CURSOR 16 Not Emissioned

CURSOR 16 Not emissioned.
Technical repair manual

I
Print notes
Product: CURSOR 16 Not emissioned.
Construction
Language: ENG
Name: P4D32C009E0816 ENG
Publication status: 04.11.2016
FPT Industrial S.p.A.

Via Puglia 15
10156 Torino
Italy
Figures and words: FPT Industrial S.p.A. 2016

All rights reserved.
www.fptindustrial.com
– P4D32C009E0816
Contents II
Technical repair manual 1

General information 2
Operating diagrams 3
Electric/electronic system 4
Scheduled maintenance 5
Removal-refitting of the main
engine components 6
General mechanical overhaul 7
Technical specifications 8
Equipment 9
Safety regulations 10
III Contents
CURSOR 16 Not emissioned. ‒ Technical repair manual
Contents 1
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
INTRODUCTION 3
Contents
Contents
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . 5
SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . 7
GENERAL WARNINGS REGARDING THE

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
Grounding and screening . . . . . . . . . . . . . . . . . . . . 9
Optional electrical and mechanical parts

installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversions between the main units of measurement

of the international system and the most commonly
used derived sizes . . . . . . . . . . . . . . . . . . . . . . . 11
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Revolutions per time unit . . . . . . . . . . . . . . . . 11
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 11
Update data . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– P4D32C009E0816
4 INTRODUCTION
– P4D32C009E0816
INTRODUCTION 5
SYMBOLS - WARNINGS
INTRODUCTION
This document provides data, specifications, instructions and methods to perform repair interventions on the assembly and its com-
ponents.
Anyhow, this document is addressed to qualified and specialised personnel.
Before performing any intervention, check that the document relating to the vehicle model on which the intervention is being per-
formed is available and also make sure that all accident prevention devices, including but not limited to, goggles, helmet, gloves,
shoes, as well as work equipment, lifting and transport equipment, etc., are available and efficient, and also make sure that the unit is
in safety conditions for intervention.
Carrying out interventions which fully comply with the indications given here, as well as the use of the specific equipment indicated,
ensures repair interventions are carried out correctly, timings are respected and the operator's safety is safeguarded.
Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by FPT.
Each intervention on the unit aimed at a modification, alteration or other which has not been authorised by FPT relieves FPT of any
liability, and, in particular, where the assembly is covered by a warranty, each intervention will immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the execution of the interventions and to provide instructions for any
cases and situations not covered in this publication.
The data contained in this issue may not be up-to-date due to possible modifications made by the Manufacturer for technical or
commercial reasons, or to adaptations required by laws in force in different countries.
In the event of discordance between the information in this publication and the actual assembly, please contact the FPT network
before performing any interventions.
The complete or partial reproduction of the text or illustrations herein is forbidden.
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in
the general table of contents.
Sections with mechanical contents include technical data, tightening torque tables, tool lists, assembly/component connections -
disconnections, overhauls at the bench and scheduled maintenance.
In the electrical/electronic system section there are the descriptions of the electric network and the electronic systems of the as-
sembly, wiring diagrams, electrical characteristics of components and the component codes.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS - WARNINGS
Danger for persons

Failure to comply with these prescriptions can result in the risk of serious injury.
Risk of serious damage to the assembly

The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify the warranty.
General danger
Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.
– P4D32C009E0816
6 INTRODUCTION
SYMBOLS - SERVICE OPERATIONS
SYMBOLS - SERVICE OPERATIONS

Removal
Intake
Disconnect
Refitting
Exhaust
Connect
Disassembly
Operation
Disassembly
Assembly
Compression ratio
Composition
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle value Rolling torque
Press or caulk Rotation
Adjustment Angle
regulation Angle value
Visual inspection
Preload
Assembly position check
Measurement
Value to be measured Revolutions per time unit
Check
Tools Temperature
Surface for machining

Pressure
Machined finished product
Oversized
Interference
Greater than ...
Forced assembly
Maximum
Undersized
Thickness
Lesser than ...
Clearance
Minimum
Lubricate Selection
Dampen Classes
Grease Oversizes
Temperature < 0 °C
Sealant
Cold
Glue
Winter
Temperature > 0 °C
Bleeding air Hot
Summer
– P4D32C009E0816
INTRODUCTION 7
GENERAL WARNINGS
GENERAL WARNINGS

The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors should be contacted
whenever a dangerous situation that has not been described occurs.
Use the specific and general equipment according to that prescribed in the respective use and maintenance handbooks. Check the working
condition and suitability of tools not subject to periodic review.
Manual handling of loads must be previously appraised regarding the weight, size and path.
Handling with mechanical equipment must be done using appropriate lifts and hoists, in terms of weight, shape and volume. Hoisters, ropes
and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by
authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally
striking workshop personnel.
Workshop activities carried out in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the
co-operator resulting from a lack of visibility or his/her incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it.
Scrupulously observe all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands and that the
manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific
safety regulations provided.
Remove the expansion tank cap only when the engine is cold, unscrewing it carefully to allow the residual pressure in the system to es-
cape.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point cards of harmful
materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent
sudden fires/explosions. Suitably store flammable, corrosive and pollutant fluids and liquids in accordance with current regulations. Strictly
avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated
with inflammable substances into suitable containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and
oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.

wear, where required by the operation, garments and protection provided for by accident prevention rules; contact with moving parts can
cause serious injuries. use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
do not leave the engine running in workshops not equipped with a pipe to extract exhaust gas outside.
do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. wear an appro-
priate respirator in the presence of paint dust.
avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. avoid direct contact with
liquids and fluids inside vehicle systems; consult the 16 remedy points sheet if accidental contact occurs.
– P4D32C009E0816
8 INTRODUCTION
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Before overhauling, clean the assemblies and make sure they are intact and complete. Place in an orderly fashion and in appropriate con-
tainers the parts removed or disassembled with their respective fixing elements (screws, nuts, etc.).
Check for the integrity of the parts which prevent screws from being unscrewed: spring lockwashers, copper pins, retaining clips, etc.
Nylon insert locknuts must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions. FPT's sales and assistance network is available to
provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
● Disconnect all electronic control units and unplug the power cable from the battery's positive terminal (connecting it to the chassis
ground) and connectors.
● Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
● Wait approximately 15 minutes before proceeding with welding.
● Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when
welding.
Should the vehicle be subjected to temperatures exceeding 80 °C (dryer ovens), remove the electronic control units.
the disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis ground cable
first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery termin-
als.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test lamp to verify circuit continuity, but proper control equipment only.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.)
conform with the FPT system and that they are carefully restored after repair or maintenance work.
Measurements on ECUs, on plug-connectors as well as on electrical connections can be made only on suitable testing lines, by means of
special plugs and plug-type bushes. Never use improvised equipment like metal wires, screwdrivers, pins or similar. In addition to the risk of
causing a short circuit, this might damage plug-type connections and this would then give rise to contact problems.
– P4D32C009E0816
INTRODUCTION 9
Grounding and screening

Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their
destruction.
Disconnect the batteries from the system before recharging them by means of an external unit.
on connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
Key programming procedures can be affected by electromagnetic disturbances (mobile phones, etc.). Therefore when key programming:
1. Make sure there are no sources of disturbance near the keys or in the cab.
2. Keys not inserted in the panel must be at least 1 metre away.
Note The connectors are viewed from the cable side. Connector views contained in the manual are representative of cable side.
For fuse identification and rating, comply with the indications present in the vehicle, since their identification or rating may be
subject to changes.
Grounding and screening
185272 Figure 1
The negative conductors connected to a system grounding point must be as short as possible and connected in a "star pattern", as
well as being tightened down correctly and as specified ref. (M).
– P4D32C009E0816
10 INTRODUCTION
Optional electrical and mechanical parts installations
d
C
d
C
88039 Figure 2
The following precautions must be observed regarding the electronic components:
● electronic control units must be connected to the system ground when equipped with metal housings.
● Electronic control unit negative cables must be connected to a system ground point, such as the dashboard compartment
ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the battery/is.
● Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal isolation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
● The metal braid of the shielded circuits must be in contact only at the control unit side to which the signal is to be sent.
● In the case of junction connectors the unshielded section (d), near to the latter, must be as short as possible.
● The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Optional electrical and mechanical parts installations

Accessory installation, additions and changes on the vehicle must be carried out in compliance with the FPT assembly directives.
it is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by bodybuilders.
Any exception to the assembly directives must be authorized by FPT.
lack of observance of above described prescriptions involves guarantee lapse.
▶ It is forbidden to make changes or connections to the ECU wiring, especially the data interconnection line between
ECUs (CAN line) must never be tampered with.
– P4D32C009E0816
INTRODUCTION 11
Conversions between the main units of measurement of the international system and the most commonly
Conversions between the main units of measurement of the international system and the most
commonly used derived sizes
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 CV unit is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 CV
Torque
1 Nm = 0.102 kgm
1 kgm = 9.81 Nm
Note Unless there is a specific need for accuracy, the unit Nm is converted into kgm for simplicity according to a ratio of 10:1, or
rather: 1 kgm = 10 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 = 10 5 Pa
Note The unit bar is converted into kg/cm² for simplicity according to a ratio of 1:1 1 kg/cm² = 1 bar.
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)
– P4D32C009E0816
12 INTRODUCTION
Update data
Update data
Section Section name Description of modification Page Revision date
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ General information
Contents 1
Contents
General information . . . . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
Contents
Contents
COMMERCIAL CODES . . . . . . . . . . . . . . . . . . . . 5
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . . . 5
CORRESPONDENCE BETWEEN TECHNICAL

CODES AND COMMERCIAL CODES . . . . . . . . . . . 6
ISOMETRIC VIEW . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . 11
– P4D32C009E0816
4 General information
– P4D32C009E0816
COMMERCIAL CODES
General information
54 COMMERCIAL CODES
The purpose of the commercial name is to make the information regarding engine characteristics easy to understand, by joining
engines from different families, origins and applications for which they are intended. The commercial code cannot be used for tech-
nical purposes in order to completely identify the parts that make up the engine, referring to the "serial number" otherwise indic-
ated as "ENGINE S/N", as the identification.

CR16 TE1W
● CR16TE1W ENGINE FAMILY IDENTIFICATION (CR = CURSOR)
● CR16TE1W DISPLACEMENT: 16 = 16,000 c.c. NOMINAL
● CR16T E1W - FUEL SUPPLY: T = TURBOCHARGED WITH AIR / AIR INTERCOOLER
● CR16TE1W - INJECTION: E = ELECTRONIC MANAGEMENT / with E.C.U.)
● CR16TE1W - LEVEL OF POWER
● CR16TE1W - ENGINE CONTROL UNIT: W = EDC17CV41
54 TECHNICAL CODES
The technical code is assigned during production; it is used to identify the main characteristics, characterise the application and the
corresponding level of power output.

F3JFA615A*D001
● F3JFA615A*D001 - ENGINE FAMILY IDENTIFICATION
● F3JFA615A*D001 - PRODUCT EVOLUTION CURSOR 16
● F3JFA615A*D001 - ENGINE WITH HW
● F3JFA615A*D001 - CYLINDER CONFIGURATION (A = 4 stroke, vertical)
● F3JFA615A*D001 - NUMBER OF CYLINDERS
● F3JFA615A*D001 - MAIN ENGINE CHARACTERISTICS (1 = Supercharged diesel with intercooled direct injection)
● F3JFA615A*D001 - APPLICATION (5 = G-Drive)
● F3JFA615A*D001 - TORQUE LEVEL OR ENGINE POWER
● F3JFA615A*D 001 - EMISSION LEVEL (D = Non emissionato)
● F3JFA615A*D001 - BASIC ENGINE VARIANT WITHIN THE SCOPE OF THE BILL OF MATERIALS: the first number
refers to the injection system (0 = 4-valve Common Rail) whereas the other numbers refer to the engine configuration.
– P4D32C009E0816
CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
54 CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES

Technical codes Commercial Codes
F3JFA615A*D001 CR16 TE1 W
540110 ISOMETRIC VIEW
247679 Figure 1
247680 Figure 2
The F3JFA615 is an in-line 6-cylinder turbo engine with intercooler and 4 valves per cylinder; it belongs to the CURSOR 16 series
and operates according to a 4-stroke diesel cycle.
The engine's fuel supply system is electronically controlled and is based on the direct injection of the fuel in the combustion cham-
ber by means of a high pressure pump and the common rail.
– P4D32C009E0816
ENGINE VIEWS
The intake and exhaust valves are actuated by the camshaft via the rocker arm assembly.
540110 ENGINE VIEWS

LEFT SIDE VIEW
247674 Figure 3
1. Intercooler delivery pipe 7. Auxiliary assembly drive belt
2. Gas outlet line from the fan 8. Flywheel housing
3. Turbocharger 9. Engine coolant return fitting
4. Heat exchanger lubricant oil 10. Water pressure sensor
5. Crankshaft rpm sensor 11. Exhaust manifold
6. Delivery line 12. Thermostat case.
– P4D32C009E0816
ENGINE VIEWS
RIGHT SIDE VIEW
247675 Figure 4
1. Cylinder head cover 9. Fuel pressure and temperature sensor
2. Oil filler cap 10. Control unit
3. Tie rod 11. Starter motor
4. Water pipe 12. Engine cable
5. Air intake manifold 13. High-pressure pump
6. Guard 14. Blow-by valve body
7. Alternator 15. Camshaft speed sensor
8. Delivery line
– P4D32C009E0816
ENGINE VIEWS
FRONT VIEW
247672 Figure 5
1. Radiator 4. Blow-by external pipe
2. Expansion tank cap 5. Oil sump drain plug
3. Radiator left support 6. Radiator right support
– P4D32C009E0816
ENGINE VIEWS
REAR VIEW
247673 Figure 6
1. Air filter clogged indicator 6. Oil sump drain plug
2. Air filter 7. Oil sump drain plug
3. Engine flywheel 8. Turbocharger lubricant oil return pipe
4. Engine interface box 9. Lubricating oil delivery pipe to turbocharger
5. Oil sump
– P4D32C009E0816
GENERAL CHARACTERISTICS
TOP VIEW
247695 Figure 7
1. Breather pipe 3. Engine cable
2. Water pipe 4. Instrument alarm transmitters
54 GENERAL CHARACTERISTICS

Type F3JFA615A*D001
Diesel 4-stroke
Cycle
Turbocharged through turbocharger with air-air
Supply
intercooler
Injection
Direct
Number of cylinders 6 in line
Bore mm 141
Stroke mm 170
– P4D32C009E0816
Type F3JFA615A*D001
Total displacement cm3 15926
compression ratio 16.5:1
POWER kW 570 600
Frequency Hz 50 60
First kWm 505 523
Stand-by kWm 557 578
Revs. rpm 1500 1800
TIMING SYSTEM
start before T.D.C. A = 19°
end after B.D.C. B = 31°
start before B.D.C. D = 50°
end after T.D.C. C = 9°
For timing check
mm −
X
mm −
Of operation
mm 0.40 ± 0.05
X
mm 0.60 ± 0.05
High pressure feed system consisting of a high
pressure pump CPN 5-22/2, electro-injectors
CRIN 3-22, hydraulic accumulator (common rail)
SUPPLY HFRN-22 with pressure relief valve PLV5-22 and
rail pressure sensor RPS4-22uc, engine
management control unit EDC17CV41,
temperature and pressure sensors.
Injection system BOSCH common rail system
Electro-injectors type CRIN 3-22
Firing order 1–4–2–6–3–5
– P4D32C009E0816
Type F3JFA615A*D001
Injection pressure bar 2200
TURBOCHARGING
Turbocharger type: HTT Wastegate turbocharger (WG)

Model: GTC45BNS
Forced by gear pump, pressure relief valve, oil

LUBRICATION
filter
– Through centrifugal water pump (fixed speed),

COOLING thermostat for adjustment, fan, radiator,
coolant/lubricant oil heat exchanger.
Water pump drive: Belt driven
Thermostat: No. 1
Maximum operating pressure 3.5
opening start: 84 °C ± 2 °C
maximum opening (min. 15 mm): 94 °C ± 2 °C
Minimum coolant temperature: - 40 °C
Maximum coolant temperature: 112°C
REFILLING:
Cooling circuit (1)(*)
Engine: litres 27
Radiator and hoses: litres 25.5
G-drive :
(**)
litres 52.5
Lubrication circuit :
(2) (4) (*)
Total capacity (3)

litres (kg) 34
Amount in circulation (engine running) litres (kg)
Amount which does not return to the sump (oil filter, oil
litres (kg)
pipes)
Oil sump at minimum level (3)
litres (kg) 24
Oil sump at maximum level (3)
litres (kg) 32
Fuel tank (5)
litres (kg)
(*) It is strictly prohibited to mix fluids of different brands inside the circuit.
(**) Frequencies valid only if the components are supplied by FPT
(1) The quantities indicated relate to the standard configuration engine. The coolant must be compliant with standard ASTM D-
6210. The coolant concentrate should be used diluted 50% with water. FPT recommends using Petronas original products.
(2) Use lubricants which meet the requirements of international standards: SAE 10W-40 API CJ-4 / ACEA E9. FPT recommends
using PETRONAS original products compliant with standard SAE 10W-40. Please refer to the section "Checks and scheduled main-
tenance procedures" for alternative products and the relative maintenance intervals.
(3) The amount indicated refers to the sump without a filter in standard conditions.
(4) The amount indicated refers to the first fill and refers to the engine, the oil sump and the filter.
– P4D32C009E0816
(5) Use standard fuel compliant with standard ASTM D975 o EN 590. Indications relating to the capacity of the fuel tank apply to
the original product as they are subject to variations depending on the different configurations.
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Operating diagrams
Contents 1
Contents
Operating diagrams . . . . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
Contents
Contents
SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5
SUPPLY SYSTEM COMPONENTS . . . . . . . . . . . . . . 6

High pressure pump CPN 5-22/2 . . . . . . . . . . . . . 6
Pressure accumulator (Common rail)
HFRN-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electro-injector CRIN 3-22 . . . . . . . . . . . . . . . 10
Pressure limiter valve . . . . . . . . . . . . . . . . . . . 12
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . 13
Lubrication circuit . . . . . . . . . . . . . . . . . . . . . 14
LUBRICATION CIRCUIT COMPONENTS . . . . . . . 15

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overpressure valve . . . . . . . . . . . . . . . . . . . . 16
Oil pressure regulator valve . . . . . . . . . . . . . . . 16
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . 18
Filter by-pass valve . . . . . . . . . . . . . . . . . . . . 19
Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . 20
Valve integrated in piston cooling nozzle . . . . . . . 21
Oil vapours . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OIL VAPOUR RECIRCULATION SYSTEM
(BLOW BY SYSTEM) . . . . . . . . . . . . . . . . . . . 21
COOLING CIRCUIT COMPONENTS . . . . . . . . . . 23

COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . 23
Water pump . . . . . . . . . . . . . . . . . . . . . . . . 25
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTAKE AND EXHAUST SYSTEM

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 26
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . 26
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
HTT Wastegate turbocharger . . . . . . . . . . . . . 29
– P4D32C009E0816
4 Operating diagrams
– P4D32C009E0816
SUPPLY SYSTEM
Operating diagrams
5420 SUPPLY SYSTEM
The Common Rail fuel system has a special pump that continuously keeps fuel at high pressure, independently from the stroke and
the cylinder which is to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from the rail takes
place in the corresponding cylinder.
The main components of the supply system are:
● Fuel tank
● Fuel pre-filter
● EDC 17CV41 engine management heat exchanger control unit
● Fuel filter
● High pressure pump CPN 5-22/2
● Common Rail hydraulic accumulator HFRN-22
● Overpressure valve PLV5-22
● Rail pressure sensor RPS4-22uc
● Electro-injectors CRIN 3-22
242532 Figure 1
A Return to the tank C Low pressure
B High pressure
– P4D32C009E0816
SUPPLY SYSTEM COMPONENTS
210171 Figure 2
A High pressure B Low pressure
1 High-pressure pump 6 Electro-injectors

2 Fuel filter 7 overpressure valve
3 Tank 8 Common rail pressure accumulator
4 Fuel pre-filter 9 Pressure sensor
5 Engine control unit

771010 High pressure pump CPN 5-22/2
This is a pump equipped with 2 pumping elements which takes its drive from the timing gear. The gear feed pump is fitted on the
timing gear control shaft.
– P4D32C009E0816
Pump connections
180252 Figure 3
1 Fuel delivery to rail 4 Fuel delivery to filter
2 Fuel supply from filter 5 Plug
3 Fuel supply from tank 6 Fuel return to tank
Technical data
Pump characteristics
Rail pressure 2200 bar
Transmission ratio 1:1
Number of cam plungers / lobes 2/3
Plunger diameter/height 9.0 / 9.0 mm (3435 mm3/rev.)
Incoming fuel temperature (gear pump) - 40 ± 80°C (90° max 100h)
Maximum 280 Nm at maximum flow
Max torque at nominal speed
Average 80 Nm at maximum flow
Average power required 18 kW
Weight 15.3 kg
Maximum speed in overspeed (250 h) 2625 rpm
Nominal speed 2100 rpm
Overspeed (1h) 3150 rpm
Useful life 10,000 hours
lubrication via fuel
Maximum pressure at gear pump output 13 bar abs
Pressure at gear pump intake 0.35 ± 1 bar abs
Maximum pressure at return: 0.8 bar rel
– P4D32C009E0816
High pressure pump section

180253 Figure 4
1 Plungers (x2) 3 Flow regulator ZME4 (220 l/h)
2 Gear pump GP5 (430 l/h)
774510 Pressure accumulator (Common rail) HFRN-22
180254 Figure 5
1 Rail pressure sensor RPS4-22uc 4 Fuel return
2 Common Rail HFRN-22 5 Overpressure valve PLV5-22
3 Pipes to injectors 6 Intake from the high-pressure fuel pump
The rail volume is of reduced size to allow a quick pressurisation at start-up, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump
operation.
This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.
Some calibrated holes have been made in the retaining fittings of the high pressure pipes, with the function of damping the oscilla-
tions in pressure generated by the opening of the injectors and the plungers of the high pressure pump.
A fuel pressure sensor (1) is screwed to the rail.
– P4D32C009E0816
The signal 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.
Characteristics
Technical data
Nominal rail volume 28.6 cm³
Inner diameter 9 mm
Nominal pressure 2,200 bar
operating temperature −40 ℃ to140 ℃
– P4D32C009E0816
775010 Electro-injector CRIN 3-22
180255 Figure 6
1 Electric connection 6 Vaporiser nozzle
2 Coil 7 Fuel return hole
3 High-pressure fuel inlet fitting 8 IQA codes
4 Injector closing force 9 Production code
5 Nozzle
The electro-injectors are fitted on the cylinder head and are controlled 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.
– P4D32C009E0816
operation
CRIN 3.3 injector section
A High pressure B Low pressure
1 Coil 5 Needle
2 High-pressure fuel inlet 6 Nozzle
fitting 7 Pressure chamber
3 filter 8 Fuel return
4 Pressure rod 9 Control volume
10 Pilot valve shutter
236468 Figure 7
The electro-injector may be considered as mainly made up of two parts:

- actuator spray nozzle consisting of a pressure rod (4), needle (5) and jet(6).
- control solenoid valve made up of coil (1) and pilot valve.
Electro-injector operation is divided into three phases:
1st Phase - Resting position
The coil (1) is cut off and the shutter (10) of the pilot valve is in the closed position.
In this condition the opening force is balanced by the closing force, because the pressure of the fuel in the control volume (9) is the
same in the pressure chamber (7).
2nd Phase- Injection start
The coil (1) is energized and causes the shutter to rise (10).
The control volume fuel (9) flows back towards the return manifold (8), causing a drop in pressure
At the same time, in the pressure chamber (7) the pressure line exerts an opening force that causes the needle (5) to rise, with
the consequent introduction of fuel into the cylinders.
3rd Phase - End of injection
The coil (1) is cut off and causes the shutter (10) to return to the closed position, recreating a balance of forces, bringing the
needle (5) back to the closed position and consequently ending injection.
– P4D32C009E0816
774513 Pressure limiter valve
158450 Figure 8
It is a safety valve mounted on the hydraulic accumulator which prevents the pressure of the fuel in the rail from exceeding the
threshold 2400 bar.
It consists of a shutter and a spring, calibrated so that when the pressure in the rail reaches too high a value, the valve regulates it by
releasing part of the fuel to the tank.
Furthermore, in case of failure of the injection pressure control system, it allows the engine to function with limited performance.
542010 Fuel filter
Technical data
Maximum load 750 ℓ/h
Nominal pressure < 13 bar
Operating temperature −40 ℃ to120 ℃
Pressure drop with new filter <0.5 bar
Pressure drop with filter at end of life >2 bar
Capacity ≈1.7 l
221058 Figure 9
1 Fitting for bleeding 4 Clogged filter sensor
2 Fuel filter 5 Fuel temperature
3 Drain valve sensor
Oil filter tightening torques

TORQUE
DETAIL
Nm kgm
1 Fitting for bleeding 18 ± 2 1.8 ± 0.2
2 Fuel filter 32.5 ± 2.5 3.25 ± 0.25
– P4D32C009E0816
LUBRICATION CIRCUIT
TORQUE
DETAIL
Nm kgm
3 Drain valve 1.5 ± 0.5 0.15 ± 0.05
4 Clogged filter sensor 30 ± 2 3 ± 0.2
5 Fuel temperature sensor 30 ± 2 3 ± 0.2
5430 LUBRICATION CIRCUIT

The engine is lubricated by a gear pump driven via gears by the crankshaft.
A heat exchanger regulates the temperature of the lubricating oil.
It houses the oil filter, indicator sensors and safety valves.
– P4D32C009E0816
LUBRICATION CIRCUIT
Lubrication circuit
242533 Figure 10
A Oil dropping C Inlet oil
B Oil under pressure
– P4D32C009E0816
LUBRICATION CIRCUIT COMPONENTS

543010 Oil pump
The oil (1) pump cannot be overhauled.
If you find any damage, replace the entire oil pump.
To change the gearing (2) of the crankshaft, see the relevant
chapter.
060560a Figure 11
Oil pump cross-section
108846 Figure 12
Technical data
Initial opening pressure - Overpressure safety valve 10 ±1 bar
– P4D32C009E0816
543076 Overpressure valve

Main data to check the overpressure valve spring
073540 Figure 13
543075 Oil pressure regulator valve

The oil pressure relief valve is located on the left-hand side of the
crankcase.
Technical data
Initial opening pressure - Oil pressure relief 4.6 ±0.5 bar
valve
161256 Figure 14
– P4D32C009E0816
Main data to check the oil pressure adjustment valve spring
161269 Figure 15
A Start opening B Opening end
– P4D32C009E0816
543110 Heat exchanger
180296 Figure 16
1 By-pass valve 3 Oil filter support seat
2 Heat exchanger
Technical data
By-pass valve opening pressure 2.5 ±0.3 bar
– P4D32C009E0816
543077 Filter by-pass valve

The valve quickly opens at a pressure of: 3.4 ± 0.3 bar..
073545 Figure 17
– P4D32C009E0816
543070 Engine oil filter
180257 Figure 18
1 Oil filter support 4 Cartridge
2 Cap O-ring 5 Closing cap
3 Cartridge O-ring 6 Drainage plug
Technical data
Maximum operating pressure 13 bar
By-pass valve opening pressure 3.4 ±0.3 bar
Tightening torque
Oil filter 1. Oil filter tank
60 ±5 N⋅m
2. Bleed plug
6.5 ±1.5 N⋅m
– P4D32C009E0816
Oil vapours
540414 Valve integrated in piston cooling nozzle

The valve allows oil to enter and thus lubrication of pistons only
above the pressure value shown below.
Technical data
Valve opening pressure 1.7 ±0.2 bar
This permits filling the circuit and therefore lubricating the most
stressed parts even when working at lower pressures.
109080 Figure 19
Oil vapours
540480 OIL VAPOUR RECIRCULATION SYSTEM (BLOW BY SYSTEM)
Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and sent into the air intake circuit.
The device is essentially composed of a rotary filter fitted to the high pressure pump/camshaft control shaft and a rear cover hous-
ing the normally closed valves that manage the flow of the mixture.
A pressure sensor that detects the clogging of the Blow-by filter is located on the rocker arm cover.
By measuring the pressure under the rocker arm cover, it is also able to detect the presence of fuel in oil.
– P4D32C009E0816
Oil vapours
Oil vapour recirculation (Blow-by) diagram
221061 Figure 20
1 Blow‐by case cover 4 Cover
2 O-ring 5 Gasket
3 Blow-by filtering element
– P4D32C009E0816
COOLING CIRCUIT COMPONENTS

5432 COOLING CIRCUIT
Description
Main water circuit
247724 Figure 21
A Cylinder head C Radiator
B Crankcase
1 Water-oil exchanger 7 Pressurized compensation tank

2 Main circuit water pump Quantity 0.7 bar
3 Air - air radiator pack 8 Water temperature transmitter
4 Water - air radiator pack 9 Thermostatic valve
5 Visual level 10 Water temperature sensor
6 Plug with safety valve 11 Water heater on crankcase
– P4D32C009E0816
247697 Figure 22
A Pump inlet water C Water leaving the thermostat (to the radiator)
B Water circulating in the engine
1 Oil heat exchanger 5 Heat exchanger with aftercooler (radiator)

2 Heat exchanger cover 6 Thermostat case
3 Water pump gasket 7 Pump water intake pipe
4 Water pump
The engine cooling system, shown in the figure, is of the closed-loop forced-circulation type and consists mainly of the following
components:
● an expansion tank which adjusts system pressure (not supplied by FPT);

● a coolant level sensor (not supplied by FPT);
● an radiator to dissipate the heat drawn by the coolant from the engine through the intercooler heat exchanger;
● a heat exchanger to cool the lubricant oil;
● a centrifugal water pump incorporated into the engine crankcase;
● a motorised throttle valve electric actuator on the exhaust;
● an electric fan (not supplied by FPT)
● thermostat to control coolant circulation.
– P4D32C009E0816
operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylin-
der head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is
channelled from here to the radiator and cooled by the fan.
The pressure inside the system due to temperature variation is controlled via the expansion tank.
543210 Water pump

Section on water pump
The water pump consists of the impeller, sealer bearing and drive
pulley.
Note Check that the pump casing shows no sign of cracking or

water leakage; replace the water pump assembly if it does.
Water pump technical data

Technical data
Maximum operating pressure 3.5 bar
60631 Figure 23
543250 Thermostat
Water circulating in the engine
221062 Figure 24
– P4D32C009E0816
INTAKE AND EXHAUST SYSTEM COMPONENTS
Water leaving the thermostat
221063 Figure 25
Check that the thermostat works properly, replace it if there is any doubt.
Thermostat technical data

Technical data
Start of stroke temperature 84 ±2 ℃
Minimum stroke temperature (15 mm) 94 ±2 ℃

5424 INTAKE AND EXHAUST SYSTEM
The intake and exhaust system consists of:
● air filter;
● Wastegate turbocharger;
● intercooler heat exchanger;
● inlet manifold;
● Exhaust manifold
● motorised throttle valve on the exhaust (Exhaust flap).
The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable.
The function of the turbocharger is to use the energy of the engine's exhaust gas to deliver pressurized air to the cylinders.
The intercooler is composed of a radiator applied on the engine coolant radiator, and it is used for lowering the temperature of
the air coming out from the turbocharger to send it to the cylinders.
– P4D32C009E0816
Turbocharging diagram
247696 Figure 26
A Cold compressed air C Compressed air (hot)
B Intake air (from the air filter) D Engine exhaust gas
1 Heat exchanger with aftercooler (radiator) 3 Air filter

2 Intake manifold 4 Turbocharger
– P4D32C009E0816
542457 Air filter
247698 Figure 27
1 External air intake 4 Condensate exhaust valve
2 Air filter clogged sensor 5 Filtering element seat
3 Air delivery to turbocharger 6 Air filter brackets
By means of the aspiration created by the engine, the outside air flows through the air socket 1 and the centrifugal movement is
imparted at high speed by the directed fins of the filter.
The larger particles of dust and dirt are separated from the air and collected in the condensate discharge valve (4).
The suctioned air then passes through the filter element before being sent inside the engine.
Make sure that the intake air filter is not obstructed or clogged, checking at the same time that the warning light (2) on the filter
does not show the "red" indicator. The air filter clogged warning light (2) indicates when it maintenance is required in order to
protect and optimise filter operation. The sensor (2) remains locked in the alarm position ("red") until the air filter is restored
– P4D32C009E0816
542410 HTT Wastegate turbocharger

The turbocharger is installed on the exhaust manifold.

