Professional Documents
Culture Documents
Cursor Series Tier 4B / Stage Iv
Cursor Series Tier 4B / Stage Iv
TIER 4B / STAGE IV
Industrial application
TIER 4B
F2CFE613E*B012
F2CFE613A*B012
STAGE IV
F2CFE613E*B013
F2CFE613A*B013
Introduction
Page
- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SYMBOLS
Warnings
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
Service operations
Example
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
! with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
Figure 2
88039
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
Power
1 kW = 1.36 CV
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1.014 CV
NOTE The unit CV is converted into hp for simplicity according to a 1:1 ratio
1 hp = 1 CV.
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Temperature
0 C = 273.15 K
0 F = 255.37 K
0 C = 32 ˚F (the conversion factor between Celsius and Fahrenheit is 1:1.8)
UPDATING
General Specifications 1
Electrical equipment 3
Maintenance planning 4
Engine overhaul 6
Technical specifications 7
Tools 8
SECTION 1
General Specifications
Page
IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . 3
HOMOLOGATION PLATE . . . . . . . . . . . . . . . . 3
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 5
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 6
PERSPECTIVE VIEW . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 12
IDENTIFICATION PLATE
Figure 1
218007
HOMOLOGATION PLATE
EPA - TIER 4B (F2CFE613E*B012 - F2CFE613A*B012)
Figure 2
218008
1. Engine type: technical code (F2CFE613E*B012 - F2CFE613A*B012) - 2. Engine serial number (XXXXX) -
3. Construction date (DD/MM/YY) - 4. Engine rating: maximum power expressed in kW (bhp) -
5. Engine model: partial technical code (F2CFE613E*B - F2CFE613A*B)
Figure 3
223506
1. Engine type: technical code (F2CFE613E*B013 - F2CFE613A*B013) - 2. Engine serial number (XXXXX) -
3. Construction date (DD/MM/YY) - 4. FPT engine P/N (5801894357 XZ - 5801894336 XZ) - 5. R24 Code
(24R-031580*00 - 24R-031578*00) - 6. R120 Code (120R-011214*00 - 120R-011210*00) - 7. Directive 2000/25/EC -
8. Directive 2010/26/EU
TECHNICAL CODE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to
characterize its application and power output level. It is stamped on a side of crank-case, close to oil filter.
F2 C F E 6 1 3 E * B 012
Emissions level:
A = TIER 4a
B = TIER 4full/STAGE IV
C = EURO 6
D = Not emissioned
Performances:
1,2,3... A,B,C...= Engine power or torque level
Application:
0 = Other application 5 = Genset
1 = Trucks 6 = Marine
2 = Buses 7 = Cars
3 = Industrial / Agricultural 8 = Railway
4 = Industrial / Agricultural 9 = Military
No. of cylinders
Cylinder configuration:
A = 4 stroke vertical treat
B = 4 stroke horizontal H = 4 stroke at V
C = 4 stroke vertical with EGR K = 4 stroke at V with post treat
D = 4 stroke horizontal with EGR L = 4 stroke vertical with EGR + post treat
E = 4 stroke vertical with post-treat M= 4 stroke at V with EGR
F = 4 stroke horizontal with post-treat N= 4 stroke at V with EGR+ post treatment
G = 4 stroke horizontal with EGR + post
COMMERCIAL CODE
The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical
purpose of recognizing the engine’s components, which is served by the ”ENGINE S/N”.
C 87 E N T Z W
PERSPECTIVE VIEW
Figure 4
F2CFE613 ENGINES
223489
The engine F2CFE613 is a 6-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the CURSOR
series and operates according to a four-stroke diesel cycle.
The engine supply system is electronically-controlled and it’s based on the direct injection of the fuel in the combustion chamber
by means of high pressure pump and common rail.
Maximum Power
Maximum Torque 218009
F2CFE613A*B012 - F2CFE613A*B013
Figure 6
Maximum Power
Maximum Torque 223490
ENGINE VIEWS
Figure 7
223481
Figure 8
223482
Figure 9
223483
FRONT VIEW
Figure 10
223484
REAR VIEW
Base - September 2015 Print P2D32C012 E
F2CFE613 ENGINES SECTION 1 - GENERAL SPECIFICATIONS 11
Figure 11
223491
TOP VIEW
GENERAL CHARACTERISTICS
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
Cycle 4-stroke Diesel
Fuel feed Turbocharged with intercooler
Direct - high pressure pump supply and common
Injection rail system
Bore mm 117
Stroke mm 135
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
REFILLING
Cooling circuit (1) L 14
Lubrication circuit (2)
total capacity (3) L (Kg) 26 (23.4)
Periodic replacement:
Sump at minimum level L (Kg) 20 (18)
Sump at maximum level L (Kg) 23 (20.7)
Fuel tank (4) L -
Urea tank (5) L 43 / 80 / 135
(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and Actifull OT
CONCENTRATE (or Actifull OT PREMIX without adding water) even during the summer months. As an alternative to
Actifull OT, use another product that complies with FPT norm FPI9.COOL002 and / or ASTM D-6210 standard.
(2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9. Recommended oil is SAE 10W-40 that
complies with FPT norm FPI9.LUBR001. FPT suggest to use original AkcelA or AmbrA lubricants compliant with SAE 10W40
standard. The oil consumption is considered to be acceptable until a quantity equaling 0.5% of fuel consumption is reached.
(3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.
(4) Use STANDARD fuel compliant to the ASTM D975 or EN 590. Instructions connected to the fuel tank capacity are the
responsibility of the vehicle/equipment manufacturer since these are subject to changes depending on the various
vehicle/equipment configurations.
(5) Only use AdBlue®/DEF (32.5% solution in water) in accordance with ISO 22241 specification.
Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection system;
! if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
! by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
SECTION 2
Main engine diagrams
Page
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 3
- Drain conditions . . . . . . . . . . . . . . . . . . . . . . . . 5
- Operating principle . . . . . . . . . . . . . . . . . . . . . . 8
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 11
- CRIN 3 Electro-injectors . . . . . . . . . . . . . . . . . 12
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . 15
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 17
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 19
- Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Page
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 24
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Waste gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Schematic diagram . . . . . . . . . . . . . . . . . . . . . . 30
- AdBlue specification . . . . . . . . . . . . . . . . . . . . . 34
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Filter disassembly . . . . . . . . . . . . . . . . . . . . . . . 41
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 42
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 1
High Pressure
Fuel backflow
1. Common Rail - 2. Electro-injector - 3. Engine Control Unit EDC17CV41 - 4. Fuel high-pressure pump - 5. Fuel filter
High Pressure
Low Pressure
223493
Fuel backflow
HYDRAULIC SYSTEM DIAGRAM
1. Common rail - 2. Electro-injector - 3. Common rail excess pressure valve (DBV) - 4. Fuel high pressure pump - 5. Fuel
return from the injectors and rail - 6. High pressure pump backflow - 7. Limiting valve on high pressure pump - 8. Fuel tank -
9. Fuel pre-filter with water separator - 10. Hand priming pump - 11. ECU cooling plate - 12. Mechanical supply pump -
13. By-pass valve - 14. By-pass valve - 15. Fuel filter - 16. Fuel metering unit
The flow rate regulator (16), placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the
low-pressure system.
Afterwards, the high-pressure pump takes care of supplying the rail properly.
This arrangement, by pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.
Function of the pressure relief valve (7), assembled on the high-pressure pump, is keeping the pressure, at the flow rate regulator
inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.
The quick coupler for fuel return housed on the cylinder head, assembled on injector return, permits the fuel return flow from
injectors.
Two by-pass valves (13 and 14) are placed in parallel with the mechanical supply pump (12). The by-pass valve (14) allows fuel
to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.
The by-pass valve (13) allows filling the supply system through the manual priming pump (3).
NOTE Due to the very high pressure that builds within this hydraulic system, the following precautions must be observed
for safety reasons:
- avoid connecting high-pressure pipe fittings with approximate tightening;
- avoid disconnecting the high-pressure pipes when the engine is running
(DO NOT make any attempt at bleeding: this is absolutely useless and dangerous!).
NOTE To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, avoid any
attempt at modification or alteration and intervene immediately if a leak is identified.
NOTE After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level. (IT
MUST NOT INCREASE).
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
72592
situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves through B.
in close position
Figure 4
72593
The high pressure pump cannot be serviced and should not therefore be removed and the fastening bolts should not
be tampered with. The only possible service operation is the replacement of the drive gear.
Figure 6
188494
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter -
6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger -
8. Fuel outlet fitting from supply pump to filter - 9. Mechanical supply pump.
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft -
7. Low-pressure fuel inlet - 8. Pumping elements supplying fuel ducts.
Operating principle
Figure 8
Sec. D - D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct -
6. Pressure regulator supply duct - 7. Pressure regulator
Pumping element (3) is oriented to pump shaft (4) cam. During intake, the pumping element is supplied through supply duct (5).
The fuel amount to be sent to the pumping element is set by the pressure regulator (7). The pressure regulator meters fuel flow
to pumping element according to the PWM signal received from ECU. During pumping element compression stage, fuel reaches
the pressure required to open the delivery valve to common rail (2) and to feed it through outlet (1).
Figure 9 Figure 10
72598 72601
Sec. C - C Sec. A - A
1. Pumping element inlet - 2. Pump lubrication ducts - 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
3. Pumping element inlet - 4. Main pumping element from pump with high pressure pipe fitting for common rail.
supply duct - 5. Pressure regulator - 6. Pumping element
inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief
valve - 9. Fuel drain from regulator inlet
Figure shows low pressure fuel paths inside the path and Figure 10 shows high pressure fuel flow through pumping
highlights: main pumping element supply duct (4), pumping element outlet ducts.
element supply ducts (1 - 3 - 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
Pressure regulator (5) establishes the fuel amount to send to
pumping elements; excess fuel is drained out through duct
(9).
5 bar pressure relief valve acts as fuel exhaust manifold and
keeps 5 bar constant pressure at regulator inlet.
Modulation) signal, modulates the change in fuel flow rate in 1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -
the high-pressure circuit by partially closing or opening the 4. Fuel inlet - 5. Fuel outlet.
sections of passage of the fuel in the low-pressure circuit.
When the engine control unit operates the pressure
regulator (via PWM signal), the solenoid (1) is energized,
which in turn generates the movement of the magnetic core
(2). The shift of the core causes the shutter cylinder (3) to
move axially, choking the flow of fuel.
Figure 12
185437
dead center and the remaining fuel is decompressed. 1. Fuel outlet (backflow to tank) - 2. Overpressure valve -
When the pumping element chamber pressure becomes less 3. Common Rail - 4. Fuel inlet coupling from high pressure
than the supply pressure, the intake valve is again opened and pump without throttle valve - 5. Fuel oulet coupling to
the cycle is repeated. electro-injector with throttle valve - 6. Rail pressure sensor
The delivery valves must always be free in their movements, The rail volume is of reduced sizes to allow a quick
free from impurities and oxidation. pressurisation at startup, at idle and in case of high flow-rates.
The rail delivery pressure is modulated by the electronic It anyway has enough volume as to minimise use of plenum
control unit, through the pressure regulator solenoid valve. chambers caused by injectors openings and closings and by
the high-pressure pump operation. This function is further
The pump is lubricated and cooled by the fuel. enabled by a calibrated hole being set downstream of the
The radialjet pump disconnection - reconnection time on the high-pressure pump.
engine is highly reduced in comparison with traditional The throttle valves or control bushes (5) have been fitted to
injection pumps, because it does not require setting. the fuel delivery couplings, which control the fuel pressure
If the pipe between fuel filter and high-pressure pump is to waves generated by the high pressure pump.
be removed-refitted, be sure that hands and components are A fuel pressure sensor (6) is screwed to the rail. The signal
absolutely clean. sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.
Overpressure valve
Overpressure valve is mounted at one rail end. Overpressure
valve task is to protect system components should rail pres-
sure sensor or CP3 pump pressure regulator malfunctioning
cause a pressure excessive increase in high pressure system.
When pressure in rail is reaching 1800 bar, the valve at start
operates in order to make fuel flow and consequently de-
crease pressure to safety values, then mechanically regulates
pressure in rail. The valve enables to operate engine for long
times with limited performance and prevents fuel excessive
overheating, so preserving pipes for fuel return to tank.
CRIN 3 Electro-injectors
The electro-injectors are mounted on the cylinder head and operated by the engine control unit.
Figure 14
204302
They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot
valve.
Figure 15
114255
Figure 16
188492
INJECTOR SECTION
1. Coil - 2. High-pressure fuel inlet fitting - 3. Filter - 4. Pressure rod - 5. Needle - 6. Nozzle -
7. Pressure chamber - 8. Control volume - 9. Pilot valve shutter - 10. Fuel return.
Fuel filter
Figure 17
218518
1. Fuel inlet from mechanical pump - 2. Fuel outlet to high-pressure pump - 3. Vent plug - 4. Fuel filter support -
5. Drain screw - 6. Fuel filter - 7. Fuel filter clogging (pressure drop) sensor - 8. Fuel temperature sensor
Characteristics:
LUBRICATION CIRCUIT
A gear pump, located at the rear of the crankcase, serves to circulate the lubricant; the oil pump is driven by the crown wheel
keyed to the tang of the crankshaft.
The lubricant is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve actuation.
