334T, M2 NEF (Iveco) Engine F4CE0354A FAM #

ENGINE
SERVICE MANUAL
334T/M2
CONSTRUCTION
87458412NA
Issued March, 2004 • 87458412NA • Bur
Copyright © 2004 CNH America LLC. All Rights Reserved.
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no-
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information
concerning repairing operations.
CNH AMERICA LLC
700 State Street
Racine, WI 53404 U.S.A.
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example: T 1 -- 2 -- 3
Progressive page number for each group
Group number (if any)
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
This symbol regards safety.

! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature qC qF qC x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min --1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
Section 1 -- Diagnostics EW--1--1
Section 2 -- Engine F4CE0354A overhaul EW--2--1
Section 3 -- Recharging and start--up EW--3--1

4 WE
MOTORI
SECTION 1
DIAGNOSTICS
INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
INDICE
EW--1--3
DIAGNOSTICS
Main engine operating anomalies:
1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

2 -- Engine overheats; 7 -- Engine knocks irregularly;
3 -- Engine lacks power and works erratically; 8 -- Engine stops;
4 -- Engine exhaust smoke black or dark grey; 9 -- Engine exceeds max. revs number;
5 -- Engine exhaust smoke grey (verging on 10 -- Excessive or insufficient oil pressure;
white); 11 -- Excessive fuel consumption;
12 -- Engine won’t stop.
1 ENGINE WON’T START
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Thermal starter in working order Replace.

NO
YES
Injection pump timed Verify correct timing as described in the relevant

NO chapter.
(to be continued)
EW--1--4
DIAGNOSTICS
Injectors in working order Check operation and adjust.

NO
YES
The feeding circuit or injection pump does not Check and blow off.
show air penetration NO
YES
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water NO tank).
YES
Prescribed compression ratio Overhaul the engine or make repairs only on

NO
concerned parts (valves, piston rings, etc.).
YES
Fuel filters in working order Replace.

NO
YES
Automatic advance variator and electric STOP Check and replace the concerned parts.
device both in working order NO
YES
Fuel pump fed correctly Check and replace (if necessary) the fuel pump.
NO
YES
Fuel tank supplied correctly Refuel.

NO
EW--1--5
DIAGNOSTICS
2 ENGINE OVERHEATS
Coolant level correct Check for leaks and restore the level.
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level.
NO
YES
Water pump in working order Overhaul or replace the unit.

NO
YES
Thermostat in working order Replace.

NO
YES
Radiator in working order Wash down thoroughly, check for fluid leaks,
NO replace (if necessary) the part.
YES
Air filter and circuit piping both in working order Clean or replace faulty parts.
NO
YES
Openings for coolant flow to the head in working Wash down thoroughly.
order NO
EW--1--6
DIAGNOSTICS
Valve timing correct Check and perform correct timing.

NO
YES
Injection pump timed Check correct timing as described in the relevant

NO paragraph.
YES
Cylinder head gasket in working order Replace.

NO
YES
Fan in working order Replace.

NO
3 ENGINE LACKS POWER AND WORKS

ERRATICALLY
Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.
YES
Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.
YES
Feeding circuit in working order Check and make (if necessary) the required
NO repairs.
(to be continued)
EW--1--7
DIAGNOSTICS
The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.
YES
Thermostat in working order Replace.

NO
YES
Fuel pump in working order Replace.

NO
YES
Injectors in working order Check operation and adjust them.

NO
YES

NO paragraph.
YES
Automatic advance variator (in injection pump) in Check and bench--adjust the injection pump.
working order NO
YES
Distributing plunger (in injection pump) in Check and bench--adjust the injection pump.
working order NO
(to be continued)
EW--1--8
DIAGNOSTICS
Injection pump rate correct Check and bench--adjust the injection pump.
NO
YES
Speed governor (in injection pump) in working Check and bench--adjust the injection pump.
order at all speeds NO
YES
Circuit and L.D.A. device both in working order Check.

NO
YES
Injection pump with peak adjusting--screw fine-- Fine--tune the peak adjusting--screw.
tuned NO
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.
YES
Prescribed compression ratio Check and bench--adjust the injection pump.

NO
YES
Turbocharger in working order Repair or replace the unit.

NO
YES
Correct tie rod length between the accelerator Adjust the tie rod length.
and injection pump NO
EW--1--9
DIAGNOSTICS
4 ENGINE EXHAUST SMOKE BLACK OR

DARK GREY
Air filter in working order Replace.

NO
YES
Thermal starter in working order Replace.

NO
YES
Automatic addition device comes into operation Check and replace (if necessary).
NO
YES
Injectors in working order Check operation and adjust them as described.

NO
YES

NO paragraph.
YES
L.D.A. device in working order Ad just the L.D.A. device.

NO
YES
Injection pump adjusted as prescribed Check and bench--adjust the injection pump.
NO
(to be continued)
EW--1--10
DIAGNOSTICS
Injection pipes intact Check the condition of pipes and replace them (if
NO necessary).
YES
Prescribed compression ratio Check by means of a Motometer 75301430 tool

NO and carry out the necessary operations.
YES
High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO
5 ENGINE EXHAUST SMOKE GREY

(VERGING ON WHITE)
The thermostat comes into operation correctly Replace.

NO
YES
Injectors in working order Check operation and adjust as described in S.I.

NO 1094.
YES

NO paragraph.
YES
Coolant level correct Possible flow of coolant into the combustion

NO
chamber; replace the cylinder head gasket or
overhaul the engine.
(to be continued)
EW--1--11
DIAGNOSTICS
High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO
6 ENGINE EXHAUST SMOKE LIGHT BLUE
Excessive oil consumption Check the oil vapour vent and cylinder compres-
YES sion. Overhaul, if necessary, the cylinder head or
engine.
7 ENGINE KNOCKS IRREGULARLY
Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine.
NO
Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect-
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.
NO
Knock detected in pistons Check the following items: play between the pis-
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.
(to be continued)
EW--1--12
DIAGNOSTICS
Knock detected in the cylinder head Check the following items: operation play be-
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for excess-
YES ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.
NO
Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace.
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.
NO
Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump.
8 ENGINE STOPS
Fuel tank filled Refuel and drain (if necessary).

NO
YES
Fuel filters in working order Replace.

NO
(to be continued)
EW--1--13
DIAGNOSTICS
Feeling circuit in working order Check the circuit and drain.

NO
YES
Regular idle speed Adjust.

NO
YES
Regular injection pump rates Bench--check the flow rates.

NO
YES
Injection pump controls in working order Replace worn parts and adjust.
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
arms.
NO
YES
Intact valves Replace the valves.

NO
9 ENGINE EXCEEDS MAX. REVS NUMBER
Speed governor in working order Check and replace (if necessary) the worn parts.
NO
EW--1--14
DIAGNOSTICS
10 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE
Pressure control valve in working order Check and replace (if necessary).
NO
YES
Oil pump and delivery pipes both in working or- Check and replace (if necessary).
der NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.
YES
Engine oil SAE viscosity conforming to stan- Replace the engine oil with equivalent of ad-
dards NO equate viscosity.
11 EXCESSIVE FUEL CONSUMPTION
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.
YES
Air filter in working order Replace.

NO
(to be continued)
EW--1--15
DIAGNOSTICS
Correct injector adjustment Check operation and adjust them.

NO
YES
Correct injection pump adjustment Check and bench--adjust.

NO
YES
L.D.A. device in working order Adjust the L.D.A. device.

NO
YES
Injection pump timed Check static force--fit of the injection pump.

NO
12 ENGINE WON’T STOP
Cut--off electromagnet in working order Replace the electromagnet.