1. Pneumatic actuator pipe 6. Turbine intake flange (from
2. Oil inlet engine)
3. Compressed air outlet 7. Exhaust gas outlet (from
4. Compressor inlet outside)
5. oil outlet 8. Control pin
9. Pneumatic actuator
221065 Figure 28
The turbocharger mainly consists of:
● a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor
wheels;
● a turbine casing and a compressor casing mounted on the end of the central body;
● an overpressure relief valve (waste-gate) applied on the turbine casing. The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the exhaust pipe, when the turbocharging pressure downstream of the tur-
bocharger reaches the calibration value.
Throttle valve
75532 Figure 29
A. Closed throttle valve B. Throttle valve open
– P4D32C009E0816
SECTION SHOWING A TURBOCHARGER WITH A WASTE-GATE VALVE
Note Verifying an anomalous operation of the engine, due to the booster system, it is recommended, before performing con-
trols on the turbocharger, to check the efficiency of the sealing gaskets and the fixing of the connection sleeves, making
sure of clogging absence inside intake sleeves, air cleaner or inside radiators.
If the turbocharger damage is due to a lack of lubrication, check that the oil circulation pipes are not burst or clogged, in
which case replace them or repair the fault.
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Electric/electronic system
Contents 1
Contents
ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
ELECTRIC EQUIPMENT 3
Contents
Contents
Location of engine electrical components . . . . . . . . . . 5
ENGINE SIDE WIRING . . . . . . . . . . . . . . . . . . . . 6

Cable on engine . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring-topographic diagram - Engine side . . . . . . . 7
Head wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EDC17CV41 control unit . . . . . . . . . . . . . . . . . 9
EDC (ECM) SYSTEM . . . . . . . . . . . . . . . . . . . 10
EDC SYSTEM OPERATION . . . . . . . . . . . . . . 10
INTERCONNECTION CONTROL UNIT . . . . . . . . 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ELECTRONIC COMPONENTS . . . . . . . . . . . . . . 20
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . 20
Rail pressure sensor (RPS) . . . . . . . . . . . . . . . . 21
Fuel metering valve . . . . . . . . . . . . . . . . . . . . 23
Fuel temperature sensor . . . . . . . . . . . . . . . . . 24
Engine coolant temperature sensor . . . . . . . . . . 25
Crankshaft rpm sensor . . . . . . . . . . . . . . . . . . 27
Camshaft timing sensor . . . . . . . . . . . . . . . . . . 29
Air temperature and pressure sensor . . . . . . . . . 30
Crankcase pressure sensor . . . . . . . . . . . . . . . 32
Engine oil temperature and pressure sensor . . . . . 33
Engine heating pre/post resistance . . . . . . . . . . . 36
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starter motor . . . . . . . . . . . . . . . . . . . . . . . 40
– P4D32C009E0816
4 ELECTRIC EQUIPMENT
– P4D32C009E0816
Location of engine electrical components
ELECTRIC EQUIPMENT
Location of engine electrical components
242529 Figure 1
1. Electro-injectors 9. Fuel temperature and pressure sensor
2. Rail pressure sensor 10. Fuel temperature and fuel filter clogged sensor (pres-
3. Coolant temperature sensor sure drop)
4. Crankcase pressure sensor 11. Starter motor
5. Engine pre-heater resistor (Grid-heater) 12. High pressure fuel pump dosing unit
6. Alternator 13. Camshaft timing sensor (segmental speed)
7. Air temperature and boost pressure sensor 14. Crankshaft speed sensor (incremental speed)
8. EDC17CV41 engine control unit 15. Engine oil temperature and pressure sensor
– P4D32C009E0816
ENGINE SIDE WIRING
ENGINE SIDE WIRING

7691 Cable on engine
Cable on engine
242532 Figure 2
1 Control unit connector 8 Crankshaft speed sensor (incremental speed)
2 Fuel filter clogged sensor 9 Engine oil temperature and pressure sensor
3 Fuel temperature sensor 10 Crankcase pressure sensor
4 Fuel pre-filter clogged sensor 11 Coolant temperature sensor
5 Air temperature and boost pressure sensor 12 Water pressure sensor
6 High pressure fuel pump dosing unit 13 In-line connector
7 Camshaft timing sensor (segmental speed)
– P4D32C009E0816
ENGINE SIDE WIRING
7691 Wiring-topographic diagram - Engine side
242531 Figure 3
KEY ( ➠ Page 7)
KEY
Ref. Description
(1) EDC17CV41 engine control unit 96 pin connector
(2) Fuel temperature sensor
(3) Coolant temperature sensor
(4) Engine oil temperature and pressure sensor
(5) Air temperature and boost pressure sensor
(6) Fuel pre-filter clogged sensor
– P4D32C009E0816
ENGINE SIDE WIRING
Ref. Description
(7) Fuel filter clogged sensor
(8) Water inlet pipe pressure sensor
(9) Crankcase pressure sensor
(10) Camshaft timing sensor (segmental speed)
(11) Crankshaft speed sensor (incremental speed)
(12) High pressure fuel pump dosing unit
(13) In-line connector
7691 Head wiring
8 7 6 5 4 3 2 1
237248 Figure 4
1 Connector of cylinder head interconnection 5 Electro-injector cylinder 3
2 Electro-injector cylinder 1 6 Electro-injector cylinder 4
3 Rail pressure sensor 7 Electro-injector cylinder 5
4 Electro-injector cylinder 2 8 Electro-injector cylinder 6
Head interconnection connector pin-out

Pin Function Cable
1 Electro-injector cylinder 1 V
2 Electro-injector cylinder 2 L
4 Electro-injector cylinder 1 B
6 Electro-injector cylinder 3 R
7 Spare –
10 Electro-injector cylinder 6 Z
11 Spare –
12 Spare –
13 Electro-injector cylinder 4 C
14 Electro-injector cylinder 5 H
16 Spare –
– P4D32C009E0816
ECU
Pin Function Cable

17 Rail pressure sensor G
18 Rail pressure sensor N
19 Rail pressure sensor S
ECU
EDC17CV41 control unit
178240 Figure 5
1 Chassis side connector (connector 1) 2 Engine side connector (connector 2)
– P4D32C009E0816
ECU
76 EDC (ECM) SYSTEM

System components
766161 EDC SYSTEM OPERATION

The electronic control unit EDC17 CV41 manages the following main functions:
● fuel injection;
● Management of the ATS system components;
● Self-diagnostics;
● Recovery.
Also permits:
● Interfacing with other on-board electric systems on the CAN EDB line (or ECB) SAEJ1939;
● EOL and Service programming;
● Diagnosis.
Fuel dosing
The fuel metering is calculated in relation to:
● the position of the accelerator pedal by the VCM (Vehicle Control Module);
● engine speed;
● the amount of air introduced.
The outcome may be corrected in relation to:
● water temperature;
● fuel temperature (DIESEL DENSITY).
Or to avoid:
● overloading;
● overheating;
The delivery can be modified in the case of:
● the engine brake or brake pedal being activated (signals via CAN);
● a limiting device cutting in (ASR, speed limiter, etc.) (signals via CAN);
● intervention of the ANTIPOLLUTION devices: NOx sensor, NH3 sensor.
● serious trouble decreasing the load or stopping the engine.
Once the control unit has determined the mass of the introduced air and measured its pressure and temperature, it calculates the
corresponding fuel load needed to inject into the cylinder (mg. per delivery). It also takes diesel temperature into account (density).
The fuel load calculated in this way is converted into crank degrees i.e. injection advance and duration.
– P4D32C009E0816
ECU
Correcting flow rate according to water temperature

When cold, the engine encounters greater resistance in operating: there is greater mechanical friction, the oil is still very viscous, the
various clearances are not yet optimised.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
De-rating
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the tem-
perature reached by the coolant.
Injection advance electronic control

The advance (starting moment, expressed in degrees) may be different from one injection to the next, and in a differentiated man-
ner from one cylinder to another, and is calculated, similarly to the flow rate, on the basis of engine load (accelerator pedal position,
engine speed and introduced air).
The advance is appropriately corrected:
● in acceleration steps;
● according to the coolant temperature;
and also to obtain:
● lower emissions, noise and overloading;

● better vehicle acceleration.
When starting the engine, a high degree of advance is used based on water temperature.
the feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.
Engine speed limiter

The control unit controls the engine speed at all rev ranges and in particular:
● at idle;
● at top speed.
Starting the engine

During the initial driven engine revolutions, the timing and recognition signals are synchronised for cylinder no.1 (flywheel sensor
and camshaft sensor). Upon ignition, the signal of the accelerator pedal that arrives via CAN is ignored. The delivery of the diesel
upon ignition is set exclusively based on the temperature of the water by means of a specific map. When the control unit detects a
number of revolutions as well as a flywheel acceleration such to consider the engine as started and no longer driven by the starter
motor, it re-enables the accelerator pedal signal.
– P4D32C009E0816
ECU
Run Up
When the key makes contact, the control unit transfers the information stored in memory when the engine was last stopped into
the main memory (see After Run) and makes a diagnosis of the system.
After run
Each time the engine is turned off with the key, the control unit continues to operate for a few seconds thanks to the internal
MAIN RELAY.
This permits the microprocessor to transfer some data from the main memory (volatile) to a non volatile, erasable and rewritable
memory (EEPROM), to make it available for the next start (see: Run Up).
The data mainly consists of:
● various settings (engine idling, etc.);

● calibration of certain components;
● faults memory.
This procedure lasts a few seconds, typically from 2 to 7 (depending on the quantity of data to save), after which the ECU deactiv-
ates the main power supply.
If this happens, system functionality remains guaranteed until the fifth time it is turned off incorrectly (also non consecutively) after
which an error is stored in the faults memory and upon the following engine start-up, the engine will function with reduced per-
formance while the EDC warning light remains on.
Repeated interruptions of the procedure could in fact lead to damage to the control unit.
Cut - off
This function cuts off fuel feed during deceleration and during engine braking etc.
Cylinder Balancing
This function permits individual, customised control over the delivery of fuel and the start of delivery for each cylinder, which can
even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.
The difference in fuel feed to each cylinder is not signalled by the ECU but by an instrument.
Synchronisation Search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with
the sequence already synchronized.
If this takes place when the engine is stopped, the control unit excites only one solenoid valve. Within a maximum of 2 revolutions
of the crankshaft, injection will take place in that cylinder. This means that the control unit simply needs to synchronise with the
firing sequence and start the engine.
To reduce the number of connections, the length of the connection cables with the injectors and, as a result, disturbances in the
transmitted signal, the control unit is mounted directly on the engine by means of a heat exchanger that cools it, using elastic dowels
which reduce the vibrations transmitted by the engine.
Internally, there is an ambient pressure sensor that is used to further improve injection system management.
– P4D32C009E0816
ECU
EDC17CV41 control unit
178240 Figure 6
1 Chassis side connector (connector 1) 2 Engine side connector (connector 2)
– P4D32C009E0816
ECU
Engine side pin out
189005 Figure 7
Pin Out ( ➠ Page 14)
Pin Out
Pin. Component
01. "Low" signal injector 1, bank 2, cylinder 4
04. Spare
05. Spare
Engine oil pressure and temperature sensor:
06.
ground for frequency input 3
Air temperature and turbocharging pressure
07.
sensor: power supply at +5V
Pre-filter clogged sensor (pressure drop)/ Water
08.
pump inlet pressure sensor
09. Spare
10. Spare
11. Rail pressure sensor: power supply at +5V
12. Fuel temperature sensor: NTC temperature signal
Engine oil temperature and pressure sensor: NTC
13.
temperature signal
Ground signal for water pump pressure sensor:
14.
incoming signal
15. Intercooler pressure sensor: outgoing signal
Exhaust gas absolute pressure sensor (P3): pres-
16.
sure signal
17. Controller Area Network 2 (high)
18. Controller Area Network 2 (low)
Pre-filter clogged sensor (pressure drop)/ Water
19.
pump inlet pressure sensor
20. Spare
21. Spare
22. Spare
– P4D32C009E0816
ECU
Pin. Component
23. Spare
24. Spare
25. "High" signal injector 1, bank 2, cylinder 4
28. Spare
29. Spare
30. Spare
Engine oil pressure and temperature sensor:
31.
power supply at +5V
Engine crankcase pressure sensor: power supply at
32.
+5V
33. (Absolute exhaust gas pressure sensor) optional
Intercooler temperature and pressure sensor:
34.
outgoing signal (optional)
35. Engine oil pressure sensor signal: pressure signal
36. Rail pressure sensor: pressure signal
Turbocharging pressure and air temperature
37.
sensor: NTC temperature signal
38. Intercooler outlet T sensor
Coolant temperature sensor: NTC temperature
39.
signal
Intercooler temperature and pressure sensor:
40.
ground signal (optional)
41. Spare
Crankcase pressure sensor/ Intercooler outlet T
42.
sensor: ground
Camshaft timing sensor (segmental speed): ground
43.
signal
44. Spare
45. Spare
46. Spare
47. Spare
48. Spare
52. Spare
53. Spare
54. Spare
55. Spare
56. Spare
57. Spare
High pressure fuel pump dosing unit: power
58.
supply
59. Analogue input 18 common ground
– P4D32C009E0816
ECU
Pin. Component
60. Rail pressure sensor: ground
61. Engine crankcase pressure sensor: pressure signal
62. Pre-filter clogged sensor (pressure drop)
63. Spare
64. Spare
Crankshaft speed positive sensor (incremental
65.
speed): positive signal
Crankshaft speed sensor (incremental speed):
66.
negative signal
Camshaft timing sensor (segmental speed): posit-
67.
ive signal
Camshaft timing sensor (segmental speed): negat-
68.
ive signal
69. Ref. speed sensors: shared ground
70. Spare
71. Spare
72. Spare
76. Spare
77. Spare
78. Fuel filter clogged sensor: ground
79. Fuel filter clogged sensor: pressure drop signal
80. Spare
81. Spare
82. Spare
83. High pressure fuel pump dosing unit: signal
84. Spare
85. Spare
Turbocharging pressure and air temperature
86.
sensor: pressure signal
87. Spare
88. Spare
89. Spare
90. Analogue input 5 ground
91. Spare
92. Spare
93. Spare
94. Spare
95. Spare
96. Spare
– P4D32C009E0816
INTERCONNECTION CONTROL UNIT

247699 Figure 8
1 Control unit supports 3 Diagnostics connector for G-DRIVE engine interface
2 Power supply connector for G-DRIVE engine interface with EDC17CV41
with EDC17CV41 4 Connection unit
– P4D32C009E0816
7661
247700 Figure 9
K1 ATS intelligent sensor K6 Fuel filter heating
K2 After run B K7 Fuel pre-filter heating
K3 Run K8 Starter motor control
K4 Starter motor CN1 Diagnosis
K5 SCR heating
To allow correct electrical operation of the control unit, the engine has been fitted with an interconnection control unit. The inter-
connection control unit controls the electronic control system of the engine and the powertrain system. Indications are provided
below regarding the components and functions which are controlled by means of programming switches.
Accessory and engine speed function controls

Function programming described below is possible by switching the respective positions of the JP switches.
JP1 (engine speed selection) + JX (connector: engine speed selection) ( ➠ Page 19)
JP2 ( ➠ Page 19)
JP3: Relay for the cold start-up heating device ( ➠ Page 19)
JP4: cold start-up warning light ( ➠ Page 19)
JP5: CAN line ( ➠ Page 20)
– P4D32C009E0816
JP1 (engine speed selection) + JX (connector: engine speed selection)

Speed
1500 rpm (50 Hz)
1800 rpm (60 Hz)
IDLE
JP2
Mode selection
Diagnostic position
Operating position (prearranged)
JP3: Relay for the cold start-up heating device

State
Connected
Not connected (prearranged)
JP4: cold start-up warning light

State
Connected
– P4D32C009E0816
ELECTRONIC COMPONENTS
JP5: CAN line

State
Connected
775010 Electro-injectors
178241 Figure 10
1 Electrical connections 2 Electromagnet assembly
Characteristics
Technical data
Maximum working pressure 2,200 bar
Minimum working pressure 250 bar
Tightening torque
Electro-injector wiring (12 M4x0.7 nuts) 1.5 ±0.25 N⋅m
Electro-injector brackets (6 M8x1.25x55 screws) 35 ±2 N⋅m
operation
This is an N.O. solenoid valve.
They are connected to the EDC ECU on connector 2.
The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm.
The electro-injector essentially consists of two parts:
● actuator - spray nozzle consisting of a pressure rod, a needle and a jet
– P4D32C009E0816
● control solenoid valve made up of coil and pilot valve
The solenoid valve checks the lift of the nozzle needle.

BEGINNING OF INJECTION
Upon being supplied with power, the coil moves up the shutter. The fuel in the control volume flows back towards the return duct
resulting in a pressure drop in control volume.
At the same time, the fuel pressure in the pressure chamber moves up the needle resulting into the fuel being injected into the
cylinder.
END OF INJECTION
When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its
closed position and stops the injection process.
774511 Rail pressure sensor (RPS)

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
196904 Figure 11
A Technical view C Recommended assembly position
B Perspective view
– P4D32C009E0816
Technical specifications
Supplier: BOSCH
Technical data
Pressure range 0 bar to2,400 bar
Tightening torque
Pressure sensor on rail RPS4-22uc (1 sensor M18x1.5) 140 ±7 N⋅m
1 2 3
190509 Figure 12
Pin-out
Wire
Pin Function ECU pin
colour
1 Ground (-) 2/60 N
2 Pressure signal on rail 2/36 S
3 Pressure sensor power supply on rail (+5V) 2/11 G
– P4D32C009E0816
771034 Fuel metering valve
178247 Figure 13
1 Fuel metering valve
Situated at the inlet of the high pressure pump, on the low pressure system, this device adjusts the quantity of fuel reaching the high
pressure pump in accordance with the commands received from the control unit.
It mainly consists of the following parts:
● tapered shutter
● valve control pin
● Pre-load spring
● Coil
In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery
mode.
The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high
pressure pump.
The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system that is managed
by the EDC.
Pin-out
Wire
colour
1 Air supply 2/58 S
2 Ground 2/83 V
– P4D32C009E0816
772656 Fuel temperature sensor

It is an N.T.C. sensor located on the fuel filter on the right side of the engine.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.
Sensor
196902 Figure 14
A Technical view C Wiring Diagram
B Perspective view
– P4D32C009E0816
Supplier: BOSCH
Technical data
Resistance 2.5 kΩ ±6 %
Note 20 °C
Technical data
Voltage 5 ±0.15 V
Tightening torque
Fuel temperature sensor (1 M12x1.5 sensor) 30 ±2 N⋅m
Pin-out
Wire
colour
1 Fuel temperature signal 2/12 H
2 Common ground 2/59 L
764274 Engine coolant temperature sensor

It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the
need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
The coolant temperature signal is used to be displayed on the Cluster and to control the fan.
– P4D32C009E0816
Sensor
196902 Figure 15
B Perspective view
– P4D32C009E0816
Supplier: BOSCH
Tightening torque
Water temperature sensor (1 fitting M12x1.5) 25 N⋅m
Technical data
Temperature range 40 ℃ to150 ℃
Resistance 2.5 kΩ ±6 %
Note Temperature 20 °C
Pin-out
Wire
colour
1 Coolant temperature signal 2/39 H
2 Common ground 2/59 L
764263 Crankshaft rpm sensor

This sensor is an inductive one and is located on the flywheel.
It generates signals obtained from the magnetic flow lines, which close through the holes obtained on the flywheel.
The electronic control unit uses this signal to detect the various engine ratings and to control the electronic rev counter.
If this signal fails the rev counter will not work.
The sensor gap is NOT ADJUSTABLE.
– P4D32C009E0816
Sensor
191894 Figure 16
B Perspective view D Connector
Characteristics:
Supplier: BOSCH
Pin-out
Wire
colour
1 Crankshaft speed signal 2/66 B
2 Common ground 2/65 N
– P4D32C009E0816
764264 Camshaft timing sensor

This inductive sensor is located on the camshaft.
It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to the
crankshaft.
The signal generated by this sensor is used by the control unit as the injection timing signal.
The sensor gap is NOT ADJUSTABLE.
Sensor
191894 Figure 17
B Perspective view D Connector
– P4D32C009E0816
Characteristics
Supplier: BOSCH
Tightening torque
Camshaft timing sensor (1 screw M6x1x12) 8 ±2 N⋅m
Technical data
Resistance 774 Ω to956 Ω
Frequency for speed ratio 58 Hz
Note Engine speed
Pin-out
Wire
colour
1 Ground 2/67 B
2 Camshaft timing signal 2/68 N
540752 Air temperature and pressure sensor

This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
– P4D32C009E0816
Sensor
196905 Figure 18
A Technical view D Wiring Diagram
B Perspective view E Connector
C Recommended assembly position
– P4D32C009E0816
Supplier: BOSCH
Technical data
Sensor power supply 5V
Storage temperature −40 to130
Pin-out
Pin Function Cable colour
1 Ground Yellow
2 Air temperature signal Red
3 Sensor power supply (+5V) Green
4 Air pressure signal Purple
7642 Crankcase pressure sensor
178245 Figure 19
It is a pressure sensor fit on the engine head.
Supplier: KAVLICO
Technical data
Storage temperature −40 to125
– P4D32C009E0816
1 2 3
190512 Figure 20
Pin-out
Wire
colour
1 Supply 2/32 L
2 Ground 2/42 Z
3 Pressure signal 2/61 G
764251 Engine oil temperature and pressure sensor

This component incorporates a temperature sensor and a pressure sensor.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low pres-
sure warning light).
The engine oil temperature is used by the EDC control unit only.
– P4D32C009E0816
Sensor
196906 Figure 21
A Technical view D Wiring Diagram
B Perspective view E Connector
C Recommended assembly position
– P4D32C009E0816
Supplier: BOSCH
Technical data
Sensor power supply 5V
Pin-out
Wire
colour
1 Ground 2/6 G
2 Engine oil temperature signal 2/13 V
3 Sensor power supply (+5V) 2/31 R
4 Engine oil pressure signal 2/35 Z
Temperature and pressure sensor resistance ( ➠ Page 36)

1) Capacity of diagnosis with minimum values that do not guarantee
2) valid only for a measuring voltage < 0.5 V
Resistance for temperature or voltage for temperature ( ➠ Page 35)
Resistance for temperature or voltage for temperature

Temperat-
Resistance R in Ω Tolerance Tolerance test with T ± 1K
ure
T in °C Rated Minimum maximum in K Minimum maximum
-40 45303 43076 47529 ± 0.9 40730 50314
-35 34273 32643 35902 ± 0.9 30908 37953
-30 26108 24907 27309 ± 0.9 23603 28829
-25 19999 19108 20889 ± 0.9 18142 22023
-20 15458 14792 16124 ± 0.8 14055 16970
-15 12000 11499 12501 ± 0.8 10945 13144
-10 9395 9015 9775 ± 0.8 8595 10261
-5 7413 7123 7704 ± 0.8 6801 8074
0 5895 5671 6118 ± 0.8 5420 6403
5 4711 4537 4884 ± 0.8 4343 5106
10 3791 3656 3927 ± 0.8 3504 4100
15 3068 2962 3174 ± 0.8 2842 3310
20 2499 2416 2583 ± 0.8 2323 2690
25 2056 1990 2123 ± 0.8 1916 2207
30 1706 1653 1760 ± 0.8 1591 1827
35 1411 1368 1455 ± 0.8 1318 1510
40 1174 1139 1209 ± 0.8 1100 1254
45 987.4 959.0 1016 ± 0.8 927.0 1051
50 833.8 810.5 857.0 ± 0.8 783.1 886.3
55 702.7 683.7 721.7 ± 0.8 661.2 746.6
60 595.4 579.7 611.0 ± 0.8 561.6 631.4
65 508.2 495.3 521.1 ± 0.8 480.2 537.8
– P4D32C009E0816
Temperat-
Resistance R in Ω Tolerance Tolerance test with T ± 1K
ure
T in °C Rated Minimum maximum in K Minimum maximum
70 435.6 424.9 446.4 ± 0.8 412.1 460.3
75 374.1 365.2 383.1 ± 0.8 354.4 394.9
80 322.5 315.0 329.9 ± 0.8 306.0 339.8
85 279.5 273.2 285.8 ± 0.8 265.7 294.0
90 243.1 237.8 248.4 ± 0.8 231.5 255.4
95 212.6 208.1 217.1 ± 0.8 202.7 223.0
100 186.6 182.9 190.3 ± 0.8 178.0 195.4
105 163.8 160.3 167.2 ± 0.8 156.2 171.6
110 144.2 141.0 147.3 ± 0.9 137.5 151.0
115 127.3 124.4 130.1 ± 0.9 121.4 133.4
120 112.7 110.1 115.2 ± 1.0 107.5 118.0
125 100.2 97.81 102.5 ± 1.0 95.55 104.9
130 89.28 87.13 91.43 ± 1.1 85.13 93.52
Temperature and pressure sensor resistance

Sym-
Parameter Value Unit
bol
Min Nom Max
Rpull-up 5
Load Us or ground resistance ¹ Kiloohm [kΩ]
Rpull-down 10
Ground outlet resistance ² , Us open Rio 1.0 1.6 2.0 Kiloohm [kΩ]
Us outlet resistance ² , ground open Rhi 1.0 1.6 2.0 Kiloohm [kΩ]
766123 Engine heating pre/post resistance

The resistance is located between the cylinder head and the intake manifold used to heat the air in pre - post heating operations.
When the key switch is actuated, if even only one of the temperature sensors (water, air, diesel) detects less than 10 °C, the elec-
tronic control unit activates pre/post-heating and turns on the relevant dashboard warning light for a time depending on the tem-
perature.
Once this time expires, the warning light starts flashing, thus telling the driver that he can now start the engine.
The warning light goes off after engine start while the resistance continues to be supplied for a variable period of time performing
post - heating.
If the engine is not started within 20 to 25 seconds after the warning light starts flashing, the operation is cancelled so as to prevent
battery discharge.
When reference temperature is above 10°C, actuating the ignition key makes the warning light go on for approximately 2 seconds
to complete the test and then turns it off to indicate the engine can be started.
– P4D32C009E0816
resistance
196907 Figure 22
A Technical view B Perspective view
technical specifications
Supplier: BorgWarner
Technical data
Rated voltage 24 V
Pick-up current 160 A to290 A
Constant current 120 A to150 A
Insulating resistance 1 MΩ
– P4D32C009E0816
760310 Alternator
Characteristics
Supplier: MITSUBISHI 24V − 90A
Technical data
Rated voltage 28.3 ±0.5 V(20 ℃)
Nominal supply current 90 A
Operating speed 5,000 rpm
Belt tension 730 N
Direction of rotation: clockwise seen from the pulley
Technical data
Weight 7 kg
Tightening torque
Tightening torque on terminal B+ (M8x1,25) 12.5 ±2 N⋅m
Alternator wiring diagram
106281 Figure 23
L To recharging indicator S Battery voltage sensor
IG Alternator activation
– P4D32C009E0816
Alternator current delivery curve
106282 Figure 24
Perspective view
106300 Figure 25
– P4D32C009E0816
Technical view
106283 Figure 26
760810 Starter motor

Characteristics
Supplier: DENSO 24V − 5.5kW
– P4D32C009E0816
Technical view

237216 Figure 27
1 Terminal 50 2 Terminal 30
Characteristic curves
137660 Figure 28
– P4D32C009E0816
Wiring Diagram
4958 Figure 29
technical specifications
Version
Characteristics
5.5 kW
Nominal power 5.5 kW
Rated voltage 24 V
Coupling system Positive approach control
Adjusted time 30 s
Direction of rotation Clockwise seen from pinion end
16 V
Operating voltage
MAX
Weight ≈ 10.5 kg
Tightening torque for terminal +30
17.6 N⋅m to24.5 N⋅m
(M10X1.5)
Tightening torque for terminal +50
2.6 N⋅m to4.6 N⋅m
(M5X0.8)
Specific power
Version
Load 5.5 kW
Test conditions Characteristics
120 A
No load 23 V MAX
(3,800 rpm)
690 A
16 V
Load MAX
(49 N⋅m)
(900 rpm)
1,260 A
Stall 6V MAX
(73.5 N⋅m)
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Scheduled maintenance
Contents 1
Contents
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
SCHEDULED MAINTENANCE 3
Contents
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks and scheduled maintenance procedures . . . . . . 5
CHECKS TO PERFORM DURING PERIOD OF

USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check engine lubricant oil level . . . . . . . . . . . . . . 6
Coolant level check . . . . . . . . . . . . . . . . . . . . . 7
Engine visual inspection . . . . . . . . . . . . . . . . . . . 7
Check of air filter and cleanliness of housing . . . . . . 8
Check tension and condition of ancillary belt . . . . . 8
Check the condition of the exhaust duct(s) . . . . . . 9
Checking the Blow-by filter . . . . . . . . . . . . . . . . 9
PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . 9
Draining the water from the fuel pre-filter (if
present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Draining condensate from the fuel tank . . . . . . . . 10
Visually inspect turbocharger . . . . . . . . . . . . . . 10
Cleaning the heat exchanger (radiator)
(example) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Change engine lubricant oil . . . . . . . . . . . . . . . 10
Replacing the engine oil filter . . . . . . . . . . . . . . 12
Replace fuel prefilter (if fitted) . . . . . . . . . . . . . 13
Replacing fuel filter . . . . . . . . . . . . . . . . . . . . 13
Change air filter (example) . . . . . . . . . . . . . . . . 14
Replacing the auxiliary assembly drive belt . . . . . . 15
Change blow-by filter . . . . . . . . . . . . . . . . . . . 15
UNSCHEDULED MAINTENANCE . . . . . . . . . . . . 17
Fan drive belt replacement . . . . . . . . . . . . . . . . 17
Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replace engine coolant . . . . . . . . . . . . . . . . . . 22
– P4D32C009E0816
4 SCHEDULED MAINTENANCE
– P4D32C009E0816
Introduction
SCHEDULED MAINTENANCE
M Introduction
To ensure best operating conditions, on the following pages are indicated the checks, tests and adjustments which shall be carried
out on the different parts at the established time.
The frequencies of the maintenance operations are indicative since the engine use and its characteristics are essential to evaluate
replacements and checks.
Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking and main-
tenance operations which do not fall among those listed below, but are recommended by good-practices and particular conditions
of use of the engine.
Furthermore, in case of clear malfunctioning of the engine, for example excessive noise of exhaust gases, high temperature of the
coolant or low oil pressure, prompt measures must be taken to verify the causes of the anomaly.
We also remind that any maintenance operation, even the easiest ones, shall be performed in compliance with accident-prevention
laws for the safety of the staff in charge of maintenance.
Scheduled Maintenance comprises the following checks and maintenance operations:
● Checks to perform during period of use

● Periodical maintenance
● Unscheduled maintenance
M Checks and scheduled maintenance procedures

Checks (during periods of use) Frequency
Check engine lubricant oil level daily
Checking the engine coolant level daily
Engine visual inspection 50 hours / 15 days
Check of air filter and container cleanliness (**)
1 month
Check tension and condition of ancillary belt 300 hours / 6 months
Check the condition of the exhaust duct(s) 6 months
Check the condition of the Blow-by filters 6 months

Periodical maintenance Frequency
Drain water from the fuel pre-filter (if present) 150 hours / 6 months (1)
Drain condensed water from the fuel tank (*)

150 hours / 6 months
Turbocharger visual inspection 6 months
Clean the heat exchanger (radiator) (**)
6 months
Change engine lubricant oil 600 hours / 1 year (2) (4)
Replacing the oil filter 600 hours / 1 year (2) (3) (4)
Replace the fuel pre-filter (if present) (**)

600 hours / 1 year (1) (2)
Replacing fuel filter 600 hours / 1 year (1) (3) (2)
Replace the air filter (*) (**)

1200 hours / 2 years
Ancillary belt replacement 1200 hours / 3 years
Change blow-by filter 1800 hours/1 year
– P4D32C009E0816
CHECKS TO PERFORM DURING PERIOD OF USE

Unscheduled maintenance Frequency
Fan drive belt replacement 600 hours/1 year
Adjustment of valve/rocker arm clearance (**)
2,400 hours
Replace engine coolant 3,000 hours / 2 years (2)
(*) Respect the hour or time period interval, whichever is reached first.
(**) The frequencies indicated are only valid if the components are supplied by FPT
(***) The first time after 600 hours
(1) Maximum period relative to the use of high quality fuel (ASTM D975 or EN 590 specifications); this is reduced based on fuel
contamination and alarm signals based on the clogging of the filter and/or the presence of water in the prefilter. The filter clogging
signal requires it to be replaced. If the signal of water present in the prefilter does not turn off after draining it, the filter must be
replaced.
(2) The frequencies apply to lubricants which comply with international standards API CJ-4 / ACEA E9 as specified in the
REFILLING table.
(3) Only use filters with the following characteristics: degree of filtering < 12 μm - filtering efficiency 99.5% (ß > 200).
(4) Equivalent replacement frequencies and any fluids:
● 600 hours / 1 year for 10W-40 API CJ-4 / ACEA E9 (Sulphur content in fuel less than 50 ppm)
(level of sulphur in the fuel less than 50 ppm)
● 500 hours / 1 year for 15W-40 API CI-4 / ACEA E7
● 300 hours / 1 year for 15W-40 API CF/ ACEA E2 / E3
● 300 hours / 1 year for 20W-50 API CF/ ACEA E2 / E3