The lubrication circuit also includes the heat exchanger and the turbocharger.
The pump contains a safety valve, while an oil overpressure valve is fitted on the crankcase.
Figure 18
166171
The oil pump (1) is housed in the rear of the crankcase (3). It’s a gear pump (6) commanded by helical gear (5).
It receives the motion from the crankshaft (4) by means of helical gear (2) fitted to the stub of the crankshaft (4).
Figure 19
218519
Figure 20
112327
Engine speed [rpm] Pump speed [rpm] Outlet pressure [bar] Flow [lpm]
1000 1515 2 62
2400 3636 6 128
Overpressure valve
The valve opening start pressure is 10.1 ± 0.7 bar.
Figure 21
191572
Figure 22
898 N/mm
219641
Figure 23
73542
188496
Heat exchanger
The heat exchanger is mounted inside the engine crankcase on the left-hand side.
Figure 25
114246
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4. Oil filter - 5. Oil filter seal
114247
1. Closure cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tank O-ring - 6. Washer - 7. Washer - 8. Support -
9. Plug M14x1.5 - 10. Plug M38x1.5 - 11. By-pass valve 3.4 bar.
Lock torques
Cap (part 1): 60 5 Nm
Plug (part 9): 30 5 Nm
Plug (part 10): 90 5 Nm
Installation rule
Use threadlock for plug (part 10).
73545
Figure 28
115878
Move the upper part of the casing thread close to the first
lower thread of the support (the cartridge cover element
should be in contact with the oil outlet duct on the support).
115876 Proceed with tightening the cartridge-casing assembly (1) on
the support (4).
Remove the plug (2).
During this stage both the seal (3) for the oil outlet
Undo the filter casing (1) by a couple of turns and wait for
duct-cartridge element and the casing-support seal (2) will
a few minutes.
gradually be involved.
In this way the remaining oil in the casing starts firstly to drip
Tighten the filter casing to a torque of 65 Nm.
and then to flow smoothly out.
Completely undo the casing and then replace the cartridge.
Figure 31
Refitting
Figure 29
115877
At the same time, the tabs on the upper plate should slide Tighten the protective cap (1) on the filter casing.
into the housings.
Oil sump
The oil sump has a new type of anchorage to the crankcase: rubber diaphragm.
The edge of the sump (2) is sealed within a thick “C“ rubber gasket (1), and the assembly is contained inside and supported
by an aluminium element (5) bolted to the crankcase with screws (3).
This solution prevents noise and improves seal quality, while using less screws than the traditional system.
Yet another benefit is that the gasket does not require replacement at every removal.
Figure 32
223492
1. Rubber gasket - 2. Oil sump - 3. Fastening screws - 4. Lubricant oil drain plug - 5. Aluminium plate
193965
COOLING CIRCUIT
Description
The engine cooling system is of the closed-circuit, forced circulation type.
It consists mainly of the following components:
- expansion tank, not supplied (by FPT);
- a heat exchanger to cool down lubrication oil;
- a water pump with centrifugal system incorporated in the cylinder block;
- fan, not supplied;
- thermostat controlling the coolant circulation.
Operation
The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the
cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the
thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan.
Figure 34
Figure 35
223537
NOTE Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.
Thermostat
The thermostat is inserted into the water inlet pipe into the pump; it is an N/C valve.
The valve begins to open with temperatures exceeding 85 ˚C.
When the valve is closed, the water arriving from the heat exchanger on the gearbox, recirculates inside the engine via the
water pump.
When the valve is open, the water arriving from the heat exchanger on the gearbox is sent directly to the radiator where it
is then cooled.
Figure 36
191251
TERMOSTAT SECTION
- The valve starts to open at: 85 ˚C ± 1.5 ˚C
- The stroke is at least: 9 mm at 95 ˚C
Figure 37
Exhaust gas
Compressed air 223497
Intake air
DIAGRAM OF TURBOCHARGING
1. Exhaust valves - 2. Exhaust manifold - 3. Motorized throttle valve (Exhaust flap) - 4. Turbocharger with waste-gate valve -
5. Intake valves - 6. Air grid-heater for cold starting (if present) - 7. Intake manifold
A. Cooled compressed air engine intake from intercooler - B. Turbocharger exhaust gas outlet from motorized throttle
valve (Exhaust flap) - C. Turbocharger filtered air inlet from air filter - D. Turbocharger compressed air outlet to intercooler
189008
Figure 39
Waste gate
NOTE Verifying an anomalous operation of the engine,
due to the booster system, it is recommended, be- The turbocharger is fitted with a pressure regulation valve,
fore performing controls on the turbocharger, to mounted on the exhaust manifold before the turbine and
check the efficiency of the sealing gaskets and the controlled by a pneumatic actuator, connected via a pipe to
fixing of the connection sleeves, making sure of the intake manifold.
clogging absence inside intake sleeves, air cleaner Its job is to limit the quantity of exhaust gas acting on the tur-
or inside radiators. bine by sending part of it directly into the exhaust pipe when
If the turbocharger damage is due to a lack of lubric- the boost pressure downstream of the compressor reaches
ation, check that the oil circulation pipes are not the maximum value set.
broken or obstructed, in such case replace them or
eliminate the trouble. Check and adjustment
Figure 40
Bearing end play check
Position the tracer point of the magnetic-base dial gauge on
the turbocharger shaft end and set to zero the dial gauge.
Move the turbocharger shaft axially and check that the clear-
ance is not higher than the prescribed value.
Replace the turbocharger if a different value is found.
62873
Cover the air, exhaust gas and lubrication oil inlets and out-
lets.
Carry out an accurate external cleaning of the turbocharger,
using the anticorrosive and antioxidant solution and perform
the check on the actuator (6).
Clamp the turbocharger in a vice.
Disconnect the pipe of the actuator (6) and apply to the actu-
ator union, the pipe of pump 99367121 (1).
Apply the magnetic-base dial gauge (2) on the exhaust gas
inlet flange in the turbine.
Position the tracer point of the gauge (2) on the tie rod (3)
end and set to zero the gauge (2).
Through the pump (1) let in compressed air, in the actuator
(6), at the prescribed pressure and make sure that such value
is kept constant for the whole check time, otherwise replace
the actuator (6).
In the above-mentioned conditions, the tie rod must have
carried out the prescribe stroke.
Figure 41
188487
Exhaust gas
Compressed air
Intake air
Coolant engine
Electric line
AdBlue
223500
In order to reduce exhaust gas emissions to within the limits required by current standards, it has proved necessary to adopt
the exhaust gas after-treatment system (ATS) which combines two devices:
- two catalytic converters for the treatment of HC (unburned hydrocarbons) and CO (carbon monoxide);
- the device DeNOx 2.2 for the treatment of NOx (nitrogen oxides).
The ATS system is electronically managed by the ECU EDC17CV41 which, based on the number of engine revs, delivered
torque, exhaust gas temperature, amount of nitrogen oxides and air humidity intake, regulates the flow rate of the AdBlue
solution to be introduced into the system.
The pump module draws the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.
Figure 43
185021
Figure 44
AdBlue
Electric line
Coolant engine
223499
1. Can line - 2. AdBlue tank - 3. AdBlue tank level sensor - 4. Urea quality sensor (UQS) - 5. AdBlue temperature sensor -
6. Engine Control Module (EDC17CV41) - 7. Humidity and temperature sensor (after air filter) - 8. NOx sensor ECU -
9. NH3 sensor ECU - 10. Supply module Denox 2.2 - 11. Urea pressure sensor - 12. NH3 sensor - 13. NOx sensor -
14. SCR downstream exhaust gas temperature sensor - 15. Clean Up Catalyst (CUC) -
16. Selective catalyst reduction (SCR) - 17. SCR upstream exhaust gas temperature sensor - 18. Mixer -
19. Dosing module - 20. Diesel Oxidation Catalyst (DOC) - 21. DOC upstream exhaust gas temperature sensor -
22. NOx sensor - 23. Engine coolant 3 way valve - 24. NOx sensor ECU.
Figure 45
223498
1. DOC upstream NOx sensor - 2. Engine coolant 3 way valve - 3. Dosing module DeNOx 2.2 -
4. Intake air humidity and temperature sensor - 5. Supply module DeNOx 2.2 - 6. AdBlue tank -
7. AdBlue tank level sensor - 8. Urea quality sensor (UQS) - 9. Selective catalyst reduction (SCR) -
10. SCR upstream exhaust gas temperature sensor - 11. Exhaust flap module - 12. Diesel Oxidation Catalyst (DOC) -
13. DOC upstream exhaust gas temperature sensor - 14. SCR downstream exhaust gas temperature sensor -
15. NH3 sensor - 16. NH3 sensor ECU - 17. SCR downstream NOx sensor
AdBlue specification
ISO 22241 / AUS32 / DIN V 70070
Urea 32.5% - solution in water
Min Max
Urea content 31.8 33.2 % by weight
Density at 20˚C 1.087 1.093 g/cm3
Refracting index at 20˚C 1.3814 1.3843
Alkalinity as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chromium 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg
Figure 46
Coolant engine
AdBlue
185019
COOLING CONDITION
1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.
The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures
reached by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously
cooled.
Figure 47
Coolant engine
AdBlue
185023
215387
The tank has a level indicator command (1) and contains the reducing substance, consisting of a 33% urea and water solution
called AdBlue. The inlet (4) is equipped with a mesh filter (3). A urea quality sensor (2) and a temperature sensor are
incorporated in the tank.
NOTE FPT recommends maintaining AdBlue temperature below 50 ˚C in the tank during operating conditions.
Tank ventilation: the circuit must be protected from dust.
215388
1. AdBlue suction - 2. AdBlue return - 3. Engine coolant outlet - 4. Engine coolant outlet pipe - 5. AdBlue heating coil -
6. Engine coolant inlet pipe - 7. Connector - 8. Engine coolant inlet - 9. Ad Blue suction pipe - 10. Filter -
11. Bottom plate (AdBlue NTC temperature sensor) - 12. Float (AdBlue level sensor) - 13. Reed pipe -
14. AdBlue return pipe
NOTE Ensure connectors are properly sealed with a moisture proof plug prior to AdBlue tank leak testing.
Electrical connections:
Figure 50
215389
Ref. Description
1 Level
2 Common ground
3 NTC signal (temperature)
185025
1. Main filter - 2. Electrical connector - 3. Pressure compensation membrane - 4. Supply pipe from tank - 5. Fluid input pipe
of pump module heating - 6. AdBlue return pipe to tank - 7. Fluid output pipe of pump module heating - 8. Delivery pipe
to dosing module
The AdBlue supply module is essentially composed of a diaphragm pump which draws the AdBlue from the tank and conveys
it to the dosing module.
It is equipped with a circuit connected to the engine cooling system which, in the event of low temperatures, prevents the AdBlue
from freezing. A pressure sensor is located inside it.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and
depend on the operating conditions of the engine and the signals sent from the sensors.
Electric power requirements of DeNOx 2.2 Supply Module (SM) for 7.2 kg/h:
24 Volt systems: max 2750 mA @ 28 Volt battery voltage
Figure 52
185029
1. Coolant connector - 2. AdBlue inlet from tank - 3. AdBlue back-flow to tank - 4. AdBlue outlet to DM - 5. Pressure
sensor - 6. Main filter - 7. Membrane pump - 8. 4/2 Way valve.
To prevent damage to the pump and dosing module, the supply module contains a filter which removes any impurities from
the AdBlue.
Please refer to the following procedure for replacement of the filter.
Figure 53
185430
185435 - Insert the tool (1) in the correct direction in the filter,
based on the colour of the filter supplied
NOTE During installation of the supply module on the
vehicle, take into account the minimum aperture
for filter replacement. Figure 57
The minimum value is approx. 155 mm.
Figure 54
185431
Figure 55
185432
185429
185428
Figure 60
Figure 63
185434
185435
Figure 61
185429
NOTE Check that the filter cover and the contact surface
of the supply module are not cracked or damaged.
If necessary, replace any damaged components.
193974
The dosing module is controlled by the engine control unit. Its function is to measure the AdBlue solution to be injected into
the exhaust pipe upstream of the SCR catalytic converter.
It is mounted on the catalytic converter and whilst operating is constantly subjected to high temperatures, hence it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
Hydraulic Capability of DeNOx 2.2 Dosing module (DM):
Normal circulation and no injection: ~ 8 kg/h
Maximum with the small urea injector: ~ 15 kg/h (8 kg/h + 7 kg/h)
Maximum with the large urea injector: ~ 20 kg/h (8 kg/h + 12 kg/h)
180580
1. Electrical connector - 2. AdBlue tank heating fluid pipe - 3. Dosing module coolant pipe - 4. Engine coolant pipe.
The switch valve is of solenoid valve 2 position/3-way type. Depending on the temperatures detected by the NTC sensor, the
switch valve closes or opens the passage of the engine coolant into the AdBlue tank heating coil. The cooling circuit of the dosing
module instead always stays open.
The first position, in fact, allows the cooling of the dosing module (DM - Dosing Module) whereas the second position allows
the cooling of the AdBlue tank, the supply module (SM - Supply Module) and the relevant pipes, besides heating the DM.
NH3 sensor
Figure 66
185027
The NH3 sensor is connected to the engine control unit and, by detecting the presence of ammonia (NH3) in the exhaust gases
exiting the catalytic converter, enables a more accurate regulation of the amount of AdBlue to be injected.