NO
YES
Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16
DIAGNOSTICS
NOTES
SECTION 2 ENGINE F4CE0354A
ENGINE F4CE0354A OVERHAUL
INDEX
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--3 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--48
Coding of source engines . . . . . . . . . . EW--2--4 Replacing the bushings . . . . . . . . . . . . . . EW--2--49
General engine features . . . . . . . . . . . EW--2--5 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49
Assembling play -- specifications . . EW--2--7
Mounting the tappets – Distributing shaft EW--2--49
Tightening torque . . . . . . . . . . . . . . . . . EW--2--13
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--2--50
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--14
Graphic indications and symbols . . . EW--2--15 Measuring the journals and crankpins . EW--2--50
General remarks . . . . . . . . . . . . . . . . . . EW--2--16 Replacing the oil pump drive gears . . . . EW--2--53
Description of main mechanic Mounting the main bearings . . . . . . . . . . EW--2--53
engine components . . . . . . . . . . . . . . . EW--2--17
Measuring the journal assembling play EW--2--53
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--17
Checking the drive shaft shoulder play . EW--2--54
Drive shaft seal rings . . . . . . . . . . . . . . . EW--2--17
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--18 Connecting rod--piston assembly . . . EW--2--55
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--56
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--20 Measuring the piston diameter . . . . . . . EW--2--56
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--2--57
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--22
Conditions for correct pin/piston
Valves and valve seats . . . . . . . . . . . . . . EW--2--23 matching. . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--57
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--2--24 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--2--57
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--25
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--58
Auxiliary component drive . . . . . . . . . . . EW--2--26
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Lubrication . . . . . . . . . . . . . . . . . . . . . . . EW--2--27
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--2--28 Checking the connecting rods . . . . . . . . EW--2--59
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Checking the torsion . . . . . . . . . . . . . . . . EW--2--59
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--30 Checking the flexion . . . . . . . . . . . . . . . . EW--2--59
Oil vapour recirculation . . . . . . . . . . . . . . EW--2--31 Fitting connecting rod--piston assembly. EW--2--60
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32
Connecting rod--piston coupling . . . . . . EW--2--60
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--2--33
Mounting the piston rings . . . . . . . . . . . . EW--2--60
Mechanic injection supply system . . EW--2--34
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Mounting the connecting rod/piston
assemblies in the cylinder liners . . . . . . EW--2--61
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--2--35
Measuring the crankpin assembling play EW--2--61
Injection assembly . . . . . . . . . . . . . . . . EW--2--36
Engine bench--overhaul . . . . . . . . . . . . EW--2--37 Checking piston protrusion . . . . . . . . . . . EW--2--62
Disassembling the engine . . . . . . . . . . . EW--2--37 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--63
Removal of compensating units . . . . . . EW--2--39 Engine flywheel . . . . . . . . . . . . . . . . . . . EW--2--65
Replacing the seal ring . . . . . . . . . . . . . . EW--2--41 Mounting the oil and water pump . . . . . EW--2--65
Repair work on cylinder cluster . . . . . EW--2--45
Mounting the water / oil heat exchanger EW--2--66
Checks and measurements . . . . . . . . . . EW--2--45
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--67
Checking head supporting surface
on cylinder unit . . . . . . . . . . . . . . . . . . . . . EW--2--46 Removing the valves . . . . . . . . . . . . . . . . EW--2--67
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--2--47 Checking cylinder head wet seal . . . . . . EW--2--68
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--47 Checking the cylinder head supporting
Checking the pin alignment . . . . . . . . . . EW--2--47 surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--68
INDEX
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69 Research of top dead centre

Valve descaling, check and grinding . . . EW--2--69 by tool 380000977 . . . . . . . . . . . . . . . . . . EW--2--79
Checking clearance between valve stem Check of top dead centre . . . . . . . . . . . . EW--2--79
and valve guide and valve centring . . . . EW--2--69
Disassembly and assembly . . . . . . . . . . EW--2--80
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--2--70
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--2--70 Ignition pump control and timing . . . . . . EW--2--82
Regrinding – replacing the valve seats . EW--2--70 Feed system bleed procedure . . . . . . . . EW--2--82
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--2--71 Replacing the injectors . . . . . . . . . . . . EW--2--83
Fitting cylinder head . . . . . . . . . . . . . . . EW--2--72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--83
Refitting the cylinder head . . . . . . . . . . . EW--2--72
Rocker arm assembly . . . . . . . . . . . . . . . EW--2--73 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--83
Mounting the injectors . . . . . . . . . . . . . . . EW--2--74 Rocker arm removal/reassembling . . EW--2--84

Rotary feed pump disassembly and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--84
assembly procedure . . . . . . . . . . . . . . . EW--2--78
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--84
Research of top dead centre
by tool 380000988 . . . . . . . . . . . . . . . . . . EW--2--79 Adjusting the tappets . . . . . . . . . . . . . . EW--2--84
EW--2--3
ENGINE F4CE0354A
Figure 1
90323
EW--2--4
CODING OF SOURCE ENGINES
F 4 C E 0 3 5 4 A * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern:
0 = 4 strokes, vertical
Engine
Type of crankcase:
C = structural 3 = 3--cylinder
Group
Engines
5 = Direct injection turbo

diesel
4 = Earthmovers
X Y Y Y Y Y Y Y Y
X = 6 rotary, 2--valve injection pump Manufacturing sequence number

Y = Engine model
EW--2--5
GENERAL ENGINE FEATURES
Type F4CE0354A *D
Cycle 4--stroke diesel engine

Feeding Turbocharged
Injection Direct
Number of cylinders In--line, 3--cylinder
Bore mm 104
Stroke mm 132
Total displacement cm3 3364
Compression ratio 17.5 : 1
Max. rating kW 58
min --1 2300
Max. torque Nm (kgm) 310 (31)

min --1 1400
No--load idle rpm min --1 —
No--load peak rpm min --1 —
BOOSTING
HOLSET HX20W
Type of turbocompressor:
Forced by means of a lobe pump,

LUBRICATION
pressure modulating valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--2--6
Type F4CE0354A *D
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: qC 81 r 2
REFUELLING
Full filling capacity 1q litres —
Ambra Super Gold
15W40 kg
10W30 -- engine sump litres
8
kg
-- engine sump + filter litres 9
kg
FEEDING
VE3 / 12 F 1150 L 947
Bosch--type injection
Pump setting —
Start of delivery mm 1 r 0.05
Type of nozzle DSLA 145 P1255
Injection sequence 1 -- 3 -- 2
Injection pressure (bar) 260

EW--2--7
ASSEMBLING PLAY -- SPECIFICATIONS
Type F4CE0354A *D
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners 1 104.000 to 104.024
Pistons: supplied with standard

spares
Measurement dimension X 59
Outer diameter 1 103.730 to 103.748
Pin seat 2 38.010 to 38.016
Piston -- cylinder liners 0.252 to 0.294
Piston diameter 1 0.4 -- 0.8
Position of pistons from crankcase X 0.28 to 0.42
Gudgeon pin 3 37.994 to 38.000
Gudgeon pin -- Pin seat 0.004 to 0.016
X1* 2.705 to 2.735

Piston ring slots X2 2.440 to 2.460
X3 4.030 to 4.050
* measured on of 101 mm
S1* 2.560 to 2.600
Piston rings S2 2.350 to 2.380
S3 3.970 to 3.990
* measured on of 101 mm
1 0.155 to 0.175
Piston rings – Slots 2 0.060 to 0.110
3 0.040 to 0.080
Piston rings 0.4 to 0.8

EW--2--8
Type F4CE0354A *D

Piston ring end opening
in cylinder liner:
X1 0.30 to 0.40
X2 0.60 to 0.80
X3 0.30 to 0.55
Connecting rod small--end

bushing seat 1 40.987 to 41.013
Connecting rod bearing seat 2 72.987 to 73.013
Connecting rod small--end bushing

diameter
Outer 4 —
Inner 3 38.019 to 38.033
Connecting rod small--end

—
bushing – seat
Gudgeon pin – Bushing 0.019 to 0.039
Measurement dimension X —
Max. error on connecting rod

axis parallelism = —
Journals 1 82.99 to 83.01

Crankpins 2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares
Bed supports no.:

n. 1--4 3 87.982 to 88.008
n. 2--3 87.977 to 88.013
EW--2--9
Type F4CE0354A *D

Half bearings -- journals:
n. 1--4 0.064 to 0.095
n. 2--3 0.059 to 0.100
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.550
Shoulder bed support X2 31.730 to 32.280
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.095 to 0.270

EW--2--10
Type F4CE0354A *D
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head 1 8.019 to 8.039
Valves:
4 7.96 to 7.98
D 60q
4 7.96 to 7.98
D 45q
Valve stem and respective guide 0.039 to 0.079
Seat on head for valve seat:

1 46.987 to 47.013
1 43.637 to 43.663
Valve seat outer diameter;

inclination of valve seats
on cylinder head:
2 47.063 to 47.089
D 60q
2 43.713 to 43.739
D 45q
Hollow X 0.356 to 1.102
X 0.104 to 0.840
Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102
Valve seats —
EW--2--11
Type F4CE0354A *D
Valve spring height:

free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seat for distributing shaft bushing

no. 4 59.222 to 59.248
Distributing shaft seats no. 1--2--3 54.089 to 54.139
Distributing shaft support pins:

14 53.995 to 54.045
Bushing outer diameter for

distributing shaft: —
Bushing inner diameter 54.083 to 54.147
Bushings and seats in crankcase —
Bushings and support pins 0.038 to 0.152

Eccentric working lift:
—
—
EW--2--12
Type F4CE0354A *D
1 Seat for tappet

collar
in the crankcase 1 16.000 to 16.030
2
Outer diameter of tappet collar:
3 2 15.929 to 15.959
2 3 15.965 to 15.980
Between the tappets and the seats 0.020 to 0.065
Tappets --
1
Rocker arm shaft 1 18.963 to 18.975
Rocker arms 2 19.000 to 19.026