.542713. Check engine lubricant oil level
Main activity
1. Only proceed when the engine is not turning and is at low tem-
perature in order not to run the risk of burns; to obtain an ac-
curate reading, make sure that the engine is in the normal oper-
ating position.
2. Use the dipstick (2) to check that the lubricant oil level is
between the "Min" and "Max" limits.
3. If the level is too low, top up the oil by removing the plug and
introducing lubricant oil through the hole (2).
Note For the top-up only use lubricant oil that complies with
the international standards as indicated in the section
CONTROLS AND MAINTENANCE.
Clean the oil plug before performing the operation so
as to minimize the risk of contaminating the system. 242541 Figure 1
– P4D32C009E0816
4. Use the dipstick (1) to check that the level does not exceed the
"Max" limit engraved on the dipstick itself.
Note Make sure that the dipstick is fully inserted and that the
filler plug is tightened fully in the clockwise direction.
.5432. Coolant level check
Main activity
Caution!
Hot coolant Pay attention to the hot coolant
▶ When the engine is hot, pressure builds up in the cooling circuits which may eject hot liquid violently, resulting in a
risk of burns. Open the coolant tank cap only if necessary and only when the engine is cold.
1. Carry out the procedure only while engine is OFF and at low temperature in order to prevent risk of burns.
2. Remove the pressurization cap from the expansion tank.
3. Visually check that the coolant in the expansion tank is above the minimum level.
4. As required top up the expansion tank with a mixture of 50% water and coolant, as shown in the table "General specifications
- FLUIDS".
5. Top up the expansion tank until the "MAX" limit is reached. If there is no level indicator on the expansion tank, make sure
that the coolant in the expansion tank is a few centimetres below the filling hole in order to allow an increase in the coolant
volume following a rise in temperature.
Note Clean the pressurization cap of the expansion tank before performing the operation so as to minimize the risk of
contaminating the system.
.540110. Engine visual inspection
Main activity
1. Carry out careful checks before the first start-up.
Caution!
Cleaning
▶ A build-up of oil or grease on the engine represents a fire risk.
2. Check for any leaks (oil, coolant and fuel), broken or weakened pipes, loose clips and bolts, worn belt, wiring (loose connec-
tions, worn or frayed cables) and a build-up of dirt. In the event of any problems, perform the operations necessary to restore
the optimal conditions for engine operation.
Note For all types of leak (coolant, oil or fuel), remove any spilt fluid. If a leak is discovered then find its source and carry
out the necessary operations
– P4D32C009E0816
.507169. Check of air filter and cleanliness of housing

Main activity
1. Proceed if the air filter clogged visual indicator (12) indicates
filter clogging. It signals the exact moment in which maintenance
must be carried out and remains in the alarm position (red
indicator) to protect filter operation.
2. The air filter clogged visual indicator is able to operate at a tem-
perature of between -30 °C and +120 °C and can withstand
the worst atmospheric conditions and any type of corrosion.
The maximum tightening torque must be 1.5 Nm. Only pro-
ceed when the engine is not turning over.
3. After having unscrewed the wing nut (2), extract the filter
element (1) and during this operation, make sure that dust does
not enter.
4. Check that there are no impurities. Otherwise, clean the filter
element (1) following the indications provided below.
247712 Figure 2
5. Blow dehumidified compressed air on the filter element (1),
working from the inside outward (maximum pressure 200 kPa).
6. Check the condition of the air filter before refitting it. Replace it
if broken or torn.
7. Check that the gasket (3) at its base is in a good condition.
8. Position the filtering cartridge (1) into its housing and tighten
the wing nut (2).
9. Fit the air filter cover (4) and fasten it by tightening the hand-
wheel screw (5).
Note When cleaning the air filter, do not use detergents and
do not use diesel. Never strike the filter element with
tools. Make sure parts are fitted correctly. Incorrect
installation may cause the engine to take in unfiltered
air, causing serious damage to the engine..
.543411. Check tension and condition of ancillary belt
Main activity
Caution!
Belt
▶ When the engine is off, but still hot, the belt may start to move without external intervention. Wait for the engine
temperature to fall to prevent serious risk of injury.
1. Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns.
2. Check that the belt is not worn, soiled with oil or fuel, or showing signs of tears. Replace if necessary.
3. Use a ½ inch square wrench to check the efficiency of the automatic belt tensioner.
– P4D32C009E0816
PERIODICAL MAINTENANCE
.507120. Check the condition of the exhaust duct(s)
Main activity
1. Visually check that the exhaust gas system is not blocked, corroded or damaged.
2. In the event of any faults or problems, perform the operations necessary to restore the optimal conditions for operation of
the exhaust pipe.
.540486. Checking the Blow-by filter
Main activity
Caution!
Disposal Engine oil
▶ Dispose of residuals in an adequate manner that complies with laws in force.
1. To prevent the risk of burns, only continue when the engine is no longer running and has cooled down sufficiently.
2. Check that the filter element is completely free of deposits. Otherwise, replace it.
.773110. Draining the water from the fuel pre-filter (if present)
Main activity
1. The high risk of refuelling with fuel polluted with foreign
particles and water means that the following check should be
performed at each refuelling in addition to the scheduled
maintenance.
2. Proceed with the engine not running.
3. Unscrew the exhaust valve (cock tap) (1) located at the bottom
of the filter; in some fittings the plug includes the fuel water
sensor.
Note Clean the exhaust valve (1) before performing the
operation so as to minimize the risk of contaminating
the system.
4. Drain the liquid until only fuel comes out. 215045 Figure 3
5. Fully retighten the plug manually.
6. Dispose of the drained liquids according to the applicable regu-
lations in force.
– P4D32C009E0816
.507220. Draining condensate from the fuel tank
Main activity
1. Proceed to drain/suction water, condensate and impurities from the fuel tank following the instructions contained in the
manual supplied by the manufacturer of the power unit.
2. Proceed as required on the basis of the structure or location of the tank: Engines that operate in adverse conditions and / or
are filled using drums or cans, require more attention when cleaning the tank.
.542410. Visually inspect turbocharger
Main activity
1. Only continue with this operation when the engine is off.
2. Only proceed when the engine is no longer turning. Visually check that the compressor and turbine impellers and the relative
inlet and outlet pipes are not clogged or damaged and replace if necessary.
.535390. Cleaning the heat exchanger (radiator) (example)

Main activity
1. The surfaces of the heat exchanger (radiator) come into con-
tact with fresh air and may be subject to deposits of impurities
(dust, mud, straw, etc.).
2. Clean when necessary with compressed air or steam.
247713 Figure 4
.542713. Change engine lubricant oil

Tightening torques
Lubricant drain plug on the sump (3 plugs M22x1.5) 30 ±3 N⋅m
– P4D32C009E0816
Main activity
1. Carry out the procedure only while engine is OFF and at low
temperature in order to prevent risk of burns.
2. Place a suitable container for catching oil below the oil sump (3)
near the engine lubricant oil drain plug (4).
3. Unscrew the lubricant oil drain plugs (4); afterwards extract the
oil level dipstick (2) and remove the lubricant oil plug (1) to aid
the flow of the engine lubricant oil.
Threaded parts
Lubricant drain plug on the sump (3 plugs M22x1.5) (4)
4. Wait until the oil sump (3) has emptied completely, then
retighten the oil drain plugs (4) to the torque of:
Tightening torque
Lubricant drain plug on the sump (3 30 ±3 N⋅m
242542 Figure 5
plugs M22x1.5) (4)
5. Refill through the hole (1) located on the head cover, using lub-
ricant oil compliant with the specifications in the table "General
specifications - REFILLING".
6. Use the oil dipstick (2) to check that the level of engine lubric-
ant oil does not exceed the "Max" limit.
7. If it is difficult to perform the measurement, clean the oil dip-
stick (2) using a clean cloth without any loose threads, and re-fit
the dipstick into its housing. Remove it again and check the level.
8. Retighten the lubricant oil plug (1).
Caution!
Disposal Engine oil
▶ Dispose of residuals in an adequate manner that com-
plies with laws in force.
9. When changing the engine lubricant oil, the oil filter must be
changed (see paragraph LUBRICANT OIL FILTER REPLACE-
MENT).
Note Clean the plugs before performing the operations so as
to minimize the risk of contaminating the system.
Make sure that after changing the engine lubricant oil
level it does not exceed the "Max" limit on the oil level
dipstick and remains above the "Min" limit.
Make sure that the dipstick is fully inserted and that the
filler plug is tightened fully in the clockwise direction.
– P4D32C009E0816
.543070. Replacing the engine oil filter

Tightening torques
Oil filter 1. Oil filter tank 60 ±5 N⋅m
2. Bleed plug 6.5 ±1.5 N⋅m
Main activity
1. Only use filters with the following specifications:
2. Degree of filtering < 12 μm.
3. filtering efficiency ß > 200 (99.5%).
4. Only proceed when the engine is not turning and is at low tem-
perature in order not to run the risk of burns.
5. Drain the spent lubricant oil (see paragraph ENGINE LUBRIC-
ANT OIL REPLACEMENT).
Caution!
Disposal Engine oil
247714 Figure 6
6. Correctly position a suitable container for collecting the spent
oil below the oil filter next to the drain plug (3).
7. Remove the filter body (2) by unscrewing it.
Threaded parts
Oil filter (2, 3) 1. Oil filter tank
2. Bleed plug
8. Replace the filter element (4) and the O-ring seal (1) contained
inside the filter body (2).
9. Clean the surface carefully.
10. Moisten the O-ring seal (1) of the new filter.
11. Tighten the drain plug (3) and the filter body (2) to the torque
indicated in the table.
Tightening torque
60 ±5 N⋅m
2. Bleed plug
6.5 ±1.5 N⋅m
12. Proceed with the refilling operation of the lubricant oil (see
paragraph ENGINE LUBRICANT OIL REPLACEMENT).
13. Operate the engine for a few minutes and then check the level
using the dipstick.
14. If necessary, top up to compensate for the quantity of oil used
to fill up the filtering cartridge.
Note Make sure that after changing the engine lubricant oil
level it does not exceed the "Max" limit on the oil level
dipstick and remains above the "Min" limit.
– P4D32C009E0816
Note Make sure that the dipstick is fully inserted and that the
filler plug is tightened fully in the clockwise direction
.773110. Replace fuel prefilter (if fitted)

Tightening torques
Fuel pre-filter cartridge 19.5 ±1 N⋅m
Main activity
1. Arrange a container below the pre-filter, open the plug (3) and
drain the diesel oil from the pre-filter.
2. Then unscrew the pre-filter and replace it.
3. Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
4. Screw the cartridge on by hand until it comes into contact with
the mounting, then tighten it to the required torque.
Tightening torque
Fuel pre-filter cartridge 19.5 ±1 N⋅m
5. Close the diesel bleed plug.

Note When replacing the cartridge, it must not have been
pre-filled. 215045 Figure 7
This is to prevent impurities getting into circulation that
could damage the injector/pump system components.
Bleed the air from the fuel circuit.
.542010. Replacing fuel filter

Tightening torques
Fuel filter 1. Filter seat cap (0 wrench 32.5 ±2.5 N⋅m
50)
2. Drainage plug. 1.5 ±0.5 N⋅m
Main activity
1. Tighten the tank plug.
2. Correctly position a container to collect any diesel which may
come out below the fuel filter in line with the drain plug (4).
3. Open the drain plug (5) and the bleeder fitting (2) and drain
any residual fuel.
4. Remove the filter element (4) by unscrewing the relative bell-
shaped support(1).
Threaded parts
Fuel filter (1) 1. Filter seat cap (0 wrench 50)
2. Drainage plug.
5. Replace the filter element (4) and the O-ring seal (3) inside the
bell-shaped support (1).
6. Moisten the O-ring seal (2) of the filter. 236766 Figure 8
7. Tighten the bell-shaped support (1) to the torque indicated in
the table.
– P4D32C009E0816
8. Tighten the bleed screw (5) and the breather plug (2) posi-
tioned in the top and bottom part of the fuel filter respectively
to a torque of:
Tightening torque
Fuel filter (1, 2) 1. Filter seat cap (0 wrench 50)
32.5 ±2.5 N⋅m
2. Drainage plug.
1.5 ±0.5 N⋅m
Note Do not fill the new filter until it has been positioned on
the support. This is to prevent impurities from entering
and damaging the circuit and injection system.
236766 Figure 8
.507169. Change air filter (example)

Main activity
1. Proceed if the air filter clogged visual indicator (6) indicates filter
clogging. It signals the exact moment in which maintenance must
be carried out and remains in the alarm position (red indicator)
to protect filter operation.
2. The air filter clogged visual indicator is able to operate at a tem-
perature of between -30 °C and +120 °C and can withstand
the worst atmospheric conditions and any type of corrosion.
The maximum tightening torque must be 1.5 Nm.
3. Only proceed when the engine is not turning over.
4. Remove the air filter cover (4) after having unscrewed the
handwheel screw (5).
5. Unscrew the wing nut (2) and take out the filter element(1);
during this operation, make sure that dust does not enter the
sleeve. 247712 Figure 9
6. Replace the filter element (1).
7. Position the filter element (1) into its housing and tighten the
wing nut (2).
8. Replace the gasket (3).
9. Restore the air filter cover (4) filter and secure it by tightening
the handwheel screw (5).
Note When cleaning the air filter, do not use detergents and
do not use diesel. Never strike the filter element with
tools. Make sure parts are fitted correctly. Incorrect
installation may cause the engine to take in unfiltered
air, causing serious damage to the engine..
– P4D32C009E0816
.543411. Replacing the auxiliary assembly drive belt

Main activity
1. Using a 1/2 inch socket wrench (3), turn in the direction of
the arrow on the automatic belt tensioner (1) and remove
the ancillary drive belt(2)from the alternator pulley, the water
pump pulley, the crankshaft pulley with the damper and the
pulley.
2. Replace the worn belt with a new one and fit it on the pulleys
and guide rollers.
Note Replace the belt if it shows signs of abrasion, cracks or
tears or if it is soiled with oil or fuel.
3. Using a 1/2 inch socket wrench (3), work on the automatic belt
tensioner (1) and key the new auxiliary assembly drive belt (2)
into position.
242546 Figure 10
Note The belt tensioner (1) is automatic therefore, no fur-
ther adjustments are to be made after fitting.
4. Make sure the belt is correctly inserted in the alternator pul-

ley (1), the water pump pulley (2), the crankshaft pulley with
damper (3) and the pulleys.
5. Fully rotate the crankshaft twice to ensure that the new ancillary
belt has settled.
242547 Figure 11
.540480. Change blow-by filter

Tightening torques
Blow-by filter 1. Step 1 - Pre-tightening (3 5 ±0.5 N⋅m
screws M6x1x40)
2. Step 2 - Tightening (3 15 ±1.5 N⋅m
screws M6x1x40)
Blow-by filter body (6 screws M6x1x25) 7 ±0.7 N⋅m
– P4D32C009E0816
Main activity
1. Carry out the procedure only while engine is OFF and at low
temperature in order to prevent risk of burns.
2. Unscrew the fastening screws (5) and remove the cover (1)
with the breather pipe and the sealing gasket (4).
Threaded parts
Blow-by filter (5) 1. Step 1 - Pre-tightening (3 screws
M6x1x40)
2. Step 2 - Tightening (3 screws
M6x1x40)
Note Carefully clean the seating of the filter and the cover.
3. Unscrew the fastening screws (3) and remove the blow-by
filter (2) from the seat in the gear casing. 240882 Figure 12
Threaded parts
Blow-by filter body (6 screws M6x1x25) (3)
4. Fit the new blow-by filter element (2) into its seat.
5. Apply Loctite 2045 on the screws (3) and tighten them to the
torque indicated in the table.
Tightening torque
M6x1x40)
5 ±0.5 N⋅m
M6x1x40)
15 ±1.5 N⋅m
Caution!
Disposal Engine oil
6. Position the sealing gasket (4), fit the cover (1) with the
breather pipe and tighten the fastening screws (5) to a torque
of:
Tightening torque
Blow-by filter body (6 screws 7 ±0.7 N⋅m
M6x1x25) (5)
– P4D32C009E0816
UNSCHEDULED MAINTENANCE
12. Start the engine and let it run for at least 30 seconds.
13. Final belt tensioning:
14. Unscrew the two nuts (4).
15. Check the tension with the Clavis meter.
16. Act on the adjustment nut (3) making it rotate in a clockwise
direction until reaching the tension of 130 Hz.
17. Tighten the two nuts (4) and the nut (1).
247717 Figure 14
18. Refit the two upper belt guards (1).
247716 Figure 15
.541230. Intake and exhaust rocker arm clearance adjustment
Work material
Tool for rotating the flywheel 99360321
Spacer (to be used with 99360321) 99360325
Tool for engine T.D.C. positioning 99360612
Box wrench
Tightening torques
Rocker arm adjustment (12 nuts M10x1.25) 39 ±5 N⋅m
– P4D32C009E0816
Note The adjustment of clearance between the rocker arms and bridges controlling the intake and exhaust valves must be done
very carefully.
Main action
187916 Figure 16
A Hole on flywheel with reference mark, corresponding D Flywheel hole with two notches corresponding to
to the TDC of pistons 1-6 position 54° before TDC of pistons 1-6 (camshaft
B Hole on flywheel with reference mark, corresponding timing reference);
to the TDC of pistons 2-5 E Flywheel hole with three notches corresponding to
C Hole on flywheel with reference mark, corresponding position 30° before TDC of pistons 1-6 (reference to
to the TDC of pistons 3-4 HP fuel pump and timing system phonic wheel timing).
1. In order to perform adjustments correctly, during each rotation phase check the positioning accuracy using the specific pin,
inserting it into the hole marked with a notch on the flywheel corresponding to piston position.
– P4D32C009E0816
187916 Figure 16
Tool / Material Product Code

– P4D32C009E0816
2. Take the cylinder in which the clearance must be adjusted to

the burst phase; these cylinder valves are closed while balancing
the symmetric cylinder valves.
Note The correspondence of the symmetrical cylinders is 1 -
6, 2 - 5 and 3 - 4.
3. In order to properly operate, follow these instructions and data
specified on the table.
4. Using a box wrench, remove the adjustment screw fastening
nut (1).
Tool / Material
Box wrench
5. Insert the thickness gauge blade (3) corresponding to the op-

erating clearance shown in the "Characteristics and data" 114287 Figure 17
table.
6. Screw or unscrew the adjustment screw of the rocker arm (2)
with the appropriate wrench.
7. Check that the feeler gauge blade (3) can slide with slight fric-
tion.
8. Lock the nut (1) by stopping the adjustment screw.
Tightening torque
Rocker arm adjustment (12 nuts 39 ±5 N⋅m
M10x1.25) (1)
9. To carry out the adjustments stated above, the sequence shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle grade [°]
120
5 2
Angle grade [°]
120
1 6
Angle grade [°]
120
4 3
Angle grade [°]
120
2 5
Angle grade [°]
Note Check during each rotation phase, the accuracy of the position by using the specific pin and inserting it into the hole
marked with a notch on the flywheel corresponding to piston position.
Conditions
● Engine flywheel side:
– P4D32C009E0816
▶ Apply the specific tool (7) and the specific spacer (8) to
the gear casing (3).
Tool / Material Product
Code
▶ With the aforementioned tool, rotate the engine flywheel

(1) in the operating direction indicated by the arrow.
185252 Figure 18
.506010. Replace engine coolant

Main activity
Caution!
High engine temperature Precautions when checking coolants
▶ Given the high temperatures which are reached inside the engine, do not carry out operations immediately after the
engine has stopped but wait until the temperature has fallen.
▶ Protect eyes and skin from any unexpected high pressure jets of coolant.
1. Only proceed when the engine is not turning over.
Caution!
Engine fluid at high pressure Precautions when checking coolants
▶ When the engine is hot, a pressure is stabilised in the cooling circuits which is able to eject the hot liquid in a very
violent manner, resulting in a risk of burns.
2. Place a container for collecting coolant under the heat exchanger (radiator).
3. Remove the pressurization cap from the expansion tank.
4. Loosen the fastening elements and remove the coupling sleeves connecting the engine cooling circuit to the heat exchanger.
5. Drain the coolant from the heat exchanger (radiator) and wait until it is completely empty.
6. After draining it, reconnect the cooling circuit making sure that the sleeves are perfectly sealed.
7. Fill the engine and heat exchanger until the cooling circuit has been filled with a mixture of 50% purified water and coolant, as
indicated in the "Technical specifications - REFILLING" section. Do not completely fill the expansion tank.
8. With the coolant filler plug open, start the engine and let it idle for approx. one minute. This helps to completely release all
the air from the cooling circuit.
– P4D32C009E0816
9. Stop the engine and top off if necessary.

10. When the engine is cold, make sure that the coolant in the expansion tank is a few centimetres below the filling hole.
11. In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by
making 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.
– P4D32C009E0816
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Removal-refitting of the main engine
Contents 1
Contents
Removal - refitting of main components . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
Removal - refitting of main components 3
Contents
Contents Removal - refitting of the fuel pipes . . . . . . . . . . . . 47
Removal-installation of radiator guards . . . . . . . . . . . 5 Removal - Refitting of the EDC 17CV41 control

unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removal-installation of radiator belt . . . . . . . . . . . . . 6
Blow-by filter removal - refitting . . . . . . . . . . . . . . 49
Removal-installation of radiator pipes . . . . . . . . . . . . 8
Removal - refitting of the high pressure pump . . . . . . 50
Removal-installation of radiator supports . . . . . . . . . . 9
Intake manifold removal-refitting . . . . . . . . . . . . . . 55
Removal-installation of radiator suspensions . . . . . . . 10
Tappet cover removal-refitting . . . . . . . . . . . . . . . 57
Removal-installation the air filter pipes . . . . . . . . . . 11
Removal - refitting of the rocker arm unit . . . . . . . . 58
Removal-installation of air filter . . . . . . . . . . . . . . . 14
Removal - refitting the electro-injector wirings . . . . . 64
Removal-installation of the interface housing . . . . . . . 17
Common rail removal-refitting . . . . . . . . . . . . . . . 66
Removal-refitting of ancillary belt . . . . . . . . . . . . . . 18
Removal - refitting of the electro-injectors . . . . . . . . 69
Removal - refitting of the automatic belt
tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cylinder head removal-refitting . . . . . . . . . . . . . . . 73
Alternator removal-refitting . . . . . . . . . . . . . . . . . 20 Removal - Refitting of the crankshaft front sealing

ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Water pump removal-refitting . . . . . . . . . . . . . . . 22
Removal - refitting of the engine flywheel . . . . . . . . . 78
Removal - refitting of the thermostat . . . . . . . . . . . 23
Removal - refitting of the crankshaft rear seal
Removal - refitting of the damper flywheel . . . . . . . . 26 ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Removal - refitting of the crankshaft drive pulley . . . . 27
Starter motor removal-refitting . . . . . . . . . . . . . . . 29
Engine cable removal-refitting . . . . . . . . . . . . . . . . 30
Turbocharger removal-refitting . . . . . . . . . . . . . . . 31
Exhaust manifold removal-refitting . . . . . . . . . . . . . 34
Engine oil filter removal - refitting . . . . . . . . . . . . . 36
Heat exchanger removal-refitting . . . . . . . . . . . . . . 37
Oil sump removal-refitting . . . . . . . . . . . . . . . . . . 39
Removal -Refitting of suction strainer and recover oil

in sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel filter removal-refitting . . . . . . . . . . . . . . . . . . 43
Removal - Refitting vehicle fuel filter mount . . . . . . . 44
Removal-Refitting of the oil dipstick guide tube . . . . . 46
– P4D32C009E0816
4 Removal - refitting of main components
– P4D32C009E0816
Removal-installation of radiator guards
Removal - refitting of main components

.506015. Removal-installation of radiator guards
Tightening torques
Radiator guards (11 screws M8x1.25) 0+0
+0 N⋅m

+0 N⋅m
Main activity
.506015. Removal of radiator guards
1. Undo the screws (2, 3) and remove the guards (1, 4).
Threaded parts
Radiator guards (11 screws M8x1.25) (2, 3)
247678 Figure 1
2. Undo the screws (1, 4) and remove the guards (2, 3, 5).
Threaded parts
Radiator guards (11 screws M8x1.25) (1, 4)
247719 Figure 2
– P4D32C009E0816
Removal-installation of radiator belt
.506015. Radiator guards installation

3. Position the radiator guards (2, 3, 5) and tighten the screws (1,
4) to the specified torque.
Tightening torque
Radiator guards (11 screws 0+0
+0 N⋅m
M8x1.25) (1, 4)
247719 Figure 3
4. Position the radiator guards (1, 4) and tighten the screws (2,
Tightening torque
Radiator guards (11 screws 0+0
+0 N⋅m
M8x1.25) (2, 3)
247678 Figure 4
.506010. Removal-installation of radiator belt
Technical data
Radiator belts pre-tensioning frequency (8, 9) 80 Hz to90 Hz
Radiator belt tensioning (8, 9) 130 Hz
Preparatory operation
▶ Remove the radiator guards. ( ➠ Page 5)
– P4D32C009E0816
Removal-installation of radiator belt
Main activity
.506010. Removal of radiator belts
1. Loosen the nuts(2, 4), and turn the nut (1) in a clockwise dir-
ection until the belt tensioner (6) allows the belts(8, 9) to be
removed.
2. Remove the belts (8, 9) from belt tensioner pulley, fan pulley
(7) and crankshaft pulley (5).
247717 Figure 5
.506010. Radiator belts installation

3. Correctly position the belt (9) on the fan hub and the Fan pul-
ley (7).
4. Correctly position the belt (8) on the crankshaft hub and the
crankshaft pulley (5).
5. Fit the belt (8, 9) positioning first the belt in the grooves of the
crankshaft pulley (5) and then onto the fan pulley (7). Turn the
fan so it goes over the side of the pulley.
6. Rotate the adjustment screw (3) in an anticlockwise direction.
7. Check the tension of the belts (8, 9) with a Clavis frequency
meter on the long branch.
Technical data
Radiator belts pre-tensioning frequency (8, 80 Hz to90 Hz
9) 247717 Figure 6
8. Start the engine and turn it off after at least 30 seconds.
9. Check the tension of the belts (8, 9) again using the Clavis
frequency meter on the long branch.
Technical data
Radiator belt tensioning (8, 9) 130 Hz
10. Tighten the counternut (1).
Subsequent operation
▶ Install the radiator guards. ( ➠ Page 6)
– P4D32C009E0816
Removal-installation of radiator pipes
.506044. Removal-installation of radiator pipes
Tightening torques
Radiator tie-rod (4 nuts M12x1.75x10 41.5 ±4.5 N⋅m
Main activity
.506044. Removal of radiator pipes
1. Unscrew the screw securing the collar (4) and remove the air
delivery pipe (3) from the turbocharger to the radiator.
2. Unscrew the screw securing the collar (8) and remove the
water outlet pipe from the engine (2).
3. Unscrew the screw securing the collar and remove the air deliv-
ery pipe to the intake manifold (9).
4. Remove the clips and detach the deaeration pipe (5, 7) from
the radiator.
5. Remove the nuts (1, 6) and separate the tie rod from the en-
gine.
Threaded parts
Radiator tie-rod (4 nuts M12x1.75x10 (1, 6)
247677 Figure 7
6. Remove the screws securing the collars (1, 4) and remove the
engine water inlet pipes (2, 3).
247718 Figure 8
– P4D32C009E0816
Removal-installation of radiator supports
.506044. Radiator pipes installation

7. Correctly position the engine water inlet pipes (2, 3) and after
having inserted the relevant collars (1, 4) tighten the relevant
screws.
247718 Figure 9
8. Correctly position the tie rod and tighten the nuts(1, 6).
Tightening torque
Radiator tie-rod (4 nuts 41.5 ±4.5 N⋅m
M12x1.75x10 (1, 6)
9. Correctly position the air delivery pipe to the intake manifold

(9) and tighten the screw of the relative collar.
10. Correctly position the deaerating pipes (5, 7) and secure the
relative clips.
11. Correctly position the air delivery pipe from the compressor to
the radiator (3) and tighten the screw of the collar(4).
12. Correctly position the water supply pipe to the engine (2) and
tighten the screw of the collar (8).
247677 Figure 10
.506010. Removal-installation of radiator supports
Tightening torques
Radiator supports 1. (4 screws M12x1.75x30) 80 ±8 N⋅m
2. (4 screw M10x1.5x25) 45.5 ±4.5 N⋅m
– P4D32C009E0816
Removal-installation of radiator suspensions
Main activity
.506010. Removal of radiator supports
1. Unscrew the screws (3, 7), remove the reference pins (1,
8) and unscrew the screws (4, 6). Then remove the radiator
supports (2, 9) from the radiator (5 ) and from the engine.
Threaded parts
Radiator supports (3, 4, 6 1. (4 screws M12x1.75x30)
7) 2. (4 screw M10x1.5x25)
247676 Figure 11
.506010. Radiator supports installation

2. Position the radiator supports (2, 9) on the engine and on the
radiator (5) with the help of the reference pins (1, 6), then
secure them using the screws(3, 4, 6 7).
3. Tighten the screws (3, 4, 6, 7) to the specified torque.
Tightening torque
Radiator supports (3, 4, 6 1. (4 screws M12x1.75x30)
7) 80 ±8 N⋅m
2. (4 screw M10x1.5x25)
45.5 ±4.5 N⋅m
247676 Figure 12
.506013. Removal-installation of radiator suspensions
Tightening torques
Radiator suspensions (6 screws M16x2x60) 1. Step I - Tightening to 100 ±10 N⋅m
torque
2. Step II - Tightening to 60°
angle
– P4D32C009E0816
Removal-installation the air filter pipes
Main activity
.506013. Radiator suspension removal
1. Unscrew the screws (3, 4) and remove the radiator suspen-
sions (3, 4).
Threaded parts
Radiator suspensions (6 1. Step I - Tightening to torque
screws M16x2x60) (3, 4) 2. Step II - Tightening to angle
247693 Figure 13
.506013. Radiator suspensions installation

2. Correctly position the radiator suspensions (1, 2) and tighten
the screws (3, 4) to the specified torque.
Tightening torque
screws M16x2x60) (3, 4) 100 ±10 N⋅m
2. Step II - Tightening to angle
60°
247693 Figure 14
.542457. Removal-installation the air filter pipes
Tightening torques
Air filter pipe (2 screws M8x1x18 23 ±2 N⋅m
– P4D32C009E0816
Main activity
.542457. Air filter pipe removal
1. Loosen the worm screw collars (3, 4) and remove the pipe (2)
from the air filter(1).
247684 Figure 15
2. Loosen the worm screw collar (4), unscrew the screws (2) and
remove the air filter pipe (3) from the crankcase (1).
Threaded parts
Air filter pipe (2 screws M8x1x18 (2)
247683 Figure 16
3. Loosen the worm screw collars (2, 5) and remove the air deliv-
ery pipes (3, 4) from the turbocharger (1).
247681 Figure 17
– P4D32C009E0816
4. Loosen the worm screw collar (1) and remove the air delivery
pipe (3) from the turbocharger (2).
247690 Figure 18
.542457. Air filter pipe installation