Figure 67
185028
Figure 68
102302
Figure 69
102303
Figure 70
102304
125531
Figure 72
223113
223534
FILTER LOCATION
1. Dosing valve filter (36 m) - 2. Dosing module - 3. Supply module backflow-filter (100 m) -
4. Supply module pre-filter (100 or 70* m) - 5. Tank neck filter (300 or 100* m) - 6. AdBlue tank -
7. Supply module inlet-filter (100 m) - 8. Supply module - 9. Supply module main-filter
SECTION 3
Electrical equipment
Page
- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Electro-injectors (CRIN 3) . . . . . . . . . . . . . . . 17
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 1
223496
1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor - 4. Fuel temperature and filter
clogging (pressure drop) sensor - 5. Crankcase pressure sensor - 6. Grid-heater resistance for engine pre-heating -
7. Alternator - 8. Boost pressure and air temperature sensor - 9. Engine oil pressure and temperature sensor - 10. Engine
Control Unit EDC17CV41 - 11. Fuel high pressure pump metering unit - 12. Starter electric motor - 13. Flywheel increment
speed sensor (crankshaft) - 14. Motorized throttle valve actuator connector (Exhaust flap) - 15. Timing segment speed sensor
(camshaft) - 16. Exhaust gas absolute pressure sensor
Figure 2
223501
1. Electro-injector (cylinder 6) - 2. Electro-injector (cylinder 5) - 3. Electro-injector (cylinder 4) - 4. Electro-injector (cylinder 3) - 5. Electro-injector (cylinder 2) -
6. Rail pressure sensor - 7. Electro-injector (cylinder 1) - 8. Bulkhead connector (wires passage) - 9. Engine decompression electrovalve insertion (Engine brake) - 10. Coolant
temperature sensor - 11. EDC engine side connector 96 pin - 12. In line vehicle side connector 7 pin - 13. Crankcase pressure sensor - 14. Boost pressure and air temperature
sensor - 15. Engine oil pressure and temperature sensor - 16. Fuel filter clogging (pressure drop) sensor - 17. Fuel temperature sensor - 18. Fuel high pressure pump metering unit
- 19. Timing segment speed sensor (camshaft) - 20. Exhaust gas absolute pressure sensor - 21. Motorized throttle valve actuator connector (Exhaust flap) - 22. Flywheel
F2CFE613 ENGINES
Print P2D32C012 E
F2CFE613 ENGINES SECTION 3 - ELECTRICAL EQUIPMENT 5
Figure 3
189003
Fuel injection
Accessory functions such as cruise control, speed limiter, PTO and the like
Self-diagnosis
Recovery
It also enables:
Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating
Synchronization search
The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.
If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the
sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection
occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence
and start the engine.
Figure 4
EDC 17CV41 control unit wiring diagram - Vehicle side (part 1/2)
218026
1. Vehicle connector EDC 96 pin - 2. CAN BUS to Customer’s application computer - 3. Diagnostic connector - 4. Controller Area Network C - 5. SCR downstream NOx
ECU - 6. SCR downstream NOx sensor - 7. DOC upstream NOx ECU - 8. DOC upstream NOx sensor - 9. NH3 ECU - 10. NH3 sensor - 11. Urea Quality sensor -
12. In line connector - 13. Battery Disconnection Switch (BDS) - 14. Alternator - 15. Alternator connector kit (J1) - 16. Starter electric motor - 17. Battery -
18. Battery charge warning lamp - 19. SCR hose suction line heater - 20. Fuel pre-filter heater relay - 21. Fuel pre-filter heater - 22. SCR electrical heater -
23. SCR heater relay - 24. Fuel filter/pre-filter heater relay - 25. Fuel filter heater - 26. Grid-heater relay - 27. Water in fuel switch - 28. ATS intelligent sensors auxiliary relay -
29. Grid-heater - 30. Starter control relay - 31. Starter relay - 32. Body controller starter interlock (Vehicle safety) - 33. Body controller starter interlock relay - 34. Key switch -
35. Alternative connections (A. ECU under time relay - B. ECU under BDS - C. ECU not under BDS)
F2CFE613 ENGINES
Print P2D32C012 E
Print P2D32C012 E
Figure 5
F2CFE613 ENGINES
EDC 17CV41 control unit wiring diagram - Vehicle side (part 2/2)
218027
1. Vehicle connector EDC 96 pin - 2. Controller Area Network B - 3. SCR tank level and temperature sensor - 4. Diagnostic LED - 5. DEF dosing module -
6. SCR downstream exhaust gas temperature sensor - 7. SCR upstream exhaust gas temperature sensor - 8. DOC upstream exhaust gas temperature sensor -
9. Humidity and ambient temperature sensor - 10. SCR tank heating valve - 11. SCR Pump module
(A. SCR pressure sensor - B. SCR reverting valve - C. SCR pump motor)
SECTION 3 - ELECTRICAL EQUIPMENT
9
Pin out EDC 17CV41 control unit - Vehicle side connector (connector 1)
Figure 6
189004
223503
1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Engine oil pressure and temperature sensor -
5. Boost pressure and air temperature sensor - 6. Fuel filter clogging (pressure drop) switch - 7. Motorized throttle valve actuator connector (Exhaust flap) - 8. In line connector -
9.Crankcase pressure sensor - 10. Timing segment speed sensor (camshaft) - 11. Flywheel increment speed sensor (crankshaft) - 12. Fuel high pressure pump metering unit -
13. Exhaust gas absolute pressure sensor - 14. Engine decompression electrovalve insertion (Engine brake) - 15. Bulkhead connector (wires passage) - 16. Rail pressure sensor
SECTION 3 - ELECTRICAL EQUIPMENT
(RDS4) - 17. Electro-injector (cylinder 6) - 18. Electro-injector (cylinder 5) - 19. Electro-injector (cylinder 4) - 20. Electro-injector (cylinder 3) - 21. Electro-injector (cylinder 2) -
22. Electro-injector (cylinder 1)
13
Pin out EDC 17CV41 control unit - Engine side connector (connector 2)
Figure 8
Colour legend
C ORANGE
A SKY BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE 189005
Electro-injectors (CRIN 3)
Figure 9
114255
The electro-injectors are mounted on the cylinder head and operated by the engine control unit.
They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot valve.
It is an N.A. type solenoid valve. The solenoid valve controls the lift of the nozzle needle.
The resistance of the coil of each individual injector is 0.56 ÷ 0.57 .
The injectors are connected to the control unit via the engine cable.
Pressure regulator
Located at high-pressure pump inlet, on low pressure system,
it modulates the amount of fuel for high-pressure pump supply
based on commands received from ECU.
It mainly consists of parts below:
- rapezoidal-section lock pin;
- valve control pin;
- pre-load valve;
- coils.
A
When no control signal is present, the pressure regulator is
normally open, therefore the high pressure pump is in max B
delivery condition.
C
The ECU modulates a PWM control signal to extend or
reduce section of fuel supply line to high-pressure pump. D
The component cannot be replaced as an individual part,
therefore it cannot be removed.
The quantity of high-pressure supply fuel is metered by a 3
proportional valve positioned on low-pressure system and it
is managed by the ECU.
E
The delivery pressure to rail is modulated between 250 and
1400 bars by ECU operating on pressure regulator solenoid
valve.
It is a NO solenoid valve. 191577
Cable
PIN DESCRIPTION TO
colour
1 Supply EDC17, pin 2/58 S
2 Signal EDC17, pin 2/83 V
Figure 11 Figure 12
190509 190512
Cable Cable
PIN DESCRIPTION TO PIN DESCRIPTION TO
colour colour
1 Ground (-) EDC17, pin 2/60 N 1 Supply EDC17, pin 2/32 L
2 Signal (Output) EDC17, pin 2/36 S 2 Ground EDC17, pin 2/42 Z
3 Supply Voltage (+) EDC17, pin 2/11 G 3 Signal EDC17, pin 2/61 G
CHARACTERISTIC VALUE
Pressure range 0 2400 bar
Supply Voltage 5V
Output voltage 0.5 4.5V
Tightening torque 140 Nm
NOTE If this signal fails the rev counter will not function.
Figure 13
190511
Figure 15
190510
Cable
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/66 B
2 Signal (-) EDC17, pin 2/65 N
CHARACTERISTIC VALUE
Resistance 850 870
Tightening torque 6 10 Nm
190599
Figure 16
190511
Figure 18
190510
Cable
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/68 B 6+1
2 Signal (-) EDC17, pin 2/67 N
CHARACTERISTIC VALUE
Resistance 850 870
115825
Tightening torque 6 10 Nm
Figure 19
1 2
190515
Figure 21
113561
Cable 190516
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/12 H
2 Signal (-) EDC17, pin 2/59* L
* Common ground
CHARACTERISTIC VALUE
Tightening torque 20 ± 5 Nm
Figure 22 Figure 24
1
2
3
4
113561 190517
Cable Cable
PIN DESCRIPTION TO PIN DESCRIPTION TO
colour colour
1 Signal (+) EDC17, pin 2/39 H 1 Ground EDC17, pin 2/6 G
2 Signal (-) EDC17, pin 2/59* L Temperature
2 EDC17, pin 2/13 V
Signal
* Common ground
3 Supply (+5V) EDC17, pin 2/31 R
4 Pressure Signal EDC17, pin 2/35 Z
CHARACTERISTIC VALUE
Tightening torque 25 Nm
Figure 23 Figure 25
PRESSURESENSOR
4
1 2
190515 190518
Boost pressure and temperature sensor Main fuel filter clogging switch
It is mounted on the intake manifold. This is an electrically normally-closed sensor which identifies
the clogging of the fuel filter, looking if there is a delta pressure
between its two ports - exceeding a certain threshold.
Figure 26
Figure 28
210296 190523
Cable Cable
PIN DESCRIPTION TO PIN DESCRIPTION TO
colour colour
1 Ground EDC17, pin 2/90 G 1 Ground EDC17, pin 2/78 H
2 Temperature EDC17, pin 2/37 R 2 Signal EDC17, pin 2/79 Z
Signal
3 Supply (+5V) EDC17, pin 2/7 V
CHARACTERISTIC VALUE
4 Pressure Signal EDC17, pin 2/86 Z
Nominal Voltage 12 / 24 Vcc
Maximum switched tension 200 mA
Differential opening pressure 150 ± 10 KPa
Maximum working pressure 500 KPa
Operating temperature - 40˚C / +120˚C
Tightening torque 30 ± 2 Nm
Figure 27
1 Figure 29
PRESSURESENSOR
4 P
190518 190524
Figure 30
221074
Cable 223502
PIN DESCRIPTION TO
colour
1 Ground EDC17, pin 2/70 -
2 Signal EDC17, pin 2/95 -
CHARACTERISTIC VALUE
Voltage range 9 ÷ 16 V
Power requirement 13.9 W
Operating temperature - 40˚C / +130˚C
Tightening torque 32 ± 3.2 Nm
Figure 31
223511
Figure 33
188487
Figure 34
188489
Figure 35 Figure 36
50
30
223510 223509
ELECTRICAL WIRING
1. Current contactor - 2. Command electromagnet - 3. Starter electric motor - 4. Batteryr
The starter motor runs the engine, gaining its inertia and friction, and bringing it to a certain number of revolutions such as to initiate
the formation of the mixture required for combustion and then the autonomous movement of the engine.
The movement is transmitted by a DC electric motor, powered by the battery, via an engagement pinion which rotates the sprocket
formed on the engine flywheel.
Due to a free wheel engagement, the pinion turns off when the main engine rotates faster than the starter motor.
A relay energized by the current of the starter motor engages the pinion by means of a fork.
The starter motor included is a translation type and starts by means of the pinion, with relay housed directly above the starter motor.
Ignition is usually controlled via the ignition switch on the control panel and provides a positive voltage to the relay located on the
starter motor.
Specifications:
Type: DENSO
Nominal voltage: 24 V
Nominal rated power: 4.5 kW
Number of poles: 4
Direction of rotation: clockwise (seen from flywheel side)
Alternator
Figure 37
223508
Figure 38 Figure 39
223507 106282
B terminal: Positive - S terminal: Battery voltage sensor - IG terminal: Alternator ignition - L terminal: to charging light
It is frontally located on the right-hand side of the engine and is controlled by the auxiliary members’ belt.
Specifications:
Type: MITSUBISHI
Nominal voltage: 24 V
Nominal rated current: 90 A @ 5,000 rpm
Stand-by current consumption: ≤ 1mA
Maximum continuous rotation velocity: ≤ 16,000 RPM
Operating temperature range: 100 ˚C Max (continuous)
Weight: 6.9 kg
Direction of rotation: clockwise
Number of poles: 12
SECTION 4
Maintenance planning
Page
MAINTENANCE PLANNING . . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE PROCEDURES . . . . . . . . . . . . 5
- Planned maintenance . . . . . . . . . . . . . . . . . . . 8
- Extraordinary maintenance . . . . . . . . . . . . . . . 13
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by
common sense and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure,
immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
(*) Frequency for construction equipment application: - 100 hours versus standard application.
(**)Indicated frequencies are valid only if the component (s) supplied by FPT.
(1) Maximum period relative to the use of high quality fuel, (specification ASTM D975 or EN 590); this is reduced based on fuel
contamination and the alarm signals due to filter clogging and/or the presence of water in the pre-filter. The filter clogging
signal indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off after drainage,
the filter must be replaced.