2
Between the rocker arm and the
0.025 to 0.063
shaft
EW--2--13
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 r 5 (5 r 0.5)
screws M12x1.75x140 40 r 5 (4 r 0.5)
screws M12x1.75x180 70 r 5 (7 r 0.5)
2nd pphase: 90q
3rdd phase: (only for screws 140 and 180 mm long) 90q
p fastening
Bed cap g screws 1st p
phase 50 r 6 (5 r 0.6)
nd
2 p phase 80 r 6 (8 r 0.6)
3rd phase 90q
Connecting g rod cap
p fastening
g screws 1st p
phase 30 r 5 (3 r 0.5)
2nd p
phase 50 r 5 (5 r 0.5)
rd
3 phase 60q r 5q
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 r 5 (3 r 0.5)
Angle 60q r 5q
Injector fastening 60 r 5 (6 r 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 r 5 (2.5 r 0.5)
Valve gear cover and case fastening screw 25 r 5 (2.5 r 0.5)
Container fastening screw 25 r 5 (2.5 r 0.5)
Intake manifold fastening screw 25 r 5 (2.5 r 0.5)
Fuel pump fastening screw 25 r 5 (2.5 r 0.5)
Exhaust manifold fastening screw 53 r 5 (5.3 r 0.5)
Tappet cover fastening nut 25 r 5 (2.5 r 0.5)
Rocker arm support fastening screw 48 r 8 (4.8 r 0.8)
Nut for rocker arm adjusting screw 25 r 5 (2.5 r 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 r 5 (5 r 0.5)
Angle 90q
Distributing shaft shoulder plate fastening screw 25 r 5 (2.5 r 0.5)
Fan support fastening screw 25 r 5 (2.5 r 0.5)
Injection pump fastening screw 12 r 5 (1.2 r 0.5)
Fan pulley fastening screw 45 r 5 (4.5 r 0.5)
Turbocompressor fastening screw 25 r 5 (2.5 r 0.5)
Heat exchanger fastening screw 25 r 5 (2.5 r 0.5)
Oil pump and front cover fastening screw 25 r 5 (2.5 r 0.5)
Starter motor fastening screw 55 r 5 (5.5 r 0.5)
Alternator fastening screw 45 r 5 (4.5 r 0.5)
Water pump fastening screw 25 r 5 (2.5 r 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 r 5 (4.5 r 0.5)
-- Lubrication with oil

EW--2--14
TOOLS
380000216 Rocking sling for removing/installing engine
380000220 Compression tool for fitting engine piston (60--125 mm)
380000221 Piston ring removal and refitting pliers (65--110 mm)
380000228 Dial gauge (0--5 mm)
380000301 Assemblies overhaul revolving stand (capacity 1000 daN, torque 120 daN/m)
380000302 Engine valves remover/installer
380000304 Gauges pair for the angular tightening with 1/2” and 3/4” square connection
380000362 Crakshaft lifting tackle
380000364 Comparator holder base for different surveys (use with 380000228)
380000661 Brackets fixing engine to revolving stand 380000301
Bracket fixing engine to revolving stand 380000301 (use with 380000661)
380000663 Tool to remove crankshaft rear gasket
380000664 Crankshaft rear seal installer
380000665 Tool to remove crankshaft front gasket
380000666 Crankshaft front seal installer
380000667 Cramshaft bush assembly and disassembly punch (use with 380000668)
380000668 Handle interchangeable driver
380000669 Tools for removing gaskets
380000670 Remove cartridge filter
380000671 Tool to remove injectors
380000975 Box with valve seat regrinding tools and attachments
380000976 Spring load tester
380000977 Tool to check top dead centre (use with 380001005)
380000988 Flywheel crank handle
380000989 Adapter cylinder compression test (use with 380001006)
380000998 Hand pump to measure pressure and vacuums
380001002 Universal Goniometer/Clinometer
380001003 Square complete for checking connecting rods perpendicularity
380001005 Dial gauge (0--10 mm)
380001006 Diesel engine cylinder compression tester
380001084 Dial gauge holder for rotary injectiion pump timing (use with 380000228)
380001990 Locking PIN
EW--2--15
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
¸ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

§
Replacement
Countersink
Genuine spares
Adjustment
Rotation
Setting
Warning Angle
! Note Angular value
Visual check
Preload
Mounting position check
Measurement
Dimension to be measured Revs number
Check
Equipment Temperature
Surface to be machined
Pressure
Machining finish bar
Increase
Interference
Greater than .....
Forced mounting
Maximum
Decrease
Thickness
Smaller than ....
Play
Minimum
Lubricate Selection
Moisten Classes
Grease Increases
Temperature < 0 qC
Sealant Cold
Winter
Temperature < 0 qC
Air bleed Hot
Summer
EW--2--16
GENERAL REMARKS
Figure 2
90324
1. Turbocharger -- 2. Belt tensioner – 3. Fan pulley – 4. Alternator –

5. Fan, alternator and water pump drive belt – 6. Water pump – 7. Pulley on crankshaft –
8. Injection pump – 9. Grid heater – 10. Blow--by
EW--2--17
DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Drive shaft
It is made of steel and rests on four induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
Inside the drive shaft are the lubricating oil ducts.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, damper flywheel and
The second main half bearing is equipped with a
auxiliary component drive pulley.
shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 3
88723
1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear
Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000665 and 380000663, and mounted by means of tools 380000666 and 380000664.
EW--2--18
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 4
84038
EW--2--19
Pistons
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1 and 2, trapezoidal in shape and with ce-
Three slots (piston ring seats) are provided: the first ramic chrome coating.
one and the second one are obtained from a cast-- Ring 3, with double scraper ring shoe with inner
iron insert with trapezoidal section. spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 5
88724
EW--2--20
Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.
Figure 6
70164
88725
EW--2--21
Valve control
Figure 7
88726
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones –

6. Cup – 7. Spring – 8. Tappet – 9. Distributing shaft
EW--2--22
Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5).
Figure 8
88727
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--23
Valves and valve seats
Figure 9
88728
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45q (exhaust valves)
- 60q (intake valves).
Figure 10
88729
Figure 10 shows the oil seals mounted on valve

stems.
EW--2--24
Valve guides
Figure 11
INTAKE EXHAUST
84046
DETAIL OF VALVE GUIDES AND SEATS

EW--2--25
Engine flywheel
The flywheel needs a fixed position on the engine
shaft because a reference hole is made on it.
Figure 12
86454
1. Flywheel -- 2. Fixing screws

EW--2--26
Auxiliary component drive

A Poly--V belt (5) transmits the motion of drive The belt is stretched by means of belt tensioner (1).
shaft to water pump (4), alternator (2) and fan
pulley (3).
Figure 13
90325
1. Belt tensioner -- 2. Alternator -- 3. Fan pulley -- 4. Water pump -- 5. Poly--V belt

EW--2--27
LUBRICATION
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the crank-
lowing components: case;
- oil lobe pump fitted in the front part of the base- - oil pressure regulating valve incorporated in the
ment, driven by the splined bush, keyed on the oil filter support;
hold of the engine drive shaft; - bypass valve for bypassing the clogged oil filter,
in the oil filter support;
- cartridge--type oil filter.
Figure 14
87397
Pressure oil path
Oil return drop--type path

EW--2--28
Heat exchanger
Figure 15
88732
1. Heat exchanger body – 2. Inner gasket – 3. Spacer -- 4. Water / oil heat exchanger
EW--2--29
Oil pump
Figure 16
88733
1. Rotating shaft seal -- 2. Oil pump -- 3. Seal

EW--2--30
Oil sump
The oil sump (1) is fixed with screws to the base and A seal (2) is inserted between the base and the oil
is used as a flywheel covering box. sump, it is divided in four parts: a front part, a rear
part and two side parts in other words it assures
better seal and dampens the noise.
Figure 17
90326
1. Oil sump -- 2. Seal

EW--2--31
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
Figure 18
84056
EW--2--32
COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.
Figure 19
TO RADIATOR
FROM
RADIATOR
87398
Water flowing out of the thermostat
Water recirculating in the engine

Water flowing into the pump
EW--2--33
Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 20
84058
Figure 21
84059
EW--2--34
MECHANICAL INJECTION SUPPLY

SYSTEM
FUEL FILTER
The filter is positioned next to the supply and priming On the base of the filtering cartridge there is a water
pump, it holds impurities and separates the water discharge screw for periodical discharging.
container in the fuel.
Figure 22
88210
1. Fuel filter support -- 2. Filtering cartridge -- 3. Water discharge screw

EW--2--35
Mechanic fuel pump

Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.
Figure 23
84249
1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank
Figure 24
88209
1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--36
INJECTION ASSEMBLY
Figure 25
87400
1. Injector fuel pipe -- 2. Fuel exhaust pipes from injectors -- 3. Fuel feed rotary pump -- 4. Connector for
LDA pressure gauge pipe within suction collector -- 5. KSB thermal bulb -- 6. Electro--valve -- 7. Injector
EW--2--37
ENGINE BENCH--OVERHAUL Figure 28

Disassembling the engine
Figure 26
87744
87683
In order to apply the brackets 380000661 the engine On the left hand side:
block to fix it on to the stand 380000301 for the over- - assemble the second bracket 380000661
haul, it is necessary to perform the following opera- throughout the screw--threaded ports (1).
tions:
- Lift the engine using the rocker arm 380000216
On the right hand side: and put it on the turning stand 380000301.
- disassemble lubrication oil exhaust pipe (2) from - Drain the oil through the cap underneath the
the turbo--blower: plug.
Underneath the turbo--blower loosen the screws
(1); finally loosen and remove the union (5) from
the block; plug the pipe ends and the exhaust of Figure 29
the turbo--blower.
- oil level rod (4);
1
- oil filter (3).
Figure 27
75675
Proceed disassembling the supercharger:

- Loosen the fixing nut (1) and remove the lubrica-
tion pipe from the turbocharger. Analogously
87712 carry out the same operation on the other end of
the pipe and remove it from the upper part of the
heat exchanger.
- Disassemble the starter;
properly hold the starter (2) and loosen the two - Loosen the screw nuts fixing the supercharger
fixing screws (1); on the exhaust manifold.
assemble the supporting bracket 380000661 - Hold up the turbocharger and after lifting it
using the threaded ports on the block. remove the gasket.
EW--2--38
Figure 30 Figure 32
4
3
1
2
87404
87405
- Place a container under the fuel filter and screw Disconnect the LDA pipe (1) from the head and from
out the condense drain cap underneath said fil- the feed pump. Pipe the ends of the pipelines as well
ter. Carry out complete drainage of the fuel con- as the feed pump and the engine head.
tained therein.
- Screw out completely the faucet and, using Figure 33
equipment 380000670 disassemble fuel filter
(1).
- Disconnect fuel pipelines (2 and 3) respectively
from priming pump to filter bearing and from this
last one to the feed pump.
- Remove the fuel filter bracket (4) from the
bracket fixed to the engine head.
Figure 31
87406
Remove tappet caps:

loosen the fixing screws (1) and lift the caps (2);
remove the gaskets.
IMPORTANT -- On the central cap there is a

blow--by valve for the lubrication oil vapours.
70126 All the gaskets shall always be replaced during
assembly.
Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
bring fork (1) back to the locking position (detail B)
after adapter hes been removed.
EW--2--39
Figure 34 Removal of compensating units

Figure 36
1
87407
75683
- Disconnect the pipelines (1) and (2) that provide
- Disassemble rocker arm bearings; loosen the
feed and fuel recovery between pump and injec-
two fixing screws (2) and remove the complete
tors; screw out the nuts fixing the pipes to the
rocker arm bearing; withdraw tappet rods.
pumping elements; loosen the fuel recovery pipe
Repeat the operation for all the remaining rocker
collar on the injection pump; operate on the nuts
arm bearings.
assembled to the injectors and loosen the
screws fixing the fuel recovery pipeline; loosen - Disassemble water temperature transmitter (1).
the screws holding the fixing brackets of such pi-
pelines; pipe the pipeline ends. Figure 37
- Disassemble the injectors and remove them
from their slot: remove the gaskets.
Figure 35
87410
Loosen the two fastening screws (2) and remove the

priming pump (1).
For dismounting the injection pump, see what
87409 described at page EW--2--78 in Rotary feed pump
disassembly and assembly procedure.
Disassemble suction and exhaust manifolds:
loosen the screws (1) fixing the suction manifold pla-
te to the cylinder head;
from the exhaust manifold side, loosen the eight (2)
fixing screws; remove the gaskets.
EW--2--40
Figure 38 Figure 41
87411
- Loosen the screw (1) adjusting the belt tightening 87414
pulley in order to release the belt (2) until enab- Loosen the screws (1) and withdraw the alternator
ling to withdraw it from the convey and drive bearing (2).
pulleys. Figure 42
- Remove the belt tightening pulley (3).
Figure 39
87412
87415
Disassemble thermostat unit; loosen the three fixing
- Loosen the screws (1) and disassemble the oil fil-
screws (1), disassemble the thermostat unit (2) and
ter/heat exchanger bearing (2), the interlayer
remove the gasket (3) and the thermostat (4).
plate and remove the relating gaskets.
- Disassemble injection pump (see specific proce-
Figure 40 dure) and the power take--off underneath (if
available).
Figure 43
87413 87416
Duly hold the alternator (2) removing it from its sup- - Loosen the four screws (1) and disassemble the
port by loosening the screw (3) and from the bracket pulley (2) from the bearing underneath.
by loosening the screw (1); recover nuts and - Proceed disassembling the bearing.
washers.
EW--2--41
Figure 44 Figure 46
87417
Disassemble the cylinder head:

- loosen the fastening screws (1) and (2) remove
the cylinder head (3);
- remove the sheath (4).
Hook the brackets with metal ropes and, throu-
ghout a hoist withdraw cylinder head from the
block.
Figure 45 87418
- Loosen the screws (1) and withdraw water pump

(2).
- Loosen the screws (3) and remove the pulley (4).
Replacing the seal ring

Figure 47
87747
- Use the tool 380000988 to operate on the flywhe-

el cover box (1) in order to block flywheel rotation
(2).
- Loosen the flywheel fixing screws (3) to engine
drive shaft.
78256
Apply tool 380000665 (4) on drive shaft front shank

(2).
Drill inner seal ring (1), through tool 380000665 (4)
guide holes, with an inset ( 3.5 mm) down to a
depth of 5 mm.
Secure tool 380000665 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).
EW--2--42
Figure 48 Figure 50
78257
Apply the proper tension rod (3) of tool 380000669 to

outer seal ring (2) as shown in the figure, then take 87420
the same off front cover (1) by means of lever (4).
Remove the front cover.
- Screw out the opposite screws (1) from the ports
Figure 49 and introduce the withdrawal pins (see picture
following).
- Loosen remaining flywheel fixing screws (3) to
the engine drive shaft (2).
- Remove the flywheel block tool (2).
Figure 51
87419
- Loosen the screws (2) and remove the front co-

ver (1).
- Remove the gasket.
IMPORTANT -- Take note of the screw (2) assem-

bly position, since the screws have different length.
87421
Screw up two medium length screws in the ports (4)

to sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
EW--2--43
Figure 52 Figure 54
87422
78258
Apply tool 380000663 (3) on drive shaft rear shank Loosen the screws (2) and remove the flywheel co-
(5). ver box (1).
Drill inner seal ring (1), through tool 380000663 (3)

guide holes, with an inset ( 3.5 mm) down to a IMPORTANT -- Take note of the screw (2) assem-
depth of 5 mm. bly position, since the screws have different length.
Secure tool 380000663 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2). Figure 55
Figure 53
87423
- Turn the engine upside--down.

78257
- Loosen the screws (2), take out the oil sump (1)
Apply the proper torsion bar (3) of tool 380000669 to keep the seals.
outer seal ring (2) as shown in the figure, then take
the same off flywheel cover case (1) by means of
lever (4).
EW--2--44
Figure 56 Figure 59
70159
Remove screws (1) and take off bed caps (2).

87655
Remove the gear (1) transmitting motion to the igni- Figure 60

tion pump and the relevant support.
Figure 57
70160
The penultimate bed cap (1) and its respective sup-

87424
port have half bearing (2) provided with shoulder.
Remove the screws (1) and disassemble the gears
(3) and (4) from the camshaft (2). IMPORTANT -- Take note of the mounting position
Figure 58 of lower and upper half bearings; in fact, if they have
to be used again, they must be mounted in the
same position they had prior to being taken off.
Figure 61
70158
Remove connecting rod cap (2) fastening screws (1),
then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part. 87722
IMPORTANT -- Half bearings must be kept in their Remove the output shaft (1) from the block.
respective housings; in fact, if they have to be used
again, they must be mounted in the same position
they had prior to being taken off.
EW--2--45
Figure 62 Figure 65
70165
70162 Remove tappets (1) from the engine crankcase.

Take off main half bearings (1).
Remove screws (2) and take off oil nozzles (3).
Figure 63
REPAIR WORK ON CYLINDER CLUSTER

Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
70163
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Remove screws (1) and take off distributing shaft (3)
Check the condition of working caps. They must be
retaining plate (2).
replaced if they are rusty or their sealing properties
are in doubt.
IMPORTANT -- Take note of plate (2) mounting
position. Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
Figure 64
70164
Carefully remove the distributing shaft from the

crankcase.
EW--2--46
Figure 66 Figure 68
70166
The check of cylinder liner inner diameter (in order to -

measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter. §
NOTE – If no ring gauge is available, use a micro-

meter to perform reset.
Figure 67
87753
IMPORTANT -- In case of reconditioning, all the lin-

ers must be machined to the same increase (0.4 --
0.8 mm).
Check the main bearing seats as follows:

- mount the bed caps on the supports without
bearings;
70167
- tighten the fastening screws to the specified
Measurements must be taken for each single cylin- torque;
der, at three different heights of the liner and on two - check, by means of an adequate internal com-
planes perpendicular to each other: one parallel to parator, that the seat diameter is the same as the
the engine longitudinal axis (A), the other perpen- specified value.
dicular (B); the greatest amount of wear is usually
found on the latter plane and during the first If a greater value is found, replace the crankcase.
measurement.
When detecting out--of--roundness, taper or wear, Checking head supporting surface on cylinder
the cylinder liners must be bored and refaced. Cylin- unit
der liner reconditioning must be performed with re- When finding the distortion areas, replace the cylin-
gard to the spare piston diameter increased by der unit.
0.5 mm of the rated value, and to the prescribed as-
sembling play. Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, re-
place them in case of uncertain seal or if rusted.
EW--2--47
VALVE GEAR
Distributing shaft
Figure 69
87723
MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins
The shaft support pin and eccentric surfaces must be Figure 70

perfectly smooth; if, on the contrary, they show
traces of seizing and scoring, it is advisable to re-
place the shaft and its respective bushings.
Checking the pin alignment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle
support, that the alignment error is not greater than
0.04 mm; otherwise, replace the shaft.
70171
Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes per-
pendicular to each other.
EW--2--48
BUSHINGS Figure 71
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.
70172
Figure 72
87724
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
EW--2--49
Replacing the bushings Mounting the tappets – Distributing shaft

Figure 73 Figure 75
70174 70176
To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000667 (2) and handle 380000668 (3) to remove seats of the crankcase.
and reassemble the bushings.
IMPORTANT -- Bushings (1) must, upon mounting,

be turned in such a way that the lubricating holes
match with the holes available on the crankcase
seats.
Tappets
Figure 74 Figure 76
84053 70164
MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage
the bushings or supporting seats during operation.
EW--2--50
Figure 77 Figure 79
70238 70180
Place distributing shaft (3) retaining plate (1) with the Mount nozzles (2) and tighten fastening screws (1)
slotted hole facing the crankcase upper side and the to the specified torque.
stamping facing the operator, then fasten screws (2)
to the specified torque. DRIVE SHAFT
Measuring the journals and crankpins
Figure 78 Figure 80
70179
70182
Check the distributing shaft end play (1).

If traces of excessive seizing, scoring or out--of--
roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.
NOTE -- It is advisable to write down the measured

values on a table.
See Figure 81.
EW--2--51
Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crankpins
must be marked with a special stamping made on
the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters MB.
Figure 81
87726
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN

MEASURING VALUES MUST BE WRITTEN DOWN
* Rated value
EW--2--52
Figure 82
87727
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ¤
IMPORTANT ĭ
SECONDARY
Figure 83
87728
EW--2--53
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 84 Figure 86
87741 87722
Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1).
shaft (2) are not damaged or worn; otherwise, pro-
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 6 minutes in a small furnace at a temperature of
160 qC and force--fitted onto the drive shaft by putting
the key in between.
Mounting the main bearings
Figure 85 Figure 87
70186
70185
Check the play between the drive shaft journals and
their respective bearings by following the procedure
IMPORTANT -- If main bearings do not need replac- below:
ing, they must be fitted in the same order and posi-
tions they had when removed. - clean thoroughly the parts and eliminate traces
(if any) of oil;
Main bearings (1) are supplied as spares reduced on - place a piece of gauged wire (3) (parallel to the
their inner diameter by 0.250 – 0.500 mm. longitudinal axis) on drive shaft pins (4);
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided

with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided
with shoulder half rings.
EW--2--54
Figure 88 Figure 90
70187 70189
Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases.
The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 r6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 r6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check;
once the prescribed play has been obtained, lubri-
cate main bearings and mount the supports definitely
by tightening the fastening screws as described
above.
Checking the drive shaft shoulder play

Figure 89 Figure 91
70188 70190
- 3rd phase with tool 380000304 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60q r5q. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--55
CONNECTING ROD--PISTON ASSEMBLY
Figure 92
70191
PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws --
6. Half bearings -- 7. Connecting rod -- 8. Bushing
NOTE -- Pistons are supplied as spares increased by 0.5 mm.
Figure 93 Figure 94
32613 32614
Taking piston rings (1) off piston (2) by means of The piston rings (2) retaining the piston pin (1) are re-
pliers 380000221 (3). moved by means of a mark scraper (3).
EW--2--56
Figure 95
87730
MAIN DATA OF PISTON
Pistons
Measuring the piston diameter
Figure 96 Figure 97
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner
micrometer (2) to determine the assembling play. can also be measured by means of a thickness
gauge (1) as shown in the figure.
NOTE -- The diameter must be measured 58 mm far

from the piston skirt base.
EW--2--57
Gudgeon pins Figure 101

Figure 98
84097 84100
Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 99
Figure 102
84098
Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 100
84101
SCHEME FOR MEASURING PLAY X

FOR THE TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
84099
In this position, check, by means of a thickness
Check the thickness of seal rings (2) by means of a gauge, the play (X) between the ring and the slot: it
micrometer (1). must correspond to the specified value.
EW--2--58
Figure 103 Figure 105
CONNECTING ROD BODY
70194
CONNECTING WEIGHT
ROD NO.
Measuring the play between the ends of piston rings
(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).
Connecting rods
Figure 104
CONNECTING ROD CAP
CONNECTING YEAR
ROD CAP DAY
* * *
88730
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
ment, it is therefore necessary to number the
70195 new connecting rod with the same number as
the replaced one.
MAIN DATA OF CONNECTING ROD, GUDGEON - By a letter (on the connecting rod body) which
PIN BUSHING AND HALF BEARINGS indicates the weight class of the factory--as-
* Dimension of inner diameter to be obtained after sembled connecting rod:
driving into the connecting rod small--end and refac- -- V, 1600 to 1640 (marked in yellow);
ing by means of a reamer. -- W, 1641 to 1680 (marked in green);
-- X, 1681 to 1720 (marked in blue).
** This dimension cannot be measured in a free
state. Replacement rods are supplied class W and
marked in green *.
Material removal is not permitted.
IMPORTANT -- The connecting rod--connecting rod
cap matching surfaces are knurled to ensure better
match.
Therefore, it is recommended not to remove knurls.
EW--2--59
Bushings Checking the torsion

Verify that the bushing in the connecting rod small-- Figure 107
end is not loosened and does not show traces of
scoring or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes
allowing oil to flow onto the bushing and the connect-
ing rod small--end correspond to each other. Use a
reamer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 106
61694
Check connecting rod torsion (5) by comparing two

points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the com-
parator is preloaded by a 0.5 mm on pin (3) at point
A, then set comparator (2) to zero. Move spindle (4)
with connecting rod (5), then compare the deviation
(if any) on opposite side (B) of pin (3): the difference
between A and B must not be greater than 0.08 mm.
Checking the flexion

Figure 108
61696
Check the parallelism of connecting rod axes (1) by
means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two

points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle
with connecting rod (5) and repeat the highest point
check on opposite side (D) of pin (3). The difference
between points C and D must not be greater than
0.08 mm.
EW--2--60
Fitting connecting rod--piston assembly Figure 111

Connecting rod--piston coupling
Figure 109
72705
Insert pin (1) fastening piston rings (2).

87731
The piston crown is marked as follows:

1. Part number and design modification number; Mounting the piston rings
2. Arrow showing piston assembling direction into
Figure 112
cylinder barrel, this arrow shall face the front key
of the engine block;
3. Date of production (only for pistons of super-
charged engines);
4. Marking showing 1st slot insert testing.
Figure 110
84093
Use pliers 380000221 (3) to fit piston rings (1) on pis-

ton (2).
The rings must be mounted with the writing “TOP”
facing upwards; moreover, the ring apertures must
be turned in such a way that they are offset to each
other by 120q.
87732
Connect piston (2) to connecting rod (4) with pin (3) IMPORTANT -- Spare piston rings are supplied in
so that the reference arrow (1) for fitting the piston (2) the following dimensions:
into the cylinder barrel and the numbers marked on
the connecting rod (5) are read as shown in the fig- -- standard, marked with yellow paint;
ure. -- increased by 0.5 mm, marked with yellow/green
paint.
EW--2--61
87733
70200
Mount half bearings (1) both on the connecting rod DIAGRAM FOR CONNECTING ROD--PISTON
and the cap. ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each
IMPORTANT -- If connecting rod bearings do not other by 120q;
need replacing, they must be fitted in the same - connecting rod--piston assemblies shall have the
order and positions they had prior to being taken off. same weight;
No matching operation must be carried out on half - the arrow marked on the piston crown shall be
bearings. facing the front side of the engine block or the slot
obtained on the piston skirt shall be correspon-
ding to the oil nozzle position.
Mounting the connecting rod/piston
assemblies in the cylinder liners Measuring the crankpin assembling play
70201
70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the pro-
rings and the cylinder liner inside. cedure below:
Use band 380000220 (2) to mount the connecting - clean thoroughly the parts and eliminate any
rod--piston assemblies (1) into the cylinder liners; trace of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their
respective half bearings (4);
EW--2--62
70204
- tighten screws (1) (previously lubricated with en- 70207
gine oil) to the specified torque by means of a If the measured play is different from the specified
torque wrench (2). one, replace half bearings and repeat the check.
Figure 118 Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them
definitely by tightening the connecting rod cap
fastening screws as described.
§
IMPORTANT -- Prior to mounting the connecting

rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.
Check manually that connecting rods (1) run axially

on the drive shaft pins, and that the end play of the
70205
same (as measured by means of a thickness gauge
- Apply tool 380000304 (1) on the compass (2) is 0.250 to 0.275 mm.
wrench, then tighten screws (2) further in a criss--
cross sequence. Checking piston protrusion
70206
- Take off the cap and calculate the existing play 70208
by comparing the width of gauged wire (1) with After the connecting rod--piston assemblies have
the scale graduation shown on the wire envelope been mounted, check, by means of comparator
(2). 380000228 (1) equipped with base 380000364 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.18 to 0.42 mm.
EW--2--63
Valve timing Figure 124