5. Correctly position the air delivery pipes (3) on the turbochar-
ger (2) and tighten the worm screw collar (1).
247690 Figure 19
6. Correctly position the air delivery pipes (3, 4) on the tur-

bocharger (1) and tighten the worm screw collars (2, 5).
247681 Figure 20
– P4D32C009E0816
Removal-installation of air filter
7. Correctly position the air delivery pipe (3) on the crankcase(1),

tighten the screws (2) and the worm screw collar (4).
Tightening torque
Air filter pipe (2 screws 23 ±2 N⋅m
M8x1x18 (2)
247683 Figure 21
8. Correctly position the pipe (2) on the air filter (1) and tighten
the worm screw collars (3, 4).
247684 Figure 22
.507169. Removal-installation of air filter
Tightening torques
Air filter (4 nuts M10x1.5) 45.5 ±4.5 N⋅m
Engine breather external pipe 1. (1 M8x1x20 screws) 23 ±2 N⋅m
2. (1 screw M10x1.5x20) 41.5 ±4.5 N⋅m
3. (1 M8x1x16 screws) 20.5 ±2.5 N⋅m
Air filter bracket 1. (2 M8x1x20 screws) 23 ±2 N⋅m
2. (1 M8x1x25 screws) 23 ±2 N⋅m
– P4D32C009E0816
Main activity
.507169. Air filter removal
1. Unscrew the nuts, (3 )remove the air filter (1) from the sup-
port(2 ).
Threaded parts
Air filter (4 nuts M10x1.5) (3 )
247685 Figure 23
2. Unscrew the screws (1) and the collar screw (2), then remove
the external engine breather pipe (4) from the blow-by filter
cover (3).
Threaded parts
Engine breather external 1. (1 M8x1x20 screws)
pipe (1) 2. (1 screw M10x1.5x20)
3. (1 M8x1x16 screws)
247689 Figure 24
3. Unscrew the screws (1, 3 ) and remove the air filter support
(4 ) from the gear case (2).
Threaded parts
Air filter bracket (1, 3 ) 1. (2 M8x1x20 screws)
247686 Figure 25
– P4D32C009E0816
.507169. Air filter installation

4. Correctly position the air filter support (4 ) on the gear case
(2) and tighten the screws (1, 3 ) to the specified torque.
Tightening torque
Air filter bracket (1, 3 ) 1. (2 M8x1x20 screws)
23 ±2 N⋅m
23 ±2 N⋅m
247686 Figure 26
5. Connect the engine breather external pipe (4), connect it to

the blow-by filter cover using the collar (2), then tighten the
screws (1).
Tightening torque
Engine breather external 1. (1 M8x1x20 screws)
pipe (1) 23 ±2 N⋅m
2. (1 screw M10x1.5x20)
41.5 ±4.5 N⋅m
20.5 ±2.5 N⋅m
247689 Figure 27
6. Correctly position the air filter (1) on the support (2 ) and

tighten the nuts (3 ) to the specified torque.
Tightening torque
Air filter (4 nuts M10x1.5) (3 ) 45.5 ±4.5 N⋅m
247685 Figure 28
– P4D32C009E0816
Removal-installation of the interface housing
.7661. Removal-installation of the interface housing
Tightening torques
Interface housing (4 nuts M6x1x8 9 ±1 N⋅m
Interface housing support (2 screws M16x2x45) 115 ±15 N⋅m
Main activity
.7661. Interface housing removal
1. Unscrew the nuts (3) and remove the interface housing (1)
from the support(2).
Threaded parts
Interface housing (4 nuts M6x1x8 (3)
247687 Figure 29
2. Unscrew the screws (2) and remove the interface housing

support (1).
Threaded parts
Interface housing support (2 screws M16x2x45) (2)
247692 Figure 30
– P4D32C009E0816
Removal-refitting of ancillary belt
.7661. Interface housing installation

3. Correctly position the interface housing support (1) on the
crankcase and tighten the screws (2) to the required torque.
Tightening torque
Interface housing support (2 screws 115 ±15 N⋅m
M16x2x45) (2)
247692 Figure 31
4. Position the interface housing (1) on the support (2) and

tighten the nuts (3) to the indicated torque.
Threaded parts
Interface housing (4 nuts M6x1x8 (3)
247687 Figure 32
.543411. Removal-refitting of ancillary belt
Main activity
.543411. removal
1. Using a 1/2 inch socket wrench (5), turn in the direction of
the arrow on the automatic belt tensioner (4) and remove the
ancillary drive belt(2)from the alternator pulley (6), the water
pump pulley (3), the crankshaft pulley with the damper (1) and
the pulley.
240845 Figure 33
– P4D32C009E0816
Removal - refitting of the automatic belt tensioner
.543411. refitting
into position.
240845 Figure 34

damper (3) and the pulleys.
belt has settled.
242547 Figure 35
.543417. Removal - refitting of the automatic belt tensioner
Tightening torques
Automatic belt tensioner (1 screw M10x1.5x70) 66 ±4 N⋅m
▶ Remove the ancillary belt. ( ➠ Page 18)
– P4D32C009E0816
Alternator removal-refitting
Main activity
.543417. removal
1. Unscrew the fastening screw (2) and remove the automatic
belt tensioner (1) from the alternator support (3).
Threaded parts
Automatic belt tensioner (1 screw M10x1.5x70) (2)
240847 Figure 36
.543417. refitting
2. Fit the automatic belt tensioner (1) on the support (3) and
tighten the fastening screw (2) to a torque of:
Tightening torque
Automatic belt tensioner (1 screw 66 ±4 N⋅m
M10x1.5x70) (2)
240847 Figure 37
▶ Refit the ancillary belt. ( ➠ Page 19)
.760310. Alternator removal-refitting
Tightening torques
Alternator 1. (1 M8x1.25x30 screw) 0+0
+0 N⋅m
2. (1 M10x1.5x110 screw) 0+0

+0 N⋅m
1. Remove the ancillary belt. ( ➠ Page 18)
2. Remove the automatic belt tensioner. ( ➠ Page 20)
– P4D32C009E0816
Alternator removal-refitting
Main activity
.760310. removal
1. Unscrew the screws (1, 2), extract the spacer (4) and remove
the alternator (3) from the relative supports.
Threaded parts
Alternator (2, 4) 1. (1 M8x1.25x30 screw)
2. (1 M10x1.5x110 screw)
240846 Figure 38
2. Unscrew the screws (1, 4) and remove the supports (2, 3).
240848 Figure 39
.760310. refitting
3. Tighten the screws (1, 4) and secure the supports (2, 3).
240848 Figure 40
– P4D32C009E0816
Water pump removal-refitting
4. Position the alternator (3) on its supports, insert the spacer (4)
and tighten the fastening screws (1, 2) to a torque of:
Tightening torque
0+0
+0 N⋅m
2. (1 M10x1.5x110 screw)
0+0
+0 N⋅m
240846 Figure 41
1. Refit the automatic belt tensioner. ( ➠ Page 20)
2. Refit the ancillary belt. ( ➠ Page 19)
.543210. Water pump removal-refitting
Tightening torques
Water pump (4 screws M8x1.25x20) 24.5 ±2.5 N⋅m
▶ Remove the ancillary belt. ( ➠ Page 18)
Main activity
.543210. removal
1. Position a suitable container to collect any coolant which may
leak out.
2. Unscrew the fastening screws(3) and remove the water pump
(2) recovering the gasket (1).
Threaded parts
Water pump (4 screws M8x1.25x20) (3)
240849 Figure 42
– P4D32C009E0816
Removal - refitting of the thermostat
.543210. refitting
3. Apply a new sealing ring (1) to the water pump (2).
4. Fit the water pump (2)in its seat and tighten the fastening
screws (3) to a torque of:
Tightening torque
Water pump (4 screws 24.5 ±2.5 N⋅m
M8x1.25x20) (3)
240849 Figure 43
▶ Refit the ancillary belt. ( ➠ Page 19)
.543250. Removal - refitting of the thermostat
Tightening torques
De-aeration pipes (2 fittings M10x1.5) 38 ±4 N⋅m
Thermostat body/Coolant output pipe 1. Step 1 - (4 screws Tightening sequence: 1- 3- 2- 6- 7- 4- 5
M8x1.25x100) 30 ±3 N⋅m
2. Step 1 - (2 screws Tightening sequence: 1- 3- 2- 6- 7- 4- 5
M8x1.25x50) 30 ±3 N⋅m
3. Step 1 - (1 screw Tightening sequence: 1- 3- 2- 6- 7- 4- 5
M8x1.25x140) 30 ±3 N⋅m
M8x1.25x100) 30 ±3 N⋅m
M8x1.25x50) 30 ±3 N⋅m
M8x1.25x140) 30 ±3 N⋅m
– P4D32C009E0816
Main activity
.543250. removal
1. Disconnect the clamp (2) of the engine cable from the thermo-
stat body (4).
2. Unscrew the de-aeration pipes (5, 3) from the thermostat
body (4) and the crankcase.
Threaded parts
De-aeration pipes (2 fittings M10x1.5) (5, 3)
240850 Figure 44
3. Unscrew the fastening screws (1, 2, 3), remove the thermostat

body (4) together with the engine coolant delivery pipe to the
radiator and recover the gasket from its seat on the cylinder
head.
Threaded parts
Thermostat body/Coolant 1. Step 1 - (4 screws M8x1.25x100)
output pipe (1, 2, 3) Tightening sequence: 1- 3- 2- 6- 7-
4- 5
2. Step 1 - (2 screws M8x1.25x50)
Tightening sequence: 1- 3- 2- 6- 7-
4- 5
3. Step 1 - (1 screw M8x1.25x140)
Tightening sequence: 1- 3- 2- 6- 7- 240851 Figure 45
4- 5
4. Step 2 - (4 screws M8x1.25x100)
Tightening sequence: 8- 9- 10- 11-
12- 13- 14
5. Step 2 - (2 screws M8x1.25x50)
12- 13- 14
6. Step 2 - (1 screw M8x1.25x140)
12- 13- 14
– P4D32C009E0816
.543250. refitting
4. Place a new gasket (2) on the cylinder head and fit the thermo-
stat body (4), complete with the engine coolant delivery pipe to
the radiator, tighten the fastening screws (1, 2, 3).
5. Tighten the fastening screws in the order indicated below.
240851 Figure 46
6. tighten the fastening screws (1, 2, 3) to a torque of:

Tightening torque
4- 5
30 ±3 N⋅m
2. Step 1 - (2 screws M8x1.25x50)
4- 5
30 ±3 N⋅m
3. Step 1 - (1 screw M8x1.25x140)
4- 5
30 ±3 N⋅m
4. Step 2 - (4 screws M8x1.25x100)
Tightening sequence: 8- 9- 10- 11- 240879 Figure 47
12- 13- 14
30 ±3 N⋅m
5. Step 2 - (2 screws M8x1.25x50)
12- 13- 14
30 ±3 N⋅m
6. Step 2 - (1 screw M8x1.25x140)
12- 13- 14
30 ±3 N⋅m
– P4D32C009E0816
Removal - refitting of the damper flywheel
7. Connect the clamp (2) of the engine cable (1)to the thermo-
stat body (4).
8. Connect de-aeration pipes (3, 5) from the thermostat body
(4) and the crankcase.
Tightening torque
De-aeration pipes (2 fittings 38 ±4 N⋅m
M10x1.5) (3)
240850 Figure 48
.540860. Removal - refitting of the damper flywheel
Consumables
Engine oil
Work material
Tool for retaining the flywheel 99360351
Tightening torques
Damper flywheel (6 screws M14x100) 190 ±20 N⋅m
Main activity
.540860. removal
1. Block the engine flywheel rotation using the specific tool(1).
Code
71702 Figure 49
– P4D32C009E0816
Removal - refitting of the crankshaft drive pulley
2. Unscrew the fastening screws (1) remove the fan drive pulley
(2) and remove the damper flywheel (3) from the drive pulley
(4).
Threaded parts
Damper flywheel (6 screws M14x100) (1)
240853 Figure 50
.540860. refitting
3. Fit the damper flywheel (3) on the drive pulley (4), then insert
the fan drive pulley (2) and tighten the screws (1) to a torque
of:
Tightening torque
Damper flywheel (6 screws 190 ±20 N⋅m
M14x100) (1)
Tool / Material
Engine oil
Note Before installing, lubricate the screw thread (1) with

engine oil.
240853 Figure 51
.540821. Removal - refitting of the crankshaft drive pulley
Work material
Pair of gauges for angular tightening with 1/2" and 3/4" 99395216
square heads
Torque wrench
Tightening torques
Crankshaft pulley (6 screws M16x2x80) 1. Pre-tightening 120 N⋅m
2. Angle tightening 60°
1. Remove the damper flywheel. ( ➠ Page 26)
2. Remove the ancillary belt. ( ➠ Page 18)
– P4D32C009E0816
Removal - refitting of the crankshaft drive pulley
Main activity
.540821. removal
Code
71702 Figure 52
2. Unscrew the fastening screws (1), remove the spacer(3) and

remove the pulley (2) from the crankshaft (4).
Threaded parts
Crankshaft pulley (6 screws 1. Pre-tightening
M16x2x80) (1) 2. Angle tightening
237209 Figure 53
.540821. refitting
Code
71702 Figure 54
– P4D32C009E0816
Starter motor removal-refitting
4. Key (4) the crankshaft pulley (2) and the spacer (3) onto the
crankshaft and tighten the fastening screws (1) in two steps:
Tightening torque
M16x2x80) (1) 120 N⋅m
2. Angle tightening
60°

Code
square heads
Torque wrench 237209 Figure 55
Note Use specific tool for angle tightening.
1. Refit the ancillary belt. ( ➠ Page 19)
2. Refit the damper flywheel. ( ➠ Page 27)
.760810. Starter motor removal-refitting
Tightening torques
Starter motor 1. (3 M12x1.75x30 studs) 37.5 ±7.5 N⋅m
2. (3 M12x1.75x12 nuts) 74 ±8 N⋅m
Main activity
.760810. removal
1. Make sure that the electric starter motor(2) is suitably suppor-
ted.
2. Unscrew the fastening nuts (3) and remove the electric starter
motor (2).
3. Unscrew the studs (1) if necessary from the flywheel housing.
Threaded parts
Starter motor (1, 3) 1. (3 M12x1.75x30 studs)
2. (3 M12x1.75x12 nuts)
240854 Figure 56
– P4D32C009E0816
Engine cable removal-refitting
.760810. refitting
4. If removed, tighten the studs (1) in the flywheel housing.
5. Fit the electric starter motor (2) on the studs (2).
6. Tighten the fastening nuts (3) to a torque of:
Tightening torque
37.5 ±7.5 N⋅m
2. (3 M12x1.75x12 nuts)
74 ±8 N⋅m
240854 Figure 57
.769140. Engine cable removal-refitting
Main activity
.769140. removal
1. Disconnect the connector (2) for the engine cable from the
control unit (1) and from all the sensors to which it is connec-
ted.
2. To remove the engine cable (2) release the clips securing the
crankcase from the cylinder head, the intake manifold and the
gear casing.
240855 Figure 58
– P4D32C009E0816
Turbocharger removal-refitting
.769140. refitting
3. Arrange the engine cable in the correct position on the engine.
4. Connect the engine cable to all the injection system sensors and
finally the connector (2) of the engine cable to the control unit
(1).
5. To secure the engine cable , restore/attach the retaining clamps
to the crankcase, the cylinder head, the intake manifold and the
gear casing.
240855 Figure 59
.542410. Turbocharger removal-refitting
Tightening torques
Turbocharger lubricant return pipe (4 M8x1.25x25 screws) 24.5 ±2.5 N⋅m
gas exhaust pipe collar (1 screw M6x1x50) (1 fitting M18x1.5) 7 ±1 N⋅m
Lubricant delivery pipe to turbocharger 1. (1 fitting M18x1.5) 50 ±2.5 N⋅m
2. (2 screws M8x1.25x35) 24.5 ±2.5 N⋅m
3. (1 M10x1.5x14 screw) 24.5 ±2.5 N⋅m
Turbocharger on the exhaust manifold 1. (4 M12x1.75 nuts) 50 ±20 N⋅m
2. (4 M12x1.75x30 studs) 0+0
+0 N⋅m
Lubricant delivery pipe to turbocharger 1. (1 fitting M18x1.5) 32.5 ±2.5 N⋅m

2. (2 screws M8x1.25x35) 24.5 ±2.5 N⋅m
3. (1 M10x1.5x16 screw) 44 ±4 N⋅m
Main activity
.542410. removal
1. Position a suitable container to collect the oil.
2. Unscrew the fastening screws (1) of the lubricant oil return
pipe (3) from the lower part of the turbocharger and recover
the relative gasket.
3. Unscrew the fastening screws (5) from the crankcase (4) and
remove the lubricant oil return pipe (3).
Threaded parts
Turbocharger lubricant return pipe (4 M8x1.25x25 screws) (1, 5)
240856 Figure 60
– P4D32C009E0816
4. Unscrew the screw (3) of the relative collar and disconnect the
turbocharger gas outlet pipe (2) from the turbocharger (1).
Threaded parts
gas exhaust pipe collar (1 screw (1 fitting M18x1.5)
M6x1x50) (3)
247682 Figure 61
5. Position a suitable container to collect the oil.

6. Unscrew the screw (6) of the retaining clamp of the lubricant
oil delivery pipe (1) to the turbocharger.
7. Unscrew the fitting (5) from the heat exchanger (4) and the
fastening screws (2) to the turbocharger (3) and remove the
pipe (1) delivering lubricant to the turbocharger.
Threaded parts
Lubricant delivery pipe to 1. (1 fitting M18x1.5)
turbocharger (6, 5, 2) 2. (2 screws M8x1.25x35)
3. (1 M10x1.5x14 screw)
240857 Figure 62
8. Unscrew the fastening nuts (4) and remove the turbocharger

(5) together with the Wastegate valve and the relative gasket
(3).
9. Unscrew the studs (2) if necessary from the exhaust manifold
(1).
Threaded parts
Turbocharger on the exhaust 1. (4 M12x1.75 nuts)
manifold (4, 2) 2. (4 M12x1.75x30 studs)
240858 Figure 63
– P4D32C009E0816
.542410. refitting
10. If necessary, tighten the studs (2) on the exhaust manifold (1).
11. Place the turbocharger(5) gasket(3) on the exhaust manifold
(1).
12. Fit the turbocharger (5) together with the Wastegate valve and
tighten the fastening nuts (4)to a torque of::
Tightening torque
manifold (2, 4) 50 ±20 N⋅m
2. (4 M12x1.75x30 studs)
0+0
+0 N⋅m
240858 Figure 64
13. Correctly position the turbocharger gas outlet pipe (2) on the
turbocharger (1)and tighten the screw (3) of the relative collar.
Threaded parts
M6x1x50) (3)
247682 Figure 65
14. Fit the lubricant oil delivery pipe (2) to the turbocharger and
tighten the fitting (3) and the fastening screws (1) to the spe-
cified torque.
15. Tighten the screw (4) of the retaining clamp of the lubricant oil
delivery pipe (2) to the turbocharger to a torque of:
Tightening torque
turbocharger (1, 3, 4) 32.5 ±2.5 N⋅m
2. (2 screws M8x1.25x35)
24.5 ±2.5 N⋅m
3. (1 M10x1.5x16 screw)
44 ±4 N⋅m
236439 Figure 66
– P4D32C009E0816
Exhaust manifold removal-refitting
16. Fit the oil lubricant return pipe (3) in the crankcase and tighten
the fastening screws (2) to the specified torque.
17. Position the relative gasket and tighten the screws (1) securing
the lubricant oil return pipe (3) to the lower part of the tur-
bocharger to a torque of:
Tightening torque
Turbocharger lubricant return pipe 24.5 ±2.5 N⋅m
(4 M8x1.25x25 screws) (1, 2)
236438 Figure 67
.540720. Exhaust manifold removal-refitting
Tightening torques
Exhaust manifold 1. Step 1 - Pre-tightening 30 ±5 N⋅m
(24 screws M10x1.5x70)
2. Step 2 - Tightening (24 60 ±5 N⋅m
screws M10x1.5x70)
3. V collar (4 screws 8 ±0.5 N⋅m
M6x1x55)
▶ Remove the turbocharger. ( ➠ Page 31)
Main activity
.540720. removal
1. Remove the screws (3) recovering the spacers (4) and remove
the exhaust manifold (6) together with the relative gaskets (2)
from the cylinder head (1).
2. To remove the exhaust manifold, loosen the collars (7) by
unscrewing the screws (5).
Threaded parts
Exhaust manifold (3, 5) 1. Step 1 - Pre-tightening (24 screws
M10x1.5x70)
M10x1.5x70)
3. V collar (4 screws M6x1x55)
240859 Figure 68
– P4D32C009E0816
Exhaust manifold removal-refitting
.540720. refitting
3. Screw the threaded bar (4) onto the cylinder head (1).
4. Position the exhaust manifold (3) on the threaded bar and after
interposing the relative gaskets (2), rest the exhaust manifold
(3) on the cylinder head (1).
240937 Figure 69
5. Fit the exhaust manifold (6) in position together with the new
gaskets (2) on the cylinder head (1) and tighten the fastening
screws (3) together with the spacers (4) and the fastening
screws (5) of the V collars (7).
Tightening torque
Exhaust manifold (4) 1. Step 1 - Pre-tightening (24 screws
M10x1.5x70)
30 ±5 N⋅m
M10x1.5x70)
60 ±5 N⋅m
8 ±0.5 N⋅m 240859 Figure 70
Note Always replace the gaskets (1) with new spare parts.
Check the thread of the fastening screws: it must not
show signs of wear or deposits of dirt.
236450 Figure 71
6. Place the pre-assembled exhaust manifold on the cylinder head using the specific tool fitted in the positions7b-6c.
7. Lubricate the fastening screws with graphitised oil before fitting the exhaust manifold.
– P4D32C009E0816
Engine oil filter removal - refitting
236450 Figure 71
8. Tighten the fastening screws to a torque of 30 Nm in the order: 8a-7a-6a-5a-1a-4a-2a-3a; 8b-2b-6b-5b-3b-4b-1b; 8c-7c-3c-
5c-1c-2c-4c.
9. Remove the specific tool and tighten the fastening screws in the positions 6c-7b.
10. Tighten the fastening screws to a torque of 30 Nm in the order: 7b-6c.
11. Tighten the fastening screws to a torque of 60 Nm in the order: 8a-7a-6a-5a-1a-4a-2a-3a; 8b-7b-6b-5b-1b-2b-3b-4b; 8c-7c-
6c-5c-1c-2c-3c-4c.
▶ Refit the turbocharger. ( ➠ Page 33)
.543070. Engine oil filter removal - refitting
Tightening torques
Main activity
.543070. removal
1. Position a container to collect the used oil below the oil filter
tank (3).
2. Unscrew the bleed plug (4) to drain the oil.
3. Unscrew the oil filter tank (3) from the filter body (1).
Threaded parts
Oil filter (4) 1. Oil filter tank
2. Bleed plug
4. Remove the filtering cartridge (2) and recover the O-ring (5)
from the oil filter tank (3).
240860 Figure 72
– P4D32C009E0816
Heat exchanger removal-refitting
.543070. refitting
5. Moisten the O-ring (5) with a thin layer of oil and place it in its
seat on the oil filter tank(3).
6. Insert the filtering cartridge (3)into the oil filter tank (2).
7. Manually screw the oil filter tank (3) onto the filter body (1)
until the O-ring (2) adheres fully.
8. Tighten the oil filter tank (3) further to a torque of:
Tightening torque
60 ±5 N⋅m
2. Bleed plug
6.5 ±1.5 N⋅m
9. Close the bleed plug (4) and top up to compensate for the 240860 Figure 73
quantity of oil used to fill up the filtering cartridge.
10. Let the engine run for a few minutes and then check the engine
oil level using the dipstick.
.543110. Heat exchanger removal-refitting
Tightening torques
Oil filter body 1. 5 screws M8x1.25x65 24.5 ±2.5 N⋅m
2. 1 screws M8x1.25x40 24.5 ±2.5 N⋅m
Oil heat exchanger 1. Step 1 - Pre-tightening Tightening sequence: 1 - 18
(17 screws M8x1.25x40 11.5 ±3.5 N⋅m
+1 screw M8x1.25x55)
2. Step 2 - Tightening (17 Tightening sequence: 1 - 18
screws M8x1.25x40 + 1 24.5 ±2.5 N⋅m
screw M8x1.25x55)
▶ Remove the engine oil filter. ( ➠ Page 36)
– P4D32C009E0816
Heat exchanger removal-refitting
Main activity
.543110. removal
1. Unscrew the fastening screws (4, 3) and remove the filter
casing (1) and the gasket (2).
Threaded parts
Oil filter body (4, 3) 1. 5 screws M8x1.25x65
2. 1 screws M8x1.25x40
240861 Figure 74
2. Remove the oil return pipe from the turbocharger as described in procedure removal ( ➠ Page 31).
3. Unscrew the fastening screws (4), recover the spacer (5), re-
move the heat exchanger body (1) complete with the internal
plate element and recover the gasket (3).
Threaded parts
Oil heat exchanger (4) 1. Step 1 - Pre-tightening (17
screws M8x1.25x40 +1 screw
M8x1.25x55)
Tightening sequence: 1 - 18
M8x1.25x40 + 1 screw
M8x1.25x55)
240862 Figure 75
.543110. refitting
4. Position the gasket (3), fit the heat exchanger body (1) com-
plete with the internal plate element , place the spacer (5) in
between and tighten the fastening screws (4) to a torque of:
Tightening torque
Oil heat exchanger (4) 1. Step 1 - Pre-tightening (17
M8x1.25x55)
11.5 ±3.5 N⋅m
M8x1.25x55)
Tightening sequence: 1 - 18 240862 Figure 76
24.5 ±2.5 N⋅m
– P4D32C009E0816
Oil sump removal-refitting
240928 Figure 77
5. Tightening sequence of the screws securing the heat exchanger.
6. Fit the oil return pipe from the turbocharger as described in procedure refitting ( ➠ Page 33).
7. Fit the filter body (1) interposing the gasket (2) on the heat
exchanger and tighten the fastening screws (3,4) to a torque
of:
Tightening torque
Oil filter body (1) 1. 5 screws M8x1.25x65
24.5 ±2.5 N⋅m
2. 1 screws M8x1.25x40
24.5 ±2.5 N⋅m
240861 Figure 78
▶ Refit the engine oil filter. ( ➠ Page 37)
.540430. Oil sump removal-refitting
Tightening torques
Engine oil sump (16 M10x1.5x80 screws) 1. Step 1 - Pre-tightening Tightening sequence: 1 - 16
20 ±2 N⋅m
2. Step 2 - Tightening Tightening sequence: 1 - 16
45 ±4.5 N⋅m
– P4D32C009E0816
Oil sump removal-refitting
Main activity
.540430. removal
1. Position an appropriate container for the oil collection below
the sump (3) in line with the drain plugs (5, 6, 7).
Note It is recommended that the oil is drained while hot.
2. To facilitate the flow of oil, remove the oil dipstick (2).
3. Unscrew the drain plugs(5, 6, 7), recover the sealing gasket (4,
1, 8) and let the lubricant contained in the oil sump (3) flow
out.
Threaded parts
Lubricant drain plug on the sump (3 plugs M22x1.5) (5, 6, 7)
240864 Figure 79
4. Unscrew the screws (3), remove the gasket (1) and disconnect
the oil sump (2) from the lower crankcase plate.
Threaded parts
Engine oil sump (16 1. Step 1 - Pre-tightening
M10x1.5x80 screws) (3) Tightening sequence: 1 - 16
2. Step 2 - Tightening
240865 Figure 80
.540430. refitting
5. Fit the gasket (1) on the oil sump (2).
6. Place the oil sump (2) on the lower crankcase plate and tighten
the fastening screws (3) following the order indicated in the
figure below to a torque of:
Tightening torque
20 ±2 N⋅m
45 ±4.5 N⋅m
240865 Figure 81
– P4D32C009E0816
Removal -Refitting of suction strainer and recover oil in sump
7. Tightening torque of the oil sump fastening screws.
240929 Figure 82
8. Place the sealing gasket (1, 4, 8) in the lower part of the oil
sump (2) and tighten the drain plugs (5, 6, 7) to a torque of:
Tightening torque
Lubricant drain plug on the sump (3 30 ±3 N⋅m
plugs M22x1.5) (5, 6, 7)
9. Top-up with oil, replace the oil filler plug on the tappet cover
and introduce the oil dipstick.
240864 Figure 83
.543062. Removal -Refitting of suction strainer and recover oil in sump
Tightening torques
Oil sump recovery pipe bracket (3 screws M8x1.25x16) 24.5 ±2.5 N⋅m
Oil intake suction strainer in the sump (2 screws M8x1.25x55) 24.5 ±2.5 N⋅m
▶ Remove the oil sump. ( ➠ Page 40)
– P4D32C009E0816
Removal -Refitting of suction strainer and recover oil in sump
Main activity
.543062. removal
1. Remove the screws (1, 2) securing the brackets (3, 5) retain-
ing the oil recovery pipe (4).
Threaded parts
Oil sump recovery pipe bracket (3 screws M8x1.25x16) (1, 2)
240866 Figure 84
2. Remove the fastening screws (1), remove the oil sump intake
suction strainer (2) and recover the sealing gasket (3) from the
lower crankcase.
Threaded parts
Oil intake suction strainer in the sump (2 screws M8x1.25x55) (1)
240867 Figure 85
.543062. refitting
3. Place the sealing gasket (3) on the lower crankcase.
4. Fit the oil sump intake suction strainer (2)and tighten the
fastening screws (1) to a torque of:
Tightening torque
Oil intake suction strainer in the 24.5 ±2.5 N⋅m
sump (2 screws M8x1.25x55) (1)
240867 Figure 86
– P4D32C009E0816
Fuel filter removal-refitting
5. Place the sealing gasket (1) on the lower crankcase.

6. Fit the retaining brackets (3, 5) of the oil sump (4) recovery
pipe and tighten the fastening screws (1, 2) to the specified
torque.
Tightening torque
Oil sump recovery pipe bracket (3 24.5 ±2.5 N⋅m
screws M8x1.25x16) (3, 5)
240866 Figure 87
▶ Refit the oil sump. ( ➠ Page 40)
.542010. Fuel filter removal-refitting
Tightening torques
50)
Fuel pipes between pump and cylinder head (4 M16x1.5 fittings) 42.5 ±2.5 N⋅m
Fuel filter 1. Filter seat cap (1 50 32.5 ±2.5 N⋅m
wrench)
2. Filter bleeder screw (1 1.5 ±0.5 N⋅m
screw)
3. Filter bleed plug (1 11 18 ±2 N⋅m
wrench)
Main activity
.542010. removal
1. Position a container to collect any diesel which may come out
from below the filter seat cap (5).
2. Drain the diesel using the plug at the bottom of the filter seat
cap (5).
3. Using a suitable wrench, unscrew the filter seat cap (5) from
its relative support (7), remove the filter cartridge (6) and
recover the gasket (4).
Threaded parts
2. Drainage plug.
4. Unscrew the fittings (1, 3) and disconnect the delivery pipes

from the low pressure pump to the fuel filter (8) and the deliv-
ery pipe (2) from the fuel filter to the high pressure pump. 240869 Figure 88
– P4D32C009E0816
Removal - Refitting vehicle fuel filter mount
Threaded parts
Fuel pipes between pump and cylin- (4 M16x1.5 fittings)
der head (1, 3)
240869 Figure 88
.542010. refitting
5. Insert the filter cartridge (4) in the filter seat cap (1), position
the O-ring gasket (3) and use a suitable wrench to tighten the
filter seat cap (1) on the relative mount to the specified torque.
6. Tighten the bleeder screw (5) and the bleed plug (2) located
respectively in the lower and upper part of the fuel filter to a
torque of:
Tightening torque
Fuel filter (1, 2, 5) 1. Filter seat cap (1 50 wrench)
32.5 ±2.5 N⋅m
2. Filter bleeder screw (1 screw)
1.5 ±0.5 N⋅m
3. Filter bleed plug (1 11 wrench)
18 ±2 N⋅m
236451 Figure 89
.542014. Removal - Refitting vehicle fuel filter mount
Tightening torques
Fuel filter sensors 1. Fuel temperature sensor 30 ±2 N⋅m
(1 fitting M12x1.5)
2. Filter clogged sensor (1 30 ±2 N⋅m
fitting M12x1.5)
Fuel filter support 1. (4 spacers M8x1.25) 0+0
+0 N⋅m
2. (4 screw M8x1.25x30) 0+0

+0 N⋅m
1. Remove the engine cable. ( ➠ Page 30)
2. Remove the fuel filter. ( ➠ Page 43)
– P4D32C009E0816
Removal - Refitting vehicle fuel filter mount
Main activity
.542014. removal
1. Remove the fuel temperature (3) and filter clogged (5) sensors
from the fuel filter support (2).
Threaded parts
Fuel filter sensors ( 3, 5) 1. Fuel temperature sensor (1 fitting
M12x1.5)
2. Filter clogged sensor (1 fitting
M12x1.5)
2. Unscrew the fastening nuts(4), remove the fuel filter support

(2); If necessary, unscrew the spacers (1) from the crankcase.
Threaded parts
Fuel filter support ( 4, 1) 1. (4 spacers M8x1.25)
2. (4 screw M8x1.25x30)
240870 Figure 90
.542014. refitting
3. If removed, fit the spacers (1) on the crankcase.
4. Fit the oil filter support (2) and tighten the fastening nuts (4) to
a torque of:
Tightening torque
Fuel filter support (1, 4) 1. (4 spacers M8x1.25)
0+0
+0 N⋅m
2. (4 screw M8x1.25x30)
0+0
+0 N⋅m
5. Fit the temperature sensor (3) and the fuel filter clogged (5)
onto the fuel filter support (2).
Tightening torque
Fuel filter sensors (3, 5) 1. Fuel temperature sensor (1 fitting 240870 Figure 91
M12x1.5)
30 ±2 N⋅m
M12x1.5)
30 ±2 N⋅m
1. Refitting the vehicle fuel filter.
2. Refit the engine cable. ( ➠ Page 31)
– P4D32C009E0816
Removal-Refitting of the oil dipstick guide tube
.542713. Removal-Refitting of the oil dipstick guide tube
Tightening torques
Oil dipstick guide tube 1 fitting M18x1.5 0+0
+0 N⋅m
Dipstick guide tube support bracket (1 fitting M8x1.25) 0+0

+0 N⋅m
Main activity
.542713. Removal of the oil dipstick guide tube
1. Extract the engine oil level dipstick (2).
2. Unscrew the fitting (4) from the crankcase, the screw (1) and
remove the dipstick (2) guide pipe (5).
Threaded parts
Oil dipstick guide tube (4, 1) 1 fitting M18x1.5
3. Unscrew the fastening screw (3) and remove the retaining

bracket from the crankcase.
Threaded parts
Dipstick guide tube support bracket (1 fitting M8x1.25) (3)
240868 Figure 92
.542713. refitting
4. Fit the retaining bracket and secure it to the crankcase tighten-
ing the fastening screws (3) to the specified torque.
Tightening torque
Dipstick guide tube support bracket 0+0
+0 N⋅m
(1 fitting M8x1.25) (3)
5. Fit the engine oil dipstick (2) guide tube (5) onto the crankcase
and tighten the fitting (4) and the screw (1) to a torque of:
Tightening torque
Oil dipstick guide tube (4, 1) 1 fitting M18x1.5
0+0
+0 N⋅m
6. Introduce the engine oil dipstick (2).