(2) To be performed every year even if the specified operating hours interval has not been reached.
(3) The frequencies are applicable for lubricants which meet the international standards API CJ-4 / ACEA E9 as specified in the
REFILLING table.
(4) Only use filters with the following specifications:
- degree of filtering < 12 μm
- filtering efficiency 99.5% (ß > 200).
(5) To be performed every two years even if the specified operating hours interval has not been reached.
(6) To be performed every three years even if the specified operating hours interval has not been reached.
(7) To be performed every 15 days even if the specified operating hours interval has not been reached.
(8) To be performed every six months even if the specified operating hours interval has not been reached.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
NOTE Diesel fuel for low temperatures. Standard EN590 defines different classes of Diesel fuels, identifying the
characteristics of those most suitable for use in low ambient temperatures.
Compliance with the regulations regarding the distribution of fuels suitable for the climatic and geographic conditions
of the various countries is entirely up to the oil companies.
The time intervals given in this plan are merely approximate as they refer to using the engines in an industrial environment
with average use in relation to displacement.
Always ensure the oil added has the same - Visual check of fumes (colour of exhaust emissions)
characteristics of the oil contained in the sump. - Visual check of cooling liquid level, in the expansion tank.
Mixing is not allowed as this would not guarantee
correct lubrication of the internal parts of the
engine.
Air filter and housing cleanness check Tension and conditions check of auxiliary members’
belt
Figure 2 Proceed only with engine not running and at low
temperature to avoid any risk of burns.
- Check that there are no tears in the belt and that it shows
no obvious signs of wear and tear or of soiling from oil
or fuel. Replace belt if these signs are present.
- Using the wrench square drive 1/2 inch to check the
efficiency of the automatic belt tensioner.
Figure 3
215046
223485
- Place a proper container for the oil collecting under the Lubricant oil filter replacement
pan connected with the drain plug (3).
- Unscrew the plug (3) and then take out the control dip- Figure 6
sick (not supplied by FPT) and the inserting plug (1) to
ease the downflow of the lubrication oil.
- Wait until the oil sump (2) has completely emptied, then
retighten the lubricant oil drain plug (3) under the sump
(2). 223486
Replace the filter element (3) and the sealing gasket (2)
contained inside the filter (4).
Carefully clean the surfaces of the support (1) in contact with
the sealing gasket (2).
Moisten the sealing gasket (2) of the new filter (4) with a thin
layer of oil.
Manually tighten the new filter (4) on the support (1) until it
comes into contact with the gasket (2).
Additionally tighten it using a specific tool to a torque of
60 ± 5 Nm.
Operate the engine for a few minutes and then check the
level using the dipstick. If necessary, top up to compensate for
the quantity of oil used to fill up the filtering cartridge.
Figure 7 Figure 8
215045
Figure 9
215046
Figure 11 Figure 12
223488
Figure 13
114287
Unscrew the screws (2). - Use special spanner to lock/unlock adjustment screw.
Remove cylinder head cover (1) and its gasket. - Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
Ref. No. Description
(2) 20 M6x1x50 Follow the firing order indicated in the table below.
Tightening
Ref. No. Description torques
(1) 12 M10x1x1.25 39 ± 5 Nm
Fit the valve cover (1) with the related gasket and insert all - Refill the engine and the heat exchanger until the cooling
the screws (2). circuit has been completely refilled using amixture of 50%
Tighten the fastening screws (2) to the prescribed torque water and Actifull OT CONCENTRATE, as contained in
following order and mode shown in the figure below. the REFILLING table.
Do not fill the expansion tank to the brim.
Tightening - With the coolant cap open, start the engine and let it idle
Ref. No. Description torques for approx. one minute. This helps to completely bleed
(2) 20 M6x1x50 8.5 ± 1.5 Nm the air contained in the cooling circuit.
- Stop the engine and top up with more coolant, if
Figure 16 necessary.
- When the engine is cold, make sure that the coolant in
the expansion tank is a few centimetres below the filling
hole.
- In the event of an externally located level indicator as
regards the heat exchangers, proceed with the top up
operation bymaking sure that the coolant does not
overfill the internal volume of the exchanger in order to
allow the expansion of coolant volume during increases
in temperature.
SECTION 5
Removal and refitting of main engine
components
Page
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP
REMOVAL / REFITTING . . . . . . . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Page Page
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OIL SUMP REMOVAL / REFITTING . . . . . . . . . . 25
- Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INJECTOR REMOVAL / REFITTING . . . . . . . . . 14 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 2
223488 223505
Pull the automatic belt tensioner (8) by using appropriate Unscrew fastening screws (1 and 3) and remove the
tool (7) and remove the auxiliary members’ belt (4) from alternator (4), recovering spacer (2).
alternator (1), water pump (3), fan control pulley (2),
crankshaft pulley with damper (6) and fixed guide roller (5).
Figure 3
223513
Refitting
Apply a new seal ring (1) to the coolant pump (2).
Assemble the water pump (2) complete with its sealing
gasket (1) and tighten the fastening screws (3) to the
prescribed torque.
223514 218014
Assemble the thermostat unit: fit the thermostat (1), a new Disconnect the engine cable (1) from the ECU (5), as
sealing ring (2) and the engine coolant outlet pipe (5) described in the relative section.
complete with its gasket (3); tighten the fastening screws (4)
Position a suitable container to catch any fuel.
to the prescribed torque.
Disconnect the retainer (2) and remove the low pressure
Ref No. Description Tightening torques fuel pipe from fuel pre-filter to the engine control unit heat
exchanger.
(4) 5 M8x1.25x70 24.5 ± 2.5 Nm
Disconnect the retainer (4) and remove the low pressure
fuel pipe from the engine control unit heat exchanger to to
mechanical pump, as described in the relative section.
Figure 7
Unscrew the fastening nuts (3), and remove the ECU (5),
including the heat exchanger.
Refitting
Fit the ECU (5) including the heat exchanger on the
crankcase and tighten the fastening nuts (3) to the prescribed
torque.
Connect the low pressure fuel pipe from the mechanical
pump to the engine control unit heat exchanger by means
of the retainer (4), as described in the relative procedure.
223513
Connect the low pressure fuel pipe from fuel pre-filter to the
Connect the engine cable (4) to the coolant temperature engine control unit heat exchanger by means of the retainer
sensor (3), as described in the relative section. (2).
Close the strap (1) retaining the engine cable (4) to the Connect the engine cable (1) to the ECU (5), as described
engine coolant outlet pipe (2). in the relative section.
223515 218016
During this operation don’t smoke and don’t use Fit the fuel filter support (2) together with the fuel filter
free flames. clogging (pressure drop) sensor (5) and NTC temperature
Avoid to breathe the vapours coming from filter. sensor (4) on the engine cable supporting bracket (1) and
tighten the fastening screws (3) to the prescribed torque.
Figure 10
223515
Connect the fittings (1) of the low pressure fuel pipes from
fuel filter to high pressure pump and from mechanical pump
218016 to fuel filter.
Place a container for collecting diesel under the fuel filter Connect the sensor connections (4) of the engine cable (2)
support (2). to the fuel filter support (3), as described in the relative
Unscrew the fastening screws (3) and remove the fuel filter procedure.
support (2) together with the fuel filter clogging (pressure
drop) sensor (5) and NTC temperature sensor (4) from the
Ref No. Description Tightening torques
engine cable supporting bracket (1).
(1) 2 M16x1.5 40 ± 5 Nm
Ref No. Description
(3) 4 M8x1.25x30
Figure 13
218018
218019
Refitting Figure 18
Figure 16
218017
Fit the fuel filter bracket (1) and tighten the fastening screws
218019 (2 and 4) to the prescribed torque.
Fit the fuel high-pressure pump (1) complete with the Connect the the high-pressure fuel pipe (5) from
mechanical pump (2) and the gear (4) into the flywheel high-pressure pump to cylinder head and tighten the hose
housing-gear box carter (5). couplings (3 and 10) and the screw (6) to the prescribed
torque.
Tighten the fastening screws (3) to the prescribed torque.
Connect the low pressure fuel pipe (11) from fuel filter to
high-pressure pump and the pipe (12) from mechanical
pump to fuel filter and tighten the fittings (7 and 9) to the
Ref No. Description Tightening torques prescribed torque.
(3) 3 M8x1.25x40 33 ± 3 Nm
Fasten the engine cable to the retainers and connect the
electrical connection to the fuel high-pressure pump
Figure 17 metering unit (8), as described in the relative procedure.
Figure 19
193948 218022
Unscrew the screws (2). Unscrew n˚ 3 screws (1); remove common rail (2) and
spacers (3).
Remove cylinder head cover (1) and gasket.
Remove cable on head.
Refitting
Figure 20 Figure 22
218023 218022
Disconnect fuel delivery pipes (5) between common rail (4) Install rail (2) and spacers (3) on cylinder head.
and electro-injectors, fuel supply pipe (3) between Lock n˚ 3 retaining screws (1) by hand.
high-pressure pump and common rail (4) and fuel return pipe
(1) between common rail (4) and cylinder head.
Unscrew the fastening screws (2) and remove the bracket Ref No. Description Tightening torques
(6) from the cylinder head. (1) 3 M8 23 ± 2 Nm
Figure 23
NOTE The high-pressure fuel delivery pipes must be
replaced every time they are removed. The hose
couplings must be tightened to torque using
spanner 99368542 and torque wrench 99389833.
218021
NOTE After the assembly procedure, the fuel lines must
definitely not touch each other so as not to get
Install the common rail (3) and high-pressure fuel delivery damaged because of the high stress due to engine
pipes by proceeding as follows: vibration.
- Fit the common rail (3) on the cylinder head (5) and The MINIMUM distance between the individual
manually tighten the fastening screws (12). pipes must NOT be LESS than 2 mm.
- Check that the injectors are installed in correct position
(equidistant from the springs) and locked to required
torque. End assembly procedure by connecting engine cable on head
to injectors and rail sensor.
- Fit the high-pressure fuel delivery pipes (6 and 8) and
manually tighten the hose couplings (4, 7 and 13) first of
all from common rail side and then from injector
-cylinder head side;
Figure 24
- Fit the low-pressure fuel backflow pipe (1) and manually
tighten the hose couplings (2) first of all from common
rail side and then from cylinder head side;
- Tighten the hose couplings (2, 7 and 13) of injector-
cylinder head side to the prescribed torque.
- Tighten the screws (12) fixing the common rail (3) onto
cylinder head (5) to the prescribed torque.
- Tighten the hose couplings (2 and 4) of common rail side
to the prescribed torque.
- Mount the bracket (10) and manually tighten the
fastening screw (9).
- Tighten the screw (11) locking the high-pressure fuel
193948
delivery pipe (8) to the prescribed torque.
- Tighten the fastening screw (9) fixing the bracket (10) Fit the valve cover (1) with the related gasket and insert all
onto cylinder head (5) to the prescribed torque. the screws (2).
Tighten the fastening screws (2) to the prescribed torque
following order and mode shown in the figure below.
Ref No. Description Tightening torques Ref No. Description Tightening torques
(2) 2 M16x1.5 35 ± 2 Nm (2) 20 M6x1x50 8.5 ± 1.5 Nm
(4) 7 M18x1.5 40 ± 2 Nm
(7) 6 M14x1.5 35 ± 2 Nm
(9) 1 M8x1.25x16 24 ± 3 Nm
(11) 1 M6x16 10 ± 1 Nm
(12) 3 M 8x45 24 ± 3 Nm
(13) 1 M14x1.5 35 ± 2 Nm
Figure 26
218020
Figure 27
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and remove
shaft, remove crosspieces (3) from cylinder head.
Refitting Figure 30
Figure 28
223535 223536
Install crosspieces (5) on valve rod. Remove lock blocks (1) and tighten the fastening screws (4)
to prescribed torque. Remove tool 99360558 (2) from the
rocker arm shaft (3) by using a hoist.
NOTE Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws (2) have
been fully unscrewed.
Ref No. Description Tightening torques
(4) 7 M12x1.75 104.5 ± 10.5 Nm
Apply tool 99360558 (1) and related lock blocks (3) to the
rocker arm shaft (4).
Lift and install the rocker arm shaft (4) on the cylinder head Figure 29
(6) by using a hoist.
70567A
Figure 31
115880
114287
Fit the head internal electric wire (injectors + pressure
sensor) and securing it using bands as illustrated in the
Adjustment of clearance between rocker arms and diagram ().
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted;
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Figure 33
Symmetric cylinders are 1-6; 2-5 and 3-4.
In order to perform these operations correctly, refer to
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in ”Characteristic and data” tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
Figure 35
169827
114024
Disconnect fuel pipelines (1) from injector rail, fuel supply Ref No. Description
line (2) of high pressure pump to rail and return line (3).
Unlock rocker arm shaft retaining screws (4). (1) 6 M10x1.5x40
Figure 36
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and remove
shaft, remove crosspieces (3) from cylinder head.
169826
Position the tool 99342157 (1) and hook on the injector (2).
Figure 41
169828
Drive out the injector (1) complete with bracket and seal (2).
Refitting
169816
Lubricate the injector fastening O-Rings using the
following lubricants: PDE SILIKONFETT 22, NLG Install new pipes on rail and lock fittings by hand.
