (8x1. 25x45) wed 24204 (M8x1.25x30) Ded 24204 ‘Connecting rod bolt(MI 1x1 25) Ist stage 3023 30203 2nd stags 6085 60205 3rd stage worese Ladder fare asseribly (MIOX1 25x25) Bes 43208 Oi rifle plugs (Mio!) eel 06 £01 (Mia) We lt £02 ‘Assemble ol suction tube (M1 25520) Wet 2a zoA Oi pan assembly (M8x1.25%25) ded 24204 (iss 50) x9 60408 Setting pin Sat O5=01 Fuel pump assembly MB screw ded 2d x04 Me serew lox! Toxo! M6 nut lost 10201 MIOKI.S ange head nuts pre-torque 10-15 i 50-55 50-55 Fuel pump gear (drive gear nut) Saug tome 15-20 15=20 Fral torque 85 -90 85-90 “Tening pin cap of fuel pump 7 30-35 30-35 Rocker assys (MB) - ted ‘Cylinder head bolts (M1270) 50 +90° 50 + 90° (MI2x140) 40 + 180° 40+ 120° (I2x180) 70+ 180° 70+ 180° ‘Assy rocker covers (MBx1 25x25) ded 2A = Od Intake manifold (M8x-25) Med aed ‘Assy air intake connection (Mel 25) ded As 04 (Oil bypass valve into libefiter head (M22x1 5x10) ‘w28 80 +08 Plug (M121 5x12) T= | [o=0i Exhaust maniford (MIOx1 5x65) Be6 43206 ‘Water pump (M8x1 25x25) Bed 2Az04 Water outlet connection (8.25438) ded 24x04 (M8«1.25%70) ded 2Ax04 Fan support (MIOx! 5x20) aes 33205 Fan alley (M6) loe2 low 02 (ei) Bee 4320672 oroR 0, Feaunny 2003 SECTION 3 -DUTY —INDUSTRIAL APPUCATION ‘COMPONENT TORQUE No len Rear ling bracket (FID. 75%30) We Tsi2 “Crahaft pulley (Mid 75<109) T0=5 11005 Fywheel housing (rt2«120) 85210 85210 (041280) 85 x10 85210 (041080) ws 49205 (1040) was 4905 Fiywhes housing (412x125) Tet tage wed 30204 Ind stage ras ‘Assy rear cover plate Uo fywheel housing (MB xd 25x16) wed Daxod Fuel injectors a5 60205 Fuel it pur | BES) 2a z04 “Turbocharger to exhaust manifold (M10) Bab 43206 Oil feed o ol fiter head a4 24=04 Gil feed to turbocharger (MIDI) 35 35205 Oil dra (Mx. 25%18) = a4 24204 “Aerator to altemator suppor (MBxd.25%30) ad 2404 “Altematorto water inlet conn assy (Mx 2530) Wad 2404 Lower aerator mounting (MIOxl-25%25) re] 24204 ‘Aterator upper pivot to support (F110) Hes 49 05 “Atterator mounting hardware (M12. 755120) B26 4306 “Alternator wiring (M6xI nt) to? 1002 Starter motor to gear case (MIO) a5 49205SECTION 3 - DUTY -NOUSTRIAL APPLICATION. ED FERUARY 2001 PART TWO ~ ELECTRICAL EQUIPMENT ENGINES B” ENGINES FD. FEBUARY 2003 SECTION 3 -DUTY “INDUSTRIAL AFPUCATION,FemuaRy 2m ELECTRICAL COMPONET LAYOUT (4 CYL. ENGINES WITH ROTARY POMP) Figure 215 “The electrical components provided with FABEO484 Engine are listed here folowing: 1. Cooling liquid ternperature sensor; 2 Starter; 3, KSB Water temperature sensor; 4 Electromagnets assembled to feed pump: (A) on hydraulic head unit (8) on KSB; Fuel heater: pressure switch; Resistor for cold start (whether specifically designed) Alternator76 ENONES SECTION 3 -DUTY “INDUSTRIAL APPLICATION, Cooling liquid temperature sensor Starter Figure 216 Figure 217, Ie isa component integrating a temperature sensor It is assembled to the engine head close to the thermostat Uunitandits duty isto detect engine cooling quid temperatu- Specitications Range of working temperatures: ‘Connection side “40 4 +150°C for < 10 min, Bulb side on engine: “40+ +140°C Workingtensions 6 +28 Settings: Bore 0304 +0342 k0 2orc 2.262 + 27602 lore 8244 + 10661 KO Starferie usually driven by tarting unt placed on the vehicle 284p OF pur aLasauC ‘éund yu sise ye ainve oy sas04 ait >peuD | woRla 10 sau fry aMp w SoRANG ay ‘dand Jajsuen 20 ory ap a2eydas 40 MeWEO) ‘adds sad ON, BAY ue BFY ON wwars4s pa} UEIQ jpryss puE yum way ie aru! -2y duund vonsafur stp uesp pur apueusig| fe passaidusco jo a 2 usr ways usp ple ex0Y aig D=WU0251q) um any aia U JoreM.10 sysodog, 2989p sno 995 “dan onze aiy aun Aj2aui0> pur »pa4D ‘dnd uonrala jo Busy pawio>y ‘Papouo> Aenea nu ain pu eu sy ape aig apeday ‘seuu Kong yuo rina a ui pure Sue u pepaio> semua Avene 01 SuoRDSULED “Kreseoeu List eq spejdoy soneg aBseypas pue 32D ane 20 ey og 1L8 JOU se0p augue ou | BION. ACaLER BSNVD ST@SSOd ‘AIWWONYSECTION 3 -DUTY ~INDUSTRIAL APPLICATION. ED. FeRUARY 2002 ‘Buneos prey Jepu fo sigazedasso Aqpas sanenaigareday seven Sep 40 papetso> "wing says Bupedas fo sauesee> snip snadén pur sue RGU vsOMaq sUReE RULOUIY ‘sed Ging oun soeroy ‘jae? duund uoppalu uaa st 4s uonselu pur ary 2 Use Jo anus “apsreoau) aed pur SURUI Bey By PBODD| wares pa} weg Tarye) pue ue [pay woy seqem asouny duind uossalur eta Lapp pur apuewsic) se passaiduica jo l= Bugn woun Ueap pur s9s0y aig >sUUO>SC, souy jy alg Joye 40 sanuincy Tap nek 395 "ma SY ‘duird uopoatijo oy eF BSI "wipe WeURSTibe un ISrIP m9] 003 wd ap no si sudue aus apaii0ou Buneiado jon sejap sno 205| _duund vol sip sneds! 0 4D] -uod soup Hsed8 p09 205 29 BSA sus jay sup azeday seuraeieduiy 0} [38381204 GENS ony ea ony aug a2e day Tony agexnsun jo asn aug o1 arp Buusioy seis uyered um pada warsts jong seumeied ua} mo] 32 LEE ou Soop sue SUL ION ACID 6Nvo FUgIssOd ‘EIWHONYMorar FD FERUARY 205, SECTION - DUTY “INDUSTRIAL APPLICATION, wR|e=p INeK a95| sore Bas ip ayeiqye> fpeu0> pue>paL0 | ‘ojeyrBas paads 0 vonesqye> pauieoU) “duund vouselu ened 1929810 eae UoIsd ase “duund uonsely axed s0 9240 | Banepa jew a2vep e2uenpe pioa uawoune BSN “duund ves Appauo> pue Bun 7p24> ‘duund vogpelu Jo Sun awio>4) samod ‘92| pure sees} uoneiedo aug “kaessa00u y soe! 40 Jay AP 24 WD) Peon sauRap ae LG) ai2=p snot 995 aye eds ayes uoIDalu axa ein 05 (pug 2 uo duind aig 40 9321 anyap ayn paL05| “duurd vorpelu Jo voneiqre> pauioay ‘Aypauios sum pue Bun 734) oan audue paueauy "uROSS LAR sop dr-doy, 70] 08 AS] SURIOOD | a2nap ons Jo Buyaiom ye1s09 2payp uauossua| yrewionre uy pepwoid suonesidde UO) 116g 2440 ssounyfa aun snipe pue 94D) ;Pasn pou Buyessep jo 2d oan 4) paypads sprepuns a4: Bumojay WEEN qmroueyr ag eerie asouiay SuUODUTVEN oped an ood -3y Auessooau y 229dau puBYUN 218 99ALD ‘dnd sagem Ayneg saayono oudus au | LON | ACH SNVD STEISSOd ‘ATWHONYSECTION 3 -DUTY ~INDUSTRAL APPLICATION, 0, FepUNRy ona 88 MoTOR Ba|eap unos 39g ‘flue payoeds aig w sinano oIDal] su yep 0s dund aig0 dh-es ey 2aN0 ‘duund voupefu jo dr-aas 214004} ‘paiuep Asnoues ase mip asoup eam “payparg sau rg suo} jo uoneiedo Ayre Bunpouy euuouge Yom Suns 9483 PuRUUOD ayp BUA CF sposen ay pparenpe Ajauioou J2%9] uonen8 -21pue pad soyes9;2078 usaNaq spOu SL | veyeap_snas 29g 'uOWpUo> peo} ry Japun ws sua 2 0} uonzas “Usunesaid se ayenbape aaynap "OT yo uopesede Ayney See yon aad: sea sabewpocpra Aye {eid pace pue spain “sadde| ue sue yeusure> uaenieg Meld 3911090} sumete pany usp (aese999u 3) IPAs pur wisps aup Leap ArySIED uate uop2afa pu any ap Ul aye Jo saqunau Suonela a] reyiano Karaidiso> pue soon axtidoudde | suo natu jo uote sawed yp Zusn sreswuoyeunjo sazz0U YR URED | Jado Ayne} 10 sa7z0U Jo aBBPOR feNeY| ye) PUR sepBauu | uonesado BURL LON Cab ‘snv9 71818804 AIWWONY.o.FeaunRy 200 ~dund ‘dh-jas a1g 321105 | uoppalu aun uo Aap anssanxe ues 204 | [RPGR aif Ul PSaLDSOp #8 AsO Buon op asnipe pur seisat e fq uoneiedo >9a10)| -Duryeutio uomeiqye> jo n0 s208P ESN ‘age uoReiqi © o1p u uonS exp ata uum eouepioase “yous i809 ‘SECTION3 - DUTY ~INDUSTRIAL APPLICATION sijeap snk a9s| uy Asanjapsenfpe pue duund arp auvo>siG) andyno dnd wnuipeu angie | 10 299g Ayeuulouge serous suse Sul “Bugzes pur syaddey| ‘sep enen su pue swas aned a Uae -3q fed snsseoxe Ou 51 sia 4p Bud vayoxq ou av avaia eta »payp pur ade | UR sue yeypure> uaas2q jd a4 snp uu Asn ‘Buyeng mau yum ara sBugees pou aip ur sBuysne 35007 ‘uysng peu pue| Buying pos aup u pue sqny uossd Jo Aer vorsid atgso,purreuinol uoisd ayiazedoy | anssamx oxanp seuinol usd wu04) 290N ‘sp01 ain somday| spouyo waunulyes,| ‘racy paysads ap oF sa.38 ay Ue UaYBnpuesMalns pauesoo| aazeday| ayy Buunose swans yo ByLas007| “yaypuen jo wane >paLp | PaDUEIEQUN YEUSHUED 1 ‘iapynoys Uo fed anse92%0 49] seu sug ain s2e{day “sBueeq s9yeuis|sBuureoq pau 40 uu! ajoU 40 30 uo Aad : TRU pur yeysquern aiayo sud aig Ajzoay anstaaxs Busme> yeysiuei> Jo Buppouy| —Buppouy jeuuouce yyss Suuuns auBU BON AgaWa4 asnvo aTaIss04 IWWONYSECTION 3 -DUTY INDUSTRIAL APPUICATION. Ep. Feauny oa Tesouuayn