240868 Figure 93
– P4D32C009E0816
Removal - refitting of the fuel pipes
.542020. Removal - refitting of the fuel pipes
Tightening torques
Fuel pipe between pump and control unit 1. (2 fitting M18x1.5) 0+0
+0 N⋅m
2. (2 fitting M16x1.5) 0+0

+0 N⋅m
Control unit bracket (2 screws M6x1) 0+0

+0 N⋅m
▶ Remove the engine cable. ( ➠ Page 30)
Main activity
.542020. removal
1. Unscrew the fittings (1, 3) and remove the low pressure fuel
pipe (2) from the control unit heat exchanger and the high
pressure pump.
pipe (4) from the tank to the control unit heat exchanger.
Threaded parts
Fuel pipe between pump and 1. (2 fitting M18x1.5)
control unit (1, 3, 5) 2. (2 fitting M16x1.5)
3. Unscrew the screws (7) and remove the heat guard (6) from
the control unit (8).
Threaded parts
Control unit bracket (2 screws M6x1) (6)
240871 Figure 94
.542020. refitting
4. Fit the low pressure fuel pipe (4) from the tank to the control
unit heat exchanger and tighten the fittings (3, 5) to the spe-
cified torque.
5. Connect the low pressure fuel pipe (2) to the control unit heat
exchanger and the high pressure pump and tighten the fittings
(3, 1).
Tightening torque
Fuel pipe between pump and 1. (2 fitting M18x1.5)
control unit (1, 3, 5) 0+0
+0 N⋅m
2. (2 fitting M16x1.5)
0+0
+0 N⋅m
6. Position the heat guard (6) on the control unit (8) and tighten
the screws (7).
240871 Figure 95
Tightening torque
Control unit bracket (2 screws 0+0
+0 N⋅m
M6x1) (7)
– P4D32C009E0816
Removal - Refitting of the EDC 17CV41 control unit
▶ Refit the engine cable. ( ➠ Page 31)
.766161. Removal - Refitting of the EDC 17CV41 control unit
Tightening torques
Control unit with fuel heat exchanger 1. (2 screws M8x1.25x60) 0+0
+0 N⋅m
2. (1 screw M8x1.25x45) 0+0

+0 N⋅m
Control unit supports 1. (2 M6x1x30 screws) 0+0

+0 N⋅m
2. (4 screws ST5.5x1.8x45) 0+0

+0 N⋅m
2. Position a suitable container to collect the fuel.
3. Disconnect the low pressure fuel pipes from the engine management control unit as described in the procedure:
4. Remove the fuel pipes. ( ➠ Page 47)
Main activity
.766161. removal
1. Unscrew the fastening screws (1, 3) and remove the engine
management control unit (2) together with the heat exchanger
and recover the spacers(2).
Threaded parts
Control unit with fuel heat 1. (2 screws M8x1.25x60)
exchanger (1, 3) 2. (1 screw M8x1.25x45)
240872 Figure 96
2. Unscrew the screws (2, 5) and remove the blocks (1, 3, 4)

from the control unit (6).
Threaded parts
Control unit supports (2, 5) 1. (2 M6x1x30 screws)
2. (4 screws ST5.5x1.8x45)
240873 Figure 97
– P4D32C009E0816
Blow-by filter removal - refitting
.766161. refitting
3. Place the blocks (1, 3 , 4) supporting the engine control unit
(6), fit the rubber blocks and tighten the fastening screws (2,
Tightening torque
0+0
+0 N⋅m
2. (4 screws ST5.5x1.8x45)
0+0
+0 N⋅m
240873 Figure 98
4. Position the control unit (2) on the engine crankcase and

tighten the fastening screws (1, 3).
Tightening torque
exchanger (1, 3) 0+0
+0 N⋅m
2. (1 screw M8x1.25x45)
0+0
+0 N⋅m
240872 Figure 99
1. Connect the low pressure fuel pipes to the engine management control unit as described in the procedure:
2. Refit the fuel pipes. ( ➠ Page 47)
.540480. Blow-by filter removal - refitting
Tightening torques
screws M6x1x40)
screws M6x1x40)
– P4D32C009E0816
Removal - refitting of the high pressure pump
Main activity
.540480. removal
1. Unscrew the fastening screws (5) and remove the cover (1)
with the breather pipe and the sealing gasket (4).
Threaded parts

filter (2) from the seat in the gear casing.
Threaded parts
M6x1x40)
M6x1x40)
240882 Figure 100
.540480. refitting
3. Fit the blow-by filter (2) into the seat on the gear casing and
tighten the fastening screws (3) to the specified torque.
Tightening torque
M6x1x40)
5 ±0.5 N⋅m
M6x1x40)
15 ±1.5 N⋅m
4. Position the sealing gasket (4), fit the cover (1) with the
breather pipe and tighten the fastening screws (5) to a torque
of:
Tightening torque
240882 Figure 101
Blow-by filter body (6 screws 7 ±0.7 N⋅m
M6x1x25) (5)
.771010. Removal - refitting of the high pressure pump
Work material
Tool for removing the high pressure pump gear 99366198
Tightening torques
Bracket securing the high pressure pipes ( 2 nuts M6x1). 9 ±1 N⋅m
Fuel drain pipes between pump and cylinder head (2 M18x1.5 fittings) 0+0
+0 N⋅m
High-pressure pump support bracket 1. (2 screws M12x1.75x30) 32.5 ±2.5 N⋅m

2. (2 screws M10x1.5x20) 47.5 ±2.5 N⋅m
– P4D32C009E0816
High-pressure pump support bracket 3. (2 screws M8x1.25x20) 25 ±2.5 N⋅m

4. (3 screw M8x1.25x16) 25 ±2.5 N⋅m
High pressure pump control gear (1 nut M24x1.5) 275 ±25 N⋅m
High pressure pump to support flange (4 screws M10x1.5x35) 37.5 ±2.5 N⋅m
2. Remove the Blow-by filter. ( ➠ Page 50)
Main activity
.771010. removal
1. Unscrew the nuts (2) from the relative brackets.
Threaded parts
Bracket securing the high pressure pipes ( 2 nuts M6x1). (2)
2. unscrew the fittings (1) and (4) and remove the high pressure
fuel delivery pipes (3, 5) to the rail.
Threaded parts
der head (1, 4)
3. Unscrew the fittings (6) and remove the fuel return pipe (7)
from the head to the high pressure pump.
Threaded parts
Fuel drain pipes between pump and (2 M18x1.5 fittings) 240876 Figure 102
cylinder head (6)
4. Unscrew the fastening screws (5) and remove the bracket (1).
5. Unscrew the fastening screws (3, 4, 5) and remove the sup-
port bracket (2).
Threaded parts
High-pressure pump support 1. (2 screws M12x1.75x30)
bracket (3, 4) 2. (2 screws M10x1.5x20)
3. (2 screws M8x1.25x20)
4. (3 screw M8x1.25x16)
240930 Figure 103
– P4D32C009E0816

Code
71702 Figure 104
7. Unscrew the nut (4), apply the specific extractor (1) to the
control gear (3) using the holes for securing the Blow-by fil-
ter and remove it from the shaft (2) of the high pressure fuel
pump.
Threaded parts
High pressure pump control gear (1 nut M24x1.5) (4)

Code
240877 Figure 105
8. Unscrew the fastening screws (3) and remove the high pres-
sure pump (2) from its seat (1).
Threaded parts
High pressure pump to support flange (4 screws M10x1.5x35) (3)
240878 Figure 106
.771010. refitting
9. Bring the flywheel to 36° before TDC of the first cylinder.
– P4D32C009E0816
Note This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to
the 30° position marked by THREE notches (4) and continuing to turn the flywheel in the same direction until reach-
ing the next hole (by 6°).
If the engine flywheel does not have the three notches, to identify the reference hole, simply turn the flywheel in the
opposite direction from the operating direction until reaching the position marked with two notches (54° before the
T.D.C. cyl. 1), then continue to rotate by three holes in the engine operating direction (remembering that each hole
corresponds to a flywheel rotation of 6°).
10. Insert the specific tool through the seat of the flywheel sensor in the corresponding flywheel hole.
11. Mount the HP pump and make sure that the seat of the key (1)
on the pump shaft is facing the pump intakes (2).
187918 Figure 107
12. Tighten the fastening screws (3) of the high pressure pump (2)
on the designated seat (1).
Tightening torque
High pressure pump to support 37.5 ±2.5 N⋅m
flange (4 screws M10x1.5x35) (1)
240878 Figure 108
– P4D32C009E0816
13. Fit the pump control gear (3) and tighten the nut (4) to a
torque of:
Tightening torque
High pressure pump control gear (1 275 ±25 N⋅m
nut M24x1.5) (1)
240877 Figure 109
14. Remove the specific tool.

15. Fit the bracket (1, 2) and tighten the fastening screws (3, 4, 5)
to a torque of:
Tightening torque
bracket (3, 4, 5) 32.5 ±2.5 N⋅m
2. (2 screws M10x1.5x20)
47.5 ±2.5 N⋅m
3. (2 screws M8x1.25x20)
25 ±2.5 N⋅m
4. (3 screw M8x1.25x16)
25 ±2.5 N⋅m
240930 Figure 110
16. Position the high pressure pipes (3, 5) on the high pressure
pump and onto the cylinder head, tighten the fittings (4, 1).
Tightening torque
der head (1, 4) 42.5 ±2.5 N⋅m
17. Position the brackets securing the high pressure pipes (3, 5)
from the high pressure pump to the cylinder head, tighten the
nuts (2).
Tightening torque
Bracket securing the high pressure 9 ±1 N⋅m
pipes ( 2 nuts M6x1). (2)
18. Position the pipe (7) and tighten the fittings (6). 240876 Figure 111
– P4D32C009E0816
Intake manifold removal-refitting
Tightening torque
Fuel drain pipes between pump and (2 M18x1.5 fittings)
cylinder head (6) 0+0
+0 N⋅m
1. Refit the Blow-by filter. ( ➠ Page 50)
.540710. Intake manifold removal-refitting
Tightening torques
Air temperature and pressure sensor (1 screw M6x1x20) 10 ±2 N⋅m
Contactor (2 screws M10x140) 0+0
+0 N⋅m
Engine air inlet pipe (5 screws M10x1.5x140 + 1 screw M10x1.5x100) 0+0

+0 N⋅m
▶ Remove the engine cable. ( ➠ Page 30)
Main activity
.540710. removal
1. If necessary, unscrew the fastening screw (1) and disassemble
the turbocharging air and pressure sensor (6) from the intake
manifold (2).
Threaded parts
Air temperature and pressure sensor (1 screw M6x1x20) (1)
2. Unscrew the fastening screws (5), remove the contactor (4) ,

and remove the spacer (3).
Threaded parts
Contactor (2 screws M10x140) (5)
240874 Figure 112
– P4D32C009E0816
Intake manifold removal-refitting
3. Unscrew the fastening screws (4, 5) remove the intake man-

ifold (6) together with the device (1) for engine start-up and
the relative gasket(3) from the corresponding seat on the en-
gine crankcase (2).
Threaded parts
Engine air inlet pipe (5 screws M10x1.5x140 + 1 screw M10x1.5x100) (4,
5)
240875 Figure 113
.540710. refitting
4. Fit the intake manifold (6) complete with the device (1) for en-
gine start-up together with the relative gasket (3), the support
bracket and the spacers; then tighten the fastening screws (4,
Tightening torque
Engine air inlet pipe (5 screws 0+0
+0 N⋅m
M10x1.5x140 + 1 screw
M10x1.5x100) (4, 5)
240875 Figure 114
5. Fit the contactor (4) together with the spacer (3) and tighten
the fastening screws (5) to a torque of:
Tightening torque
Contactor (2 screws M10x140) (5) 0+0
+0 N⋅m
6. If removed, fit the turbocharging air pressure and temperature

sensor (6) housed on the intake manifold (2) and tighten the
fastening screw (1) to a torque of:
Tightening torque
Air temperature and pressure 10 ±2 N⋅m
sensor (1 screw M6x1x20) (1)
240874 Figure 115
▶ Refit the engine cable. ( ➠ Page 31)
– P4D32C009E0816
Tappet cover removal-refitting
.540630. Tappet cover removal-refitting
Tightening torques
Absolute exhaust gas pressure sensor 1 fitting M12 17.5 ±2.5 N⋅m
Tappet cover (24 screws M6x1x25) 8.5 ±1.5 N⋅m
Main activity
.540630. removal
1. Unscrew the pressure transducer(1 ).
Threaded parts
Absolute exhaust gas pressure sensor 1 fitting M12
2. Unscrew the fastening screws (2), remove the head cover (4)
and remove the gasket (3).
Threaded parts
Tappet cover (24 screws M6x1x25) (1)
240883 Figure 116
.540630. refitting
3. Fit the head cover (2) and tighten the fastening screws (1) in
the order and manner indicated to the specified torque.
240883 Figure 117
– P4D32C009E0816
Removal - refitting of the rocker arm unit
236767 Figure 118

4. Position the head cover and insert all the screws.
5. Screw in the screws until making contact with the spacers in the order 1-24 according to the sequence indicated in the figure.
6. Tighten the screws in the order 1-24 in the sequence indicated in the figure to a torque of:
Tightening torque
7. Retighten the screws 1-2 indicated in the figure to the specified torque.
8. Tighten the pressure transducer(1).
Tightening torque
Absolute exhaust gas pressure sensor 1 fitting M12 (1) 17.5 ±2.5 N⋅m
.541230. Removal - refitting of the rocker arm unit
Work material
Tool for rocker arm shaft assembly and fitting 99360553
square heads
Torque wrench
Box wrench
– P4D32C009E0816
Tightening torques
Rocker arm shaft (7 screws M16x1.5x76) 1. Step 1 - Pre-tightening Tightening sequence: 1 - 7
25 N⋅m
2. Step 2 - Pre-tightening Tightening sequence: 1 - 7
60 N⋅m
80 N⋅m
4. Phase 4 - Tightening to Tightening sequence: 1 - 7
angle 60°
▶ Remove the tappet cover. ( ➠ Page 57)
Main activity
.541230. removal
1. Release the check springs (1) of the engine brake lever.
236738 Figure 119
2. Apply the specific tool (2)to the rocker arm shaft (4)using a
hoist.
Code
3. Unscrew the fastening screws (3) and position the locking ele-
ments (1) correctly.
Threaded parts
Rocker arm shaft (7 screws 1. Step 1 - Pre-tightening
M16x1.5x76) (3) Tightening sequence: 1 - 7
2. Step 2 - Pre-tightening
4. Phase 4 - Tightening to angle
236737 Figure 120
– P4D32C009E0816
4. Lift and remove the rocker arm shaft (4) from the relative
seats on the cylinder head (5) using a hoist.
236736 Figure 121
.541230. refitting
5. Apply the specific tool (1)and the relative lock elements(3) to
the rocker arm shaft(4).
Code
Note before refitting the rocker-arm shaft assembly (4),

make sure that all the adjustment screws (2)have been
fully unscrewed.
6. Lift and fit the rocker arm shaft (4) into the relative seat on the
cylinder head (5) using a hoist.
236736 Figure 122
– P4D32C009E0816
7. Remove the lock elements (1) and tighten the fastening screws
(3) to the specified torque.
8. Remove the specific tool (2) from the rocker arm shaft (4)
using a hoist.
Code
236737 Figure 123
9. Screw the screws in four steps as follows:

Threaded parts
Rocker arm shaft (7 screws 1. Step 1 - Pre-tightening
M16x1.5x76) (1 - 7) Tightening sequence: 1 - 7

Code 183461 Figure 124
Torque wrench
square heads
10. Fit the engine brake lever retainer springs (1).
236738 Figure 125
– P4D32C009E0816

very carefully.
187916 Figure 126

– P4D32C009E0816


6, 2 - 5 and 3 - 4.
nut (1).
Tool / Material
Box wrench
table.
tion.
Tightening torque
M10x1.25) (1)
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle grade [°]
120
5 2
Angle grade [°]
120
1 6
Angle grade [°]
120
4 3
Angle grade [°]
120
2 5
Angle grade [°]
Conditions
– P4D32C009E0816
Removal - refitting the electro-injector wirings
Code

185252 Figure 128
▶ Refit the tappet cover. ( ➠ Page 57)
.769142. Removal - refitting the electro-injector wirings
Work material
Torque screwdriver (1-6 Nm) for adjusting the locking 99389834
nut of the injector solenoid valve connectors
Tightening torques
Elector-injector wiring (12 nuts M4x0.7) 1.5 ±0.25 N⋅m
Electro-injector wiring (2 M6x1x12 nuts) 8.5 ±1.5 N⋅m
Electro-injector connector (4 M6x1x12 nuts) 8.5 ±1.5 N⋅m
2. Remove the tappet cover. ( ➠ Page 57)
– P4D32C009E0816
Removal - refitting the electro-injector wirings
Main activity
.769142. removal
1. Disconnect the wiring (5) from the electrical connections (3)
of the electro-injectors (4).
Threaded parts
Elector-injector wiring (12 nuts M4x0.7) (3)

Code
Torque screwdriver (1-6 Nm) for adjusting the locking nut 99389834
of the injector solenoid valve connectors
2. Disconnect the wiring (5) from the rail pressure sensor (2).
3. Release the collars (6) of the wiring lock clamps (5).
Threaded parts
Electro-injector wiring (2 M6x1x12 nuts) (6) 240933 Figure 129
4. Unscrew the screws (7) and remove the connector (1) from
inside the seat in the cylinder head.
Threaded parts
Electro-injector connector (4 M6x1x12 nuts) (7)
.769142. refitting
5. Connect the wiring (5) to the electrical connections (3) of the
electro-injectors (4).
Tightening torque
Elector-injector wiring (12 nuts 1.5 ±0.25 N⋅m
M4x0.7) (3)

Code
6. Connect the wiring (5) to the rail pressure sensor (2).

7. Position the connector (1) to the inside of the seat in the cylin-
der head and tighten the screws (6) to a torque of:
240933 Figure 130
Tightening torque
Electro-injector connector (4 8.5 ±1.5 N⋅m
M6x1x12 nuts) (6)
8. Secure appropriately using wiring straps (5) and lock using the
collars (7).
Tightening torque
Electro-injector wiring (2 M6x1x12 8.5 ±1.5 N⋅m
nuts) (7)
1. Refit the tappet cover. ( ➠ Page 57)
– P4D32C009E0816
Common rail removal-refitting
.774510. Common rail removal-refitting
Work material
Tightening torques
High pressure fuel pipes from the rail to the electro-injectors (16 fittings M16x1.5) 42 ±2 N⋅m
Low pressure fuel return pipes from the rail (2 fittings M16x1.5) 55 ±5 N⋅m
High pressure fuel pipes from the cylinder head to the rail (4 fittings M16x1.5) 42 ±2 N⋅m
Fuel pipe support bracket from the pump to the cylinder head (3 screws M8x1.25x16) 24.5 ±2.5 N⋅m
Common rail 1. (3 screw M8x1.25x45) 24.5 ±2.5 N⋅m
2. (1 M8x1.25 nut) 24.5 ±2.5 N⋅m
Electro-injector connector (4 M6x1x12 nuts) 8.5 ±1.5 N⋅m
Electro-injector wiring (2 M6x1x12 nuts) 8.5 ±1.5 N⋅m
▶ Disconnect the engine head cable. ( ➠ Page 65)
Main activity
.774510. removal
1. Unscrew the fittings (5) first from the rail side (6) and then the
fittings (1) from the injector side (7) and disconnect the high
pressure fuel pipes.
Threaded parts
High pressure fuel pipes from the rail to the electro-injectors (16 fittings
M16x1.5) (1, 5)
2. Unscrew the fittings (4, 2) and disconnect the fuel return pipes
(3) from the rail.
Threaded parts
Low pressure fuel return pipes from the rail (2 fittings M16x1.5) (2, 4)
240885 Figure 131
– P4D32C009E0816
3. Unscrew the fittings (2, 4) from the rail (5) and cylinder head
(1) respectively and disconnect the high pressure fuel delivery
pipes (3).
Threaded parts
High pressure fuel pipes from the cylinder head to the rail (4 fittings
M16x1.5) (2, 4)
4. Unscrew the nuts (6) and release the support brackets of the
fuel supply pipes (3).
Threaded parts
Fuel pipe support bracket from the pump to the cylinder head (3 screws
M8x1.25x16) (6)
Note The high pressure fuel pipes cannot be re-used but 240886 Figure 132
must be replaced each time they are removed.
5. Unscrew the screws (1) and the nut (3) from the filter ele-
ment (4) and remove the common rail (2) from the cylinder
head.
Threaded parts
Common rail (1, 3) 1. (3 screw M8x1.25x45)
2. (1 M8x1.25 nut)
240887 Figure 133
.774510. refitting
Note The high pressure fuel pipes cannot be re-used but must be replaced each time they are removed
6. Fit the common rail (2) onto the cylinder head and tighten
the screws (1) on the cylinder head and the nut (3) to the
threaded element (4) to a torque of:
Tightening torque
24.5 ±2.5 N⋅m
2. (1 M8x1.25 nut)
24.5 ±2.5 N⋅m
240887 Figure 134
– P4D32C009E0816
7. Connect the high pressure fuel pipes, manually screwing in the

fittings (1) first from the rail side (6) and then the fittings (5)
from the injector side (7).
Note Before tightening the couplings to torque make sure
that the pipes are not touching each other.
8. Complete assembly of high pressure fuel pipes by first tighten-
ing the injector side fittings and then those on the rail side to a
torque of:
Tightening torque
High pressure fuel pipes from the 42 ±2 N⋅m
rail to the electro-injectors (16
fittings M16x1.5) (1, 5)
240885 Figure 135
9. Connect the fuel return pipe (3) from the rail and tighten the
fittings (2, 4) to a torque of:
Tightening torque
Low pressure fuel return 55 ±5 N⋅m
pipes from the rail (2 fittings
M16x1.5) (2, 4)
10. Connect high pressure fuel pipes (3) and tighten the fittings
(2, 4) from the cylinder head (1) and rail (5) respectively to a
torque of:
Tightening torque
High pressure fuel pipes from the 42 ±2 N⋅m
cylinder head to the rail (4 fittings
M16x1.5) (2, 4)
11. Secure the fuel supply pipe support brackets (3), tightening the
nuts (6) to a torque of:
Tightening torque
Fuel pipe support bracket from 24.5 ±2.5 N⋅m
the pump to the cylinder head (3
screws M8x1.25x16) (3) 240886 Figure 136
.769142. refitting
Tightening torque
M4x0.7) (3)

Code
2. Connect the wiring (5) to the rail pressure sensor (2).

240933 Figure 137
– P4D32C009E0816
Removal - refitting of the electro-injectors
Tightening torque
Electro-injector connector (4 8.5 ±1.5 N⋅m
M6x1x12 nuts) (6)
collars (7).
Tightening torque
Electro-injector wiring (2 M6x1x12 8.5 ±1.5 N⋅m
nuts) (7)
.775010. Removal - refitting of the electro-injectors
Work material
Extraction tool for injectors 99342157
Torque wrench
Tightening torques
Engine brake cylinders (12 screws M8x1.25x20) 25 ±2.5 N⋅m
2. Remove the rocker arm shaft. ( ➠ Page 59)
3. Disconnect the engine head cable. ( ➠ Page 65)
Main activity
.775010. removal
1. Unscrew the fastening screws (1) and remove the engine brake
cylinders (3) from the cylinder head (2).
Threaded parts
Engine brake cylinders (12 screws M8x1.25x20) (1)
240934 Figure 138
– P4D32C009E0816
2. Unscrew the screws (1), remove the washers and the brackets
(2) securing the electro-injectors.
Threaded parts
Electro-injector brackets (6 M8x1.25x55 screws) (1)
169827 Figure 139
3. Position the specific tool (1) and extract the electro-injectors

(2) from the cylinder head.
Code
169826 Figure 140
– P4D32C009E0816
4. Remove the sealing gasket (2) on the electro-injectors(1).
169828 Figure 141
– P4D32C009E0816
.775010. refitting
5. Replace the sealing gasket (2) on the injectors(1).
169828 Figure 142
6. Fit the retaining brackets (5)on the electro-injectors (3)

equipped with sealing gaskets (4) and position them in the
relevant seats in the cylinder head.
7. Manually screw in the fastening screws (1) complete with wash-
ers (2). Before tightening them to torque, fit the high pressure
fuel pipes referring to the indications provided in the proced-
ureRail installation .
8. After having fitted the high pressure fuel pipes, lock the fasten-
ing screws (1) securing the injector brackets (5)to a torque of:
Tightening torque
Electro-injector brackets (6 35 ±2 N⋅m
M8x1.25x55 screws) (1)
Tool / Material
Torque wrench
236730 Figure 143
– P4D32C009E0816
Cylinder head removal-refitting
9. Fit the engine brake cylinders (1) and use a torque wrench to
tighten the fastening screws (2) to a torque of:
Tightening torque
Engine brake cylinders (12 screws 25 ±2.5 N⋅m
M8x1.25x20) (2)
Tool / Material
Torque wrench
240934 Figure 144
1. Refit the engine head cable. ( ➠ Page 68)
2. Refit the rocker arm shaft. ( ➠ Page 60)
.540610. Cylinder head removal-refitting
Work material
square heads
Torque wrench
Metal ropes
Tightening torques
Cylinder head (6 M18x2x175 screws + 20 1. Step 1 - Pre-tightening 75 N⋅m
M18x2x196 screws) 2. Step 2 - Tightening 150 N⋅m
Cylinder head (6 M18x2x175 screws + 20 1. Phase 3 - Tightening to 90°
M18x2x196 screws) angle
2. Phase 4 - Tightening to 90°
angle
2. Remove the thermostat. ( ➠ Page 24)
4. Remove the common rail. ( ➠ Page 66)
5. Remove the rocker arm shaft. ( ➠ Page 59)
6. Remove the electro-injectors. ( ➠ Page 69)
7. Remove the exhaust manifold. ( ➠ Page 34)
8. Remove the intake manifold. ( ➠ Page 55)
– P4D32C009E0816
Main activity
.540610. removal
1. Unscrew the cylinder head screws (3).
Threaded parts
Cylinder head (6 M18x2x175 screws + 20 M18x2x196 1. Step 1 - Pre-tightening
screws) 2. Step 2 - Tightening
Cylinder head (6 M18x2x175 screws + 20 M18x2x196 1. Phase 3 - Tightening to angle
screws) 2. Phase 4 - Tightening to angle
Note The cylinder head fastening screws are to be replaced each time you remove them.
2. Using metal ropes, lift the cylinder head (1).

Tool / Material
Metal ropes
3. Take off the gasket (2).
60515 Figure 145
.540610. refitting
4. Check that the pistons: 1 and 6 are exactly at the T.D.C.
5. Put the gasket (2) on the crankcase.
6. Place the cylinder heads (1) on the crankcase.
60515 Figure 146
– P4D32C009E0816
236470 Figure 147

7. Tighten the fastening screws in the sequence shown in the figure.
Note New screws must be used at each assembly of the head.
Lubricate the thread of the screws with engine oil before assembly.
8. Pre-tighten using the torque wrench (1):

Tightening torque
Cylinder head (6 M18x2x175 1. Step 1 - Pre-tightening
screws + 20 M18x2x196 75 N⋅m
screws)
150 N⋅m
Tool / Material
Torque wrench
60565 Figure 148
– P4D32C009E0816
Removal - Refitting of the crankshaft front sealing ring
9. Perform angle tightening with specific tool (1):

Tightening torque
Cylinder head (6 M18x2x175 1. Phase 3 - Tightening to angle
screws + 20 M18x2x196 90°
screws)
90°

Code
square heads
60566 Figure 149
1. Refit the intake manifold. ( ➠ Page 56)
2. Refit the exhaust manifold. ( ➠ Page 35)
3. Refit the electro-injectors. ( ➠ Page 72)
4. Refit the rocker arm shaft. ( ➠ Page 60)
5. Refit the common rail. ( ➠ Page 67)
7. Refit the thermostat. ( ➠ Page 25)
.540442. Removal - Refitting of the crankshaft front sealing ring
Work material
Extraction tool for crankshaft front ring seal 99340053
Key to fit crankshaft front gasket 99346250
Centring ring of crankshaft front gasket cover 99396035
Tightening torques
Front cover (8 screws M8x1.25x16) 25 ±2.5 N⋅m
▶ Remove the crankshaft pulley. ( ➠ Page 28)
– P4D32C009E0816
Removal - Refitting of the crankshaft front sealing ring
Main activity
.540442. removal
1. Apply the specific extractor (2) and extract the crankshaft
sealing gasket (1).
Code
Extraction tool for crankshaft front ring seal 99340053
2. Unscrew the fastening screws and remove the flange(3).

Threaded parts
Front cover (8 screws M8x1.25x16)
60490 Figure 150
.540442. refitting
3. By means of centring ring (2), check the exact cover position
(1), otherwise act as necessary and tighten the screws (3).
Tightening torque
Front cover (8 screws 25 ±2.5 N⋅m
M8x1.25x16) (3)

Code
60563 Figure 151
4. Apply the part (3) of the special tool to the front crankshaft
tang securing it with the screws (2) and keying it onto the new
sealing ring (6).
Code
5. Position part (5) on part (3), tighten the nut (4) on the screw
(1) until the sealing ring is completely installed (6) in the front
cover.
240935 Figure 152
▶ Remove the crankshaft pulley. ( ➠ Page 28)
– P4D32C009E0816
Removal - refitting of the engine flywheel
.540850. Removal - refitting of the engine flywheel
Work material
square heads
Torque wrench
Tightening torques
Engine flywheel (10 screws M19x1.5x75) 1. Step 1 - Tightening 180 ±9 N⋅m
angle
Main activity
.540850. removal
1. Use the specific tool to lock the engine flywheel (3) which is
fitted and unscrew the fastening screws (2). Then, remove the
tool (3) and remove the engine flywheel (1).
Threaded parts
Engine flywheel (10 screws 1. Step 1 - Tightening
M19x1.5x75) (2) 2. Phase 2 - Tightening to angle

Code
242592 Figure 153
.540850. refitting
2. Position the flywheel (1) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down.
3. Lock rotation using a specific tool (3); tighten the screws (2) in
two steps.
Code
4. Tighten using a torque wrench (4).

Tightening torque
M19x1.5x75) (2) 180 ±9 N⋅m
120°
49037 Figure 154
Tool / Material
Torque wrench
– P4D32C009E0816
Removal - refitting of the crankshaft rear seal ring
5. Tighten at angle with specific tool (1).