12, PDE LUBRICOMET GR 220 NLG12. - supply line (2) of high pressure pump to rail;
- return line (3);
Install the injector comprehensive of bracket and seal in the - n˚ 6 fuel pipelines (1) between injectors and rail.
seat on the cylinder head.
Figure 40
169827
Figure 42
193973
Check that the injectors (2) are equidistant from After fitting the high-pressure pipelines, during the
! the springs (1). Distance ”X” which separates ! following 20 hours of work, frequently check
them should always be the same. engine oil level (IT MUST NOT INCREASE).
Lock fittings on rail (A, C) at required torque. NOTE After the assembly procedure, the fuel lines must
Lock fittings on injectors and head (B, C) at required torque. definitely not touch each other so as not to get
damaged because of the high stress due to engine
vibration.
The MINIMUM distance between the individual
pipes must NOT be LESS than 2 mm.
Figure 43 Figure 44
223535 223536
Install crosspieces (5) on valve rod. Remove lock blocks (1) and tighten the fastening screws (4)
to prescribed torque. Remove tool 99360558 (2) from the
rocker arm shaft (3) by using a hoist.
NOTE Before refitting rocker arm shaft assembly, check
that all adjustment screws (2) have been fully
unlocked. Ref No. Description Tightening torques
(4) 7 M12x1.75 104.5 ± 10.5 Nm
Figure 45
Apply tool 99360558 (1) and related lock blocks (3) to the
rocker arm shaft (4).
Lift and install the rocker arm shaft (4) on the cylinder head
(6) by using a hoist.
70567A
Figure 46
114287
115880
Adjustment of clearance between rocker arms and Fit the head internal electric wire (injectors + pressure
intake/exhaust valve control crosspieces must be performed sensor) and securing it using bands as illustrated in the
with utmost care. Bring to blast phase cylinder to be adjusted; diagram ().
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced.
Symmetric cylinders are 1-6; 2-5 and 3-4. Figure 48
In order to perform these operations correctly, refer to
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in “Characteristic and data“ tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
218020
TURBOCHARGER Refitting
REMOVAL / REFITTING Mount a new gasket on exhaust manifold; fit the
Removal turbocharger and screw n˚ 4 nuts.
Figure 52
169819
Disconnect oil return pipe (1) and oil delivery pipe (2).
169820
Figure 53
169822
- unscrew n˚ 4 nuts;
- remove turbocharger and gasket. Ref No. Description Tightening torques
M10x1.5x38
(2) 24 1st phase 30 ± 5 Nm
2nd phase 60 ± 5 Nm
Figure 55
171168
Screw the oil filter by hand until it touches the support, then
tighten 3/4 of a turn to the required torque.
Add the required amount of recommended engine oil
through the filler.
119976
Figure 57
169823
Figure 59
NOTE Under oil cooler place a container for engine
coolant drain.
Figure 58
169825
169824
Ref No. Description
Unscrew n˚ 16 M8 screws (1).
Remove oil cooler body (4) and its gasket (2). (1) 3 M6x1
Unscrew n˚ 2 screws (5).
Separate oil cooler (3) from oil body cooler.
Figure 60
Ref No. Description
(1) 16 M8x1.25x50
(5) 2 M12x1.75x30
Refitting
Assemble the oil cooler body with oil cooler, screwing in 2
screws.
Mount the oil cooler complete with new gasket to the
crankcase housing.
Figure 61
169825 223516
Install blow-by body (2) with related seal and lock screws Disconnect the engine cable (2) from the boost pressure and
n˚ 3 M6 (1) at required torque. air temperature sensor (1) fitted on the intake manifold (3).
Figure 64
Figure 62
223517
219644 Unscrew the fastening screws (5) and remove the intake
manifold (6), recovering relevant gaskets (1, 4) and air
grid-heater (if present) or spacer (3) from the cylinder head
Install the centrifugal filter element (1) on the timing gear (5) (2).
and tighten the fastening screws (2).
Fit the timing cover (3) and tighten the fastening screws (4).
223517
Fit the intake manifold (6) together with new gaskets (1, 4) 193050
and air grid-heater (if present) or spacer (3) on the cylinder
head (2). Unscrew the fastening nuts (2) and remove the starter
Tighten the fastening screws (5) to the prescribed torque. electric motor (1).
Remove the studs.
Figure 66 Refitting
Screw the studs into flywheel housing and fit starter electric
motor (1).
Tighten fastening nuts (2) to prescribed torque.
223516
Connect the engine cable (2) to the boost pressure and air
temperature sensor (1) fitted on the intake manifold (3).
Figure 68
223504
Figure 70
223485
Unscrew the drain plug (3) from the oil sump (2) and then
take out oil level dipstick (not supplied by FPT) and oil filler
cap (1) to ease the down flow of lubricant oil.
Remove the oil filter as described in the relative procedure.
218523
Refitting Figure 73
Figure 71
170127
Turn engine.
223504
Install gasket (5) onto the oil sump (3) and fit the oil sump
(3) together with spacer (2) on the crankcase (4).
NOTE Before assembling the suction rose, it is necessary Tighten fastening screws (1) to prescribed torque following
to seal the contact area between basement, order and mode shown in the figure below.
flywheel casing and front cover with LOCTITE,
following the herein instructions. Clean the surfaces
of the parts to be joined removing impurities and oil
residuals. Ref No. Description Tightening torques
(1) 26 M10x1.5x45 41.5 ± 3.5 Nm
Figure 72
223518
218523
Fit oil suction strainer (2) and pipe (6) and tighten fastening
screws (5) to prescribed torque.
Install brackets (1 and 3) and tighten fastening screws (4) to
prescribed torque.
Figure 75 Figure 76
193945
223485
Lock drain plug (3) under oil sump (2) at prescribed torque.
Install the oil filter as described in the relative procedure.
Add the required amount of recommended lubricant oil
through the oil filler cap (1) and refit oil level dipstick (not
supplied by FPT).
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
SECTION 6
Engine overhaul
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 5
- Engine lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Engine cleaning . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 20
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 21
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 21
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 23
Page Page
- Measuring main journals and crank pins . . . . . 27 - Checking assembly clearance of big end pins . 52
- Thickness of the big end half-bearing . . . . . . . 33 - Replacing - Reaming the valve seats . . . . . . . . 55
- Replacing the timing control gear and the oil pump 43 - Checking cam lift and pin alignment . . . . . . . . 57
- Fitting the connecting rod-piston assembly into the - Engine flywheel installation . . . . . . . . . . . . . . . 66
piston liners . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Page
- Camshaft installation . . . . . . . . . . . . . . . . . . . . 69
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 71
- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 73
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 73
- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 77
INTRODUCTION
The following description covers general mechanical overhaul starting from the engine which has been removed from the vehicle.
NOTE Refer to the specific publication for removing the engine from the vehicle.
Engine removal operations, as with overhauling, must be carried out by specialised personnel with specific equipment.
- the operations to perform for mounting the engine on the rotating stand
- the sequence of removal operations for the main components
- overhaul of the engine block and the cylinder head
- the sequence of refitting operations for the main components
- operations required for completing engine assembly after removal from the rotating stand
- final checks and tests.
Part of the operations covered in this section can be performed directly on the engine still fitted in the vehicle, in relation to their
accessibility in the engine compartment and on the vehicle version; these are listed in Section 5 - Removal/refitting of main the
engine components.
Figure 1
223519
Install the lifting eyelets (3) and tighten the screws to the Engine cleaning
prescribed torque.
Plug all openings (air intake, exhaust duct, fuel pipes, coolant
Apply the engine lifting sling 99360585 (2) to lifting eyelets (3) pipes).
and to hoist (1). Remove the main electrical components (engine control unit,
Adjust the lifting points on the tool so that the engine remains starter electric motor, alternator).
in equilibrium when it is raised. Cover all electrical components not removed (sensors, cables,
connectors, ECU) with plastic and tape before washing with
high-pressure water jets in order to prevent damage.
223520
1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor - 4. Crankcase pressure sensor -
5. Fuel temperature and filter clogging (pressure drop) sensor - 6. Boost pressure and air temperature sensor -
7. In line connector - 8. Engine Control Unit EDC17CV41 - 9. Engine oil pressure and temperature sensor -
10. Fuel high pressure pump metering unit - 11. Flywheel increment speed sensor (crankshaft) -
12. Timing segment speed sensor (camshaft) - 13. Motorized throttle valve actuator connector (Exhaust flap) -
14. Exhaust gas absolute pressure sensor
Before fitting the engine onto the rotating stand 99322230, remove the engine cable by unplugging it from the engine control unit
(9), from the motorized throttle valve actuator connector (13) and from all the sensors and transmitters to which it is
connected.Open the straps holding the engine cable to the engine block and remove it completely.
Figure 4 Figure 6
223522 218036
Position a suitable container to catch any coolant. Position a suitable container under lubricant oil heat
exchanger to catch any coolant.
Remove engine coolant delivery (4) and return (7) pipes of the
motorized throttle valve actuator by proceeding as follows: Unscrew fastening screws (2) together with spacers (3) and
remove lubricant oil heat exchanger (4) complete with
- unscrew the fittings (1 and 3) and remove the engine
relevant gasket (1) from crankcase (5).
coolant delivery pipe (4);
- unscrew the retaining screws (5 and 6) and the fittings (2
and 8) and remove the engine coolant return pipe (7). Ref No. Description
(2) 16 M8x1.25x50
Ref No. Description
(1) 1 M14x1.5
(3) 1 M16x1.5
(2,8) 2 M14x1.5
(5,6) 2 M8x1.25x18 Figure 7
Figure 5
223523
Unscrew the fastening screws (1) and remove the cover (6),
retrieving relative sealing O-ring (7).
If the power take-off (PTO) is present, remove the power
steering pump and the service air/conditioning compressor
218035 with relative coolant pipes.
Unscrew fastening screw (3) and loosen V-clamping collar (1) Ensure that the starter electric motor (3) is suitably supported.
to remove motorized throttle valve (2) together with actuator Unscrew the fastening nuts (2) and remove the starter electric
(4) from turbocharger (5). motor (3).
Unscrew the studs (4) from the flywheel housing (5).
223524
Fit brackets 99361046 to the engine block and mount the engine on the rotating stand 99322230.
223527
Figure 10
Figure 12
223526
Figure 13
NOTE The flywheel blocking device can aid the removal of
the damper pulley (2) fitted onto the crankshaft
pulley (6).
223529
218041
223530
218017
218016 218043
Place a container for collecting diesel under the fuel filter Disconnect the fittings (4 and 8) and the screw (1) to remove
support (2). the low pressure fuel pipe (3) from ECU to mechanical pump.
Unscrew the fastening screws (3) and remove the fuel filter Disconnect the fittings (2 and 7) and the screw (5) to remove
support (2) together with the fuel filter clogging (pressure the backflow fuel pipe (6) from high-pressure pump to fuel
drop) sensor (5) and NTC temperature sensor (4) from the tank.
engine cable supporting bracket (1). Ref No. Description
Ref No. Description (4,8) 2 M16x1.5
(3) 4 M8x1.25x30 (2,7) 2 M16x1.5
(1) 1 M8x1.25x25
(5) 1 M8x1.25x16
223531
Unscrew the fastening screws (7) and remove the oil pressure
and temperature sensor (6). 218046
Unscrew the fastening screws (10, 12) and remove the Unscrew the screw (3) fixing the lubrication oil delivery pipe
bracket (11). (2) to oil filter bracket (4)
Unscrew the fastening screw (2) and remove the crankcase Position a suitable container to catch any oil.
pressure sensor (1).
Unscrew the hose couplings (1 and 5) and remove the
Unscrew the fastening screws (8) and remove the intake lubrication oil delivery pipe (2) from crankcase to
manifold (9) together with boost pressure and air turbocharger.
temperature sensor from the cylinder head, recovering
grid-heater resistance (4) and relative gasket (3, 5). Ref No. Description
(1,5) 2 M18x1.5
Ref No. Description (3) 1 M8x1.25x20
(2) 1 M12x1.5
(10) 1 M10x1.5x16
(12) 1 M8x1.25x16 Figure 22
(8) 2 M10x1.5x110
(8) 3 M10x1.5x100
(8) 1 M10x1.5x150
223532
Figure 23 Figure 25
218048
218050
Position a suitable container to catch any oil.
Unscrew the fastening screws (6 and 7) and remove the oil Unscrew fastening screws (4) and remove exhaust manifold
filter (5) with its support recovering relative gasket (2) and the (1) recovering relevant gaskets (3) from cylinder head (2).
bracket (1).
Unscrew the fastening screws (4) and remove the oil pressure
relief valve (3) from the crankcase.
Figure 24
218049
Figure 26
192060
Unscrew the screws (1) and remove the high pressure pump
(2).
Figure 27
114020
Use specific spanner to unlock screws (2) and remove gear (3)
complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure Ref No. Description
pump. (1) 5 M8x1.25x20
Remove rpm sensor (1). (4) 3 M12x1.5
192061
Figure 32
192063
114022
166329
Apply extractor and remove crankshaft rear seal.
Unlock screws (1) and remove flywheel box (2). Use extractor (2) and remove the crankshaft front seal (1)
from the front cover (3).