au sree oy J2puro aig voupuorsy | -u.20 perpoig yexouuag) poo 00% au on | “suas a 40 sepin8 so Sura Sumo} aj sener-soping| Bre aa brown Bussed yo euluy ‘ouBue oun mewionc) 9 9p -o jo Busrom 10 $844 worn so pan 4] besne> sBuy uoud oun was vo Jo Bu Topsla anne ‘esol anes Basonouny sajeop nok 995 curd vorsfu soe 10 e245) Bu sonop soURpE pes aaRWOTE BEY a saqeap snot 995 chun xp jo dns 213138400) “und uonsaly ufjp anssong | yn 0: Eupuen ous fd ‘ong fai 'og -Buspoyg parzed ‘nou 24 apeas Auesoseu azoys| 34 04 anp potpusd sato4 jo pu2 seu pur sutunso pub ho sUoRpunD JaeND | eu AEIMEUN Ue YM sary UoRAle Page> AS02410 #04 ‘vopefu! ag aeiqy> 10 aneday|-2oluyo sada warayp sonata ageuneUn Poisnipe [peg 10 peisoURI sane ‘ia sopuyo use ssurd anpee aig 03 sv08 ‘s8us agnay lo% 10 »pms -vaniqu aig yuo Suu ap ean | 04 arp aula avg u Uossasdate> Jo S507 “yan Jeyy ag aoedal10 veaD] __palRIOUBIAP 10 pepo BLAS AY ‘uauidnbo arin Buen U0 reuduo aig Ama pue weap 10 soisla| pape Aaique 10 Ayes are (us. - nau jo soles ei sioDeu! ait a>edoy|Jo vos 40) seEUuONE ay UL SOY SUL 7 vous (a8 109 “én ayn neuen |-pe ayttona ue sey dund vom aul] 40 »pmg Mmwouge soyeu susue ouL| 310N Aaa B5NWO TIBISSOd I KWHONYSECTION 3 DUTY “INDUSTRIAL AFPLICATION 0, FUARY 203, avones 91 PART FOUR ~ MAINTENANCE PLANNINGENGNES FD. FEBUARY 2on3 SECTION 3 ~DUTY INDUSTRIAL APPUCATIONSECTION 3 “DUTY ~INDUSTIUAL APPLICATION .FesuaRy zon ENGINES 93 MAINTENANCE PLANNING Recovery “To ensure optimised working conditions inthe following pages we are proving instructions forthe overhaul controlintervertion, checks and setting operations that must be performed on the engine at due planned dates “The frequency ofthe maintenance operationssjustan indication since the use ofthe engine isthe main characteristic to determine land evaluate replacements and ded. Itismot only allowed butracommendet thatthe stain charge of he maintenance should also carry outthenecessary maintenance ‘and controling operations even ifnot being nehided inthe ones ited here below bu that may be suggested by commen sere {and by the specie conditions in which the engine is run. Planning of controls and periodical Controls and periodical intervention Frequency (hours) Visual check of engine : Daily (Check presence of water in fuel ter or pre-fiter Daily (Check of belt wear status - (Check and setting of tppet clearance 4000 Replacement of engine's oil and fiter 500 Replacement of fuel pre-fiter . +000 Replacement of fuel fiter 500 Replacement of bet 1500 ‘The frequency of the maintenance operationsisjust anindication since the use ofthe engine isthe main characteristic IN| 10 determine and evahate replacements and checks The maintenance operations are vad only ifthe setter fully complies with all the nstallation prescriptions Furthermore the users assembled by the setter shal alvays be in conformance to couple, power and number ofturns bbased on which the engine has bean designed,94° ENGINES 0. FEBUARY 005, SECTION 3 ~DUTY ~ INDUSTRIAL APPLICATION. Checks not included in maintenance planning-daily checks | Ikisa goodhabitto execute, before engine tata series of imple checks hat might represent valid warranty to avoidinconven- ences even serious, curing engine running Such checks are sally up to the operators and to the vehicle's drivers. “Level controls and checks of any eventual leakage ffom the fuel, cooling and lubricating crits Notify the maintenance if any inconvenience i detected of i any fillngis necessary. After engine start and wile engine is running, proceed with the following checks and control: ~ check presence of any eventual leakage from the fuel, cooling and lubrcating circuits Verify absence of noise or unusual rattle during engine working, erty tsing the vehicle devices the prescribed pressure temperature and other parameters. Visual check of fumes (colour of exhaust emissions) Visual check of cooling quid level, inthe expansion tank. MAINTENANCE PROCEDURES - CHECKS. Figure 234 [AND CONTROLS Engine oil level check. The check must be executed when the engine is disconnected and possbly cool The check can be made using the specially provided fxiblerod Os MIN “Toprovide fing, operate through the upper top (I) or through | ‘the leteral top (2). During fling operation, the tops must be re ‘moved as well asthe rodin order to make the cl flow easier Some applicationsare equipped with level transmitter alerting | dashboard instruments in case of insufficient lubrication oll within the pan. “The engine oil is highly polluting and harmful K Draw off therod omits slot andcheck thatthe levelis within 1 caso ct contact withthe skin ins well with the etched tgs of minimum and maxima level and detergent. Whether it should be cificut to make the evaluation, proceed cleaning the rod using a dean cloth with no raggrindingand put ‘Adaquately protect the skin and the eyes, operate in tbackin its slot Draw it off again and check the level ful compliance with safety regulations Incase the level resltsbing lose to the tag showingminimum Pee dae eee level, provide fling lbreation of the engine's components Pas uti the torardcegaktoneta faceSECTION 3- DUTY -INDUSTIVAL AFPUCATION Ep. FauARY 2m ENGNES 95, Check of fuel system The check must be executed both when the engine discon: nected and when it ® unning “The check operation consists in examining the fue pipelines running from the tak: to the prefer (ifprouidedin te specie equipment, to the fer, to the injection pump andto the injec Cooling system check “The check must be executed both when the engine discon- ‘ected and when itis running. ‘Check the pipelines from the engine tothe radiator from the ‘expansion tankand vice-versa Find outany blow-by ventythe status ofthe pipes specially close to the hoking strips. Verify thatthe radiator i clean, the correct working ofthe fan Aywheals, the presence of any leakage from the connectors, om the manifold and fom the racating unt, Due to the high temperatures achieved by the 5ys- tom, do not operate immediately after the engine’ disconnection, but wat forthe time deemed necess- ary forthe cooling, pressure jet of cooling quid “The density of the cooling quid must be hacked any how ‘every year before winter season and be replaced in any cae every wo year Ih case of new filling, proceed bleeding system, ‘through the bleeds on the engine, 7X | bleeding ofthe system is not caried out, serious in- | conwenience might be caused to the engine due to the presence of ai pockets inthe engine'shead. Protect the eyes and the skin from any eventual high | Lubricating system check The check must be executed both when the engine diecon- nected and when i is turning, Veritythe presence ofany oilleakage or blow-by Fom thehead, from the engine pan of from the heat exchanger The engine oli highly polluting and harmful In case of contact with the skin, rinse well with water and detergent. ‘Adequately protect the skin and the eyes, operate in ful compliance with safety regulations Disposal must be carried outproperly. and in fll com pliance with the law and regulations in force Check of water presence within fuel filter or precfilter “The components ofthe sytem can he damaged very uicly in presence of water er impurity within the fuel. AN aN Timely proceed operating onthe pre-fiter (not aval- able on the engine block) to carry out the drainage fof the water within the feed crcut. Fuel fiter is equipped with pump screw-vale to drain the water eventually mixed with fuel (some applications of 6 cyin- ders engines willbe equipped with two fue fits, both pro- vided with drainage, Place a container undemeath the iter and slightly Ioosen the screw Drain the water eventualy contaned nthe fte’sbot- tom. Lock the screw (max 0.5 Nm locking couple) 3s soon a fue! starts Bleeding96 vanes Check of drive belt tensioning. Some applications are equipped with an automatic tensioner shat provides correcting belt tensioning Check of belt's tear and wear status Carefully