Code
square heads
49036 Figure 155
.540462. Removal - refitting of the crankshaft rear seal ring
Work material
Key to fit crankshaft rear gasket 99346266
▶ Remove the engine flywheel. ( ➠ Page 78)
Main activity
.540462. removal
1. Apply a suitable puller (2) and remove the sealing gasket (1).
237241 Figure 156
– P4D32C009E0816
Removal - refitting of the crankshaft rear seal ring
.540462. refitting
2. Apply the part (1) of the special tool to the rear crankshaft tang
securing it with two screws (2) and fit the new sealing ring (6).
Code
3. Position part (5) on part (1) tighten the nut (4) on screw (3)
until the sealing ring (6) is completely installed in the flywheel
housing.
240936 Figure 157
▶ Refit the engine flywheel. ( ➠ Page 78)
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ General mechanical overhaul
Contents 1
Contents
GENERAL MECHANICAL OVERHAUL . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
GENERAL MECHANICAL OVERHAUL 3
Contents
Contents
ENGINE DISASSEMBLING AT BENCH . . . . . . . . . . 5
COMPREHENSIVE CRANKCASE CHECKS . . . . . . . 42
OVERHAULING THE CONNECTING ROD-PISTON

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . 81
COMPLETE TIMING SYSTEM OVERHAUL . . . . . . . 87
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 97
– P4D32C009E0816
4 GENERAL MECHANICAL OVERHAUL
– P4D32C009E0816
ENGINE DISASSEMBLING AT BENCH
GENERAL MECHANICAL OVERHAUL

.540110. ENGINE DISASSEMBLING AT BENCH
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Crankshaft lifting tool 99360500
Arm for engine removal and refitting 99360585
Brackets for fastening engine to 99322230 rotary stand 99361036
Socket threaded wrench
Metal ropes
Tightening torques
Radiator supports (4 screws M12x1.75x30) 80 ±8 N⋅m
torque
angle
Intake air delivery pipe collar (1 screw M6x1) 0+0
+0 N⋅m

Air compressor (3 nuts M12x1.75) 170 ±10 N⋅m
Front right engine suspension (4 screws M14x35) 0+0
+0 N⋅m
Front left engine suspension (4 screws M14x35) 0+0

+0 N⋅m
Oil pressure relief valve (2 screws M8x1.25x20) 0+0

+0 N⋅m

+0 N⋅m
2. (1 M10x1.5x110 screw) 0+0

+0 N⋅m

Lower alternator support (3 screws M10x1.5x80) 0+0
+0 N⋅m
Top alternator support (2 screws M8x1.25x30) 0+0

+0 N⋅m
Rear right engine suspensions (4 screws M16x2x60) 1. Step 1 - Pre-tightening 120 ±12 N⋅m
angle
Rear left engine suspension (4 screws M16x2x60) 1. Step 1 - Pre-tightening 120 ±12 N⋅m
– P4D32C009E0816
Rear left engine suspension (4 screws M16x2x60) 2. Phase 2 - Tightening to 50°

angle
Camshaft timing sensor (1 nut M6x1x12) 8 ±2 N⋅m
De-aeration pipe fittings 1. (1 fitting M10x1.5) 38 ±4 N⋅m
2. (1 fitting M16x1.5) 42 ±4.2 N⋅m
M8x1.25x100) 30 ±3 N⋅m
M8x1.25x50) 30 ±3 N⋅m
M8x1.25x140) 30 ±3 N⋅m
M8x1.25x100) 30 ±3 N⋅m
M8x1.25x50) 30 ±3 N⋅m
M8x1.25x140) 30 ±3 N⋅m
2. (2 screws M8x1.25x35) 24.5 ±2.5 N⋅m
3. (1 M10x1.5x14 screw) 24.5 ±2.5 N⋅m
2. (4 M12x1.75x30 studs) 0+0
+0 N⋅m

screws M10x1.5x70)
M6x1x55)
Oil filter support 1. Step I (5 screws 11.5 ±3.5 N⋅m
M8x1.25x40 )
2. Step II (5 screws 24.5 ±2.5 N⋅m
M8x1.25x40 )
(17 screws M8x1.25x40 11.5 ±3.5 N⋅m
screws M8x1.25x40 + 1 24.5 ±2.5 N⋅m
screw M8x1.25x55)
Heat exchanger elements (4 screws M8x1.25x45) 19 ±3.8 N⋅m
2. (3 M12x1.75x12 nuts) 74 ±8 N⋅m
+0 N⋅m

+0 N⋅m
– P4D32C009E0816
Fuel pipes between pump and filter 1. (2 M18x1.5 fittings) 0+0

+0 N⋅m
2. (2 M16x1.5 fittings) 0+0

+0 N⋅m

50)
(1 fitting M12x1.5)
fitting M12x1.5)
+0 N⋅m
2. (4 screw M8x1.25x30) 0+0

+0 N⋅m

+0 N⋅m
Retaining bracket for dipstick guide tube base (2 nuts) 0.0+0

+0 N⋅m
Fuel pipe between the pump and control unit 1. (4 M22x1.5 fittings) 50 ±5 N⋅m
2. (4 screw M8x1.25x16) 24.5 ±2.5 N⋅m
3. (2 screws M8x1.25x25) 24.5 ±2.5 N⋅m
4. (1 fitting M18x1.5) 37 ±3 N⋅m
5. (1 fitting M16x1.5) 37 ±3.7 N⋅m
Control unit heat guard (2 screws) 10 ±2 N⋅m
+0 N⋅m
2. (1 screw M8x1.25x45) 0+0

+0 N⋅m

+0 N⋅m
2. (4 screws ST5.5x1.8x45) 0+0

+0 N⋅m
20 ±2 N⋅m
45 ±4.5 N⋅m
Oil intake suction strainer in the sump (2 screws M8x1.25x55) 24.5 ±2.5 N⋅m
screws M6x1x40)
screws M6x1x40)
Timing gear cover (20 screws M6x1x25) 10 N⋅m
Blow-by pressure sensor ( 1 fitting M10x1) 17.5 ±2.5 N⋅m
Fuel pipe retaining springs between pump and cylin- (2 screws M6x1x35 + 2 nuts 8 ±2 N⋅m
der head M6x1)
2. (2 screws M10x1.5x20) 47.5 ±2.5 N⋅m
3. (2 screws M8x1.25x20) 25 ±2.5 N⋅m
4. (3 screw M8x1.25x16) 25 ±2.5 N⋅m
High pressure pump drive gear (1 M24x1.5 nut) 250 ±15 N⋅m
– P4D32C009E0816
Rocker arm shaft (7 M16x1.5x76 screws) 1. Step 1 - Pre-tightening Tightening sequence: 1 - 7

25 N⋅m
60 N⋅m
80 N⋅m
angle 60°
2. (1 M8x1.25 nut) 24.5 ±2.5 N⋅m
High pressure pump support flange (6 screws M8x1.25x30) 24.5 ±2.5 N⋅m
Camshaft timing sensor (1 screw M6x1) 8 ±2 N⋅m
angle
Flywheel housing 1. Step 1 - (2 M12x1.75x70 20 N⋅m
screws)
2. Step 2 - (2 M12x1.75x70 63 ±7 N⋅m
screws)
3. Step 1 - (4 M12x1.75x35 20 N⋅m
screws)
4. Step 2 - (4 M12x1.75x35 63 ±7 N⋅m
screws)
5. Step 1 - (2 M10x1.5x30 20 N⋅m
screws)
6. Step 2 - (2 M10x1.5x30 45.5 ±4.5 N⋅m
screws)
7. Step 1 - (10 20 N⋅m
M12x1.75x100 screws)
8. Step 2 - (10 63 N⋅m
M12x1.75x100 screws)
9. Step 1 - (2 M12x1.75x193 20 N⋅m
screws)
10. Step 2 - (2 M12x1.75x193 63 N⋅m
screws)
11. Step 1 - (1 M12x1.75x120 20 N⋅m
screw)
12. Step 2 - (1 M12x1.75x120 63 N⋅m
screw)
Double gear (3 screws M12x1.75x90) 0+0
+0 N⋅m
Connecting rod (1 screw M8x1.25x16) 0+0

+0 N⋅m
Oil recovery pump 1. (2 screws M8x1.25x70) 24.5 ±2.5 N⋅m
– P4D32C009E0816
Oil recovery pump 2. (1 M8x1.25x35 screw) 24.5 ±2.5 N⋅m

Cylinder head (6 M18x2x175 screws + 20 1. Step 1 - Pre-tightening 75 N⋅m
M18x2x196 screws) 2. Step 2 - Tightening 150 N⋅m
Cylinder head (6 M18x2x175 screws + 20 1. Phase 3 - Tightening to 90°
M18x2x196 screws) angle
angle
Big-end bearing caps (24 screws M12x1.25x70) 1. Step 1 - Tightening 12 ±0.6 N⋅m
2. Step 2 - Tightening 40 ±2 N⋅m
angle
Lower crankcase (14 M18x2x196 internal screws) 1. Step 1 - Pre-tightening 160 N⋅m
angle
angle
Lower crankcase (25 M12x1.75x125 external screws 1. Step 1 - Pre-tightening 30 N⋅m
+ 1 M12x1.75x58 external screw) 2. Phase 2 - Tightening to 60°
angle
Oil sprayers (6 sprayers M14x1.5) 50 ±5 N⋅m
main activity
1. Before proceeding, carry out the following: Removal of radiator guards ( ➠ Page 5) Removal of radiator pipes ( ➠ Page 8)
Removal of radiator belts ( ➠ Page 7) Air filter pipe removal ( ➠ Page 12) Air filter removal ( ➠ Page 15).
.540110. Removal of Power Generation outfitting

2. Unscrew the screws (1, 2) and remove the radiator supports
(3, 4).
Threaded parts
Radiator supports (4 screws M12x1.75x30) (1, 2)
247723 Figure 1
– P4D32C009E0816
3. Unscrew the screws (3, 4) and remove the suspensions (1, 2).
Threaded parts
screws M16x2x60) (3, 4) 2. Step II - Tightening to angle
247693 Figure 2
4. Unscrew the screw (1) of the relative collar and remove the
intake manifold air delivery pipe (3) from the intake manifold
(2).
Threaded parts
Intake air delivery pipe collar (1 screw M6x1) (1)
247722 Figure 3
5. Unscrew the screw (3) of the relative collar and remove the
turbocharger gas outlet pipe (2) from the turbocharger (1).
Threaded parts
M6x1x50) (3)
247682 Figure 4
6. Before mounting the engine on the specified rotating stand, remove the following parts that may interfere with mounting the
brackets.
7. Disconnect the engine cable from the electrical components and remove it from the engine.
– P4D32C009E0816
.790510. Air compressor removal

8. Disconnect the fittings (1, 3) and remove the water delivery
pipe (2) to the compressor (6).
9. Disconnect the fitting (4) and remove the water return pipe
(5) to the compressor (6).
240894 Figure 5
10. To disconnect the water return and delivery pipes from the re-
lative connection fitting, press and hold the clip (2) and extract
the quick release coupling (1).
242578 Figure 6
11. Unscrew the nuts (3), remove the air compressor (2) together
with the gear (1) and recover the gasket (4).
Threaded parts
Air compressor (3 nuts M12x1.75) (3)
12. If necessary, remove the studs (5) from the crankcase.
240895 Figure 7
– P4D32C009E0816
.505711. Removing the front suspension mounts

13. Unscrew the fastening screws (3) and remove the front engine
mount (2) from the crankcase (1) (alternator side).
Threaded parts
Front right engine suspension (4 screws M14x35) (3)
240893 Figure 8
14. Unscrew the fastening screws (3) and remove the front engine
mount (2) from the engine crankcase (1) (heat exchanger
side).
Threaded parts
Front left engine suspension (4 screws M14x35) (3)
240896 Figure 9
.543075. Oil pressure relief valve removal

15. Disconnect the engine cable from the crankcase pressure
sensor (1) and remove the screws (2).
16. Unscrew the fastening screws (3) and remove the oil pressure
regulation valve (4) and the O-ring (5).
Threaded parts
Oil pressure relief valve (2 screws M8x1.25x20) (4)
242551 Figure 10
– P4D32C009E0816
.540110. Fitting the engine on the stand

Caution!
Engine lifting Lift the engine only by using the specific tool for engine removal and refitting and the specific lifting eye-
lets.
▶ The only method recommended for lifting the engine consists in using the specific tool for engine removal and re-
fitting and the specific lifting eyelets.. As the tool is adjustable, make sure that the lifting points keep the engine bal-
anced, as shown in the figure. Use a hoist to lift the engine slowly with a longitudinal load, as an angular load consid-
erably reduces the lifting capacity.
▶ Handle all the parts with great care. Never place hands or fingers between parts. Wear suitable personal protective
equipment such as a visor, gloves and safety shoes.
242605 Figure 11
17. Fit the brackets (1, 2, 3, 5) on the engine and tighten the relative fastening screws.
18. Using the designated lifting hooks and a specific beam and hoist, lift the engine and place it on the rotating stand (4).
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230
19. Use the fastening screws to secure the brackets (1, 2, 3, 5) to the rotating stand (4).
20. Drain the engine lubricant by unscrewing the oil drain plug housed in the lower part of the oil sump.
– P4D32C009E0816
242605 Figure 11
Threaded parts
Lubricant drain plug on the sump (3 plugs M22x1.5)
.540860. Damper flywheel removal

Code
71702 Figure 12
– P4D32C009E0816
22. Unscrew the fastening screws (4), remove the fan drive pulley
(3) and the damper (2) from the crankshaft (1).
Threaded parts
Damper flywheel (6 screws M14x100) (4)
240901 Figure 13
.543411. Ancillary belt removal

23. Using a 1/2 inch socket wrench (1), act on the automatic belt
tensioner (2) in the direction indicated by the arrow.
242579 Figure 14
24. Remove the ancillary drive belt (5) from the alternator pulley
(1), from the pulleys (3, 6), from the water pump pulley (2)
and from the drive pulley (4).
Note The spring belt must be replaced with a new one every
time it is removed from the vehicle.
240902 Figure 15
– P4D32C009E0816
.543417. Automatic belt tensioner removal

25. Unscrew the fastening screw (2) and remove the automatic
belt tensioner (1) from the seat on the crankcase (3).
Threaded parts
Automatic belt tensioner (1 screw M10x1.5x70) (2)
240903 Figure 16
.760310. Alternator removal

26. Remove the fastening screws (2, 4), recover the spacer (3)
and remove the alternator (1) from the relative supports.
Threaded parts
2. (1 M10x1.5x110 screw)
240904 Figure 17
.543210. Water pump removal

27. Unscrew the fastening screws (3) and remove the water pump
(2) and the sealing ring (1).
Threaded parts
Water pump (4 screws M8x1.25x20) (3)
240906 Figure 18
– P4D32C009E0816
.540821. Removal of the crankshaft pulley

Code
71702 Figure 19
29. Unscrew the fastening screws (2), and remove the pulley (3)
from the crankshaft (1).
Threaded parts
M16x2x80) (2) 2. Angle tightening
240909 Figure 20
.544011. Alternator support removal

30. Unscrew the fastening screws (3) and remove the lower altern-
ator support (4).
Threaded parts
Lower alternator support (3) (3 screws M10x1.5x80)
31. Unscrew the fastening screws (2) and remove the upper al-
ternator support (1).
Threaded parts
Top alternator support (2) (2 screws M8x1.25x30)
240905 Figure 21
– P4D32C009E0816
.505712. Removal of the rear suspension mounts

32. Unscrew the fastening screws (1) and remove the rear engine
mount (2) from the flywheel housing (3).
Threaded parts
Rear right engine suspensions 1. Step 1 - Pre-tightening
(4 screws M16x2x60) (2) 2. Phase 2 - Tightening to angle
242559 Figure 22
33. Unscrew the fastening screws (3) and remove the rear engine
mount (2) from the flywheel housing.
Threaded parts
Rear left engine suspension 1. Step 1 - Pre-tightening
(4 screws M16x2x60) (2) 2. Phase 2 - Tightening to angle
34. Unscrew the screw (6) and remove the incremental speed
sensor from the crankshaft (2).
Threaded parts
Camshaft timing sensor (1 nut M6x1x12) (6)
242552 Figure 23
.543251. Removal of the water outlet pipe/thermostat casing

35. Unscrew the fitting (2) of the relative de-aeration pipe, re-
move the fitting (3) from the cylinder head and remove the
de-aeration pipe (1) also removing the 1/8 fitting from the
thermostat cover.
Threaded parts
De-aeration pipe fittings (2, 1. (1 fitting M10x1.5)
3) 2. (1 fitting M16x1.5)
240907 Figure 24
– P4D32C009E0816
36. Unscrew the screws (2, 3, 4) remove the thermostat cas-

ing/water outlet pipe (1) together with the relative gasket (5).
Threaded parts
4- 5
2. Step 1 - (2 screws M8x1.25x50)
4- 5
3. Step 1 - (1 screw M8x1.25x140)
4- 5
4. Step 2 - (4 screws M8x1.25x100) 240908 Figure 25
12- 13- 14
5. Step 2 - (2 screws M8x1.25x50)
12- 13- 14
6. Step 2 - (1 screw M8x1.25x140)
12- 13- 14
37. Unscrew the screws (4), separate the water outlet pipe (5)
from the thermostat seat (2), recover the thermostat (3) and
the gasket (1).
240852 Figure 26
– P4D32C009E0816
.542410. Turbocharger removal

38. Unscrew the screws (2) securing the lubricant oil return pipe
(4)from the lower part of the turbocharger (1) and recover
the relative gasket.
39. Unscrew the screws (3) from the crankcase, recover the relat-
ive gasket and remove the lubricant oil return pipe (4).
Threaded parts
Turbocharger lubricant return pipe (4 M8x1.25x25 screws) (1, 2)
242543 Figure 27
40. Unscrew the fitting (5) and the fastening screws (2), remove
the pipe (6) delivering lubricant oil to the turbocharger (1) and
remove the gasket (4).
Threaded parts
turbocharger (2, 5) 2. (2 screws M8x1.25x35)
3. (1 M10x1.5x14 screw)
242542 Figure 28
41. Unscrew the fastening nuts (2) and remove the turbocharger
(3) together with the Wastegate valve.
Threaded parts
manifold (2, 4) 2. (4 M12x1.75x30 studs)
42. Recover the turbocharger(3) gasket(1) from the exhaust mani-

fold.
43. Unscrew the studs (4) if necessary from the exhaust manifold.
242544 Figure 29
– P4D32C009E0816
.540720. Exhaust manifold removal

44. Unscrew the fastening screws (6), remove the spacers (2),
remove the exhaust manifold (3), recover the gaskets (7) from
the cylinder head (1).
Threaded parts
Exhaust manifold (6, 4) 1. Step 1 - Pre-tightening (24 screws
M10x1.5x70)
M10x1.5x70)
242545 Figure 30
45. Loosen the V collars (5) acting on the fastening screws (4) to
remove the exhaust manifold (3).
.543070. Oil filter removal

46. Position a container to collect the used oil below the oil filter
tank (3).
47. Unscrew the bleed plug (4) to drain the oil.
48. Unscrew the oil filter tank (3) from the filter body (1).
Threaded parts
2. Bleed plug
49. Remove the filtering cartridge (5) and recover the O-ring (2)
from the oil filter tank (3).
242548 Figure 31
50. Unscrew the fastening screws (4, 3)and remove the oil filter
support (1) from the heat exchanger (2).
Threaded parts
Oil filter support (4, 3) 1. Step I (5 screws M8x1.25x65 + 1
screw M8x1.25x40 )
2. Step II (5 screws M8x1.25x65 + 1
screw M8x1.25x40 )
242549 Figure 32
– P4D32C009E0816
.543110. Heat exchanger removal

51. Unscrew the fastening screws (5, 6), remove the heat ex-
changer body (4) complete with the internal plate element (1)
from the designated seat on the crankcase (2) and recover the
gasket (3).
Threaded parts
Oil heat exchanger (5, 6) 1. Step 1 - Pre-tightening (17
M8x1.25x55)
M8x1.25x55)
Tightening sequence: 1 - 18 242550 Figure 33
52. Unscrew the screws (4), remove the internal elements (2) of
the heat exchanger (3) and recover the gaskets (1).
Threaded parts
Heat exchanger elements (4 screws M8x1.25x45) (4)
240863 Figure 34
.760810. Removal of the electric starter motor

53. Unscrew the fastening nuts (3) and remove the electric starter
motor (2).
54. If necessary, unscrew the studs (1) from the flywheel housing
(4).
Threaded parts
2. (3 M12x1.75x12 nuts)
242556 Figure 35
– P4D32C009E0816
.540710. Intake manifold removal

55. Unscrew the fastening screw (1) and remove the turbocharging
pressure and air temperature sensor (2) from the intake mani-
fold (6).
Threaded parts
Air temperature and pressure sensor (1 screw M6x1x20) (1)
56. Unscrew the fastening screws (4), remove the spacer (3) and
remove the contactor (5) together with the support bracket.
Threaded parts
Contactor (2 screws M10x140) (4)
242557 Figure 36
57. Unscrew the screws (5), remove the engine air inlet pipe (6)
and recover the relative gasket (4).
Threaded parts
Engine air inlet pipe (5 screws M10x1.5x140 + 1 screw M10x1.5x100) (5)
58. Recover the engine start-up device (3) and the relative gasket
(4).
242558 Figure 37
.542020. Removal of the low-pressure fuel pipes

59. Release the low pressure fuel pipes (3, 6) freeing the retaining
clips (2).
60. Unscrew the fittings (1, 4, 5, 7) and disconnect the low pres-
sure fuel pipes (3, 6) from the high pressure pipe and from the
fuel filter.
Threaded parts
Fuel pipes between pump 1. (2 M18x1.5 fittings)
and filter (1, 4, 5, 7) 2. (2 M16x1.5 fittings)
236753 Figure 38
– P4D32C009E0816
.542011. Fuel filter removal

61. Position a container to collect any diesel which may come out
from below the filter seat cap (5).
62. Drain the diesel using the valve plug (4) at the bottom of the
filter seat cap (5).
63. Using a suitable wrench, unscrew the filter seat cap (5) from
its relative support (1), remove the filter cartridge (3) and
recover the O-ring (2).
Threaded parts
2. Drainage plug.
242580 Figure 39
.542014. Removal of the fuel filter mount

64. Remove the fuel temperature (3) and filter clogged (5) sensors
from the fuel filter support (2).
Threaded parts
Fuel filter sensors (3, 5) 1. Fuel temperature sensor (1 fitting
M12x1.5)
M12x1.5)
65. Unscrew the fastening nuts (4) and remove the support (2)
also removing the spacers (1) if necessary.
Threaded parts
Fuel filter support (1, 4) 1. (4 spacers M8x1.25)
2. (4 screw M8x1.25x30)
240870 Figure 40
.542713. Removal of the oil filler pipe and dipstick

66. Extract the engine oil level dipstick (1).
67. Unscrew the fitting (5) and remove the dipstick (1) guide tube
(6) from the crankcase.
Threaded parts
Oil dipstick guide tube (5) 1 fitting M18x1.5
68. Unscrew the fastening screws (2, 4) and remove the retaining
bracket (3) to the crankcase.
Threaded parts
Retaining bracket for dipstick guide tube base (2 nuts) (4, 6)
242553 Figure 41
– P4D32C009E0816
.542020. Removal of the low-pressure fuel pipes

69. Unscrew the screws (8, 9) of the retaining collars and fittings
(2, 4) and disconnect the low pressure fuel pipe (3) from the
heat exchanger of the control unit and from the high pressure
pump.
pipe (6) from the tank to the control unit heat exchanger.
71. Unscrew the fittings (1, 10) and remove the return fuel pipe
(11) from the pump, from the common rail and from the in-
jectors to the tank.
Threaded parts
Fuel pipe between the pump 1. (4 M22x1.5 fittings)
and control unit (1, 2, 4, 5, 2. (4 screw M8x1.25x16)
7, 10)
3. (2 screws M8x1.25x25) 236750 Figure 42
.766161. Removal of the engine management control unit

72. Unscrew the fastening screws (6) and remove the heat guard
(5).
Threaded parts
Control unit heat guard (6) (2 screws)
73. Unscrew the fastening screws (1, 4) and remove the engine
management control unit (3) together with the heat exchanger
and recover the spacers(2).
Threaded parts
exchanger (1, 4) 2. (1 screw M8x1.25x45)
242555 Figure 43
74. Unscrew the fastening screws (2, 5), remove the brackets (1,
3, 4) supporting the engine management control unit (6) and
remove the rubber blocks.
Threaded parts
2. (4 screws ST5.5x1.8x45)
240873 Figure 44
– P4D32C009E0816
.540430. Oil sump removal

75. Unscrew the oil drain plugs (3) from the oil sump (2) and re-
cover the relative gaskets (1).
Threaded parts
Lubricant drain plug on the sump (3 plugs M22x1.5) (3)
242583 Figure 45
76. Unscrew the fastening screws (1), remove the gasket (3) and
the oil sump (2) from the crankcase.
Threaded parts
242582 Figure 46
.543060. Suction strainer removal

77. Unscrew the fastening screws (1), remove the suction strainer
(3) supports (2, 4) from the engine crankcase.
Threaded parts
Oil sump recovery pipe bracket (3 screws M8x1.25x16) (1)
242584 Figure 47
– P4D32C009E0816
78. Unscrew the fastening screws (2), remove the oil intake suction
strainer (1) and recover the gasket (3) from the crankcase.
Threaded parts
Oil intake suction strainer in the sump (2 screws M8x1.25x55) (2)
242585 Figure 48
.540486. Blow-by filter removal

casing (2).
Threaded parts
filter (5) from the seat on the crankcase (6).
Threaded parts
M6x1x40)
M6x1x40)
242560 Figure 49
81. Open the hooks (3) and remove the cover (4), remove the
filter cartridge (2) from the blow-by filter cover (1).
242586 Figure 50
– P4D32C009E0816
.540452. Timing gear cover removal

82. Unscrew the fastening screws (1) and remove the timing gear
cover (2) from the gear casing (4).
Threaded parts
Timing gear cover (20 screws Tightening sequence: 1 - 20
M6x1x25) (1)
242564 Figure 51
83. Remove the gasket (2) from the timing gear cover (1).
181826 Figure 52
.540630. Removal of head cover

84. Unscrew the blow-by pressure sensor (1) from the head cover
(3).
Threaded parts
Blow-by pressure sensor ( 1 fitting M10x1) (1)
85. Unscrew the fastening screws (2), remove the head cover (3)
and remove the gasket (4).
Threaded parts
Tappet cover (24 screws M6x1x25) (2)
242573 Figure 53
– P4D32C009E0816
.542020. Removing the high pressure fuel pipes

86. Acting on the bolts (2), release the clips (1) retaining the high
pressure fuel delivery pipes (3).
Threaded parts
Fuel pipe retaining springs between (2 screws M6x1x35 + 2 nuts
pump and cylinder head (2) M6x1)
87. Unscrew the fittings (4, 5) and remove the high pressure fuel
delivery pipes (3).
Threaded parts
der head (4, 5)
Note The disassembled high pressure pipes cannot be used

again and must always be replaced. 242561 Figure 54
.771010. High pressure pump removal

88. Unscrew the fastening screws (1, 2, 4) and remove the bracket
(3).
Threaded parts
bracket (1, 2, 4) 2. (2 screws M10x1.5x20)
3. (2 screws M8x1.25x20)
4. (3 screw M8x1.25x16)
242587 Figure 55
Code
71702 Figure 56
– P4D32C009E0816
90. Unscrew the nut (4), apply the specific extractor (1) to the
control gear (3) using the holes for securing the Blow-by fil-
ter and remove it from the shaft (2) of the high pressure fuel
pump.
Threaded parts
High pressure pump drive gear (1 M24x1.5 nut) (4)

Code
236460 Figure 57
91. Unscrew the fastening screws (3) and remove the high pres-
sure pump (2) from its seat (1).
Threaded parts
High pressure pump to support flange (4 screws M10x1.5x35) (3)
242562 Figure 58
.541230. Rocker arm shafts removal

92. Release the check springs (1) of the engine brake lever.
242589 Figure 59
– P4D32C009E0816
93. Apply the specific tool (2)to the rocker arm shaft (4)using a
hoist.
Code
94. Unscrew the fastening screws (3) and position the locking ele-
ments (1) correctly.
Threaded parts
Rocker arm shaft (7 1. Step 1 - Pre-tightening
236737 Figure 60
95. Lift and remove the rocker arm shaft (4) from the relative
seats on the cylinder head (5) using a hoist.
236736 Figure 61
– P4D32C009E0816
.541237. Removal of the jumpers

96. Remove the guide braces (1) from the valve stems.
242590 Figure 62
97. Disconnect the wiring (2) from the electrical connections (3)
of the electro-injectors.
Tightening torque
M4x0.7) (2)

Code
98. Release the collars of the wiring lock clamps (1).

99. Unscrew the screws (4) and remove the connector (5) from
inside the seat in the cylinder head.
242591 Figure 63
– P4D32C009E0816
.774510. Rail removal
236733 Figure 64
100. Unscrew the fittings first from the rail side and then from the injector side and disconnect the high pressure fuel pipes in the
sequence (1 - 2 - 3 - 6 - 5 - 4).
Threaded parts
High pressure fuel pipes from the rail to the electro-injectors (16 fittings M16x1.5)
101. Unscrew the nuts (9) and release the support brackets of the fuel supply pipes.
Threaded parts
Fuel pipe support bracket from the pump to the cylinder head (3 screws M8x1.25x16) (9)
102. Unscrew the fittings and disconnect the high pressure fuel supply pipes (8) from the common rail (6).
Threaded parts
High pressure fuel pipes from the cylinder head to the rail (4 fittings M16x1.5)
103. Unscrew the fittings (2, 5) and disconnect the fuel return pipes (4) from the rail.
Threaded parts
Low pressure fuel return pipes from the rail (2 fittings M16x1.5)
– P4D32C009E0816
104. Unscrew the screws (2) and the nut (5) and remove the com-
mon rail (1) from the cylinder head (4).
Threaded parts
2. (1 M8x1.25 nut)
242576 Figure 65
.775010. Removal of electronic injectors

105. Unscrew the fastening screws (1) and remove the engine brake
cylinders (2).
Threaded parts
Engine brake cylinders (12 screws M8x1.25x20) (1)
242577 Figure 66
106. Unscrew the screws (1), remove the washers and the brackets
(2) securing the electro-injectors.
Threaded parts
Electro-injector brackets (6 M8x1.25x55 screws) (1)
169827 Figure 67
– P4D32C009E0816
107. Position the specific tool (1) and extract the electro-injectors
(2) from the cylinder head.
Code
169826 Figure 68
108. Remove the sealing gasket (2) on the electro-injectors(1).
169828 Figure 69
– P4D32C009E0816
.541210. Camshaft removal

109. Install the appropriate plugs in the place of the injectors (1).
110. Extract the camshaft (2).
60514 Figure 70
.773020. Removal of the pump support flange

111. Unscrew the fastening screws (2)and remove the high pressure
pump support (3) flange.
Threaded parts
High pressure pump support flange (6 screws M8x1.25x30) (2)
112. Unscrew the screw (4) and remove the camshaft timing sensor
(3).
Threaded parts
Camshaft timing sensor (1 screw M6x1) (4)
242563 Figure 71
.540850. Engine flywheel removal

113. Use the specific tool to lock the engine flywheel (3) which is
fitted and unscrew the fastening screws (2). Then, remove the
tool (3) and extract the engine flywheel (1).
Threaded parts
M19x1.5x75) (2) 2. Phase 2 - Tightening to angle

Code
242592 Figure 72
– P4D32C009E0816
.540463. Flywheel housing removal

114. Unscrew the fastening screws (1) and remove the flywheel
housing (2).
Threaded parts
Flywheel housing (1) 1. Step 1 - (2 M12x1.75x70 screws)
2. Step 2 - (2 M12x1.75x70 screws)
3. Step 1 - (4 M12x1.75x35 screws)
4. Step 2 - (4 M12x1.75x35 screws)
5. Step 1 - (2 M10x1.5x30 screws)
6. Step 2 - (2 M10x1.5x30 screws)
7. Step 1 - (10 M12x1.75x100 screws)
8. Step 2 - (10 M12x1.75x100 screws)
9. Step 1 - (2 M12x1.75x193 screws) 237239 Figure 73
10. Step 2 - (2 M12x1.75x193 screws)
11. Step 1 - (1 M12x1.75x120 screw)
12. Step 2 - (1 M12x1.75x120 screw)
.541010. Double gear removal

115. Unscrew the screws (4) and remove the spacer (1) and re-
move the double gear (3) from the gear pin (2).
Threaded parts
Double gear (3 screws M12x1.75x90) (4)
242594 Figure 74
116. Unscrew the screw (1) and remove the connecting rod (3) and
the gear pin (2).
Threaded parts
Connecting rod (1 screw M8x1.25x16) (1)
242571 Figure 75
– P4D32C009E0816
.543010. Removing the oil pump

117. Unscrew the fastening screws (2, 3) and remove the oil pump
(1).
Threaded parts
Oil recovery pump (2, 3) 1. (2 screws M8x1.25x70)
2. (1 M8x1.25x35 screw)
242572 Figure 76
.540610. Cylinder head removal

118. Unscrew the screws fixing the cylinder heads.
Threaded parts
Cylinder head (6 M18x2x175 screws + 20 M18x2x196 1. Step 1 - Pre-tightening
screws) 2. Step 2 - Tightening
Cylinder head (6 M18x2x175 screws + 20 M18x2x196 1. Phase 3 - Tightening to angle
screws) 2. Phase 4 - Tightening to angle
Note The cylinder head fastening screws are to be replaced each time you remove them.
119. Using metal ropes, lift the cylinder head (1).