Ref No. Description
(1) 1 M10x1.5x110
(1) 3 M10x1.5x35
(1) 1 M12x1.75x120
(1) 1 M10x1.5x180
(1) 7 M12x1.75x80
(1) 2 M12x1.75x193
Figure 34
Figure 36
114023 218501
Remove screws (2) and double gear (3). Unscrew the fastening screws (3) and remove the front cover
(1) from the crankcase (5), recovering the washers (2).
Remove retaining screw (5) and connecting rod (4).
Remove oil pump (1).
NOTE Crankcase (5) has two reference studs (4) that must
match with related housings on the front cover (1).
Ref No. Description
(1) 3 M8x1.25x45 Ref No. Description
(1) 5 M8x1.25x60 (3) 9 M8x1.25x20
(2) 3 M12x1.75x90
(5) 1 M8x1.25x16
192067
114027
Unlock rocker arm shaft retaining screws (4). Remove retaining brackets (3) and remove injectors (4).
Disconnect fuel pipelines (1) from injector rail, fuel supply line Remove retaining screws (1) and remove rail (2).
(2) of high pressure pump to rail and return line (3).
Ref No. Description
Ref No. Description (1) 3 M8
(1) 6 M18x1.5 (3) 1 M10x1.5x40
(1) 6 M14x1.5
(2) 1 M18x1.5
(2) 1 M14x1.5
(4) 7 M12x1.75 Figure 40
Figure 38
192068
192075
Use metallic ropes to lift cylinder head (1) and remove seal (2).
Apply tool 99360558 (1) to rocker arm shaft (2) and remove
shaft, remove crosspieces from cylinder head.
Ref No. Description
(-) 26 M16x2x170
Figure 42
191584
114035
Figure 46
34994
47571
Remove the main bearing shells (1), unscrew the screws and Figure 44
take out the oil nozzles (2).
Remove the cylinder liners as described under the relevant
subheading on Replacing cylinder liners paragraph.
114035
1 = 1st measuring
2 = 2nd measuring
3 = 3rd measuring
Figure 47
225036
A = Selection class 117 — 117.012 mm
B = Selection class 117.010 — 117.022 mm
In case of maximum wear >0.150 mm or maximum
ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
Figure 48
114037
A = Ø 130.500 to 130.525 mm
B = Ø 129.510 to 129.535 mm
C = Ø 130.461 to 130.486
D = Ø 129.475 to 129.500 mm
The figure shows the outer diameters of the cylinder liners and
the relative seat inner diameters.
The cylinder liners can be extracted and installed several times
in different seats, if necessary.
CYLINDER LINERS
Figure 49
114038
Figure 50
193967
Figure 51
DETAIL A
145837
Figure 52
DETAIL B
145838
Figure 53
77812
47577
With dial gauge 99395603 (5) placed on base 99370415 (6)
measure the cylinder barrel protrusion compared to the
Place details 99360706 (1 and 2) and plate 99360724 (4) as cylinder head supporting plane, it must be 0,035 to 0,065 mm
shown in the figure, by making sure that the plate (4) is (figure below); otherwise replace the adjusting ring
properly placed on the cylinder liners. (1, previous figure) fitted with spare parts having different
thickness.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the block.
Figure 56
Figure 54
114041
CYLINDER LINER PROTRUSION
Figure 57
16798
CRANKSHAFT
Figure 58
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
Figure 59 Figure 60
114043 114044
47536
47535
Figure 63
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
Ø MIN.
Ø MAX.
Ø MIN.
Ø MAX.
PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
- On the rear of the crankcase a set of seven numbers (A) are marked.
- The value of each number may be 1, 2 or 3 depending on the nominal diameter class of each seats.
- The main bearing caps (B) are marked by one sets of progressive numbers for locate them on the crankcase.
Figure 64
210298
Figure 65
210301
- A: The set of seven digits, refers to the crankpins and is preceded by a single digit:
G 1st digit shows the status of the journals (1 = STD, 2 = -0.127),
G Six digits, taken singly, give the class of diameter of each of the crankpins
- B: The set of eight digits, refers to the main journals and is preceded by a single digit:
G 1st digit shows the status of the journals (1 = STD, 2 = -0.127),
G Seven digits, taken singly, give the class of diameter of each of the main journals.
- C: The numbers of five digits, refers to the part number of the crankshaft.
Figure 66
210302
Example:
Figure 67
210315
Figure 68
210303
Example:
Figure 69
210316
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected in classes of tolerance marked by a colored sign (red-green - red/black
- green/black)
Figure 70
210304
1. Color marking
210308
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).
Figure 71
210305
1. Color marking
210311
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.
210306 210299
1 2 3
STD CLASS 99.000 99.010 99.020
99.010 99.020 99.030
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).
210306 210299
1 2 3
-0.127 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).
210306 210299
1 2 3
-0.254 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
210307
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).
210306 210299
1 2 3
-0.508 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
210307
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).
SELECTING THE BIG END BEARING SHELLS (JOURNALS WITH NOMINAL DIAMETER)
On the body of the connecting rod, in the position shown in the view from “A“ there are three markings:
1) Letter indicating the weight class:
A (yellow) = 3308÷ 3338 g.
B (green) = 3339 ÷ 3368 g.
C (blue) = 3369 ÷ 3398 g.
2) Number identifying the diameter grade:
1 = 85.987÷ 85.996 mm
2 = 85.997 ÷ 86.005 mm
3 = 86.006 ÷ 86.013 mm
3) Progressive number for identifying the connecting rod.
NOTE The identification colors of the marks are given in the table on CONNECTING ROD paragraph.
The number, indicating the class of diameter of the bearing shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal by following the indications in the table (Figure 201455).
Figure 72
201455
210309 210312
1 2 3
STD CLASS 85.987 85.997 86.006
85.996 86.005 86.013
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.
210309 210312
1 2 3
-0.127 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.
210309 210312
1 2 3
-0.254 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
210310
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.
210309 210312
1 2 3
-0.508 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
210310
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.
Figure 73
210314
After fitting the gear (1) on the crankshaft (2), heat it for ~15
minutes in an oven at temperature not higher than 180C.
Let them cool down after the installation.
Figure 74
114034
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
114049
Fit the oil jets (2) aligning the dowel with the opening (3) in
the crankcase.
Position the half-bearings (1) and the thrust bearing half rings
on bearing journals as shown in the figure.
Figure 77 Figure 79
145839
114050
Clean accurately the parts and remove any trace of oil;
Fit caps (1), including the half bearings (2) on the relevant
Place bearing halves (1) on main journals (2). supports.
Check the installation clearance between the main journals
and the relative bearings as follows. Figure 80
Figure 78
210313
208346
Figure 82
193957
Make sure the piston does show any trace of seizing, scoring, cracking; replace as necessary.
Removal Figure 85
Figure 83
126311 49026
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin (1).
(1).
If removal is difficult use the appropriate beater.
Figure 84 Figure 86
126312 32618
Remove the piston pin split rings (2) using the round tipped Measuring the gudgeon pin diameter (1) with a micrometer
pliers (1). (2).
Figure 87
191256
Piston rings
Figure 88
3513
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
16552
Check the clearance between the sealing rings (2) and the If the distance between ends is lower or higher than the value
relative piston housings (1) using a thickness gauge (3). required, replace split rings.
CONNECTING ROD
Figure 92
209171
NOTE The connecting rod/cap is of ”torn” type; before assembly verify that the connecting rod is not damaged.
Each connecting rod can assembled with the relative cap only. If the cap is assembled on the reverse side, the connecting
rod must be rejected.
NOTE In spare parts catalogue there are connecting rod grade B only, use it for any replacement
NOTE All dimensions indicated in figure, must be controlled with bush assembled and finished.
On the external breaking line, gap area allowed must be < 5 mm2.
No cracks are allowed in the threaded area.
NOTE Make sure that the values of small end bush are between values listed in the Section 8:Technical Specification Cylinder unit
and crankshaft components; otherwise, replace the connecting rod.
Figure 93
193969
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from the
front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
3308 g - 3338 g 85.997-86.005 Green
Yellow
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
3339 g - 3368 g 85.997-86.005 Green
Green (*)
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
3369 g - 3398 g 85.997-86.005 Green
Blue
86.006-86.013 Blue
(*) As spares, only Grade B connecting rod are provided and can replace Grade A and C.
Conditions for correct gudgeon pin-piston Fitting the connecting rod-piston assembly
coupling into the piston liners
Figure 94
Figure 97
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight finger
pressure and it should not come out by gravity.
115885
Mounting the connecting rod - piston assembly Mount the selected half-bearings (1) both on the connecting
rod and the cap.
Figure 96
If the cap (1) is fitted upsidedown, the connecting
rod should be discarded.
NOTE The connecting rod screws can be reused as long Fit the connecting rod-piston assemblies (1) into the piston
as the diameter of the thread is not less than 11.4 liners (2) using band 99360605 (1, following Figure). Check
mm. the following:
- the openings of the split rings are offset by 120;
47593
49029
Figure 99
188462
Checking assembly clearance of big end pins Ref No. Description Tightening torques
M12x1.25x69
To check the clearance proceed as follows: (2) 12 1st phase 50 ± 2.5 Nm
connect the connecting rods to the relative main journals, 2nd phase 60˚
place a length of calibrated wire on the latter.
Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
Figure 100 envelope containing the wire.
115886
Fit the connecting rod caps (1) together with half-bearings and
tighten the screws (2) to the torque indicated in the table using
tool 99395216 (3).
47583
Install and fix tool 99360257 equipped with part 99360256 (2)
with bracket (4); tighten by lever (1) until cotters are removed
(3); remove the tool (2) and the upper plate (5), the spring (6)
and the lower plate (7).
Repeat the operation on all the valves.
Turn the cylinder head upside down and remove the valves
(8).
92841
VALVE GUIDES
Figure 105
191585
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves
47585
Figure 106
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.53 mm.
41032
Ream the valve seats (2) on cylinder head using tool (1).
193958
204132 193971
Rated assembling play between idler gear bushings and pins: Replacing the bushings
0.040 0.080 mm.
Bushings (1) can be replaced when they are worn. Put up the
bushing, then grind it so as to bring it to a dimension of
65.010 0.10 mm.
Camshaft
Checking cam lift and pin alignment
Figure 112
47506
Place the camshaft (4) on the live centre (1) and using a centesimal dial gauge (2) check the lift value of the cams (3) indicated in
the DATA -ASSEMBLY CLEARANCE table.
Figure 113
47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed
0.030 mm.
If misalignment exceeds this value, replace the shaft.
Figure 114
1
47505
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.
Figure 115
204131
Bushes
Figure 116
114214
The bush surfaces must not show any sign of seizing or scoring; Measure the bush inner diameters with a baremeter and replace
if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360505.
Base - September 2015 Print P2D32C012 E
F2CFE613 ENGINES SECTION 6 - ENGINE OVERHAUL 59
Use beater 99360505 to change bushings Fitting the valves and oil seal ring
Removal
Figure 119
Figure 117
114280
Figure 118
Valve closed
NOTE Should valves not have been overhauled or
replaced, remount them according to numbering
performed on dismounting.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre.
Valve open
Figure 120
114215
86290
ROCKER SHAFT
Figure 121
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker a
rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
Shaft
Figure 122
114217
114219
114218
Figure 125
117690
218502
Clean the surface of the parts to be joined removing impurities
and oil residuals. Apply silicon LOCTITE 5970 (1) to the cover - Fit part (4) of the tool 99346265 on the front tang (3) of
(2) as shown in the picture. the crankshaft; fasten it with the screws (5) and spline the
new tight ring (6) on it.
The diameter of the sealing string must be 1.5 0.5/0.2.
- Fit part (1) on part (4), screw-tighten the nut until the
assembly of the tight ring (6) into the front cover (2) is
completed.
Fit the front cover within 10 minutes after applying
the sealer.
218501 218503
Install front cover (1) on crankcase (5) and tighten fastening Fit the oil pump (4) on crankcase (2) and tighten fastening
screws (3) to the prescribed torque after having interposed screws (1 and 3) to the prescribed torque.
washers (2).
NOTE Crankcase (5) has two reference studs (4) that must
match with related housings on the front cover (1).
218028
218505
Fit gear pin (2) in position into clearance adjusting rod (1) and
install double gear (5) complete with shoulder plate (4).
Tighten fastening screws (3) in two phases to prescribed
torque.
218506
Use two suitable lifting hooks (2) in order to lift and fit flywheel
box (1) to engine block (3) by using a hoist.
Ref No. Description Tightening torques
M12x1.75x90
(3) 3 1st phase 30 Nm
2nd phase 90˚
218508
218509
Figure 139
NOTE The screws (1) must be tightened following a
”spiral” pattern starting in the middle and going
outwards.
198348
Figure 138
45267
ENGINE FLYWHEEL
Figure 140
218514
- Fit part (6) of the tool 99346260 on the rear tang (3) of
the crankshaft; fasten it with the screws (1) and spline the
new tight ring (2) on it.
- Fit part (5) on part (6), screw-tighten the nut (4) until the
assembly of the tight ring (2) into the flywheel box is
completed.
NOTE Crankshaft has a reference pin that must match with related housing on engine flywheel.
Figure 141
114265
A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to
piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2 notches,
position corresponding to 54.
145832 192078
Position flywheel (1) on crankshaft, lubricate screws (2) Install rail on cylinder head and lock retaining screws by hand.
threading with engine oil and lock them.