verify the alt surfacein order to detect any sign of Incision, crack, excessive wearin correspondence of toothing; check end and surface grinding Danger: ifthe engine isswitched offbutis still hot, un. ‘expected motion of the belt may occur, Wit fr engine temperature cooling a a precaution in order to avoid serious danger injury, IN Check and setting of tappet clearance SECTION 3 ~DUTY INDUSTRIAL AFFUCATION. Inorder to more quickly perform the operating clear- ance adjustment for rocker arms - valves, proceed as follows: rotate the drive shaft balance cylinder I valves and adjust the valves marked by the asterisk as shown in ‘he table yin a inte cuales a TT exhaust =e Rotate the drive shaft of 360 deg, balance ofinder 6 ‘valve and adjust the valves marked bythe asterisks shown in the table finder. TTsTF Tse [extwust | Engine with 4 cyinder:rotate the drive shaft balance ‘finder I valves and adjust the valves marked by the azteris as shown in the table: inden To 2 3s 74 intake aes eae = exhaust Ea ae ‘Adjust clearance between rockers and valves using setscrew ‘wrench (1), box wrench (3) and feeler gauge (2). ‘Working clearance shall be a fellows: intake valves 030 = 0.05 mm = exhaust valves 055 # 0.05 mm, Rotate the drive shaft of 360 deg, balance cinder 4 ‘valves and adjust the vals marked by the asterisks shown in the table ender n, TPs] 4 intake =e Te exhaust =a [aron) anewSECTION 3 ~DUTY ~ NDUSTRIAL APPLICATION 0, FERUARY 2002 evones 97 ‘Oil motor and filter replacement Waring, We recommend to wear proper protec- ‘ons because ofhigh motor service temperature, ‘The motor oll reaches very high temperature: you must always wear protection gloves. Due to the several applications, the pan shape and the oil quantity can change slightly However, the folowing operations are vald forall applications. \Werecommendto carry out the oildrainage when themotor ichot Place a proper container forthe oil collecting under the an connected wit the drain pve Cr Unscrew the plug and then take out the control dipsck andthe inserting plug to ease the downflow ofthe lubrica tion ai ‘The oil motor is very pollutant and harmful In case of contact with the skin, wash with much water and detergent Protect properly skin and eyes: operateaccording to slety rules Dispose ofthe resicual properly following the rules. Cr Atterthe complete drainage, screw the plug and carry out the clean oi filing, Use only the recommended oil oro having the re- quested features forthe correct motor functioning bh case of topping up, don't mix ois having efferent features Ifyou don't comply with theses nus, the service war- ranty iso more valid. Check the level through the dipsck until when the filling ‘next to the maximum level notch inécated on the dp- sce ‘Whereas you replace the Mbrcation ol, itisnecessary tore place the fier According tothe application the fiter can belocatedin diferent positions the folowing procedure is valid guide for allappia- tions 1 Thetiteriscomposed by asupportanda itering cartridge, For the eattdge replacement use acceptable tools ‘Warning the ol fter contains inside a quantity of oll of about | kg Place properly a container forthe liquid ‘Warning avoid the contact of skin wth the mator ol in case of contact wash the skin with running water ‘The motor os very poltant:it must be disposed of according to the rules Replace the fitering cartidge with a new one and screw ‘manually uti when the gasket sin contact with the sup- Port Tighten by means of acceptable tools thrae fourth tur, Operate the moter fr some minutes and chack the level through the dpskkcagain, Iitisnecersary carry outa top: Pingu to.compensate the quantty of of used for the il Ing ofthe fltenng cartridge98 ENGINES: Fuel filter replacement [A] During this operation don't smoke and donttuse free JX flames == Avoid to breathe the vapors coming rom fiter: ‘After fers replacement the supply equipment Cdeaeration must be carried out, a ‘According tothe applications the tes poston andthe quan ‘iy can change, Howeerthe following operatonsarealitoralppeatins | Drain the fuel inside the fiter by operating the water re lease screw. Collect the fuel ina container without impu- | is. | Unscrew the eartridae by using acceptable tools Collect the eventual ful inside the fitering cartridge ‘Clean the gasket seat on the support and oll lightly the gasket on the new ering carve. ‘Screw manual the new fitering cartarig until when the gasket is completely on its seat. Tighten using acceptable tools to 5-10 Nm torque. oo coo ED, FEBUARY 2002 SECTION 3 -DUTY ~ INDUSTRIAL APPLICATION, Alternator belt replacement (Duet several applications the beltrun can changevery much, We cescribe the replacement ofa belt mounted ona 4-cyin- ders motor with tradional belt tension and a 6-cyinders ‘moter with an automatic screw couping Jip] Warn: with switched off motor ot si hot he 1N | bet can operate without advance notice. ‘Wait for the motor temperature lowering to avoid very serious accidents. Figure 236 == Di Unioose the serew (1) onthe tension staff the alterna: torbelt by unloosing the lock ut (2). Unscrew the screw {G)inarcertounloceethebelt (4) untiwhen Rispossible to withdaw the control and driven pulleys. Replace the toothed beit with a sniar one. Mount the belt (4) and serew it without clamping the screw (1) 50 that can slide inside the staff slot (5) D1 Adjust the belt tension by operating the screv. After achieving a correct tension lock the lock nut 2) and the serow (I), Di Operatethe motor forsome hours and check the correct bolt tension,SECTION 3 ~DUTY ~ NDUSTRIAL APPUCATION ep, FEBUARY 203, For the application with an automatic screw coupling the pro- cedure isthe following Figure 237 a D Unscrew the screws which fx the belt guard (2) to the support and dismount it. (Operate on the tghtener (1) and withdraw the bok (3) {fom the aterator and water pumps from pulleys and from the retums pumps Replace the worn belt with a new part Place the belt onthe pulleys and the guide roles. Place the automatic ightenerin order to key the belt in ‘the functioning position. Further adjustments are not required. o Be aieie ENGINES Py100 eNines ED. FEBUARY 2003 SECTION 3 “DUTY ~ INDUSTRIAL APPUCATION.SECTION OVERHAUL AND TECHNICALSPECIRCATIONS ED. FEQUARY 2003 avons 1 SECTION 4 ‘Overhaul and technical specifications Pagina GENERAL SPECIRCATIONS 3 CLEARANCE DATA ENGINE OVERHAUL u ENGINE REMOVAL AT THE BENCH u REPAIR OPERATIONS 2 [ounce 2 Checks and measurements: 12 1 Sheaing ned suporing sre on . “TING SYSTEM 8 D1 Carshar 6 _Checking cam it and pn alignment “4 BUSHES 7 4 21 bush eptcement | Oh Tappets 16 LO Fitting tappets— camshaft | OUTPUT SHAFT "7 Measuring jours and cranks 7 Replacing ol pump control gear 21 Fitting main bearings 21 Finding journal clearance 21 Checking output shat shoulder clearance 22 CONNECTING ROD - PISTON ASSEMBLY 2 Pistons 2B Measuring piston dameter 23 | Piston pins 2-4 (Conditions for proper pin-piston couping 24 Spl rings 4 G1 Comecting rods = O_ Bushes 2 checking connecting rode % Checking torsion 2%2 eG ED.FEBUARY 2009 SECTION 4 “OVERHAUL AND TECHNICAL SPECIRCATIONS Pega Pagina 1 Fitting connecting rod-piston assembly 26 “Cl Rersea cute poincediged | 1. Comecting rod-pston coupling 2g | |__Breireveles_ Ey Df ene 2) |9 Qrtegemesmremet eon waves a Finding crankpin clearance 28 VALVE SEATS: 2 Checking piston protrusion 2» _Regrining ~ replacing the valve seats 3 |_CYUNDER HEAD 30 | _VAIVE SPRINGS 34 CL Remi bo | nscunnenrea0 » C1 Cig nr ted 31) | Esty ee * Checking eyinder head supporting surface __31_| | TIGHTENING TORQUE 36SECTION 4 “OVERHAUL AND TECHNICAL SPECIRCATIONS ED, FERUARY 2003 ENGINES GENERAL SPECIFICATIONS. 