Tool / Material
Metal ropes
120. Take off the gasket (2).
60515 Figure 77
– P4D32C009E0816
.540840. Piston removal

121. Remove the retaining piston rings (2) using round tipped pliers
(1).
155942 Figure 78
122. Remove the piston pin (1) If removal is difficult use a suitable
drift.
155943 Figure 79
– P4D32C009E0816
.540830. Connecting rod removal

123. Turn the crankcase (1) into vertical position.
47574 Figure 80
124. Unscrew the screws (2) fixing the connecting rod cap (3) and
remove it.
Threaded parts
Big-end bearing caps (24 1. Step 1 - Tightening
screws M12x1.25x70) (2) 2. Step 2 - Tightening
Note Keep the big end half-bearings in their respective hous-

ings and/or note down their assembly position since, if
reusing them, they will need to be fitted in the position
found upon removal.
60518 Figure 81
.540830. Axis alignment check

125. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
126. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
127. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 82
– P4D32C009E0816
.540416. Lower crankcase removal

128. Using an appropriate wrench and the socket threaded wrench
unscrew the screws (1) and (2) and take off the lower crank-
case.
Threaded parts
Lower crankcase (14 1. Step 1 - Pre-tightening
M18x2x196 internal 2. Phase 2 - Tightening to angle
screws) (1)
Lower crankcase (25 1. Step 1 - Pre-tightening
M12x1.75x125 external
screws + 1 M12x1.75x58 2. Phase 2 - Tightening to angle
external screw) (2)
Tool / Material
Socket threaded wrench 60519 Figure 83
Note Note down the assembly position of the top and bot-
tom main half-bearings since, if reusing them, they will
need to be fitted in the position found upon removal.
.540810. Crankshaft removal

129. Using the specified tool (1), remove the crankshaft (2).
Code
47570 Figure 84
– P4D32C009E0816
COMPREHENSIVE CRANKCASE CHECKS
.540816. Main bearings removal

130. Disassemble the main half-bearings(1).
47571 Figure 85
.540414. Oil sprayer removal

131. Unscrew the screws and remove the oil sprayers (2).
Threaded parts
Oil sprayers (6 sprayers M14x1.5) (2)
132. Remove the cylinder liners as described in the related para-

graph.
Note once the engine disassembly is complete, clean accur-
ately the removed parts and check their integrity.
The following pages give instructions for checks and
main measurements to do as to determine whether the
parts can be reused.
47571 Figure 86
.540110. COMPREHENSIVE CRANKCASE CHECKS
Consumables
LOCTITE 270
Work material
Cylinder liner protrusion gauge (to be used with 99360334
99370415-99395603 and special plates)
Tool for cylinder liner fastening 99360703
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
Dial gauge base to adjust lay shaft bearings (use with 99370415
99395603)
square heads
– P4D32C009E0816
Dial gauge (0-5 mm) 99395603

Bore meter
Ring gauge
Micrometer
Dial gauge
Tightening torques
Protrusion checking tool screw 225 N⋅m
angle
Technical data
Cylinder liner protrusion compared to the cylinder head supporting surface 0.045 mm to0.075 mm
Load in the axial direction 29,100 N
Additional gear driving load 6,000 N
Heating temperature for gear fitting 180 ℃
Main activity
.540410. Crankcase checks
1. After disassembling the engine, thoroughly clean the cylinder-
crankcase assembly.
2. Carefully inspect the crankcase for cracks.
3. Check cast hole plugs conditions and replace them in case of
uncertain seal or if rusted.
4. When assembling plugs, apply the recommended sealant on
them.
Tool / Material
LOCTITE 270
5. In order to check the inner diameter of cylinder liners and

identify the degree of ovalisation, taper and wear, use bore
meter (2) fitted with a centesimal dial gauge (1) previously re-
set (3) on the 135 mm ring gauge.
Tool / Material
34994 Figure 87
Bore meter
Dial gauge
Ring gauge
Note If the 135 mm ring gauge is not available, use a micro-

meter.
– P4D32C009E0816
6. Measurements should be carried out for every single cylinder

liner at three different heights (1°, 2°, 3°)and on two (A-B)
perpendicular plane levels as illustrated in figure.
60596 Figure 88
1 1st measurement 3 3rd measurement
2 2nd measurement
7. When wear is over 0.150 mm or maximum ovalisation is 0.100

mm compared to the values shown in the figure, replace the
cylinder liner since it is not possible to adjust, lap or dress it.
Note Cylinder liners are equipped with spare parts belonging
to selection class «A».
238071 Figure 89
A Selection class Ø
141.000 - 141.024
mm
– P4D32C009E0816
8. The illustrated diagram refers to the outer diameters of cylinder

liners (C) and (D) and the inner diameters of their seats (A)
and (B).
60597 Figure 90
A = Ø 156.000 - C = Ø 155.961- 155.986
156,025 mm
B = Ø 154.480 - D = Ø 154.390 -
154.550 mm 154.415 mm
60598 Figure 91
9. Cylinder liners can be removed and fitted several times into different seats, if needed.
– P4D32C009E0816
221075 Figure 92
10. During checks, make sure that the main data for the cylinder liners is the same as in the figure.
.540420. Cylinder liners Removal

11. Position the specified parts (2) and the plate (4), as shown in
the figure, checking that the specified plate (4) rests on the
cylinder liner correctly.
Code
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
12. Fasten the screw nut (1) and take off the cylinder liner (3)
from the crankcase.
47577 Figure 93
– P4D32C009E0816
.540420. Cylinder liner refitting and protrusion check

13. Always replace the sealing rings (3, 4, 5).
14. Fit the adjustment ring (1) on the cylinder liner (2), lubricate
the bottom part and fit it on the cylinder assembly using the
appropriate tool.
Note The adjustment ring (1) is supplied as a spare part in
the following thicknesses 0.08 mm - 0.10 mm - 0.12
mm - 0.14 mm.
16798 Figure 94
15. Check the protrusion of the cylinder liners using the specific
tool (2) with spacers and tighten the screw (1) to the torque
specified below.
Tightening torque
Protrusion checking tool screw 225 N⋅m

Code
Cylinder liner protrusion gauge (to be used with 99370415- 99360334
99395603 and special plates)
60520A Figure 95
– P4D32C009E0816
16. Using the dial gauge provided with dial gauge stand (3), meas- 0,045 ÷ 0,075
ure the cylinder liner protrusion compared to the cylinder head
supporting surface, which must be the value indicated in the
figure. Otherwise, replace the adjusting ring , supplied as spare
part in different thicknesses.
Technical data
Cylinder liner protrusion compared to the 0.045 mm to0.075 mm
cylinder head supporting surface

Code
Dial gauge (0-5 mm) 99395603
99395603)
60520B Figure 96
17. On completing assembly, lock the cylinder liners (1) on the

crankcase (2) with the specified stud bolts (3).
Code
Tool for cylinder liner fastening 99360703
60521 Figure 97
– P4D32C009E0816
.540810. Crankshaft measurements
240942 Figure 98
18. Check the condition of the crankshaft main journals. There must not be any signs of scoring, ovalisation or excessive wear.
The data indicated refers to the nominal diameter of the pins.
– P4D32C009E0816
.540811. Measuring main journals

19. Before grinding the crank pins using a micrometer (1), measure
the main journals and the crank pins (2) and decide, on the
basis of the undersizing of the bearings, the final diameter to
which the pins are to be ground.
Tool / Material
Micrometer
Note It is advisable to enter readings in a table.
Note For a more accurate reading, take different measure-

ments on more than one point of the shaft and calcu-
late the average value.
47535 Figure 99
20. During the grinding operation, pay attention to the values of the
main journal couplings shown in the details X.
Note All journals and crankpins must also be ground to the
same undersizing class, in order to avoid any alteration
to shaft balance.
242514 Figure 100

X Main journals fillet
detail
A Polished. B Refaced.
– P4D32C009E0816
36061 Figure 101

21. Write the measurements of the crankshaft main journals in the table.
.540812. Measuring crankpins

22. Before grinding the crank pins using a micrometer (1), measure
the main journals and the crank pins (2) and decide, on the
basis of the undersizing of the bearings, the final diameter to
which the pins are to be ground.
Tool / Material
Micrometer
Note For a more accurate reading, take different measure-

ments on more than one point of the shaft and calcu-
late the average value.
47536 Figure 102
– P4D32C009E0816
36061 Figure 103

23. Write down the measurements of the crankpins of the crankshaft in the table.
24. During the grinding operation, pay attention to the values of the
crankpins shown in Y.
Note All journals and crankpins must also be ground to the
same undersizing class, in order to avoid any alteration
to shaft balance.
242515 Figure 104

Y Crankpin fillet detail
A Polished. B Refaced.
– P4D32C009E0816
.540816. Defining the diameter class of the seats for half-bearings on the crankcase
190208 Figure 105

25. To identify the diameter class of the seats for the main half-bearings, look at the front part of the crankcase in the position as
indicated in the figure.
– P4D32C009E0816
190208 Figure 105

DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF-BEARINGS ON THE CRANKCASE
CLASS RATED DIAMETER OF MAIN BEARINGS
A 126.000 - 126.009
B 126.010 - 126.019
C 126.020 - 106.030
26. Read the 2 sets of numbers on the front part of the crankcase.
– P4D32C009E0816
Note The first set of digits (four) is the coupling number of the upper and lower crankcase.
The following seven digits, taken individually, are the diameter class of each of the seats they are referred to.
Each of these digits may be A, B, C.
.540816. Location of diameter classes of crankpins and main journals
210301 Figure 106

27. In order to identify the diameter class of the crankpins and main journals, identify the three sets of figures marked on the
front of the crankshaft.
Note A: the series of seven digits refers to the crankpins, specifically: the isolated digit indicates the status of the pins (1 =
STD, 2 = -0.127); the other six digits taken individually, represent the diameter class of each crankpin to which they
refer.
B: the series of eight digits refers to the main journals, specifically: the isolated digit indicates the status of the pins (1 =
STD, 2 = -0.127); the other seven digits taken individually, represent the diameter class of each main journal to which
they refer.
C: the five digit number is the part number of the shaft.
– P4D32C009E0816
.540816. Definition of the diameter class of the main journals (nominal diameter)
221130 Figure 107

28. Before selecting the main bearings, define the diameter class of each main journal.
Definition of the diameter class of the main journals (nominal diameter)
CLASS RATED DIAMETER OF MAIN JOURNALS
1 119.970 - 119.979
2 119.980 - 119.989
3 119.990 - 120.000
– P4D32C009E0816
236461 Figure 108

29. Example of diameter classes of main journals.
.540816. Main half-bearing selection
210304 Figure 109

30. Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from
one journal to another).
– P4D32C009E0816
210304 Figure 109

Main half-bearing thickness
Main half-bearings
STD +0.127 +0.254 +0.508
Red 2.955 - 2.965 – 3.082 - 3.092 3.209 - 3.219

Red/Black – 3.019 - 3.029 – –
Green 2.965 - 2.975 – – –
Green/Black – 3.029 - 3.039 – –
Yellow 2.975 - 2.985 – – –
Yellow/Black – 3.039 - 3.049 – –
Note Depending on the thickness of the half-bearings, the tolerance classes are selected, distinguished by a coloured mark.
The tables give the specifications of the main bearings available as spare parts in the standard sizes (STD) and in the
permissible oversizes (+0.127, +0.254, +0.508).
.540816. Main half-bearing selection (nominal diameter pins)

31. After reading off the main data, for each main journal, on the crankcase and crankshaft, choose the type of half-bearings to
use according to the following table.
– P4D32C009E0816
Main half-bearing selection (nominal diameter)
A B C
STD CLASS 126,009 126,010 126,020
126,000 126,019 126,030
3 Red Red Green

120,000
119,990 Red Green Green
2 Red Green Green

119,989
119,980 Green Green Yellow
1 Green Green Yellow

119,979
119,970 Green Yellow Yellow
.540816. Main half-bearing selection (rectified diameter crankpins)

32. After detecting, for each main journal, the necessary data on the crankcase and crankshaft, select the type of half-bearings to
be used, in compliance with the following table.
Main half-bearing selection (rectified diameter crankpins)
3 2 3
-0.127 CLASS 126,009 126,010 126,020
126,000 126,019 106,030
3 Red/Black Red/Black Green/Black

119,873
119,863 Red/Black Green/Black Green/Black
2 Red/Black Green/Black Green/Black

119,862
119,853 Green/Black Green/Black Yellow/Black
1 Green/Black Green/Black Yellow/Black

119,852
199,843 Green/Black Yellow/Black Yellow/Black
– P4D32C009E0816
Note If using main half-bearings of a different thickness, fit the thicker bearings at the bottom (plate side).
33. If the pins have been rectified, make sure that the new diameters of the pins is as indicated in the table and fit the only type of
half-bearing indicated for the undersizing in question.
3 2 3
-0.254 CLASS 126,009 126,010 126,020
126,000 126,019 126,030
Red Red Red
1
119,746
119,726
Red Red Red
1 2 3
-0.508 CLASS 126,000 126,010 126,020
126,009 126,019 126,030
Red Red Red
1
119,492
119,472
Red Red Red
– P4D32C009E0816
.540831. Definition of the connecting rod diameter class
240729 Figure 110

1 Standard numbers 2 Letter indicating the weight class
3 Number indicating the selection of the diameter of the 4 Engine type

big end bearing seat 5 Connecting rod identification plate
34. Select the big end half-bearings by referring to the markings on the connecting-rod body, in the indicated position.
Identifying the weight class of the connecting rod
CLASS CONNECTING ROD WEIGHT (g)
A 6763 - 6893
B 6840 - 6915
C 6916 - 6991
Identifying the diameter class of the big-end bearings seat

DIAMETER OF THE
CLASS CONNECTING ROD HEAD
BEARING
1 109.987 - 109.996
2 109.997 - 110.005
3 110.006 - 110.013
Note The number, which indicates the half-bearing seat diameter class, may be 1, 2 or 3.
– P4D32C009E0816
.540831. Definition of the diameter class of the crankpins (nominal diameter)
223408 Figure 111

35. The diameter class of each big-end bearing must be selected before identifying the diameter of each crankpin.
Definition of the diameter class of the crankpins (nominal diameter)
CLASS CRANKPINS NOMINAL DIAMETER
1 104.970 - 104.979
2 104.980 - 104.989
3 104.989 - 105.000
– P4D32C009E0816
236462 Figure 112

36. Example of diameter classes of crankpins.
.540831. Big-end half-bearing selection
210305 Figure 113

37. Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from
one journal to another).
– P4D32C009E0816
210305 Figure 113

Big-end half-bearing thickness
Big end
half-bearings
STD +0.127 +0.254 +0.508
Red 2.453 - 2.463 – 2.580 - 2.590 2.707 - 2.717

Red/Black – 2.516 - 2.526 – –
Green 2.463 - 2.473 – 2.590 - 2.600 2.717 - 2.727
Green/Black – 2.526 - 2.536 – –
Yellow 2.473 - 2.483 – – –
Yellow/Black – 2.536 - 2.546 – –
Note The tables give the specifications of the big-end bearings available as spare parts in the standard sizes (STD) and in the
permissible oversizes (+0.127, +0.254, +0.508).
.540831. Big-end half-bearing selection (nominal diameter pins)

38. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.
– P4D32C009E0816
Big-end half-bearing selection (nominal diameter pins)
1 2 3
STD CLASS 109,987 109,997 110,006
109,996 110,005 110,013
3 Red Red Green

105,000
104,990 Red Green Green
2 Red Green Green

140,989
104,980 Green Green Yellow
1 Green Green Yellow

104,979
104,970 Green Yellow Yellow
.540831. Big-end half-bearing selection (rectified diameter crankpins)

39. If the pins have been rectified, check (for each under-sizing) the tolerance field the new crankpins belong to, and fit the half-
bearings identified according to the relative table.
Big-end half-bearing selection (rectified diameter crankpins)
1 2 3
-0.127 CLASS 109,987 109,997 110,006
109,996 110,005 110,013
3 Red/Black Red/Black Green/Black

104,873
104,863 Red/Black Green/Black Green/Black
2 Red/Black Green/Black Green/Black

104,862
104,853 Green/Black Green/Black Yellow/Black
1 Green/Black Green/Black Yellow/Black

104,852
104,843 Green/Black Yellow/Black Yellow/Black
– P4D32C009E0816
1 2 3
-0.254 CLASS 109,987 109,997 110,006
109,996 110,005 110,013
Red Red Green

2
104,746
104,736
Red Red Green
Red Green Green

1
104,735
104,726
Red Green Green
1 2 3
-0.508 CLASS 109,987 109,997 110,006
109,996 110,005 110,013
Red Red Green

2
104,492
104,482
Red Red Green
Red Green Green

1
104,481
104,472
Red Green Green
Note If using big end half-bearings of a different thickness, fit the thicker bearing at the bottom.
Note The oversizings 0.254 - 0.508 are not fitted in production are only supplied as Spare parts.
– P4D32C009E0816
.540815. Checking the timing and oil pump gear control

40. Check that the toothing of the gear is neither damaged nor worn; if it is, take it out with an appropriate extractor and replace
it.
41. When fitting the gear (1) on the crankshaft (2), heat it for no
longer than 2 hours in an oven at the temperature indicated
below.
Technical data
Heating temperature for gear fitting 180 ℃
42. Let it cool down after pressing.

43. Ensure the gear is assembled with the load indicated below.
Technical data
Additional gear driving load 6,000 N
44. Check there is no axial displacement below the load indicated.

Technical data
Load in the axial direction 29,100 N
45. If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure. 108836 Figure 114
.540817. Checking crankshaft thrust clearance

46. Checking the thrust clearance is carried out by placing a specific
dial gauge (1) on the crankshaft (2) as indicated in the figure.
If a clearance greater than that indicated is detected, replace
the rear main half-bearings supporting the thrust bearings and
repeat the clearance check.
Code
Dial gauge (0-5 mm) 99395603
47588 Figure 115
.540831. Checking assembly clearance of crankpins

47. Connect the connecting rods to the relevant journals of the crankshaft, placing a length of calibrated wire on the journals.
48. Fit the connecting rod caps (1) complete with half-bearings.
Tighten the screws (2) securing the connecting rod caps to
the prescribed torque. Use the specific tool (3) to tighten the
screws further to the prescribed angle.
Tightening torque
screws M12x1.25x70) (2) 12 ±0.6 N⋅m
40 ±2 N⋅m
90° 242516 Figure 116
– P4D32C009E0816
OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

Code
square heads
Note Lubricate screw threads (2) with engine oil before

assembly.
49. Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the en-
velope containing the wire. After installation, check the thread
diameter of the screws (2). This must not be less than 13.4
mm, otherwise replace the screw; lubricate the crankpins and 242516 Figure 116
big-end bearings. Tighten the screws (2) as indicated above.
.5408. OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
Work material
Pliers for removing/refitting piston rings (105 -160 mm) 99360184
Boring machine
Drift
Feeler gauge
Micrometer
Technical data
Bush diameter 62.087 mm to62.072 mm
– P4D32C009E0816
main activity
242519 Figure 117

1 Connecting rod body 7 Claw seal ring
2 Half-bearings 8 Trapezoidal seal ring
3 Connecting rod cap 9 Piston pin
4 Cap fastening screws 10 Piston
5 Circlip 11 Crankpin bushing
6 Slotted oil scraper ring with spiral spring
1. Check that the pistons present no traces of seizing, scratches, fissures or excessive wear; otherwise, replace them.
– P4D32C009E0816
.540842. Piston rings removal

2. Remove the piston rings from the piston (2) using the specific
set of pliers (1).
Code
Note The pistons have three circlips. The first is a seal ring
with trapezoidal cross-section, the second seal ring is
clawed and the third is the oil scraper ring.
155941 Figure 118
.540840. Piston removal

3. Remove the retaining piston rings (2) using round tipped pliers
(1).
155942 Figure 119
– P4D32C009E0816
4. Remove the piston pin (1) If removal is difficult use a suitable

drift.
155943 Figure 120
.540840. Measuring the piston diameter

5. Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance. The diameter must be meas-
ured at the value indicated.
Tool / Material
Micrometer
155944 Figure 121
.540841. Measuring the piston pin diameter

6. Measure pin diameter (2) measuring with a micrometer (1).
Tool / Material
Micrometer
155945 Figure 122
– P4D32C009E0816
242518 Figure 123

* The distance is measured at the Ø of 140 mm
.540841. Conditions for correct pin-piston coupling

7. During the coupling phase, make sure that the main data for the journal and piston is the same as in the figure.
8. Use engine oil to lubricate the pin (1) and the relative seat on
the piston hubs. Exert a slight pressure with your fingertips
to insert the pin ensuring it does slip out of the piston due to
gravity.
155946 Figure 124
– P4D32C009E0816
.540842. Measuring seal rings

9. Check the thickness of the piston ring (2) using a micrometer
(1).
Tool / Material
Micrometer
16552A Figure 125
10. Check the clearance between the sealing rings (2) and the re-
lated housings on the piston (1) using a feeler gauge (3).
Tool / Material
Feeler gauge
181693 Figure 126
11. The sealing ring (2) of the 1st cavity is trapezoidal. Clearance "
X" between the sealing ring and its seat is measured by placing
the piston (1) with its ring in the cylinder liner (3), so that the
sealing ring comes half way out of the cylinder liner.
3513 Figure 127
– P4D32C009E0816
12. Using a feeler gauge (2), check the end gap of the sealing rings
(1) entered in the cylinder liner (3).
Tool / Material
Feeler gauge
13. If the distance between ends is lower or higher than the value
required, replace piston rings.
36134 Figure 128
– P4D32C009E0816
.540830. Connecting rod checks
242520 Figure 129

1 Standard numbers
2 Arrow indicating the pulley direction
3 Pin class
Diameter class
Date of manufacture
Caution!
Connecting rods weight class warning during assembly
▶ When installing connecting rods, make sure they all belong to the same weight class.
14. Data concerning the class section of connecting rod housing and weight are stamped on the connecting rod.
– P4D32C009E0816
242520 Figure 129

Identifying the weight class of the connecting rod
CLASS CONNECTING ROD WEIGHT (g)
A 6763 - 6893
B 6840 - 6915
C 6916 - 6991
Identifying the diameter class of the big-end bearings seat

DIAMETER OF THE
CLASS CONNECTING ROD HEAD
BEARING
1 109.987 - 109.996
2 109.997 - 110.005
3 110.006 - 110.013
Note The number, which indicates the half-bearing seat diameter class, may be 1, 2 or 3.
– P4D32C009E0816
242517 Figure 130

* Dimension to be obtained after driving the bushing
15. During checks make sure that the main data of the bushing, connecting rod, pin and half bearings is that shown in the diagram.
– P4D32C009E0816
.540830. Axis alignment check

16. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
17. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
18. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 131
.540830. Torsion check

19. Check the bend of the connecting rod (5) by comparing two
points (A) and (B) of the pin (3) on the horizontal plane of the
connecting rod axis.
20. Position the support (1) of the dial gauge (2) so that it pre-
loads by ~ 0.5 mm on the pin (3) in point and A reset the dial
gauge (2). Move the spindle (4) with the connecting rod (5)
and compare with the opposite side B of the pin (3) for any
deviation; the difference between A and B must not exceed
0.08 mm.
61694 Figure 132
– P4D32C009E0816
.540830. Bending check

21. Check the bending of the connecting rod (5) comparing the
two points C and D of the pin (3) on the vertical surface of the
connecting rod axis. Position the vertical support (1) of the dial
gauge (2) so that is rests on the pin (3) point C.
22. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condition.
23. Move spindle (4) with connecting rod (5) and repeat the
highest point check on opposite side D of pin (3).
24. The difference between points C and D must not exceed 0.08
mm.
61695 Figure 133
.540834. Connecting rod small end bush check

25. Check the bushing in the small end has not come loose and
shows no sign of scoring or seizure. Replace it if it does.
26. The bushing (2) is removed and fitted with a suitable drift (1).
Tool / Material
Drift
27. When refitting take care to make the oil holes on the bush
coincide with those on the connecting rod small end.
28. Ream the bush to obtain the diameter specified below.
Technical data
Bush diameter 62.087 mm to62.072 mm
Tool / Material
Boring machine
073535 Figure 134
– P4D32C009E0816
.540840. Piston assembly

29. Fit the piston (1) on the connecting rod (2) so that the graphic
symbol (4), showing the assembly position in the cylinder liner,
and the punch marks (3) on the connecting rod face each other
as shown in the figure.
Note The arrow (5) must face the engine flywheel.
1
2
4 5
181833 Figure 135
30. Fit the pin (2) and fasten it on the piston (1) with the piston
rings (3).
181830 Figure 136
– P4D32C009E0816
CYLINDER HEAD OVERHAUL
.540842. Fitting piston rings

31. Use pliers (3) to fit the piston rings (1) on the piston (2).
Code
32. Position the rings so that «TOP» (4) is facing upwards, direct
the ring openings so they are staggered 180° apart.
155950 Figure 137
.540610. CYLINDER HEAD OVERHAUL
Work material
Punch for valve guide removal 99360143
Tool to remove and refit engine valves (to be used with 99360259
special plates)
Tool for engine valves removal and refitting (use with 99360263
99360259)
Tool for valve guide refitting (use with 99360143) 99360296
Adjuster for gasket assembly on valve guide 99360329
99395603)
Sleeker for valve guide 99390330
Dial gauge (0-5 mm) 99395603
Bore meter
Drift
Feeler gauge
Dial gauge
Micrometer
Grinding machine
Line
Metal brush
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.74 mm to−2.06 mm
Valve guide standout 30.8 mm to31.2 mm
Injector protrusion 1.6 mm
Cylinder head heating temperature 80 ℃ to100 ℃
– P4D32C009E0816
main activity
1. Before disassembling cylinder head, check cylinder head for hydraulic seal by proper tooling; in case of leaks not caused by cup
plugs or threaded plugs, replace cylinder head.
Note When replacing the cylinder head, it is supplied as a spare part with a threaded plug, which must be removed during
assembly.
Note In the event of plug removal/replacement, apply Loctite121078 or 243 to the plugs during assembly.
.540662. Valve removal

Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have
to be overhauled or replaced.
Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.
2. Fit and secure the specific tool (2) with the bracket (4). Screw
in with the designated device (1) so that the semi-cones (3) can
be removed. Remove the tool (2) and extract the upper plate
(5), the spring (6), the lower plate (7).
Code
99360259)
special plates)
Note Repeat this operation for all the valves.

3. Turn the cylinder head upside down and remove the valves (8).
47583 Figure 138
.540610. Checking the planarity of the head on the cylinder block

4. Check the supporting surface (1) of the head on the cylinder
block with a rule (2) and a feeler gauge (3).
Tool / Material
Line
Feeler gauge
5. If deformations exist, surface the head using proper surface

grinder; the maximum amount of material to be removed is 0.2
mm.
Note After levelling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
36159 Figure 139
– P4D32C009E0816
.540662. Valve descale and check

6. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
48625 Figure 140
7. Check that the valves show no signs of seizure or cracking and

also check with a micrometer that the valve stem diameter
comes within the required values: replace the valves if it does
not.
8. Regrind the valve seats, if required, using a grinding machine and
removing as less material as possible.
Tool / Material
Micrometer
Grinding machine
9. Use a bore gauge to check that the diameter inside the valve
guide corresponds to the value indicated, after fitting.
Tool / Material
Bore meter
240939 Figure 141

A Intake valve * Measurement ob-
B Exhaust valve tained after fitting the
valve guides
.540661. Regrinding - replacing the valve seats

Note The valve seats are reground whenever the valves or the valve guides are ground and replaced.
– P4D32C009E0816
237766 Figure 142

1 Intake valve seat 2 Exhaust valve seat
10. When replacing/checking the valve seats, refer to the main data provided in the figure.
11. Check the valve seats (2). If there are light scorings or burnings,
regrind them with a suitable tool (1) according to the angles
shown in the previous figure.
12. Having to replace them, with the same tool and taking care not
to affect the cylinder head, remove as much material from the
valve seats as possible until it is possible to extract them from
the cylinder head with a punch.
13. Heat the cylinder head to 80 - 100° C and using a drift, fit the
new seat valves (2) which will have been previously chilled
in liquid nitrogen. Using the tool (1), regrind the valve seats
according to the angles indicated in the figure above.
Technical data
Cylinder head heating temperature 80 ℃ to100 ℃
Tool / Material
41032 Figure 143
Drift
– P4D32C009E0816
14. After reaming the valve seats, use the specific tool and the dial
gauge to make sure that the valve position, with respect to the
cylinder head surface, is equal to the values specified below:
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.74 mm to−2.06 mm

Code
99395603)
Dial gauge (0-5 mm) 99395603
.540667. Replacing the valve guides

15. Remove the valve guides using the specific drift.The specific part
determines the exact assembly position of the valve guides in
the cylinder head. As they are not available, position the valve
guides in the cylinder head so that they protrude from the cylin-
der head by a value equal to the one given below.
Technical data
Valve guide standout 30.8 mm to31.2 mm

Code
Punch for valve guide removal 99360143
Tool for valve guide refitting (use with 99360143) 99360296
16. After installing the valve guides, regrind their bores with a
smoother. 163815 Figure 144
Tool / Material Product * Measurement to be
Code made after driving in
Sleeker for valve guide 99390330 the valve guides
.775010. Checking protrusion of injectors

17. Check injector protrusion (2) using a magnetic dial gauge (1).
Technical data
Injector protrusion 1.6 mm
Tool / Material
Dial gauge
47585 Figure 145
– P4D32C009E0816
.540665. Valve spring check

18. Before assembly, check the valve spring flexibility using a suitable
tool.
70000 Figure 146
19. Compare the load and elastic deformation data with those of
the new springs indicated in the figure.
108842 Figure 147
.540662. Valve assembly

20. Lubricate the valve stem and insert the valves into the respect-
ive valve guides. Fit the lower plates (1).
193982 Figure 148
– P4D32C009E0816
COMPLETE TIMING SYSTEM OVERHAUL
.540668. Mounting the oil seal ring

21. Using the specific keying device, fit the oil seal ring (2) on the
valve guides (3) and then assemble the valves as follows.
Code
Adjuster for gasket assembly on valve guide 99360329
Note Should valves not have been overhauled or replaced,

remount them according to the numbering performed
on dismounting.
Intake valves are different form exhaust valves in that
they have a notch placed at valve head centre.
155958 Figure 149
22. Fit springs (6), upper plate (5).