Install injectors in correct position and lock to required torque.
Ref No. Description Tightening torques Ref No. Description Tightening torques
M18x1.5x72 (-) 6 M10x1.5x45 46 ± 3 Nm
(2) 8 1st phase 120 Nm
2nd phase 90˚
Figure 143
49036
Figure 145
193973
114267
198353
Figure 151
114270
Refit relay gear (2) and lock screws (1) using six-splined
spanner at required torque.
Figure 153
192060
193960
Figure 154
192072
2
3
192073
Rotate the tool (1) 99395223 in order to insert the pin (3) in
the opening (2, previous Figure) in the head. Fasten the tool
223535
(1) 99395223 using two M8x1.25 bolts (2).
Install crosspieces (5) on valve rod.
Apply tool 99360558 (1) and related lock blocks (3) to the
rocker arm shaft (4).
Lift and install the rocker arm shaft (4) on the cylinder head
(6) by using a hoist.
Figure 156 Figure 158
117691
Fit the camshaft drive gear (1) so that the fastening openings
in the shaft are aligned with the slots (2) in the drive gear.
223536
Position the gear (1) taking care to position the spokes (4) as Remove lock blocks (1) and tighten the fastening screws (4)
illustrated. to prescribed torque. Remove tool 99360558 (2) from the
Tighten the fixing bolts (3). rocker arm shaft (3) by using a hoist.
Ref No. Description Tightening torques Ref No. Description Tightening torques
M10x1.5x45 (4) 7 M12x1.75 104.5 ± 10.5 Nm
(3) 4 1st phase 25 ± 5 Nm
2nd phase 45˚
Figure 161
70567A
Timing flywheel
71774
117691
The exact position of piston 1 at 54˚ before T.D.C. is obtained
when, under the conditions described above, the specific tool Install gear (1) controlling camshaft so that fastening holes on
(1) is inserted into the hole (3) on the engine flywheel (4) shaft coincide with slots (2) on control gear.
through the engine rpm sensor seat (2).
Otherwise, rotate engine flywheel (4) to adjust its orientation. Position the gear (1) taking care to position the
NOTE
Remove the specific tool (1). spokes (4) as illustrated.
This operation is necessary in order to be able to fit
the flywheel correctly which can only be fitted in one
position in relation to the gear.
Figure 163
115063
70567A
Figure 168
223535
Apply tool 99360558 (1) and related lock blocks (3) to the
rocker arm shaft (4).
Lift and install the rocker arm shaft (4) on the cylinder head 185253
(6) by using a hoist.
As shown in the figure, position the dial gauge (1) with the flat
Figure 166 based rod (3) on the roller (4) of the rocker arm controlling
the discharge valve of cylinder 3 and preload it to at least 7
mm.
NOTE Position the flat based dial gauge rod (see detailed
part) so that its axis passes through the centre of the
roller on which it is resting.
During the CHECK phase, not during the engine
overhaul phase, the allowed tolerance of the
measurement is between -0.05 - +0.12 mm.
During OVERHAUL, the allowed tolerance is ±
0.05 mm.
223536
Remove lock blocks (1) and tighten the fastening screws (4)
to prescribed torque. Remove tool 99360558 (2) from the
rocker arm shaft (3) by using a hoist.
Ref No. Description Tightening torques
(4) 7 M12x1.75 104.5 ± 10.5 Nm
Remove tool 99360612.
Print P2D32C012 E Base - September 2015
76 SECTION 6 - ENGINE OVERHAUL F2CFE613 ENGINES
177714
114281
Using the appropriate tool, turn the flywheel in a clockwise
direction until the needle of the dial gauge reaches the
minimum value possible. In case conditions shown in previous Figure and shown at
paras 1 and 2 are not found, operate as follows:
- turn the engine flywheel until the required cam lift value
NOTE The measurement is to be taken keeping the rocker appears on the dial gauge;
arm roller in contact with the profile of the exhaust
cam on the camshaft. - release screws (2) securing gear (1) of camshaft to as to
The dial gauge is to be zeroed with the rocker arm make control gear and camshaft independent;
roller in contact with the base radius of the cam - conveniently operate on engine flywheel so as to obtain
profile. conditions indicated at paras 1 and 2, previous Figure,
considering that cam lift value must remain unchanged;
- use the slots on the gear (1); lock screws (2) and repeat
Reset the dial gauge. control as already described;
Turn the flywheel in an anticlockwise direction, until the dial
- lock screws (2) at required torque.
gauge shows the timing system cam lift value of 4.70 ± 0.05
mm. Ref No. Description Tightening torques
M10x1.5x45
Figure 170 (2) 4 1st phase 25 ± 5 Nm
2nd phase 45˚
185523
Install gear (7) of high pressure pump and lock nut (8) at
Figure 173 required torque.
204128
Fit the blow-by valve body (2) together with a new gasket and
114287 tighten the fastening screws (1) to the prescribed torque.
166177
219644
Install cylinder head cover (1) and lock screws (2) at required
torque following order shown in Figure below diagram. Install the centrifugal filter element (1) on the timing gear (5)
and tighten the fastening screws (2).
Fit the timing cover (3) and tighten the fastening screws (4)
Ref No. Description Tightening torques Ref No. Description Tightening torques
(2) 20 M6x1x50 8.5 ± 1.5 Nm (2) 3 M6x1x16 9 ± 1 Nm
(4) 6
Figure 179
218020
Figure 181
117695
192063
Fit the exhaust manifold (1) in position with new gaskets (3)
Figure 183 to the cylinder head (2) and tighten the fastening screws (4)
to the prescribed torque following order and mode shown in
the figure below.
171168
Figure 184
Tightening order layout for exhaust manifold fastening screws
The central section of the exhaust manifold (1) must be
tightened first.
223518
218049 223532
Screw the studs (3 and 5) on the exhaust manifold (1); Fit the bracket (4) together with the exhaust gas absolute
pressure sensor (5) and tighten fastening screws (3 and 7) to
Hold the turbocharger (6) together with the waste-gate valve
prescribed torque.
and place it on the exhaust manifold (1) after having
interposed a new gasket (2); Install exhaust gas pipe (2) onto exhaust manifold and tighten
hose couplings (1 and 6) to prescribed torque.
Tighten the fastening nuts (4 and 7) to the prescribed torque.
Ref No. Description Tightening torques Ref No. Description Tightening torques
(3,5) 4 M10x1.5x30 (1,6) 2 M14x1.5 30 ± 2 Nm
M10x1.25 (3,7) 2 M6x1x14 10 ± 2 Nm
(4,7) 4 1st phase 35 ± 5 Nm (9) 1 M6x1x50 7 ± 1 Nm
2nd phase 46 ± 2 Nm
Figure 188
Figure 190
218048 218046
Install the oil pressure relief valve (3) into the crankcase and Install lubrication oil delivery pipe (2) from crankcase to
tighten the fastening screws (4) to prescribed torque. turbocharger and tighten hose couplings (1 and 5) to
prescribed torque.
Fit new gasket (2) on the crankcase and install the oil filter (5)
with its support and bracket (1). Tighten the screw (3) fixing lubrication oil delivery pipe (2) to
oil filter bracket (4).
Tighten the fastening screws (6 and 7) to prescribed torque.
218043
218017 218016
Fit the fuel filter bracket (1) and tighten the fastening screws Fit the fuel filter support (2) together with the fuel filter
(2 and 4) to the prescribed torque. clogging (pressure drop) sensor (5) and NTC temperature
sensor (4) on the engine cable supporting bracket (1) and
Connect the high-pressure fuel pipe (5) from high-pressure tighten the fastening screws (3) to the prescribed torque.
pump to cylinder head and tighten the hose couplings (3 and
10) and the screw (6) to the prescribed torque.
Connect the low pressure fuel pipe (11) from fuel filter to Ref No. Description Tightening torques
high-pressure pump and the pipe (12) from mechanical pump (3) 4 M8x1.25x30 24 ± 3 Nm
to fuel filter and tighten the fittings (7 and 9) to the prescribed
torque.
Fasten the engine cable to the retainers and connect the
electrical connection to the fuel high-pressure pump metering
unit (8), as described in the relative procedure.
Figure 195
Ref No. Description Tightening torques
(7,9) 2 M16x1.5 30 ± 5 Nm
(3,10) 2 M14x1.5 35 ± 2 Nm
(6) 1 M6x16 10 ± 1 Nm
(2) 3 M8x1.25x35 24 ± 3 Nm
(4) 1 M8x25 24 ± 3 Nm
(4) 1 M10x25 37.5 ± 7.5 Nm
218042
Screw the spacers (4). Install the ECU (2) including the heat
exchanger and tighten fastening nuts (3) to prescribed torque.
Connect the fitting (5) of low pressure fuel pipe from engine
control unit heat exchanger to mechanical pump.
Fit engine oil pressure and temperature sensor (1) on the
crankcase and tighten fastening screws (6) to prescribed
torque.
Figure 196
223529
Fit the support (1) on the cylinder head and tighten the
218041
fastening screws (9) to prescribed torque.
Apply a new seal ring (1) to the coolant pump (2). Install the fan drive pulley (8) together with the bearing (2)
retained by the ring split circlip (3) and the shoulder washer
Assemble the water pump (2) complete with its sealing gasket (7) on the fan support (1) and tighten the fastening screw (6)
(1) and tighten the fastening screws (3) to the prescribed to prescribed torque.
torque.
Fit the fan-fixing spacer (4) on the fan drive pulley (8) and
tighten the fastening screws (5) to prescribed torque.
Ref No. Description Tightening torques
Ref No. Description Tightening torques
(3) 4 M8x1.25x25 24.5 ± 2.5 Nm
(5) 6 M8x1.25x50 23.5 ± 2.5 Nm
Figure 197 (6) 1 M10x1.5x80 55 ± 5 Nm
(9) 4 M8x1.25x50 34.5 ± 3.5 Nm
Figure 199
223530
223527 223525
Assemble the thermostat unit: install the thermostat (1) into Fit the auxiliary members’ belt (4) on the alternator (1), water
cylinder head together with the gasket (3); apply a new sealing pump (3), fan control pulley (2), crankshaft pulley with damper
ring (2) and fit the coolant outlet pipe (5) together with (6) and fixed guide roller (5).
coolant temperature sensor and tighten the fastening screws
Use the appropriate tool (7) on the automatic belt tensioner
(4) to the prescribed torque.
(8) in order to fit the new belt (4) in the operating position.
Ref No. Description Tightening torques Additional adjustments are not required. The belt tension is
(4) 5 M8x1.25x70 24.5 ± 2.5 Nm adjusted automatically by the calibrated spring in the
automatic belt tensioner (8).
Operate the engine for a few hours and check that the
Figure 201 auxiliary members’ belt (4) is properly fitted.
223526
Fit the alternator upper support (2) and tighten the fastening
screws (1) to prescribed torque.
Fit the alternator lower support (7) and tighten the fastening
screws (8 and 9) to prescribed torque.
Install the alternator (4) and tighten the fastening screws (3
and10), after having interposed the spacer (11).
Install the automatic belt tensioner (6) and tighten the
fastening screw (5) to prescribed torque.
Ref No. Description Tightening torques
(1) 2 M8x1.25x30 24 ± 3 Nm
(3) 1 M8x1.25x35 24 ± 3 Nm
(5) 1 M10x1.5x70 45 ± 5 Nm
(8) 2 M10x1.5x70 43 ± 3 Nm
(9) 1 M10x1.5x30 43 ± 3 Nm
(10) 1 M10x1.5x120 43 ± 3 Nm
Figure 203
218036
218035
223522
Install engine coolant delivery (4) and return (7) pipes of the 223521
motorized throttle valve actuator by proceeding as follows:
Fit the oil level dipstick pipe and lubrication oil filling pipe (if
- fit engine coolant return pipe (7) and tighten fittings (2 and present) to the crankcase.
8) and retaining screws (5 and 6) to prescribed torque;
Install the turbocharger lubrication oil discharge pipe (2) by
- fit engine coolant delivery pipe (4) and tighten fittings proceeding as follows:
(1 and 3) to prescribed torque.
- Tighten the coupling (3) on the crankcase to prescribed
torque;
Ref No. Description Tightening torques
(1) 1 M14x1.5 43 ± 3 Nm - Tighten fastening screws (1) in the lower part of the
turbocharger, after having interposed a new gasket.