2} 4 CYLINDERS 6 CYLINDERS Four-stroke cesel engine Supercharged with intercooler Injection Direct Number of oinders 4insine binding Bore om 104 Stroke om Total placement cm? ass ons TIMING ~ startbefore TDC, A ~ end after BDC, 8 - startbefore BDC. iD - ‘endaater TDC, c . ‘Checking ting . | Checking operation mm 0.152 to 0.38 x mm 0.318 (0 0.762 FUEL FEED ~ - Injection We: Bosch VE A/2F 1150LV Nozie: Injectors te DSLA 145 P Injection sequence 1-3-4-2 1-5-3-6-2-4 Injection pressure bar 7245 for FAGEO4O4A*D6 260 for others4 evanes ED,FEBUARY 2002 SECTION 4 ~ OVERHAUL AND TECHNICAL SPECIRCATIONS scunpes 6 CruNbERs COMPONENTS mam 7 x Cylinder bare AB owon0 11 04028 g Cr oa Lats ameter 2 - ia : : 5 ‘Gylinder barrels housings on - - S lenge block (interference) - A> Cunt ameter 2 - 2 yy Sinderbarls wide direter S92 - oS Pa tee xEtA Sze x 559 Sinica arr 108780 1 108.240 o Paosine 62 Soto to BON ae Paton inde bare oe 6 0208 A & Paondameter 1 as art * | Paton potion x o2er0042 Coot 2: ronan 2 380001 38006 ae Paton p= phone 0.004 w oanSECTION 4 “OVERHAUL AND TECHNICAL SPECIRCATIONS 0, FERUARY 2003, ENGINES 5. | fa} 4. CYUNDERS 6 CrUNDER CYLINDER UNIT AND CRANKSHAFT COMPONENTS 77 - xt xt 2.690, 72 Sptrng sos x2 2.440 to 2.460 2 % x3 4030 to 4.050 st si 2.560 t0 2.605 afi Spl sings 32 erouieen $3 sa 3.970 to 3.990 0245 t00265 - ge Spitcings slots, 2 0100 fo 0110 3 004 19 0080 A> spternes 08 xt ‘Split ring end opening - = x2 ineyinder barrel i x! 030 wo 040 x2 02510055 x3 025 10055 Oya ‘Smal end bush \ Soak ai snser 1013 \ Bg end bearing Ol feo. pane 22 72987 1973013 a OQ fe — gpatensnan some 0) Outise 4 40367 w 41013 ? Irae ab B3 38019 to 38033, J S Spare big end half CO] a ose s 1955 t0 1.968 a Smal end bth — housing Qe Piston pin — bash 0018 w 0038 A> Seendhabearngs 0250 005006 ENGINES ED.FUMRUAKY200) SECTION 4 OVERIIAL AND TECNICA PECITCATIONS [Sasa 7 let ni Type CYLINDERS 6 CYLINDERS | CYLINDER UNTT AND CRANKSHAFT COMPONENTS = Sie x - Max. tolerance on conpecting rd axis alignment a Sourals 1 £299 06301 Crankpins 2 68.87 062.013, Main al bearings $1 2.456 10 2464 Bigend bat bearings 1985 o L968 82 * povided x pre pat Main bearings Nos 3 £1982 088.008 No2-3-4 3 $1977 088013 Tlf beatings ~ Fouls No.P8/1-7 0.064 0 0095 No2d4/2345-6 £0059 0 0.100 Tlf bearings ~ Cranks 0.064 0 0050 ‘Main half bearings +0250 t0 +0.500 A Big ena bigs Shoulerjoumal = X1 314151037550 x1 : ae ‘Shoulder main bearing X 2 31.730 to 32,280, | Souler asngs X23 3728103738 | nip shat soar 0095100270SECTION4~GVERVALL AND TECHNICAL SPECEATIONS ED FERUARY 2003 evans 7 lita = Tipe 4 CYLINDERS. 6 CYLINDERS ‘CYLINDER HEAD - TIMING SYSTEM a _ @1 ake gi sets on cojinder head a1 019 0 8029 @2 “ a4 2 a Vale ides 2 - 23 oP ‘Vale guides andseats on head - A> vabe nice - oa Vabes a4 1963%0 7942 oa a or — o4 7963 t0 7943 x ( % i ae Vat stem and guide (0052 100052 Hong on bead fo vale set oO a 4698710 47013 a po a err oanse Vat seat aside dameter| vale seat angle on cjinde ex head a 2 470630 47069 @ o 48713104379 48° 03560 1.102 O104t0084 0050%00.102 005010 0.1028 ENGINES 0, FEBUARY 2003, SECTION 4 ~ OVERHAUL AND TECHNICAL SPECIACATIONS fia} 4 CvUNDERS 6 CYUNOERS "CYLINDER HEAD — TIMING SYSTEM mm Valve pring height ee sas H. under a load equal to: an a aa 2 ee Z (Camshaft bush 59.222 to 59.248 ose eae ° el] cone masta @2 fee = o ee 2 eee y ‘Camshaft bush outside. ® diameter; @ (59.222 to 59.248 , Bush inside 2 ameter @ 54.083 to 54.147. Seana : onblock G ia Bushes and journals 0038 to 0.162 ate bo 7 ca] oon -alicoe ine mie sarcne! niaieiat = fone sonnoes SyUNGER HEAD- THNE'SETER os ai ao = on block wI - fv a Tepe oie bist o Issa4an 13984 3 13525 15 Daron apa dha cms Ao Twpats . a ad tfederinh a} zis ais7 Ez5 Zz — 22 pao ae & ge Between rockers and shaft (0025 16 006310 ENGINES ED, FEBUARY 2003 SECTION 4 ~ OVERHAUL AND TECHNICAL SPEORCATIONS,SECTION 4 - OVERHAUL AND TECHNICAL SPECIRCATIONS ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH ‘The following instructions are prescribed on the Lnderstancing that the engine has previousy been placed on, the rotating bench and that removal of all specific ‘components ofthe equipment have been already removed ‘a well (See Section 3 of the manual herein). “The section iustrates therefore all the most important engine overhaul procedures “The following operations are relating to the 4 cylinders engine but are analogously applicable lor the 6 cylinders, Figure | ee Remove the screws (fastening the connecting rod caps (2) and remove them, ‘Withdraw the pistons inching the connecting rads fromthe top of the engne block. Keep the halFbearings into their housings since in case of use they shal be fited in the same position found at removal Remove the screws (I) and the main bearing caps (2). Fo, Frauney 208 “The second last main bearing cap (I) and the relevant support are fitted with shoulder haf-bearing (2). Take note of lower and upper halFbearing assembling postions since incase of reuse they shall S| be ftted inthe same position found at removal Use acceptable tools (1) and hoist to remove the output shaft (2) from the block, Remove the main half-bearings (I) Remove the screws (2) and remove the oll nozzles (3)2 exons Remove the screws (I)and dsconnect camthaf (2) retaining pate @). TA] te ote ote @) senting postin ‘Withdraw the tappets (I) fom the engine block 0, FeoUNRY on SECTION 4 “OVERHAUL AND TECHNICAL SPECIRCATIONS REPAIR OPERATIONS CYLINDER UNIT. |Checks and measurements Once engine is dlsassernbled, clean accurately the jlinder-block assembly Use the proper rings to handle the cylinder unit. The engine block shall nt show cracks. ‘Check operating plug conditions and replace them incase of uncertain seal orf rusted. Inspect eyinder barrel surfaces;they shallbe fre from sizing, scores. ovalsation. taper or excessive wear Inspection of eyinder barrel bore to check ovaisation, taper {and wear shall be performed using a bore dial gauge () fitod with the dial gauge previously set to zero ‘onthe ring gauge (2) of the cylinder barrel diameter FR) Sethe aug be not avaiable, we 2 {N,] micrometer for zero-seting Figure 10 yy SSS By KA& "Measurements shall be performed on each cylinder, at three different heights inthe barrel and on two. planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (8) Maxerum wear is usually found on plane {@) in correspondence with the fist measurement. ‘Should ovalsation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized bby 05 rm and to the specified assembling clearance.SECTION 4~ OVERHAUL AND TECHNICALSPECRICATIONS ED, FEWARY 2003, INGINS 13 ‘Check main bearing housings as follows fit the main bearings caps on the supports without bearings: 1D tighten the fastening screws to the specified torque | Cl use the proper internal gauge to check whether the housing diameter i fling within the specified value. Figure 11 ee |rescetnarate vers Checking head supporting surface on cylinder |_| When finding the distortion areas, replace the cylinder unt Planarity error hall not exceed 0075 mm. — | | Check cylinder unit operating plug conditions, replace them in cate of uncertain seal or i rusted 4 Da (i) ) In case of regrincing, all barrels shall have the same WA epee TIMING SYSTEM Camshaft Figure 12 CAMSHAFT MANN DATA (4 CYL) Specifed data refer te pin standard diameter4 eves, D.FERUARY 2002 SECTION4 ~ OVERHAUL AND TECHNICAL PEORCATIONS Figure 13 53.995, 54.045 cosy MAIN DATA ABOUT CAMSHATT PINS (6 CYL) CCamhaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes. if they show any traces of seizing or scoring replace the Checking cam lift and pin alignment BUSHES, Set the camshaft on the talstock andusing a I/100 gauge set Jon the central support, check whether the alignment error ie not exceeding 0.04 ren, otherwise replace the camshaft [Check cam lif; found values shall be: 6045 mm for exhaust cameand 7582 mn for nae cars in case of rent values replace the carehaf | CCanhaft bushes (2) shall be pressed into their housings intemal surfaces must not show seizing or wear Ure bore ial gauze (2) to measure cama front and rear ‘bust (2) and intermedate housing (I) diameter Measurements shall be performed on two perpendicular Check camshaft (2) pin diameter using micrometer (1) on two perpendialar avesSECTION “OVERHAUL AND TECHNICAL SECRCATIONS ED FEQUARY 002 enone 15 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes, eee) MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS “Height to be obtained after driving the bushesBush replacement Figure 18 FD. FEBUARY 2003, SECTION 4 - OVERHAUL AND TECHNICAL SPECIRCATIONS Fitting tappets - camshaft Feure 20 | using acceptable tools (2) and (3). Ta replace front and rear bushes (I), remove and reft ther \When refitting the bushes (|), direct them to make the lubricating holes (2) coincide withthe holes on the block housings. Lubrizate the tappets (|) and fit them into the relevant housings on the engine block Fgure 21 = a oO A aid a ~ 2 Pao vo LLubrzate the camshaft bushes and ft the camshaft (1) taking care not to damage the bushes or the housings MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Set carnshaft (3) retaining plate (I) with the slot facing the top ef the engine block and the marking fing the operator, ‘then tighten the screws (2) to the speciied torque.SECTION 4 ~ OVERHALA. AND TECHNICAL SPECICATION 0, Feu 202 ENGINES 17 ‘Check camshaft end float (I). It shall be 023 = 0.13 mm, Figure 24 Ss | wich the pine are tobe ground OUTPUT SHAFT Measuring journals and crankpins Grind jourals and crankpios i sing scoring or excessive cvalsation are found. Belore grnaing the pins 2) measure them with a micrometer (I) to decide the final dameter to leis recommended to insert the found vats inthe proper tabie See Figure 26 fy Underze cies are Journals and crankpin shall alvays be ground to the same undersize cas, Journal and crankpins undersize shall be marked on Fit nozzles (2) and tighten the fastening screws (I) to the speciied torque ‘the side ofthe crank arm No.l For undersized crankpins: eter M For undersized journals: letter B For undersized crankpins and journals: letters MB ama = 1 AH AL BLL IN oid fbai]* FRated value FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUESeure on? 455 mm a ‘++ [ZIBEO] basen accent jourle ‘OUTPUT SHAFT MAIN TOLERANCES ED.FEBUARY 2013 SECTION “OVERHAUL AND TECHNICAL SPECCATIONS (lesa e<} (7) “TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYPIBOL ae Tones o a Canary Tor Paxatelarn 7 DIRECTION Vertalty c Siraghiness 7 POSTION, Concentric or cooly o Tiraaroxailaion 7 OSCILLATION Tota oxaltion # oper = LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERETICS GRAPHIC SYMBOL || [CATICAL e IMPORTANT, @ [SECONDARY eo AREEARING ON TRANG 45° INTEREDRTEMAN RST HAIN BEARING ‘SYSTEM CONTROL SDE Beans ‘ONFRONT SDESECTION “OVERHAUL AND TECHNICAL SPECIRCATIONS ED FESUARY 2m Figure 28 sup amin MAX tL It rH il | [Tb — [ior | 19 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALLES Rated valve | © Measured on a radive greater than 45.5 mm ” between adjacent main journals MAIN OUTPUT SHAFT TOLERANCES20 ENGINES ED, FEBUARY 209 SECTION 4 ~OVERHALK AND TECHNICAL SPECIRCATIONS Figure 30 | anyecernc oxrmans serine Han RST HARV BEARING ON Syre COMROL SO BEANS ONT ae TOLERANCES "TOLERANCE CHARACTERBTIC GRAPHIC SYBOL a Roaches © Ginny TOF Paral 7 DIRECTION erty = Stradines = POSTION Concencky or coaxaiy o Crear osalation 7 OSCILLATION Teal oscar z Peper = TEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL cRITICAL e IMPORTANT @ SECONDARY °SECTION 4 ~ OVERHAUL AND TECHNICAL SPECFICATIONS FD. FaUARY 200 | INGNES 21 Replacing oil pump control gear Figure 31 Sale KAY ‘heck that gear toothing (I) is not damaged or worn, ‘otherwise remove it using the proper puller (3). ‘When fitting the new gear; heat i to 180°C for 10 minutes in an oven and then key it tothe output shat Fitting main bearings [Figure 32 EA Ref the main bearings that have not been replaced, in the same postion Yound at removal ‘Main bearings (1) are supplied spare with 0.250~ 0.500 ren Lundersize on the internal diameter. [apa De not try to adapt the bearings Clean accurately the main half bearings (I) having the |Nbricatng hole and fi them into their housings. “The second lat main haf bearing (|) fitted with shoulder half ings. Finding journal clearance Figure 33 fa Refit the output shaft (2) Check the backizh between output shaft main journals and the relevant bearings as follows: Figure 34 Di clean accurately the parts and remove any trace 1D position a piece of calibrated wire (3) onthe outputshatt pin (4) so that itis parallel to the longitudinal axis; 1 ftcaps (|), including the halfbearings (2) on the relevant supports © Figure 35 A Tighten the pre-lubricated screws (1) in the following three salccessve stages 1 stage, with dnamometric wrench to 50 6 New 2% stage, with dynamemetric wrench to 80 = 6 Ne.sre stago, using accoptable tots () sot as chown inthe ‘gure, tighten the screws (2) with 90° = 5° angle Figure 37 |e D1 Remove caps from supports “The backlash between the main bearings and the pins found by comparing the width of the calbrated wire (2) the narrowest point wth the scale on the envelope (I) contaning the caibrated wire “The nurrbers on the scale indicate the backlash in mm. Replace the hal bearings and repeat the check ifa diferent backlash vakle is found, Once the specified backlash is ‘obtained, lubricate the main bearings and ft the supports by tightenng the fastening screws as previously described, EDLFEBUARY 2003 SECTION 4 “OVERHAUL AND TECHNICAL SECIRCATIONS ‘Checking output shaft shoulder clearance “This chackis performed by setting amagnetic-base al gauge @) ax the output shaft (3) as shown inthe gure, standard Value is 0068 to O41 Irhigner value is found, replace main thrust half bearings of| ‘the second last rear support (I) and repeat the clearance check between output shaft pins and rain hal bearings. CONNECTING ROD - PISTON. ‘ASSEMBLY | igure 39 z a) a ee t é ° L 8 G CONNECTING ROD - PISTON ASSEMBLY (COMPONENTS |. Stop rings ~2. Pin ~3. Piston —4, Split rings ~5. Screws 6, Half bearings ~ 7, Connecting rod = 8. Bush, Pistons are supplied spare with 05 me oversizeSECTION 4 OVERIAUL AND TECHINICAL SPECIFICATIONS Remove split 99360183 (3). Figure 41 Piston pin (1) split rings (2) are removed using a sctber (3). igure 42 1, FEBRUARY 2008 ENGINES = 23, Pistons ‘Measuring piston diameter Figure 43 Using a micrometer (2), measure the diameter of the pst (1) 10 determine the assembly clearance ‘The diameter shall be measured at 12:mm from the ‘The clearance between the piston and the eylinder barrel ‘can be checked also with a feler gange (1) as shown in the] figure * 2a 2000 | | 24 aa 0 po ‘MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS © Value measured on 58 mun diameter for 4 cylinder (38.000 38.00624 ENGINES | Piston pins Figure 45 “To measure the piston pin (|) dameter use the micrometer @. Conditions for proper pin-piston coupling Figure 46 Lubricate the pin (I) and its seat on piston hubs with engine | oil the pin shall be fitted into the piston with a slight friger | pressure and shall not be withdraw by gravity. Split rings | Figure a7) Use a micrometer (I) to check spit ring (2) thickness 0, Feaunny 208 SECTION 4 ~ OVERHAUL AND TECHNICAL SPECIRCATIONS Check the clearance between the sealing rings (3) ofthe 2™ | ‘and 3* slot andthe relevant housings onthe piston (2),using 2 feder gauge (1) CIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE “TRAPEZOIDAL RING. Since the frst sealing ring ection istrapezoidal the clearance between the slot and the rng shall be measured a follows: ‘make the piston (|) protrude fram the engine biock so that the ting (2) protrudes half-way fom the cylinder barrel (3). In ths positon, use a feeler gauge to check the clearance (X) between rng and slot found value shall be the spectied one.SECTION - OVER Figure 50 from Use feeler gauge (1) 10 measure the clearance hetween the ends ofthe split rings (2) fitted ino the eylinder barrel (3), Connecting rods Figure $1 HRT 4 FESR) 73.013 MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Vine for inside diameter to