Figure 122
87653
- Place the dial gauge (1) on the timing gear (2)

and check that the slack between the gears (2)
70211 and (3) is included in the range between 0,076 --
Mark, with a felt--tip pen, the tooth of drive gear (1) 0,280 mm.
mounted on drive shaft (2), the side surface of which Figure 125
bears a stamped notch (o) for timing.
Figure 123
87654
87652 - Fit the screws (1) fastening the gears (2) to the
camshaft (3) and tighten them to the prescribed
Orient the engine drive shaft (3) and the camshaft (4) pair.
ensuring that while assembling the conveyed gear
(1) on the latter, the marks printed on the gears Figure 126
(1 and 2) coincide.
87655
- Spline the gear (1) transferring motion to the igni-

tion pump.
EW--2--64
87656 87658
- Fit the power take--off gear (2) (if available) into - Re--assemble the box (1) to the engine base-
the specially provided housing and fasten the ment.
screws (1).
- Tighten the fastening screws (2) to the same
position detected before disassembly.
Figure 128 IMPORTANT -- Before assembly, always check

that the threads of the ports and of the screws have
no evidence of wear and tear or dirt.
Figure 130
87657
DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION
It is necessary and essential to clean the surface to 87659

be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order to - Apply to the rear tongs hold (3) of the engine
form a kerbstone of a few mm. Diameter. It must be drive shaft the part (6) of the tool 380000664, fix
uniform (no crumbs), with no air blisters, thinner or it with the screws (1) and spline the new tight ring
irregular zones. to it (2).
Any eventual imperfection shall be correct as soon - Place the part (5) on the part (6), tighten the nut
as possible. (4) until tight ring assembly (2) into the flywheel
box is completed.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
After having completed seal application, the joints
must be immediately assembled (10--20 minutes
time).
EW--2--65
ENGINE FLYWHEEL Figure 134

Figure 131
87660 87663
- Check the laying surface (1) of the clutch disk: if Tighten the engine flywheel (1) fixing screws (2) in
it is scratched proceed with facing. two phases:
- Check the tooth conditions of the toothed rim (2), - 1st phase; tightening by means of dynamometric
replace it in case of broken tooth or excessive wrench to couple 30 4 Nm;
wear. Fit the new one, previously heated at the - 2nd phase, 60º 5º angle dwell.
temperature of 150 qC for 15’y20’.
Figure 132 IMPORTANT -- Angle dwell shall always be perfor-
med using 380000304 tool.
Mounting the oil and water pump

Figure 135
87661
- Screw tighten two pins (2) of appropriate length

into the ports of the engine drive shaft (3) and as- - Fit the sheath. 87664
semble the engine flywheel (1) using the - Assemble the oil pump (1).
specially provided sling. - Fit the fastening screws (2) and tighten them.
87662 87665
- Arrange the new seals on the base.

- Spline the flywheel (1) on the engine drive shaft - Assemble the oil pan (1).
by tightening the screws (2) manually. - Fit the screws (3) and tighten them to the pre-
- Duly lock the flywheel before proceeding with scribed pair.
tightening the relevant screws to the prescribed - Tighten the exhaust caps (2) to the prescribed
pair. pair.
EW--2--66

p
87666
87668
- Fit part (4) of the tool 380000666 on the front tang - Assemble the water pump (1).
(3) of the engine drive shaft; fasten it with the - Tighten the screws (2) and lock them to the pre-
screws (5) and spline the new tight ring on it (6). scribed couple.
- Fit part (1) on part (4), screw--tighten the nut (7)
until the assembly of the tight ring (6) into the Mounting the water / oil heat exchanger
front cover (2) is completed.
Figure 141
Figure 138
87415
- Assemble the following elements to the block:

87667
heat exchanger (2), new gasket, oil filter bearing.
Spline the pulley (2) on the engine drive shaft and Tighten the screws (1) and lock them to the pre-
tighten the screws to the prescribed pair and angle scribed couple.
(1).
Figure 142
Figure 139
87669
- Lubricate the fixing ring (2) using engine oil and

70221 place it on the oil filter (3).
- Manually start the oil filter (3) on the bearing
Apply to the water pump (1) a new fixing ring (2). union (1) until counter--boring, further screw up
the oil filter (3) by 3/4 turn.
EW--2--67
1 2
3
4
87414 75751
Fit the alternator support (1) and tighten the screws Valve removal shall be performed using tool
(2) fastening them to the prescribed pair. 380000302 (1) and pressing the cap (3) so that when
compressing the springs (4) the cotters (2) can be re-
Figure 144 moved. Then remove the cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves
(5).
IMPORTANT -- Should cylinder head valves be not

replaced, number them before removing in order to
refit them in the same position.
Figure 147
87676 2
Fit the bracket (1) back to fix the alternator (2) to the
engine basement. Tighten the screws (3) fastening
the alternator to the support.
Cylinder head
Removing the valves
Figure 145
1
75752
Remove sealing rings (1 and 2) from the valve guide.
90331
Intake (1) and exhaust (2) valves have heads with the
same diameter.
EW--2--68
Checking cylinder head wet seal Checking cylinder head supporting surface
Figure 148 Distortion found along the whole cylinder head shall
not exceed 0.10 mm.
If higher values are found grind the cylinder head ac-
cording to values and indications shown in the follow-
ing figure.
Figure 149
A
B
87736
This check shall be performed using the proper tools.

87735
Use a pump to fill with water heated to approx. 90qC
and 2 to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the The rated thickness A for the cylinder head is
proper beater for their removal/refitting. 95 r0.25 mm, max. metal removal shall not exceed
thickness B by 0.13 mm.
IMPORTANT -- Prior to mounting the caps, apply IMPORTANT -- After regrinding, check valve sink-
water--repellent sealant on the sealing surface of ing and regrind valve seats if required, to obtain the
the same. required value.
If leaks are detected from the cylinder head, the latter

must be replaced.
EW--2--69
VALVES Figure 152

Figure 150
INTAKE VALVE EXHAUST VALVE
18882
Check the valve stem (1) using a micrometer (2), it

shall be 7.960 -- 7.980.
87737
MAIN DATA OF INTAKE AND EXHAUST VALVES Checking clearance between valve stem
and valve guide and valve centering
Valve descaling, check and grinding Figure 153
Figure 151
87738
84186
Use a magnetic base dial gauge (1) set as shown in
Remove the carbon deposits from the valves by the figure, the assembling clearance shall be 0.052
means of the special metal brush. -- 0.092 mm.
Verify that the valves do not show traces of seizing, Turn the valve (2) and check that the centering error
crimping or burns. is not exceeding 0.03 mm.
Reface, if necessary, the valve seats by means of a
grinder 380000975, by removing as less material as
possible.
EW--2--70
VALVE GUIDE VALVE SEATS

Figure 154 Regrinding – replacing the valve seats
Figure 155
90327
Check the valve seats (2). If slight scoring or burnout

is found, regrind seats using tool 380000975 (1) ac-
cording to the angle values shown in Figure 156.
INTAKE EXHAUST
84046
Use a bore dial gauge to measure the inside diameter

of the valve guides, the read value shall comply with
the value shown in the figure.
Figure 156
88368
VALVE SEAT MAIN DATA (dimensions in mm)

A = exhaust valve
B = intake valve
EW--2--71
Figure 157
88369
VALVE SEAT HOUSING MAIN DATA (dimensions in mm)

A = exhaust valve
B = intake valve
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 155) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 qC, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 156.
VALVE SPRINGS
50676
MAIN DATA TO CHECK INTAKE

AND EXHAUST VALVE SPRINGS
Before refitting use tool 380000976 to check spring
flexibility. Compare load and elastic deformation data
with those of the new springs shown in the following
table.
87740
After regrinding, check that valve (3) sinking value is Height Under a load of
the specified one by using the base 380000364 (2)
mm N
and the dial gauge 380000228 (1).
H (free) 63,50 no load
H1 49,02 P1 329
H2 38,20 P2 641
EW--2--72
FITTING CYLINDER HEAD Refitting the cylinder head

3 1
2
87670
75759
Lubricate the valve stems (1) and fit them into the rel- Check that the of cylinder head connection surface
evant valve guides according to the position marked and the basement are clean.
at removal. Do not foul the cylinder head sheath.
Fit the cylinder head sheath (1) with the “TOP” (1)
Fit the sealing rings (2 and 3) on the valve guide.
mark towards the cylinder head direction.
The arrow indicates the point in which the sheath
Figure 161 thickness is indicated.
1 IMPORTANT -- It is recommended to keep the