(3) 1 M16x1.5 43 ± 3 Nm
(2,8) 2 M14x1.5 35 Nm
Ref No. Description Tightening torques
(5,6) 2 M8x1.25x18 24 ± 3 Nm
(1) 2 M8x1.25x25 24 ± 3 Nm
(3) 1 M30x2 110 ± 5 Nm
223520
SECTION 7
Technical specifications
Page
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 11
GENERAL CHARACTERISTICS
F2CFE613
Type
E*B012 A*B012
E*B013 A*B013
A
VALVE TIMING
mm 0.4 ± 0,05
X
X mm 0.4 ± 0,05
bar
Injection pressure bar
1800
Injector calibration bar
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
CYLINDER BLOCK AND
CRANKMECHANISM COMPONENTS mm mm
1
Bores for cylinder liners:
upper 130.500 ÷ 130.525
1
lower 129.510 ÷ 129.535
Cylinder liners:
external diameter:
L upper 130.461 ÷ 130.486
2
lower 129.475 ÷ 129.500
2 length L 226.15
Cylinder liners -
crankcase bores
upper 0.014 ÷ 0.064
lower 0.010 ÷ 0.060
External diameter 2 -
Cylinder sleeve
3
inside diameter 3A* 117.000 ÷ 117.012
X inside diameter 3B* 117.010 ÷ 117.022
Protrusion X 0.035 ÷ 0.065
* Selection class
Pistons: Federal Mogul Mahle
1
measuring dimension X 15 18
X
external diameter 1A* 116.894 ÷ 116.906 116.871 ÷ 116.883
2 external diameter 1B* 116.904 ÷ 116.916 116.881 ÷ 116.893
* Selection class pin bore 2 52.016 ÷ 52.022 52.010 ÷ 52.018
Piston - cylinder sleeve Federal Mogul Mahle
A* 0.094 ÷ 0.118 0.117 ÷ 0.141
B* 0.094 ÷ 0.118 0.117 ÷ 0.141
* Selection class
Piston diameter 1 -
X
Pistons protrusion X 0.094 ÷ 0.118
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Main journals 1
- nominal 92.970 ÷ 93.000
- class 1 92.970 ÷ 92.980
- class 2 92.980 ÷ 92.990
- class 3 92.990 ÷ 93.000
1 2 Crankpins 2
- nominal 81.915 ÷ 81.945
- class 1 81.915 ÷ 81.924
- class 2 81.925 ÷ 81.934
- class 3 81.935 ÷ 81.945
S1 S 2 Main bearing shells S1
Red 2.968 ÷ 2.978
Green 2.978 ÷ 2.988
Yellow * 2.988 ÷ 2.998
Big end bearing shells S2
Red 1.994 ÷ 2.002
Green 2.002 ÷ 2.010
Yellow * 2.010 ÷ 2.018
Main bearing housings 3
- nominal 99.000 ÷ 99.030
3 - class 1 99.000 ÷ 99.009
- class 2 99.010 ÷ 99.019
- class 3 99.020 ÷ 99.030
Bearing shells -
main journals 0.050 ÷ 0.090
Bearing shells -
0.040 ÷ 0.080
big ends
Main bearing shells 0.127 - 0.254 - 0.508
Big end bearing shells 0.127 - 0.254 - 0.508
Main journal,
thrust bearing X1
1-2-3-4-5-6 39.900 ÷ 40.100
X1 7 39.960 ÷ 40.040
X3 Thrust washer
halves X3 3.38 ÷ 3.43
1 2 Concentricity 0.040
Ovalization 0.010
Taper -
* Fitted in production only and not supplied as spares
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
CYLINDER HEAD - VALVE TRAIN mm
1
2
2 8.023 ÷ 8.038
Valve guide
3 13.012 ÷ 13.025
3
4
Valves:
4 7.970 ÷ 7.985
60 30 7 30
4 7.970 ÷ 7.985
60˚ 30 ± 7 30
1 41.985 ÷ 42.020
1 1 40.985 ÷ 41.020
Outside diameter of valve
seat; angle of valve seat
2 in cylinder head:
2
42.060 ÷ 42.075
60˚ 30’
2
41.060 ÷ 41.075
60˚ 30’
X 0.5 ÷ 0.8
Recessing of valve
X X 1.65 ÷ 1.95
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Valve spring height: A* B*
free height H 70.77 71.34
under a load of:
H H1 N 460 23 H1A {
N 460 22 H1B 51
H2
N 740 33 H2A {
N 731,4 42 H2B 39
2
Camshaft bearing
journals:
17 Ø 64.924 ÷ 64.940
1 3
Outer diameter of
camshaft bushings:
69.090 ÷ 69.130
Inner diameter of
camshaft bushings: 65.080 ÷ 65.116
8.211
1
Rocker shaft 1 31.964 ÷ 31.980
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Seats for bushes in rocker arms
32.025 ÷ 32.041
35.000 ÷ 35.016
-
35.070 ÷ 35.110
0.054 ÷ 0.110
0.045 ÷ 0.077
TIGHTENING TORQUES
PART TORQUE
Nm kgm
Piston cooling spray nozzles (6 screws M8) 50 ± 5 5.0 ± 0.5
Camshaft shoulder plate (5 screws) 20 ± 2 2.0 ± 0.2
Crankcase stiffening plate (8 screws M10x1.5x20) 49 ± 3 4.9 ± 0.3
Main bearing caps (14 screws M16x2x168)
1st phase 140 ± 7 14.0 ± 0.7
2nd phase 60˚
3rd phase 60˚
Camshaft gear (4 screws M10x1.5x45)
1st phase 25 ± 5 2.5 ± 0.5
2nd phase 45˚
Transmission gear (3 screws M12x1,5) 25 ± 5 2.5 ± 0.5
Connecting rod caps (12 screws M12x1.25x69)
1st phase 50 ± 2.5 5.0 ± 0.25
2nd phase 90˚
High pressure pump (3 screws M8x1.25x40) 33 ± 3 3.3 ± 0.3
High pressure pump gear (1 nut M18x1.5) 105 ± 5 10.5 ± 0.5
Phonic wheel timing sensor (3 screws M8x1.25) 23 ± 2 2.3 ± 0.2
Blow-by rotating filter (3 screws M6x1x16) 9±1 0.9 ± 0.1
Blow-by rotating filter cover (3 screws M6x1x16) 9±1 0.9 ± 0.1
Blow-by valve cover (3 screws M6x1) 9±1 0.9 ± 0.1
Fuel pipe from rail to electro-injectors
(6 fittings M18x1.5) 40 ± 2 4.0 ± 0.2
(6 fittings M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel pipe from high pressure pump to rail
(1 fitting M18x1.5) 40 ± 2 4.0 ± 0.2
(1 fitting M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel return pipe
(1 fitting M16x1.5) 35 ± 2 3.5 ± 0.2
(1 fitting M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel pipe from pressure pump to intermediate fitting
(2 fittings M16x1.5) 35 ± 5 3.5 ± 0.5
Fuel delivery and return pipe from pressure pump to fuel filter
(4 fittings M16x1.5) 35 ± 5 3.5 ± 0.5
Fuel pipe from injection control unit heater to pressure pump
(2 fittings M18x1.5) 40 ± 5 4.0 ± 0.5
Cylinder head (26 screws M16x2x170)
1st phase 50 ± 2.5 5.0 ± 0.25
2nd phase 100 ± 2.5 10.0 ± 0.25
3rd phase 90˚
4thphase 75˚
PART TORQUE
Nm kgm
Rocker arm shaft (7 screws M12x1.75) 105 ± 10 10.5 ± 1.0
Tappet cover (20 screws M6x1x50) 8.5 ± 1.5 0.85 ± 0.15
Engine oil pump
(5 screws M8x1.25x60) 24 ± 3 2.4 ± 0.3
(3 screws M8x1.25x45) 24 ± 3 2.4 ± 0.3
Double gear (3 screws M8)
1st phase 30 3.0
2nd phase 90˚
Crankcase front cover (9 screws M10x1.25x20) 19 ± 3 1.9 ± 0.3
Engine flywheel housing
(3 screws M10x1.5x35) 41.5 ± 3.5 4.15 ± 0.35
(1 screws M10x1.5x110) 41.5 ± 3.5 4.15 ± 0.35
(1 screws M10x1.5x180) 41.5 ± 3.5 4.15 ± 0.35
(2 screws M12x1.75x193) 63 ± 7 6.3 ± 0.7
(1 screws M12x1.75x120) 63 ± 7 6.3 ± 0.7
(7 screws M12x1.75x80) 63 ± 7 6.3 ± 0.7
Engine oil sump (26 screws M10x1.5x45) 42 ± 3 4.2 ± 0.3
Engine oil intake suction strainer (3 screws M8x1.25) 20 ± 2 2.0 ± 0.2
Engine oil drain plug (1 M22x1.5) 40 ± 10 4.0 ± 1.0
Engine oil filter housing (5 screws M8x1.25) 34 ± 4 3.4 ± 0.4
Engine oil filter body 60 ± 5 6.0 ± 0.5
Heat exchanger (4 screws M8x45) 23 ± 2 2.3 ± 0.2
Heat exchanger body (16 screws M8x1.25x50)
1st phase 11.5 ± 3.5 1.15 ± 0.35
2nd phase 24.5 ± 2.5 2.45 ± 0.25
Damper pulley (6 screws M12x1.75x30) 115 ± 5 11.5 ± 0.5
Crankshaft pulley (6 screws M14x2x60)
1st phase 70 7.0
2nd phase 50˚
Electro-injector brackets (6 screws M10x1.5x40) 46 ± 3 4.6 ± 0.3
Rail (3 screws M8) 23 ± 2 2.3 ± 0.2
Intake manifold
(3 screws M10x1.5x100) 43 ± 3 4.3 ± 0.3
(2 screws M10x1.5x110) 43 ± 3 4.3 ± 0.3
(1 screw M10x1.5x150) 43 ± 3 4.3 ± 0.3
Air conditioning compressor / PTO cover
(3 screws M12x1.75x25) 63 ± 5 6.3 ± 0.5
Starter motor (3 nuts M10x1.5) 43 ± 3 4.3 ± 0.3
(3 studs M10x1.5x30) 25 ± 5 2.5 ± 0.5
Engine brake collar (1 nut M6x1) 6±1 0.6 ± 0.1
Engine coolant return and delivery pipes to engine brake control actuator
(4 fittings M12x1.5) 25 ± 5 2.5 ± 0.5
Turbocharger (4 nuts M10x1.5) 46 ± 2 4.6 ± 0.2
Shoulder plate (5 screws M8x1.25x20) 20 ± 2 2.0 ± 0.2
PART TORQUE
Nm kgm
Oil outlet pipe from turbocharger
(2 screws M8x1.25x25) 24 ± 3 2.4 ± 0.3
(1 fitting M27x1.5) 25 ± 5 2.5 ± 0.5
(1 fitting M30x2) 110 ± 5 11.0 ± 0.5
Oil delivery pipe to turbocharger (2 fittings M16x1.5) 42± 2 4.2 ± 0.2
Bracket retaining oil delivery pipe to turbocharger (1 screw M8x1.25x16) 23 ± 2 2.3 ± 0.2
Exhaust manifold (24 screws M10x1.5x38) 45 ± 5 4.5 ± 0.5
Engine management control unit (3 nuts M8x1.25) 24 ± 3 2.4 ± 0.3
Timing sensor (1 screw M6x1) 9±1 0.9 ± 0.1
Engine rpm sensor (1 screw M6x1) 9±1 0.9 ± 0.1
Air temperature and pressure sensor (1 screw) 9±1 0.9 ± 0.1
Engine oil temperature and pressure sensor (2 screws) 9±1 0.9 ± 0.1
Water pump drive belt mobile tensioner (1 screw M10x1.5x80) 45 ± 5 4.5 ± 0.5
Engine flywheel (8 screws M18x1.5x72)
1st phase 120 ± 5 12.0 ± 0.5
2nd phase 90˚
Thermostat housing/Engine coolant outlet pipe (5 screws M8x1.25x70) 24.5 ± 2.5 2.45 ± 0.25
Coolant temperature sensor 20 ± 5 2.0 ± 0.5
Water pump (4 screws M8x1.25x25) 24.5 ± 2.5 2.45 ± 0.25
Engine coolant pipes (1 fitting M12x1.5) 20 ± 2 2.0 ± 0.2
Degassing pipe (1 fitting M12x1.5) 20 ± 2 2.0 ± 0.2
Fuel filter support (4 screws M8x1.25x30) 24 ± 3 2.4 ± 0.3
Fuel filter bracket
(3 screws M8x1.25x35) 24 ± 3 2.4 ± 0.3
(1 screw M8x25) 24 ± 3 2.4 ± 0.3
(1 screw M10x25) 37.5 ± 7.5 3.75 ± 0.75
Alternator upper support
(2 screws M8x1.25x30) 24 ± 3 2.4 ± 0.3
Automatic belt tensioner
(1 screw M10x1.5x70) 45 ± 5 4.5 ± 0.5
Alternator lower support
(2 screws M10x1.5x70) 43 ± 3 4.3 ± 0.3
(1 screw M10x1.5x30) 43 ± 3 4.3 ± 0.3
Alternator
(1 screw M8x1.25x35) 24 ± 3 2.4 ± 0.3
( 1 screw M10x1.5x120) 43 ± 3 4.3 ± 0.3
Engine coolant inlet pipe (to water pump)
(2 screws M8x1.25x50) 23.5 ± 2.5 2.35 ± 0.25
(1 screw M8x1.25x70) 23.5 ± 2.5 2.35 ± 0.25
Fan-fixing spacer
(6 screws M8x1.25x50) 23.5 ± 2.5 2.35 ± 0.25
Fan drive pulley bearing
(1 screw M10x1.5x80) 55 ± 5 5.5 ± 0.5
Fan support (on cylinder head)
(4 screws M8x1.25x50) 34.5 ± 3.5 3.45 ± 0.35
Idler guide roller
(1 screw M12x1.75x70) 60 ± 8 6.0 ± 0.8
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
99360256 Cap to take down and fit back engine valves (use with 99360257)
TOOLS
TOOL NO. DESCRIPTION
99360294 Drift for fitting valve guide (to be used with 99360288)
TOOLS
TOOL NO. DESCRIPTION
Flywheel restrainer
99360351
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3