be obtained after diving in ‘connecting rod small end and grinding, ° Value not measurable in released condition The surface of connecting rod and rod cap are Knurled to ensure better coupling, Therefore, itis recommended not 10 smooth the ns ENGINES 25, Figure $2 very connecting rod is marked as follows (On body and eap with a number showing their ‘coupling and the eoxresponding eylinde. Tn ease of replacement its therefore necessary {o mark the new connecting rod with the same numbers of the replaced one. On body with a letter showing the weight of the ‘connecting rod assembled at production: V, 1820 to 1860 (yellow marking): W, 1861 10 1900 (green marking), X, 1901 t© 1940 (bine marking); Spare connecting rods are ofthe W class with green ‘marking *, ‘Material removal is not allowed. Bushes ‘Check that the bush inthe connecting rod smal end is free from scoring or seizing and that it isnot loosen. Otherwise replace, Removal and refitting shall be performed using the proper beater ‘When refiting take care to make coincide the oll holes set, ‘on the bush with those set on the connecting rod stall end, Grind the bush to obtain the specified diameter.heck that the axes of the connecting rods (I) are parallel Using acepiabl tol (8) as fllos: G frtno connecting red () on accoptable to! (6) spindle ‘and lock it with serow (4): La setthe spindle (3) on V-blocks by resting the connecting rod (I) on the stop bar (2), Checking torsion "Figure s4 = Check connecting rod (5) torsion by comparing two points (andB) ofpin (3) on thehorizontal plane of theconnecting od axis Poston the dial gauge 2) support) to obtain a preload of approx. 05 mm on the pn (3) point A and then set the lat gauge (2) 10 zero Mowe the spindle (4) with the connecting rod (5) and compare any deviation on the ‘opposite side (8) ofthe pn (3):the diference between Aand Bical not exceed O08 mmm Ep. 2008 SECTION 4 ~ OVERHAUL AND TECHNICAL SPECIRCATIONS Checking bending ‘Chee connecting rod (8) bending by comparing two points ‘Cand 0 ofthe pin (3) on the verte! plane othe connecting rod Fositon the vertical support (I) ofthe dal gauge (2) to rest the ter on pin (3), point Move the connecting rd forwards and backwards to find pin {op postion, then in this canton reset the dal gauge (2) Move the spindle with the connecting rod (5)and repeat the hed ofthe top pomt onthe opposite side O ofthe pin ‘Thesference between point and point D shall not exceed 008 mm Fitting connecting rod-piston assembly Connecting rod-piston coupling “The piston crown is marked as follows: |L-art number and design modification number: 2. Arrow showing piston assembling direction into cylinder Darel this arrow shal face the front key ofthe engine shock, Marking showing I+ slot insert testing; 4. Manufacturing date.SECTION “OVERHAUL AND TECHNICAL SPECIRCATIONS £0, FERUARY 208, mons 27 FT] Spit engsare supped spare with the following sizes: AN] = standard, yelow marking ~ 05 mm oversize, yellow/green marking; Connect piston (2) to connecting rod (4) with pin (3) so that ‘the reference arrow (I) for fitting the piston (2) to the cyinder barrel and the numbers (8) marked on the connecting rod (5) are read as shown in the Feure. Figure 58 Fit hal bearings (1) on connecting rod and cap, Refit the main bearings that have not been replaced, in the same postion found at removal (Do net try to adapt the hal bearings. Fitting connecting rod-piston assembly into Position the piston (1) on the connecting rod according cylinder barrels ‘the diagram show in the figure, the pin (3) and stop it by the spit rings (2). gael Fitting spit rings 3 C Eas © @ o4 ® eo Gy S| ajay é& Lubricate accurately the pistons ind the split rings and se acceptable too (3) 10 ft the spt rings () onthe the cinder barrel inside piston 2). Use acceptable tools (2) to ft the connecting rod-pston Split rings shall be ftted with the marking “TOP” facing |_| assent (I) nt the cyinderbarreband check he flowing upwards and ther penings shall be deplaced wih each | | (y the rarer of each connecting rod shall correspond to ‘the cap coupling number(y- fe ee DIAGRAM FOR CONNECTING ROD-PISTON, "ASSEMBLY FITTING INTO BARREL 1D Splitring openings shallbe displaced with each other by 20%; D1 connecting rod-piston assemblies shall have the same ‘weeht D thearrow marked onthe piston crown shallbe facing the front side of the engineblock orthe slot obtained an the Piston skirt shall be corresponding, to the oil nozzle position, Finding crankpin clearance “To measure the clearance proceed as follows: clean the parts accurately and remove any trace of ci Oma pee ofaeratawir onthe outset ): ft the connecting rod caps (3) with the relevant half bearings (4). fea) C1 Lubricate the screws (I) wth engine clad then tighten ‘hem to the specied torque using the dynarnometric wrench @) gure 65 1D Apply acceptable tools (I) tothe socket wrene tighten screws (2) of 60". Femove the cap and find the existing clearance by comparing the callbrated wire width (I) with the scale cn the wire envelope (2).SECTION 4 “OVERALL AND TECHNICAL SECRCATIONS ‘Once the specified clearance has been btained, lubricate ‘the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque. Before the final ftting of the connecting rod cap Tastening screws, check that their dlameter| ‘measured atthe centre of the thread length is not ‘0.1 mnthan the diameter measured at approx. 10 ne from screw and. Check manually that the connecting rods (I) are acing _xially on the output shaft pins and that their end float, ‘measured with feeler gauge (2) 0250 to 0275 men, ae ous () = : Ee = | Ss os A S | QS ‘Once connecting rod-piston assemblies refitting is over use dial gauge () fitted with base (2) 0 check piston (3) protrusion at T.D.C. with respect tothe top of the engine ‘of the engine block Protrusion shall be 028 to O42 erm,30 ENGINES ‘CYLINDER HEAD. Removing the valves Figure 69 a Intake (I) and exhaust (2) valves have heads with «ifferent ameter /)X,| ther before remoning in order ta ret ther in the same position. A= intake side 0, Foun 200, Should cyinder head vals benot replaced, number ‘SECTION 4 “OVERHAUL AND TECHNICA SPECICATION Faure 70 Valvo romoval chal! bo performed using acceptable tool (1) and pressing the cap (3) s0 that when compressing the springs (4) the cotters 2) can be removed. Then remove the «ap (8) and the springs (4). Repeat this operation forall the valves ‘Overtum the cylinder head and withdraw the valves (5). Faure 71 Remove sealing rings (| and 2) from the valve guide. iy Sie he 0 errase eras ow 1N ‘Sealing rings (2) for exhaust valves are green.[5a {ETON -OFDO AL ND ROCA ECREATONE Ra oes checking cyinder head wet sea rs 78 rewe72 | toes Elam | ty c |. a | epee | ara | “This check shall be performed using the proper tools, (Use a pump to fill wth water heated to approx. 90°C and 2 {to 3 bar pressure Replace the cup plugs (1) if leaks are found, use the proper [beater for their removalireiting, A Replace the cylinder head ileaks are foun Before refitting, smear the plug surfaces. with \water-repellet sealant. Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0.20 mm, IPhigher values are found grind the cyinder head according to values and indications shown inthe fllowing fgure “Therated thickness A forthe eyinder head ie 95 £ 0.25 men, | max metal removal shall not exceed thickness B by | mm. Alter grinding, check valve sinking. grind the valve ‘seats, iPrequired, to obtain the specited value ZN32 ENGINES VALVES, Figure 74 EXHAUST ‘VALVE INTAKE AND EXHAUST VALVE MAIN DATA, Removing carbon deposits, checking and grinding valves | Remave carton deposit from valves using the proper metal brush, Check that the valves show no signs of seizing, scoring or en remuany 208 SECTION 4 ~ OVERHAUL AND TECHNICAL SPECFICATIONS CChede the valve stem (I) using a micrometer (2),it shall be 696 to 6980. Checking clearance between valve stem and valve guide and valve centering (sure 77) Use a magnetic base cial gauge (I) seta shown inthe figure, ‘the assembling clearance shal be 0052 # 0092 mm. cracking Roogrind the valve seats, if required using acceptable tools and removing as litle material as possible, | turnthe vale @) and check thatthe centering errors net | exceeding 003 mm,SECTION ~ OVERHAUL AND TECHNICAL SPECIRCATIONS ED. FEAUARY 03 BWI 33 VALVE GUIDE VALVE SEATS Regrinding ~ replacing the valve seats Figure 78 Use a bore dial gauge to measure the inside diameter ofthe valve guides, the read value shall comply with the vale shown inthe figure. Figare’@07 9.5") 30.55 a5" 59.5) 60.5: INTAKE Should vahe seats be not reset just by regrinding replace thor with the spare ones. Use acceptable tos (Figure 79) remove as much material as possible frorn the valve seats (fake care not to damage the cyinder head) until they can be extracted from the cylinder head using a punch, ‘Check the valve seats 2), fsght scoring or burnouts found, regi eoats using acceptable tools (according to tho angle values shown in Figure 80. 4.32 EXHAUST VALVE SEAT MAIN DATA = Hest the cylinder head to 80° — 100"C and using the proper beater ft the new valve seats, previously cooled, into the cylinder head Use acceptable tools to regind the valve seats according to ‘the values shown in Figure 60.‘After regrinding, check that vahe (3) sinking value is the specified one by using the base (2) and the lal gauge (0). VALVE SPRINGS | Figure 82 | Fea 2002 SECTION 4 ~ OVERHAUL AND TECHNICAL SECIRCATIONS FITTING CYLINDER HEAD Lubricate the valve stems (|) and ft thern into the relevant vale guides according to the postion marked at removal, Fic the sealing rings (2 and 3) on the valve guide Sealing rings (2) for take valves are yelow and cealing rings (3) for exhaust valves are green. WN =D Sp q i. Hy) + SH - Hl MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before rotting use acceptable tools to check spring flexibly, Compare load and elastic deformation data with those of the new springs shown inthe following table. Position on the eylinder head: the spring (4), the upper cap {8} se acceptable tools (1) to compress the spring (4) and lock he parts to the valve (5) by the cotters (2),SECTION 4 ~ OVERHAUL AND TECHNICAL SPECRCATIONS ED. FERUARY 2003 ENGNES 35 Refitting the cylinder head ‘Check cleanness of cylinder head and engine block couping surface. “Tike care not to foul the cyinder head gasket. Set the cyinder head gasket (I) with the marking “N. of component” (I) facing the head. ‘Thearrow showsthepointwherethe gasket thichnessisgiven. Before re-utilsing the fixing screws for the cyinder head, verify there is no evidence of wear or ‘deformation and in that case replace them,36 ENGINES, .FEBUARY 2003, SECTION 4~ OVERHAUL AND TECHNICAL SPECIICATIONS TIGHTENING TORQUE OPPONENT TORQUE Wn a | ‘Sere Pore ofr Earl eng rarer Bas 120s | Screw M12 fer festering = a Soa6 5206 [serovar neath ee 6 5208 3 stage 90° 2 5° Screw MG for tenga ongual ea pte ea za0a Sere M8 fr fastening crc gear Had 36204 Screw MI fr fstning connecting rod ope sage os5 6205 24 stage 60" 5°SECTION 5- TooIs Fea 203 ENGINES 1 SECTION 5 Tools Poe2 ENGINES 0, FEBUARY 20 SECTON 5- 1001S,SECTION §- 1001S 0, Femur 203 ENGINES 3 Tools TOOL Ne. DEFINITION TOOL Ne. DEFINITION 380000663 380000988 Teo for Rotating the Engine Flynt 380000664 Crankstat Rear Seal nstaler A, CCrankshat Front Seal Pll Crankshat Fron Seal instal 380000671 A Injector Pier 380000979 Injector Pump Puller4 ENGINE. 0, FEBUARY 2002 SECTION 5100150, tBu 200 NINES APPENDIX SAFETY PRESCRIPTIONS, Pagina2 ENGINES o.FemUnRy omaAPPEND . FeBuaey 203 ewcines 3 SAFETY PRESCRIPTIONS ‘Standard safety prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and ‘whose non fulfilment will make any other measure useless or ot sufcient to ensure safety to the personnel in-charge of ‘maintenance. Be informed and inform personnel as wall ofthe laws in force [regulating safet: providing information documentation avaiable for consutation, 1 Keep workingareasas clean as posible, ensuringadequate eration, [D Ensure that working areas are provided with emergency boxes, that must be clearly vsble and always provided with adequate sanitary equipment. 1D Provide for adequate fre extinguishing means, properly indicated and alvays having free access. Ther effiiency ‘must be checked on regular bass and the personnel must be trained on intervention methede and priorities Organize and eisplace speci ext points to evacuate the areas in case of emergency, providing for adequate Indications ofthe emergency exit ines. C1 Smoking in working areas subject to fre danger must be _sricly prohibited Provide Waring: throughout adeaunte boards signaling danger, prohibitions and indications to ensure easy ‘comprehension of the instructions even in case of emergency Prevention of injury |G) Do not wear unsuitable cloths for work, with futtering lends, nor jewels such as rings and chains when werkng close to engines and equipment in motion, Co Wear safety gloves and goggles when performing the fallowing operations: = fling inhibitors or ant-frost lubrication oll topping or replacement = utilization of compressed air or liquids under pressure (pressure alowed: = 2 bar) ‘Wear safety helmet when working close to hanging loads oF equipment working at head height level ‘Always wear safety shoes when and cloths adhering tothe body, better ifprovided with elastics atthe ends Use protection cream for hands Change wet cloths as soon as possible In presence of curent tension exceeding 48-€0 V verify efciency ofearthand mass electrical onnections Ensure that hands and feet are dry and execute working ‘operations utizing isolating foot-boards Donot carryout ‘working operations ifnot trained for Do not smoke ner ight up fares close to batteries and ‘to any uel material ooo oo oO Ca Putthedirty rags with oil diese fuel orsolventsinanti-fre specialy provided containers 1D Do not execute any intervention if not provided with necessary instructions Do not use any tool or equipment for any diferent y ipme y ‘operation from the ones they've been designed and provided for: serious injury may occur Ci Incase of test or calbration operations requiring engine Funning, ensure thatthe areaiz auffciety aerated orutiize specific vacuum equipment to eliminate exhaust gas Danger: poisoning and death During maintenance 1D Never pen filercap of cooling circu when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn, Wait unit the ‘temperature decreases under SOC. D0 Nevertop upan overheated engine with coolerand utilize only appropriate liquids Always operate when the engine is tured off whether particular crcumstances require maintenance Intervention on running engine, be aware of all risks involved with such operation, 1 Be equipped with adaquate and safe containers for crainage operation of engine liquids and exhaust oil 1D Keop the engine clean from ol tangles, diese ful and or chemical solvents. Use of solvents or detergents during maintenance may crighate toxicvepors Always keep working areas aerated, Whenever necessary wear safety mask 1 Donotleaverags impregnated with flammable substances love to the engine. [Upon engine start after maintenance, undertake proper preventing actions to stop ar suction incase of runaway peed rat, Do not utilize fst screw-tightening tools Never disconnect batteries when the engine is running. Disconnect batteries before any intervention on the lectrical system, Disconnect batteries fom system aboard to load them with the battery loader. ‘After every intervention verify thatbattry clamp polarity 's correct and that the camps are tight and safe from accidental short cireuit and oxidation oo ooo Gi Do not disconnect and connect electrical connections in presence of electrical fed |D. Before proceeding wth pipelines disassembly (pneumat, hhydrauli fuel pipes) verify presence of iquid or ar under pressure, Take all necessary precautions bleeding and