2 sheath inside its container until it the time of assem-
3 bly to the cylinder head.
4
Figure 163
5
75751
Position on the cylinder head: the protection cap (5),

the spring (4), the upper cap (3); use tool 380000302
(1) to compress the spring (4) and lock the parts to
the valve (6) by the cotters (2).
87417
Fit the head (3) on the sheath (4) assembled to the

block and insert the screws (1) and (2).
EW--2--73

18.975
18.963
19.000 19.000
19.026 19.026
32655
75704
SHAFT AND ROCKER ARM BASIC DATA

Before executing assembly, check the Rocker Arm
Check the coupling surfaces of bearing and shaft: no
driving rods: these shall not be deformed; the spheri-
evidence of excessive wear shall be detected or da-
cal ends in contact with the Rocker Arm adjustment
mages. Replace if necessary.
screw and with the tappet (arrows) shall not present
evidence of seizure or wear: in case of detection pro-
ceed replacing them. Figure 167
The rods driving the suction and exhaust valves are
identical and therefore interchangeable.
1
Rocker arm assembly

Figure 165
19.00
4 16.00
1 75702
3 ROCKER ARM ADJUSTMENT SCREW

If unscrewed, check adjustment quota.
2
Tighten the screw--threaded nut (1) to the 4 -- 6 Nm
2
couple.
1 3
75705
- Carry out the assembly of the rocker arms after

previous check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring -- 2. Spacer--
3. Rocker arms-- -- 4. Support.
EW--2--74
Figure 168 Mounting the injectors

Figure 170
2
1
1
75683
- Tighten the screws (2) to the prescribed couple 75707
and assemble water temperature sensor (1). - Assemble injectors after having replaced the
sealing gasket (1).
Figure 169
IMPORTANT -- During assembly of injectors, verify
that the injector sphere is correctly positioned on
the head housing.
Figure 171
87673
Adjust the slack between rocker arms and valves

using socket wrench (1), point wrench (3) and feeler
gauge (2).
87406
Correct working slack is:
-- suction valves 0.25 á0.05 mm
- Assemble cylinder covers (2) with the respective
-- exhaust valves 0.50 á0.05 mm. gaskets.
In order carry out a quicker adjustment of the working - Fit the seal nods and tighten the screws (1) fixing
slack between rocker arms and valves, proceed as them to the prescribed couple.
following:
rotate the engine drive shaft taking cylinder no. 1 to
end of compression phase and adjust the valves
marked with the star as indicated in the table:
Cylinder nq 1 2 3
Suction * * --
Exhaust * -- *
Rotate by 360q the engine drive shaft and adjust the
valves marked with the star as indicated in the dia-
gram:
Cylinder nq 1 2 3
Suction -- -- *
Exhaust -- * --
EW--2--75
87675 90328
- Assemble exhaust manifold (1) providing new Assemble the support (1) of the fan pulley throughout
gaskets (2). the screws (2) tightening them to the prescribed pair.
87412
- Assemble thermostat unit (2) including thermo-

90329
stat (4) and gasket (3).
- Tighten the screws (1) to the prescribed couple. Assemble the fan pulley (2) to the support (1)
throughout the screws (3) tightening them to the pair.
IMPORTANT -- The gasket must be new.

Figure 177
Figure 174
90330
87677
Assemble the belt tightening pulley (1) throughout
the screw (2) tightening it to pair.
Assemble the injection pump unit (1) into the gearbox
housing (2) and fix it, without tightening, throughout
the screws (3).
EW--2--76
90325
- Fit the Poli--V belt (5) on the pulley of the engine

drive shaft, on the water pump (4), on the alterna-
tor (2) and on the fan pulley (3).
- Execute belt tightening correct operation work-
ing on the belt tensioner (1).
IMPORTANT -- If the old belt is to be reassembled

examine it carefully in order to see if there may be
incisions or evident signs of yielding. 75700
Moreover, assemble the fastening brackets (1) of the

Figure 179 injector fuel pipes using the fastening screws (2).
Figure 181
87682
- Apply on the surface joining the suction manifold

plate (1) a sufficient coat of Loctite 5999 and pro-
vide. fixing the screws to the prescribed couple.
- Install grid heater (4) (optional) or spacer plate
87410
(4) if removed.
- If the pipe (6) of the suction manifold plate (1) has Assemble priming pump (1) providing new gasket
been removed, reassemble it after having fit a and tighten the screws (2) to the prescribed couple.
new gasket (5).
- Tighten the screws (7) to the prescribed couple.
EW--2--77
4
3
87404
87407
Assemble the pipes (1) and (2) providing fuel feed - Assemble the fuel filter bearing (4) to the bracket
and recovery between pump and injectors. fixed to the engine head.
Screw up the locking nuts and tighten the screws fi- - Connect the fuel pipelines (2 and 3) respectively
xing the fuel recovery manifold; fix the pipes to the in- from priming pump to filter bearing and from this
jectors throughout the brackets previously assem- last one to feed pump.
bled.
- Using 380000670 equipment assemble fuel filter
(1).
NOTE -- The filter shall be priory filled with fuel to

facilitate feed system bleed operations.
70126
Press clip (1) in the direction of the arrow (detail B),

87405 then connect the piping. Bring the clip back to the in-
- Fix the LDA pipeline (1) to the engine head and itial locking position (detail A).
to the feed pump.
EW--2--78
75675
Proceed assembling the turbocharger:

- Hold the turbocharger and place it on the exhaust 87712
manifold after having interposed the gasket.
- Reassemble the starter; properly hold the starter
- Screw up the fixing nuts of the turbocharger to (2) and tighten the fixing screws (1) to the prescri-
the exhaust manifold tightening them to the pre- bed couple.
scribed couple.
- Fill up engine oil.
- Tighten the lubrication pipe fixing ring (1). Opera-
te in the same way on the other end of the pipe. - Install the engine on the machine (for installation
Connect it to the upper part of the heat operations please apply to specific issue).
exchanger.
To complete engine assembly it is necessary to re-
move it from the turning stand. ROTARY FEED PUMP DISASSEMBLY
- Using rocker arm 380000216 hold the engine AND ASSEMBLY PROCEDURE
and loosen the screws fixing the brackets to the This procedure prescribes that:
turning stand 9380000301.
- The fuel pipelines (from pumping elements to in-
- Disassemble the brackets from the engine after jectors, bleeding recovery pipes from injectors to
having properly put it on a wooden bearing.
pump, LDA pipeline and feed provided by pri-
Figure 187 ming pump) shall all be disassembled.
- Electrical connection to feed pump shall be dis-
connected.
- Accelerator cable shall be disconnected.
In case feed pump replacement is necessary, this

shall be supplied pre--set already as spare part.
On the other hand, in case the pump shall be disas-
sembled and reassembled later on without being re-
paired it will be necessary to pr--set it while it is still
assembled to the engine and disassemble it only
afterwards.
The following procedure analyses this second hypo-
87683 thesis since it is the more complex.
On the right hand side:

- reassemble the lubrication oil exhaust pipeline
(2) from the turbocharger; from underneath the
turbocharger tighten the screws (1).
Tighten the union (5) to the block.
- The oil level rod (4).
EW--2--79
Figure 189 Research of top dead centre by tool 380000977
Figure 191
87712
- Disassemble the starter (2) removing the screws

(1).
88101
Remove the first injector, fit the tool 380000977 (2)

and the relevant dial gauge 380001005 (1) and re-
move the tappet cover (3).
Research of top dead centre by tool 380000988 Fit the tool 380000988 and make the engine drive
shaft rotate until taking it to the condition of 1st cylin-
Figure 190 der to TDC.
The condition of 1st cylinder to TDC at end of com-
pression phase is obtained when the dial gauge
pointer reaches maximum value and suction and ex-
haust valves are both closed and not balancing.
Check of top dead centre
Figure 192
88232
- Mount the bracket of tool 380000988 (1) for

checking the flywheel, which bracket is complete
with rotary reel (2).
- Cautiously rotate the flywheel according to its
rotation direction in order to suppress the clear-
ance of gears. 87714
- Rotate the flywheel until pin 380001990 (4) pro- After having disconnected fuel pipes of the priming
vided with tool 380000988 fits into the groove on pump, loosen the fastening screws (2) and remove
flywheel (3). the pump (1) from the basement (3).
EW--2--80
87715
Check, through the priming pump housing, that the

camshaft (1) is in (TDC) end of compression phase,
throughout the notches (2) on said shaft. 84073
If the notches are not visible, withdraw the pin from - Remove cover (1) from gear covering case (2).
the flywheel and rotate the engine by 360q until when
the notches are visible. Fit the locking pin back. - Loosen nut (3) securing the injection pump drive
gear (4).
Figure 196
Disassembly and assembly

Figure 194
87717
87716
- Remove the three nuts (2), (3), (5) fastening the
injection pump (1) to the block (4) and withdraw
- Loosen the screw (2), remove the “L” spacer (1) it from their own housing.
and lock the screw (2) to keep the pump timed
- Reattach the injection pump following the same
with the engine flywheel. order followed to execute disassembly, in re-
- Duly keep the “L” spacer with the pump unit. verse.
EW--2--81
84115
Torque--tighten nut (1) by means of torque wrench 87718