You might also like

• The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  

  From Everand

  The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  Mark Manson

  Rating: 4 out of 5 stars

  4/5 (5819)
• The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  

  From Everand

  The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  Brene Brown

  Rating: 4 out of 5 stars

  4/5 (1093)
• Never Split the Difference: Negotiating As If Your Life Depended On It

  

  From Everand

  Never Split the Difference: Negotiating As If Your Life Depended On It

  Chris Voss

  Rating: 4.5 out of 5 stars

  4.5/5 (845)
• • Magazines
  • Podcasts
  • Sheet music
• Principles: Life and Work

  

  From Everand

  Principles: Life and Work

  Ray Dalio

  Rating: 4 out of 5 stars

  4/5 (609)
• The Glass Castle: A Memoir

  

  From Everand

  The Glass Castle: A Memoir

  Jeannette Walls

  Rating: 4.5 out of 5 stars

  4.5/5 (1717)
• Grit: The Power of Passion and Perseverance

  

  From Everand

  Grit: The Power of Passion and Perseverance

  Angela Duckworth

  Rating: 4 out of 5 stars

  4/5 (590)
• Sing, Unburied, Sing: A Novel

  

  From Everand

  Sing, Unburied, Sing: A Novel

  Jesmyn Ward

  Rating: 4 out of 5 stars

  4/5 (1104)
• Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  

  From Everand

  Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  Margot Lee Shetterly

  Rating: 4 out of 5 stars

  4/5 (897)
• Shoe Dog: A Memoir by the Creator of Nike

  

  From Everand

  Shoe Dog: A Memoir by the Creator of Nike

  Phil Knight

  Rating: 4.5 out of 5 stars

  4.5/5 (540)
• The Perks of Being a Wallflower

  

  From Everand

  The Perks of Being a Wallflower

  Stephen Chbosky

  Rating: 4.5 out of 5 stars

  4.5/5 (2104)
• The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  

  From Everand

  The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  Ben Horowitz

  Rating: 4.5 out of 5 stars

  4.5/5 (348)
• Bad Feminist: Essays

  

  From Everand

  Bad Feminist: Essays

  Roxane Gay

  Rating: 4 out of 5 stars

  4/5 (1018)
• Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  

  From Everand

  Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  Ashlee Vance

  Rating: 4.5 out of 5 stars

  4.5/5 (474)
• Her Body and Other Parties: Stories

  

  From Everand

  Her Body and Other Parties: Stories

  Carmen Maria Machado

  Rating: 4 out of 5 stars

  4/5 (822)
• The Outsider: A Novel

  

  From Everand

  The Outsider: A Novel

  Stephen King

  Rating: 4 out of 5 stars

  4/5 (1866)
• The Emperor of All Maladies: A Biography of Cancer

  

  From Everand

  The Emperor of All Maladies: A Biography of Cancer

  Siddhartha Mukherjee

  Rating: 4.5 out of 5 stars

  4.5/5 (271)
• The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  

  From Everand

  The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  Viet Thanh Nguyen

  Rating: 4.5 out of 5 stars

  4.5/5 (122)
• Angela's Ashes: A Memoir

  

  From Everand

  Angela's Ashes: A Memoir

  Frank McCourt

  Rating: 4.5 out of 5 stars

  4.5/5 (441)
• Brooklyn: A Novel

  

  From Everand

  Brooklyn: A Novel

  Colm Tóibín

  Rating: 3.5 out of 5 stars

  3.5/5 (1947)
• The Little Book of Hygge: Danish Secrets to Happy Living

  

  From Everand

  The Little Book of Hygge: Danish Secrets to Happy Living

  Meik Wiking

  Rating: 3.5 out of 5 stars

  3.5/5 (401)
• A Man Called Ove: A Novel

  

  From Everand

  A Man Called Ove: A Novel

  Fredrik Backman

  Rating: 4.5 out of 5 stars

  4.5/5 (4770)
• Steve Jobs

  

  From Everand

  Steve Jobs

  Walter Isaacson

  Rating: 4.5 out of 5 stars

  4.5/5 (808)
• The World Is Flat 3.0: A Brief History of the Twenty-first Century

  

  From Everand

  The World Is Flat 3.0: A Brief History of the Twenty-first Century

  Thomas L. Friedman

  Rating: 3.5 out of 5 stars

  3.5/5 (2259)
• The Yellow House: A Memoir (2019 National Book Award Winner)

  

  From Everand

  The Yellow House: A Memoir (2019 National Book Award Winner)

  Sarah M. Broom

  Rating: 4 out of 5 stars

  4/5 (98)
• Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  

  From Everand

  Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  Gilbert King

  Rating: 4.5 out of 5 stars

  4.5/5 (266)
• The Art of Racing in the Rain: A Novel

  

  From Everand

  The Art of Racing in the Rain: A Novel

  Garth Stein

  Rating: 4 out of 5 stars

  4/5 (4208)
• A Tree Grows in Brooklyn

  

  From Everand

  A Tree Grows in Brooklyn

  Betty Smith

  Rating: 4.5 out of 5 stars

  4.5/5 (1929)
• Team of Rivals: The Political Genius of Abraham Lincoln

  

  From Everand

  Team of Rivals: The Political Genius of Abraham Lincoln

  Doris Kearns Goodwin

  Rating: 4.5 out of 5 stars

  4.5/5 (234)
• Yes Please

  

  From Everand

  Yes Please

  Amy Poehler

  Rating: 4 out of 5 stars

  4/5 (1902)
• A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  

  From Everand

  A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  Dave Eggers

  Rating: 3.5 out of 5 stars

  3.5/5 (231)
• The Woman in Cabin 10

  

  From Everand

  The Woman in Cabin 10

  Ruth Ware

  Rating: 3.5 out of 5 stars

  3.5/5 (2522)
• Fear: Trump in the White House

  

  From Everand

  Fear: Trump in the White House

  Bob Woodward

  Rating: 3.5 out of 5 stars

  3.5/5 (738)
• Wolf Hall: A Novel

  

  From Everand

  Wolf Hall: A Novel

  Hilary Mantel

  Rating: 4 out of 5 stars

  4/5 (3811)
• John Adams

  

  From Everand

  John Adams

  David McCullough

  Rating: 4.5 out of 5 stars

  4.5/5 (2409)
• LB90 110 75314397 PDF

  

  Document524 pages

  LB90 110 75314397 PDF

  Chagas Oliveira

  100% (8)
• On Fire: The (Burning) Case for a Green New Deal

  

  From Everand

  On Fire: The (Burning) Case for a Green New Deal

  Naomi Klein

  Rating: 4 out of 5 stars

  4/5 (74)
• The Light Between Oceans: A Novel

  

  From Everand

  The Light Between Oceans: A Novel

  M.L. Stedman

  Rating: 4.5 out of 5 stars

  4.5/5 (789)
• Manhattan Beach: A Novel

  

  From Everand

  Manhattan Beach: A Novel

  Jennifer Egan

  Rating: 3.5 out of 5 stars

  3.5/5 (792)
• The Constant Gardener: A Novel

  

  From Everand

  The Constant Gardener: A Novel

  John le Carré

  Rating: 3.5 out of 5 stars

  3.5/5 (104)
• The Unwinding: An Inner History of the New America

  

  From Everand

  The Unwinding: An Inner History of the New America

  George Packer

  Rating: 4 out of 5 stars

  4/5 (45)
• Pilotos de Via Interdita - 2016

  

  Document249 pages

  Pilotos de Via Interdita - 2016

  Joao Amora

  No ratings yet
• Manual Sistemas de Frenagem

  

  Document54 pages

  Manual Sistemas de Frenagem

  Joao Amora

  No ratings yet
• Rise of ISIS: A Threat We Can't Ignore

  

  From Everand

  Rise of ISIS: A Threat We Can't Ignore

  Jay Sekulow

  Rating: 3.5 out of 5 stars

  3.5/5 (137)
• Little Women

  

  From Everand

  Little Women

  Louisa May Alcott

  Rating: 4 out of 5 stars

  4/5 (104)
• Manual Dumper Ausa D900ap

  

  Document71 pages

  Manual Dumper Ausa D900ap

  Joao Amora

  No ratings yet
• 40 RQ Alfra Rotabest

  

  Document16 pages

  40 RQ Alfra Rotabest

  Joao Amora

  No ratings yet
• Patente Camiao Ferroviario

  

  Document8 pages

  Patente Camiao Ferroviario

  Joao Amora

  No ratings yet
• Pilotos de Via Interdita - 12-2016

  

  Document345 pages

  Pilotos de Via Interdita - 12-2016

  Joao Amora

  No ratings yet
• Catalogo Repuestos Deutz F6L912

  

  Document116 pages

  Catalogo Repuestos Deutz F6L912

  Joao Amora

  No ratings yet
• Manual Material Motor

  

  Document89 pages

  Manual Material Motor

  Joao Amora

  No ratings yet
• User Manual of Turbo HD DVR

  

  Document253 pages

  User Manual of Turbo HD DVR

  Joao Amora

  No ratings yet
• Manutenção Caterpillar

  

  Document13 pages

  Manutenção Caterpillar

  Joao Amora

  0% (1)
• Manual Tecnico Mahle

  

  Document232 pages

  Manual Tecnico Mahle

  Joao Amora

  100% (1)
• 9231 O&K Swing Drive Service Manual S2896979 - Motor Giro PDF

  

  Document118 pages

  9231 O&K Swing Drive Service Manual S2896979 - Motor Giro PDF

  Joao Amora

  No ratings yet
• Calcul Du Ferraillage D'une Poutre

  

  Document76 pages

  Calcul Du Ferraillage D'une Poutre

  galzim

  77% (13)
• Livro de Instruções Hatz

  

  Document36 pages

  Livro de Instruções Hatz

  Joao Amora

  No ratings yet