(2). - At the time of assembling the feed pump to the
engine it is necessary to ensure T.D.C. condi-
Figure 198 tions to the cylinder no.1 in phase of compres-
sion, as described previously.
- Assemble the injection pump unit (1), preset, into
the gearbox housing (2) and fasten it, without
tightening it, throughout the screws (3).
IMPORTANT -- The gasket removed during pump

disassembly shall not be utilised again.
Always use original spare parts.
Figure 200
84116
Apply sealant (1) as shown in the figure, then put on

small cover (2).
87719
- Partially loosen the screw (1) locking the rotation

of the pump shaft and insert the spacing washer
(2). Tighten the screw locking said washer: this
way the feed pump shaft will be free to rotate.
- Withdraw the pin of the engine flywheel locking
tool.
- Remove the flywheel rotation locking tool
380000988; place the starter into its housing.
EW--2--82
Ignition pump control and timing Figure 202

Figure 201
87721
87720
- With the ignition pump fitting into its housing and - Assemble the priming pump (1) to the block (3)
with loosened fastening screws, remove the clo- and tighten the fastening screws (2) to the pre-
sure cap placed over the pump cover. scribed pair.
- Fit the dial gauge 380000228 (2) and the relevant
tool 380001084 (1), pre--loading the rod by - Connect all pipelines (from pumping elements to
2.5 mm. injectors, bleeding recovery pipes from injectors
- Rotate the engine derive shaft to shift from the to pump, LDA pipeline and feed provided by pri-
condition of the first cylinder to TDC end of com- ming pump).
pression phase. Reset the dial gauges and rotate - Connect electrical connections to electro--ma-
the engine drive shaft into the opposite direction gnets on the hydraulic head and on KSB.
until recovering the condition of the 1st cylinder
to TDC in phase of compression. IMPORTANT -- In case pump removal has been
In this position, the relating value of presetting carried out while the engine was assembled, con-
(1 r 0.05 mm) should be read on the dial gauge. nect acceleration cable.
- Rotate the pump in anti--clockwise direction if the
stroke is shorter or in clockwise direction if the
stroke is longer, until obtaining the stroke pre-
scribed.
- Checking these conditions, lock the pump by Feed system bleed procedure
tightening the relevant nuts to the prescribed pair.
Figure 203
87751
In case any operation has been executed on the

components of the feed circuit, it is necessary to ex-
ecute bleeding of air within the system.
- Disconnect the fuel pipe (1) of the filter and re-
peat working on the drain lever (2) of the priming
pump.
- Continue the operation until when fuel outflows.
- Connect the (1) to the filter.
EW--2--83
REPLACING THE INJECTORS Reassembling

Removal Figure 206
Figure 204
84289
- Disconnect engine oil vapour recovery pipe (2)

84201
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors Mount a new seal ring (2) lubricated with petrolatum
(3). and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
Figure 205 head, then tighten them by means of a torque
wrench.
Mount new seal rings on fuel manifolds.
Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to
the blow--by.
84082
Remove injectors (2) by means of tool 380000671 (1)

and take them off the cylinder head.
EW--2--84
ROCKER ARM REMOVAL/REASSEMBLING ADJUSTING THE TAPPETS

Removal Figure 208
Figure 207
84200
84081
Ad just the play between the rocker arms and the
valves by means of an Allen wrench (2), box wrench
Loosen tappet adjuster fastening nuts (3), then (3) and thickness gauge (1).
unscrew adjusters (2).
The operation play is:
Remove screws (4) and dismount rocker arm
– intake valves: 0.25 r0.05 mm
assembly (1) made up of the rocker arm support and
arbours, then take off valves. -- exhaust valves: 0.50 r0.05 mm.
Reassembling In order carry out a quicker adjustment of the working
slack between rocker arms and valves, proceed as
Verify that the tappet adjusters are unscrewed to pre- following:
vent the latter from crawling on the rods when the rotate the engine drive shaft taking cylinder no. 1 to
rocker arm assembly is mounted. end of compression phase and adjust the valves
Mount the rocker arm assemblies made up of rocker marked with the star as indicated in the table:
arm support and arbours, then secure them to the
cylinder head by tightening the fastening screws to Cylinder nq 1 2 3
a torque of 36 Nm. Suction * * --
Ad just the tappets as described above. Exhaust * -- *
Rotate by 360q the engine drive shaft and adjust the

valves marked with the star as indicated in the dia-
gram:
Cylinder nq 1 2 3
Suction -- -- *
Exhaust -- * --
SECTION 3
RECHARGE AND START--UP
INDEX
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--3
INDEX
EW--3--3
ALTERNATOR
BOSH 6 033 G20 19B

Characteristics: 12V -- 95A
Room r.p.m. I
temperature (¥C) (min --1) (A)
25 1500 20
25 6000 95
88317
Quick diagnosis
Fault Possible causes Remedy
No recharge 1. Interruption of recharge circuit Check the recharge circuit

(warning light, fuse, connector, connections, clean and tighten
etc.) the cable terminals on the
alternator and battery
2. Voltage regulator not in Replace the component
working order
3. Interrupted rotor winding Replace the component
4. Worn brushes Replace the component
Poor recharge 1. Loose belt Apply correct tension

2. Faulty voltage regulator Replace the component
3. Excessive wear of rotor rings Replace the component
or brushes
4. Short--circuited diodes Replace the component
5. Short--circuited rotor winding(s) Replace the component
Excessive recharge 1. Loose circuit connections Check the connections to

terminals and cable terminals
of batteries, starter motor and
alternator
2. Voltage regulator not in Replace the component
working order
3. Earth fault Check earth connections
EW--3--4

334T, M2 NEF (Iveco) Engine F4CE0354A FAM #

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ENGINE

Progressive page number for each group

Group number (if any)

This symbol regards safety.

Section 1 -- Diagnostics EW--1--1

Section 2 -- Engine F4CE0354A overhaul EW--2--1

Section 3 -- Recharging and start--up EW--3--1

Main engine operating anomalies:

1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

1 ENGINE WON’T START

Thermal starter in working order Replace.

Injection pump timed Verify correct timing as described in the relevant

Injectors in working order Check operation and adjust.

Prescribed compression ratio Overhaul the engine or make repairs only on

Fuel filters in working order Replace.

Fuel tank supplied correctly Refuel.

Water pump in working order Overhaul or replace the unit.

Thermostat in working order Replace.

Valve timing correct Check and perform correct timing.

Injection pump timed Check correct timing as described in the relevant

Cylinder head gasket in working order Replace.

Fan in working order Replace.

3 ENGINE LACKS POWER AND WORKS

Thermostat in working order Replace.

Fuel pump in working order Replace.

Injectors in working order Check operation and adjust them.

Injection pump timed Check correct timing as described in the relevant

Circuit and L.D.A. device both in working order Check.

Prescribed compression ratio Check and bench--adjust the injection pump.

Turbocharger in working order Repair or replace the unit.

4 ENGINE EXHAUST SMOKE BLACK OR

Air filter in working order Replace.

Thermal starter in working order Replace.

Injectors in working order Check operation and adjust them as described.

Injection pump timed Check correct timing as described in the relevant

L.D.A. device in working order Ad just the L.D.A. device.

Prescribed compression ratio Check by means of a Motometer 75301430 tool

5 ENGINE EXHAUST SMOKE GREY

The thermostat comes into operation correctly Replace.

Injectors in working order Check operation and adjust as described in S.I.

Injection pump timed Check correct timing as described in the relevant

Coolant level correct Possible flow of coolant into the combustion

6 ENGINE EXHAUST SMOKE LIGHT BLUE

7 ENGINE KNOCKS IRREGULARLY

Fuel tank filled Refuel and drain (if necessary).

Fuel filters in working order Replace.

Feeling circuit in working order Check the circuit and drain.

Regular idle speed Adjust.

Regular injection pump rates Bench--check the flow rates.

Intact valves Replace the valves.

9 ENGINE EXCEEDS MAX. REVS NUMBER

10 EXCESSIVE OR INSUFFICIENT OIL

11 EXCESSIVE FUEL CONSUMPTION

Air filter in working order Replace.

Correct injector adjustment Check operation and adjust them.

Correct injection pump adjustment Check and bench--adjust.

L.D.A. device in working order Adjust the L.D.A. device.

Injection pump timed Check static force--fit of the injection pump.

12 ENGINE WON’T STOP

Cut--off electromagnet in working order Replace the electromagnet.

ENGINE F4CE0354A OVERHAUL

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69 Research of top dead centre

Mounting the injectors . . . . . . . . . . . . . . . EW--2--74 Rocker arm removal/reassembling . . EW--2--84

Cylinder liners 1 104.000 to 104.024

Piston diameter 1 0.4 -- 0.8

Gudgeon pin 3 37.994 to 38.000

Journals 1 82.99 to 83.01

Bushing inner diameter 54.083 to 54.147

1 Seat for tappet

Rocker arm shaft 1 18.963 to 18.975

Rocker arms 2 19.000 to 19.026