23. Apply the specific tool (2) and secure it with the bracket (4).
Screw in the lever (1) so the semi-cones (3) can be fitted.
Remove the tool (2).
Code
99360259)
special plates)
86290 Figure 150
.5412. COMPLETE TIMING SYSTEM OVERHAUL
Work material
Drift to take down and fit back camshaft bushes 99360499
Technical data
Intake valve control cam lift 7.8441 mm
Exhaust valve control cam lift 9.4196 mm
Rated assembling clearance between gear bushings and pins 0.005 mm to0.085 mm
– P4D32C009E0816
main activity
.541254. Replacement gear bush idle gear
1. Replace the bushings (2) when worn.
182092 Figure 151

1 Camshaft 6 Transmission gear
2 Bushing 7 Twin idler gear
3 Pin 8 Crankshaft driving
4 Rod gear
5 Camshaft control gear
2. After driving the bushing, bore it to obtain the diameter shown

in the figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown.
3. At the end of the boring operation, check that the gear bush-
ing/journal assembly clearance is equal to the indicated value.
Technical data
Rated assembling clearance between gear 0.005 mm to0.068 mm
bushings and pins
240938 Figure 152
– P4D32C009E0816
.541254. Replacement of the dual idle gear bushes

4. Replace the bushings (2) when worn.
182092 Figure 153

1 Camshaft 6 Transmission gear
2 Bushing 7 Twin transmission
3 Pin gear
4 Rod 8 Crankshaft driving
5 Camshaft control gear gear
242526 Figure 154

5. After driving the bushing, bore it to obtain the diameter shown in the figure.
Note The bushing must be driven into the gear in the direction of the arrow setting the latter to the dimension shown.
6. Check that the nominal assembly clearance between gear bushings and pins is equal to the value stated below.
Technical data
– P4D32C009E0816
.541211. Checking cam lift and camshaft journals alignment
47506 Figure 155

7. Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2)., comparing the values
with those specified below.
Technical data
Intake valve control cam lift 7.8441 mm
Exhaust valve control cam lift 9.4196 mm
47507 Figure 156

8. With the camshaft (4) still on the tailstocks (1), use a centesimal dial gauge (2) to check the alignment of the support pins (3).
This must not exceed 0.030 mm. If a misalignment exceeding this is detected, replace the shaft.
– P4D32C009E0816
47505 Figure 157

9. To check the assembly clearance, measure the internal diameter of the bush and the diameter of the camshaft pins (1). The
difference represents the existing clearance. If a clearance greater than 0.135 mm is detected, replace the bushings and also
the camshaft if necessary.
240941 Figure 158

10. α° = 135 °; γ° = 315 °; in this condition, the flywheel is in the reference position of pistons 1-6 at PMS.
– P4D32C009E0816
240941 Figure 158

11. The surfaces of shaft support pins and of the cams must be very smooth. If they show traces of seizing and scoring, the shaft
and relative bushing have to be replaced.
Tolerance characteristics
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Class of importance product characteristics

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
– P4D32C009E0816
.541213. Camshaft bushes check
242521 Figure 159

* Bushing inside diameter after driving in
12. The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
13. Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
107217 Figure 160

A Drift with seat for bushings to insert/extract. F Guide line.
B Dowel pin for positioning bushings. G Guide bushing to secure to the seventh bushing
C Reference mark to insert seventh bushing correctly. mount.
D Reference mark to correctly insert bushings 1, 2, 3, 4, H Plate fixing bushing G to cylinder head.
5, 6. I Grip.
E Guide bush. L Extension coupling.
14. To remove and refit the bushes, use the specific drift.
– P4D32C009E0816
.541213. Replacing camshaft bushes using beater

.541213. Removal
Note Position the drift accurately during the phase of removal.
15. Remove the bushings in the following order (7, 6, 5, 4, 3, 2,

1).
Code
Note The bushings are extracted from the front of each

seat.
Note Removal does not require the drift extension for bush-
ings 5, 6 and 7 and the guide bushing does not need to
be used. However, for bushings 1, 2, 3, 4, the exten-
sion and guide bushings are required.
.541213. assembly 71725 Figure 161

16. To insert the bushing (1, 2, 3, 4 , 5 ), proceed as follows.
107217 Figure 162

17. Assemble the drift together with the extension.
18. Position the bushing to insert on the drift (A) making the grub screw on it coincide with the seat (B) on the bushing.
19. Position the guide bushing (E) and secure the guide bushing (G) on the seat of the 7th bushing with the plate (H).
20. While driving in the bushing, fill the notch (F) with notch (M). This way, when it is driven home, the lubrication hole on the
bush will coincide with the oil pipe in its seat.
Note The bushing is driven home when the 1st reference mark (D) is flush with the guide bushing (G).
– P4D32C009E0816
21. To insert the bushing (6), proceed as follows:

22. Unscrew the grip (I) and the extension (N).
23. Position the extension (N) and the guide bushing (E) as shown
in the figure.
24. Position the bushing to insert on the drift (A) making the grub
screw on it coincide with the seat (B) on the bushing.
25. Position the guide bushing (E) and secure the guide bushing
(G) on the seat of the 7th bushing with the plate (H).
26. While driving in the bushing, fill the notch (F) with notch (M).
This way, when it is driven home, the lubrication hole on the
bush will coincide with the oil pipe in its seat.
Note The bushing is driven home when the 1st reference 71723 Figure 163
mark (D) is flush with the guide bushing (G).
27. To insert the bushing (7), proceed as follows.

28. Unscrew the grip (I) and the extension (N).
29. Refit the guide (G) from the inside as shown in the figure.
30. Position the bushing on the drift (A) and bring it close up to the
seat, making the bushing hole match the lubrication hole in the
head. Drive in.
31. The 7th bushing is driven in when the reference mark (C) is
flush with the bushing seat.
71724 Figure 164
.541233. Rocker shaft check

Note The camshaft cams directly control the 12 rocker arms for the valves. The intake valve control rocker arms are keyed
on rocker arms shaft directly. Exhaust valves control rocker arms are keyed on rocker arms shaft putting in between the
levers with engine brake control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end acts
on a bar supported by the stem of the two valves. A pad is placed between the rocker adjusting screw and the bar. Two
lubrication holes are obtained inside the rockers.
073557 Figure 165

32. Check the shaft surfaces for signs of seizure, scoring or wear. Otherwise replace the shaft.
– P4D32C009E0816
.541231. Exhaust valve rocker arm check

33. The bush surfaces must not show any trace of scoring of ex-
cessive wear; otherwise, replace bushes or the whole rocker.
242523 Figure 166
.541231. Intake valve rocker arms check

242522 Figure 167
.543751. Lever with engine brake control eccentric pin check

242524 Figure 168
– P4D32C009E0816
ENGINE ASSEMBLY
.540110. ENGINE ASSEMBLY
Consumables
Engine oil
LOCTITE 5970
LOCTITE 121078
LOCTITE 2045
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Tool for timing of phonic wheel on timing gear 99360613
Tool to check timing (use with 99395606) 99370400
square heads
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
Gauge to determine centre distance between camshaft 99395226
and high pressure pump
Dial gauge (0-30 mm) 99395606
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Box wrench for block junction bolts to the lower crank- 99350072
case
Torque wrench
Box wrench
Hooks
Hoist
Tightening torques
Lower crankcase (14 internal screws M18x2x208) 1. Step 1 - Pre-tightening 160 N⋅m
angle
– P4D32C009E0816
ENGINE ASSEMBLY
Lower crankcase (14 internal screws M18x2x208) 3. Phase 3 - Tightening to 60°

angle
Lower crankcase (25 external screws M12x1.75x130 1. Step 1 - Pre-tightening 30 N⋅m
+ 1 external screw M12x1.75x58) 2. Phase 2 - Tightening to 60°
angle
Lower crankcase inner screws Pre-tightening 160 N⋅m
Lower crankcase external screws Pre-tightening 30 N⋅m
angle
Cylinder head (6 screws M18x2x175 + 20 screws 1. Step 1 - Pre-tightening 75 N⋅m
M18x2x196) 2. Step 2 - Tightening 150 N⋅m
Cylinder head (6 screws M18x2x175 + 20 screws 1. Phase 3 - Tightening to 90°
M18x2x196) angle
angle
Oil recovery pump 1. (2 screws M8x1.25x70) 24.5 ±2.5 N⋅m
2. (1 M8x1.25x35 screw) 24.5 ±2.5 N⋅m
+0 N⋅m

+0 N⋅m
Flywheel housing 1. Step 1 - (12 screws 20 ±2 N⋅m

M12x1.75x100)
2. Step 2 - (12 screws 63 ±7 N⋅m
M12x1.75x100)
3. Step 1 - (4 screws 20 ±2 N⋅m
M12x1.75x35)
4. Step 2 - (4 screws 63 ±7 N⋅m
M12x1.75x35)
5. Step 1 - (2 screws 20 ±2 N⋅m
M12x1.75x193)
6. Step 2 - (2 screws 63 ±7 N⋅m
M12x1.75x193)
7. Step 1 - (2 screws 20 ±2 N⋅m
M12x1.75x70)
8. Step 2 - (2 screws 63 ±7 N⋅m
M12x1.75x70)
9. Step 1 - (2 screws 20 ±2 N⋅m
M10x1.5x25)
10. Step 2 - (2 screws 44 ±4 N⋅m
M10x1.5x25)
angle
Thrust plate (5 screws M8x1.25x25) 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
20 ±2 N⋅m
– P4D32C009E0816
ENGINE ASSEMBLY
idler gear (3 screws M12x1.75x110) 1. Step 1 - Pre-tightening 30 N⋅m

angle
Power take-off front cover (3 M8x1.25x20) 0+0
+0 N⋅m
Camshaft timing sensor (1 screw M6x1) 8 ±2 N⋅m
Electro-injector brackets (6 screws M8x1.25x55) 35 ±3.5 N⋅m
2. (1 M8x1.25 nut) 24.5 ±2.5 N⋅m
Head connector (5 screws M6x1x12) 0+0
+0 N⋅m
Rocker arm shaft (7 M16x1.5x76 screws) 1. Step 1 - Pre-tightening Tightening sequence: 1 - 7

25 N⋅m
60 N⋅m
80 N⋅m
angle 60°
Camshaft gearing (4 screws M14x2x60) 1. Step 1 - Pre-tightening 60 N⋅m
angle
Phonic wheel on timing gear (4 screws M8x1.25x25) 28.5 ±3.5 N⋅m
High pressure pump control gear (1 nut M24x1.5) 275 ±25 N⋅m
2. (2 screws M10x1.5x20) 47.5 ±2.5 N⋅m
3. (2 screws M8x1.25x20) 25 ±2.5 N⋅m
4. (3 screw M8x1.25x16) 25 ±2.5 N⋅m
Fuel pipe retaining springs between pump and cylin- (2 screws M6x1x35 + 2 nuts 8 ±2 N⋅m
der head M6x1)
Blow-by pressure sensor ( 1 fitting M10x1) 17.5 ±2.5 N⋅m
Timing gear cover (20 screws M6x1x25) 10 N⋅m
screws M6x1x40)
screws M6x1x40)
Blow-by casing (6 screws M6x1x25) 7 ±0.7 N⋅m
Oil intake suction strainer in the sump (2 screws M8x1.25) 20 ±2 N⋅m
– P4D32C009E0816
ENGINE ASSEMBLY
20 ±2 N⋅m
45 ±4.5 N⋅m
+0 N⋅m
2. (4 screws ST5.5x1.8x45) 0+0

+0 N⋅m

+0 N⋅m
2. (1 screw M8x1.25x45) 0+0

+0 N⋅m
Control unit heat guard (2 screws) 10 ±2 N⋅m

Fuel pipe between the pump and control unit 1. (4 M22x1.5 fittings) 50 ±5 N⋅m
2. (4 screw M8x1.25x16) 24.5 ±2.5 N⋅m
3. (2 screws M8x1.25x25) 24.5 ±2.5 N⋅m
4. (1 fitting M18x1.5) 37 ±3 N⋅m
5. (1 fitting M16x1.5) 37 ±3.7 N⋅m
+0 N⋅m

+0 N⋅m

+0 N⋅m
2. (4 screw M8x1.25x30) 0+0

+0 N⋅m

(1 fitting M12x1.5)
fitting M12x1.5)
50)
Fuel pipes between pump and filter 1. (2 M18x1.5 fittings) 0+0
+0 N⋅m
2. (2 M16x1.5 fittings) 0+0

+0 N⋅m

+0 N⋅m

+0 N⋅m

2. (3 M12x1.75x12 nuts) 74 ±8 N⋅m
Heat exchanger elements (4 screws M8x1.25x45) 19 ±3.8 N⋅m
(17 screws M8x1.25x40 11.5 ±3.5 N⋅m
screws M8x1.25x40 + 1 24.5 ±2.5 N⋅m
screw M8x1.25x55)
Oil filter support 1. Step I (5 screws 11.5 ±3.5 N⋅m
M8x1.25x40 )
2. Step II (5 screws 24.5 ±2.5 N⋅m
M8x1.25x40 )
– P4D32C009E0816
ENGINE ASSEMBLY

screws M10x1.5x70)
M6x1x55)
2. (4 M12x1.75x30 studs) 0+0
+0 N⋅m

2. (2 screws M8x1.25x35) 24.5 ±2.5 N⋅m
3. (1 M10x1.5x14 screw) 24.5 ±2.5 N⋅m
M8x1.25x100) 30 ±3 N⋅m
M8x1.25x50) 30 ±3 N⋅m
M8x1.25x140) 30 ±3 N⋅m
M8x1.25x100) 30 ±3 N⋅m
M8x1.25x50) 30 ±3 N⋅m
M8x1.25x140) 30 ±3 N⋅m
Rear right engine suspensions (4 screws M16x2x60) 1. Step 1 - Pre-tightening 120 ±12 N⋅m
angle
Rear left engine suspension (4 screws M16x2x60) 1. Step 1 - Pre-tightening 120 ±12 N⋅m
angle
Top alternator support (2 screws M8x1.25x30) 0+0
+0 N⋅m
Lower alternator support (3 screws M10x1.5x80) 0+0

+0 N⋅m

+0 N⋅m
2. (1 M10x1.5x110 screw) 0+0

+0 N⋅m

+0 N⋅m

+0 N⋅m

+0 N⋅m

+0 N⋅m
– P4D32C009E0816
ENGINE ASSEMBLY

torque
angle
Technical data
Lower crankcase external screws (angle closing) 60°
Lower crankcase internal screws (angle closing) 90°
Cam timing dial gauge value 6.34 ±0.05 mm
Rated assembly play between the timing gear and the idling gear 0.080 mm to0.185 mm
main activity
1. Fasten the crankcase to the stand using the specific brackets.
.540414. Oil sprayer assembly

2. Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
Tightening torque
Oil sprayers (6 sprayers 50 ±5 N⋅m
M14x1.5) (2)
47586 Figure 169
– P4D32C009E0816
ENGINE ASSEMBLY
.540816. Main bearings assembly

3. Install the half-bearings (1) on the main bearings in the crank-
case (2).
Note Refit the main bearings that have not been replaced, in
the same position found at removal.
4. If you have to replace the bearings, choose them according to
selection described in chapters Selecting the main half-bearings
(nominal diameter pins) and Main half-bearings selection (recti-
fied) .
49021 Figure 170
.540810. Crankshaft assembly

5. Lubricate the half-bearings.
6. Using the specific hoist and hook (1) assemble the crankshaft
(2).
Code
Hoist
47570 Figure 171
.540416. lower crankcase assembly

7. Install the half-bearings (1) on the main bearings in the lower
crankcase (2).
49021 Figure 172
– P4D32C009E0816
ENGINE ASSEMBLY
8. Apply the specified sealant onto the crankcase using an appro-

priate (1) tool.
Tool / Material
LOCTITE 121078
47595 Figure 173
9. Apply the sealant following the diagram in the figure.

Note fit the lower crankcase within 10' of the application of
the sealant.
245535 Figure 174
10. Fit the lower crankcase (1) by means of a suitable hoist and
hooks.
Tool / Material
Hoist
Hooks
60559 Figure 175
– P4D32C009E0816
ENGINE ASSEMBLY
11. Using a torque wrench (3) tighten the internal screws (1) to
the required torque, then using a specific tool (4) tighten them
in two phases to the specific angles, following the tightening
sequence diagram indicated below for the screws securing the
lower crankcase.
Tightening torque
Lower crankcase (14 internal 1. Step 1 - Pre-tightening
screws M18x2x208) (1) 160 N⋅m
90°
60°

Code 47581 Figure 176
Torque wrench
Box wrench for block junction bolts to the lower crankcase 99350072
square heads
Note Always use new screws each time you assemble the
lower crankcase.
12. Using a torque wrench (2), tighten the outer hex-socket screws
(1) to the prescribed torque, then using the specific tool (3)
tighten to an angle.
Tightening torque
Lower crankcase (25 external 1. Step 1 - Pre-tightening
screws M12x1.75x130 30 N⋅m
+ 1 external screw
M12x1.75x58) (1)
60°

Code
Torque wrench
Box wrench for block junction bolts to the lower crankcase 99350072
square heads 47581 Figure 177
– P4D32C009E0816
ENGINE ASSEMBLY
245532 Figure 178

13. First step:
Tightening torque
Lower crankcase inner screws Pre-tightening
160 N⋅m
14. Second step:

Technical data
15. Third step:

Technical data
245533 Figure 179

16. Fourth step:
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
Lower crankcase external screws Pre-tightening
30 N⋅m
245534 Figure 180

17. Fifth step:
Technical data
Lower crankcase external screws (angle closing) 60°
.540831. Big-end half-bearing fitting

18. Lubricate the half-bearings (1 ) and fit them in the connecting
rod and the cap.
Note Not finding it necessary to replace the big-end bearings,
you need to fit them back in exactly the same sequence
and position as in removal.
If you have to replace the big-end bearings, choose
them according to selection described in chapter Main
half-bearings selection and Selecting the connecting rod
half-bearings .
Note Do not make any adjustment on the half-bearings.
155951 Figure 181
.540840. Assembling connecting rod - piston assemblies in the cylinder liners

19. Rotate the crankcase placing it vertically.
20. Lubricate the pistons, piston rings and inside the cylinder liners.
– P4D32C009E0816
ENGINE ASSEMBLY
21. Using the clamp (1), install the connecting rod-piston assemblies
(2) in the cylinder linings, according to the diagram in the previ-
ous figure.
22. Check that the number of each connecting rod corresponds to
the cap coupling number.
Caution!
Connecting rods Precautions for cylinder liners
▶ During assembly, pay utmost attention to prevent the
connecting rod from hitting against the cylinder liner
walls.
23. Make sure that the symbol stamped on the piston crown is fa- 60616 Figure 182
cing the engine flywheel, or that the slot obtained on the piston
skirt corresponds to the oil nozzle position.
Code
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Note Before reusing the screws, measure the diameter of

the thread. This must not be less than 13.4 mm, other-
wise, replace the screw. Before assembly, lubricate the
screw thread with engine oil.
24. Connect the connecting rods to the relative pins of the

crankshaft, fit the connecting rod caps (1) complete with
half-bearings. Tighten the screws securing the connecting rod
caps (2) to the prescribed torque. Use the specific tool (3) to
tighten the screws further to the prescribed angle.
Tightening torque
screws M12x1.25x70) (2) 12 ±0.6 N⋅m
40 ±2 N⋅m 242516 Figure 183
90°

Code
square heads
– P4D32C009E0816
ENGINE ASSEMBLY
.540442. Crankshaft front gasket installation

25. By means of centring ring (2), check the exact cover position
(1), otherwise act as necessary and tighten the screws (3).
Tightening torque
Front cover (8 screws 25 ±2.5 N⋅m
M8x1.25x16) (3)

Code
60563 Figure 184
26. Apply the part (3) of the special tool to the front crankshaft
tang securing it with the screws (2) and keying it onto the new
sealing ring (6).
Code
27. Position part (5) on part (3), tighten the nut (4) on the screw
(1) until the sealing ring is completely installed (6) in the front
cover.
240935 Figure 185
.540610. Cylinder head assembly

28. Check that the pistons 1-6 are exactly at the T.D.C.
29. Put the gasket (2) on the crankcase.
30. Place the cylinder heads (1) on the crankcase.
60515 Figure 186
– P4D32C009E0816
ENGINE ASSEMBLY
236470 Figure 187

31. Tighten the fastening screws in the sequence shown in the figure.
Note New screws must be used at each assembly of the head.
Lubricate the thread of the screws with engine oil before assembly.
32. Pre-tighten using the torque wrench (1):

Tightening torque
Cylinder head (6 screws 1. Step 1 - Pre-tightening
M18x2x175 + 20 screws 75 N⋅m
M18x2x196)
150 N⋅m
Tool / Material
Torque wrench
60565 Figure 188
– P4D32C009E0816
ENGINE ASSEMBLY
33. Perform angle tightening with specific tool (1):

Tightening torque
Cylinder head (6 screws 1. Phase 3 - Tightening to angle
M18x2x175 + 20 screws 90°
M18x2x196)
90°

Code
square heads
60566 Figure 189
.543010. Installing the oil pump

34. Fit the oil pump (1) and tighten the fastening screws (2, 3) to a
torque of:
Tightening torque
Oil recovery pump (2, 3) 1. (2 screws M8x1.25x70)
24.5 ±2.5 N⋅m
2. (1 M8x1.25x35 screw)
24.5 ±2.5 N⋅m
242572 Figure 190
.541010. Double gear assembly

35. Fit the connecting rod (3) on the pin (2) and tighten the screw
(1) to a torque of:
Tightening torque
Connecting rod (1 screw 0+0
+0 N⋅m
M8x1.25x16) (1)
242571 Figure 191
– P4D32C009E0816
ENGINE ASSEMBLY
36. Fit the gear pin (2), the double gear (3), the spacer (1) and
tighten the screws (4) to a torque of:
Tightening torque
Double gear (3 screws 0+0
+0 N⋅m
M12x1.75x90) (4)
Note Lubricate the screws (1) with engine oil before as-
sembly.
242594 Figure 192
.540463. Fitting flywheel box

37. Apply the specified sealant onto the flywheel housing using a
suitable tool (1) as shown in the figure.
Tool / Material
LOCTITE 5970
Note Fit the flywheel housing within 10' after sealant applica-
tion.
47592 Figure 193
38. Use a torque wrench to tighten the fastening screws (1) of the
flywheel housing (2), in the sequence shown in the following
figure to a torque of:
Tightening torque
Flywheel housing (1) 1. Step 1 - (12 screws M12x1.75x100)
20 ±2 N⋅m
2. Step 2 - (12 screws M12x1.75x100)
63 ±7 N⋅m
3. Step 1 - (4 screws M12x1.75x35)
20 ±2 N⋅m
4. Step 2 - (4 screws M12x1.75x35)
63 ±7 N⋅m 242596 Figure 194
5. Step 1 - (2 screws M12x1.75x193)
20 ±2 N⋅m
6. Step 2 - (2 screws M12x1.75x193)
63 ±7 N⋅m
7. Step 1 - (2 screws M12x1.75x70)
20 ±2 N⋅m
8. Step 2 - (2 screws M12x1.75x70)
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
Flywheel housing (1) 8. 63 ±7 N⋅m
9. Step 1 - (2 screws M10x1.5x25)
20 ±2 N⋅m
10. Step 2 - (2 screws M10x1.5x25)
44 ±4 N⋅m
39. Tightening sequence diagram for flywheel housing fastening

screws.
242595 Figure 195
.540462. Crankshaft rear gasket assembly

40. Apply the part (2) of the special tool to the rear crankshaft tang
securing it with two screws (3) and fit the new sealing ring (6).
Code
41. Position part (5) on part (2) tighten the nut (4) on screw (1)
until the sealing ring (6) is completely installed in the flywheel
housing.
242597 Figure 196
– P4D32C009E0816
ENGINE ASSEMBLY
.540850. Engine flywheel assembly

42. Position the flywheel (1) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down.
43. Lock rotation using a specific tool (3); tighten the screws (2) in
two steps.
Code
44. Tighten using a torque wrench (4).

Tightening torque
M19x1.5x75) 180 ±9 N⋅m
120°
49037 Figure 197
Tool / Material
Torque wrench
45. Tighten at angle with specific tool (1).

Code
square heads
49036 Figure 198
– P4D32C009E0816
ENGINE ASSEMBLY
.541210. Fitting camshaft

46. Position the crankshaft with the pistons 1 - 6 at the T.D.C. This
condition occurs when:
47. The hole with one reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
48. The specific tool (1), through the seat (2) of the engine speed
sensor, enters the hole (3) in the flywheel (4).
Code
49. If this condition does not occur, turn the flywheel (4) appropri-
ately.
50. Remove the specific tool (1).
Code
182251 Figure 199
51. Fit the camshaft (2) inside the bushing on the cylinder head (1)
positioning it with the reference marks (→) as shown in the
figure.
236480 Figure 200
52. Lubricate the seal (2) and fit it on the thrust plate (4).
53. Fit the thrust plate (4) complete with the steel sheet gasket
(5) on the camshaft (1) and tighten the fastening screws (3)
according to the sequence indicated, to a torque of:
Tightening torque
Thrust plate (5 screws 1. Tightening sequence: 1 - 2 - 3 - 4 -
M8x1.25x25) (3) 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 -
10
20 ±2 N⋅m
242599 Figure 201
– P4D32C009E0816
ENGINE ASSEMBLY
54. Diagram of the tightening sequence for the camshaft thrust

plate fastening screws.
151833 Figure 202
55. Apply the specific tool(1) on the camshaft (2).

Code
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
56. Check and adjust the position of the connecting rod (3) for the
idler gear, tighten the fastening screw (4) to a torque of:
Tightening torque
Connecting rod (1 screw 0+0
+0 N⋅m
M8x1.25x16) (4)
242600 Figure 203
57. Refit the idler gear (2) and tighten the fastening screws (1) to a
torque of:
Tightening torque
idler gear (3 screws 1. Step 1 - Pre-tightening
M12x1.75x110) (1) 30 N⋅m
90°
Note Lubricate the screws (1) with engine oil before as-
sembly.
58. Position the power take-off front cover (4) and the sealing ring
(3) on the designated seat on the flywheel housing and tighten
242569 Figure 204
the screws (5).
Tightening torque
Power take-off front cover (3 0+0
+0 N⋅m
M8x1.25x20) (5)
– P4D32C009E0816
ENGINE ASSEMBLY
59. Position the gear (5) on the camshaft so that the 4 eyelet holes
are centred in relation to the camshaft fastening holes but do
not tighten the fastening screws (2) fully.
Note Lubricate the fastening screws (2) with engine oil be-
fore assembly.
60. Using a magnetic base dial gauge (1), check the clearance
between the gears (4, 5) which should be:
Technical data
Rated assembly play between the timing 0.080 mm to0.185 mm
gear and the idling gear
61. Otherwise, adjust the assembly clearance as follows.

62. Loosen the screws (3) securing the idler gear (4). 236729 Figure 205
63. Loosen the connecting rod fastening screw (2), move the con-
necting rod (3) in order to obtain the required clearance.
64. Lock the rod fastening screw (2) and the idle gear fixing screws
(4) to the required torque.
.773020. Fitting the pump support flange

65. Apply the specific gauge (1) to correctly position the high pres-
sure pump support flange (2).
Code
Gauge to determine centre distance between camshaft and 99395226
high pressure pump
242598 Figure 206
66. Fit the high pressure pump support flange on the specific tool
(2) and tighten the fastening screws (3) to a torque of:
Tightening torque
High pressure pump support flange 24.5 ±2.5 N⋅m
(6 screws M8x1.25x30) (3)

Code
Gauge to determine centre distance between camshaft and 99395226
high pressure pump

68. Insert the camshaft timing sensor (2) in the designated seat on
the flywheel housing and tighten the screw (4).
242563 Figure 207
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
Camshaft timing sensor (1 screw 8 ±2 N⋅m
M6x1) (4)
242563 Figure 207
.775010. assembling electro-injectors

69. Replace the sealing gasket (2) on the injectors(1).
169828 Figure 208
– P4D32C009E0816
ENGINE ASSEMBLY
70. Fit the retaining brackets (5)on the electro-injectors (3)

equipped with sealing gaskets (4) and position them in the
relevant seats in the cylinder head.
71. Manually screw in the fastening screws (1) complete with wash-
ers (2). Before tightening them to torque, fit the high pressure
fuel pipes referring to the indications provided in the proced-
ureRail installation ( ➠ Page 119).
72. After having fitted the high pressure fuel pipes, lock the fasten-
ing screws (1) securing the injector brackets (5)to a torque of:
Tightening torque
Electro-injector brackets (6 screws 35 ±3.5 N⋅m
M8x1.25x55) (1)
Tool / Material
Torque wrench
236730 Figure 209
73. Fit the engine brake cylinders (1) and use a torque wrench to
Tightening torque
Engine brake cylinders (12 screws 25 ±2.5 N⋅m
M8x1.25x20) (2)
Tool / Material
Torque wrench
242577 Figure 210
.774510. Rail installation

– P4D32C009E0816
ENGINE ASSEMBLY
74. Fit the common rail (1) onto the cylinder head (4) and tighten
the screws (2) and the nut (5) to a torque of:
Tightening torque
24.5 ±2.5 N⋅m
2. (1 M8x1.25 nut)
24.5 ±2.5 N⋅m
242576 Figure 211
236733 Figure 212

75. Connect the high pressure fuel pipes in the sequence (1 - 2 - 3 - 6 - 5 - 4) tightening the fittings by hand from the rail side
and then from the injector side.
Note Before tightening the couplings to torque make sure that the pipes are not touching each other.
76. Complete injector assembly operations by tightening the fastening screws to the specified torque.
Tightening torque
77. Complete assembly of the high pressure fuel pipes by tightening the fittings in order (1 - 2 - 3 - 6 - 5 - 4) on the injector side
first and then the rail side.
Tightening torque
High pressure fuel pipes from the rail to the electro-injectors (16 fittings 42 ±2 N⋅m
M16x1.5)
78. Connect the high pressure fuel supply pipes (8, 10) and tighten the fittings to a torque of:
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
High pressure fuel pipes from the cylinder head to the rail (4 fittings 42 ±2 N⋅m
M16x1.5)
79. Secure the fuel supply pipe support brackets, tightening the screws (9) to a torque of:
Tightening torque
Fuel pipe support bracket from the pump to the cylinder head (3 screws 24.5 ±2.5 N⋅m
M8x1.25x16) (9)
80. Connect the fuel return pipe (7) from the rail and tighten the fittings to a torque of:
Tightening torque
.541237. Fitting the jumpers

Tightening torque
M4x0.7) (1)

Code
Tightening torque
242591 Figure 213
Head connector (5 screws 0+0
+0 N⋅m
M6x1x12) (5)
collars (4).
84. Mount the guide braces (1) on the valve stem, all with the
largest hole in the same direction.
242590 Figure 214
– P4D32C009E0816
ENGINE ASSEMBLY
.541230. Fitting rocker shaft assembly

85. Apply the specific tool (1)and the relative lock elements(3) to
the rocker arm shaft(4).
Code
Note before refitting the rocker-arm shaft assembly (4),

make sure that all the adjustment screws (2)have been
fully unscrewed.
86. Lift and fit the rocker arm shaft (4) into the relative seat on the
cylinder head (5) using a hoist.
236736 Figure 215
87. Remove the lock elements (1) and tighten the fastening screws
88. Remove the specific tool (2) from the rocker arm shaft (4)
using a hoist.
Code
236737 Figure 216
– P4D32C009E0816
ENGINE ASSEMBLY
89. Screw the screws in four steps as follows:

Tightening torque
Rocker arm shaft (7 1. Step 1 - Pre-tightening
M16x1.5x76 screws) (1 - 7) Tightening sequence: 1 - 7
25 N⋅m
60 N⋅m
80 N⋅m
4. Phase 4 - Tightening to angle 183461 Figure 217
60°

Code
Torque wrench
square heads
90. Fit the retaining springs (1) on the engine brake lever (2).
242589 Figure 218
– P4D32C009E0816
ENGINE ASSEMBLY
.541210. Camshaft timing

91. Apply the specific tool (7) and the specific spacer (8) to the
gear casing (3).
Code
Note The arrow shows the direction of rotation of the en-

gine when running.
92. Using the above-mentioned tool, turn the engine flywheel (1) in
the direction of rotation of the engine so as to take the piston
of cylinder no.1 to 54° before T.D.C. in the phase of compres-
sion (cylinder 6 in discharge phase).
Note This condition is verified when the hole with two
notches (5) on the engine flywheel (1) is visible
through the small inspection window (2).
185252 Figure 219
93. Check that the specific tool (1) enters the hole (3) in the en-
gine flywheel (4) through the seat (2) of the engine speed
sensor. IN this conditions, the flywheel is in the reference po-
sition (piston 1 at 54° before T.D.C.).
Code
94. If this condition does not occur, turn and adjust the flywheel (4)
appropriately.
95. Remove the specific tool (1).
Code
71774 Figure 220
– P4D32C009E0816
ENGINE ASSEMBLY
96. Carefully clean the surface of the head on which the rocker arm
cover rests.
97. Using the specific magnetic base support (2) as shown in the
figure, position the specific dialogue (1) with the flat based rod
(3) positioned on the rocker arm roller (4) which controls the
exhaust valves of cylinder no. 3 and preload to at least 7 mm.
Code
Tool to check timing (use with 99395606) 99370400
Dial gauge (0-30 mm) 99395606
185253 Figure 221
Caution!
Dial gauge pointer Pointer correct positioning
▶ 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.
Caution!
Tolerances measure Checking and overhauling values
▶ 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.
177714 Figure 222

98. Using the specific tool turn the crankshaft in the opposite direction of the operating direction until the pointer of the dial
gauge reaches the minimum value beyond which it can no longer fall.
– P4D32C009E0816
ENGINE ASSEMBLY
177714 Figure 222
Note The measurement must be taken holding the rocker roller in contact with the profile of the exhaust cam of the cam-
shaft.
99. reset the dial gauge.

Note The dial gauge is to be zeroed with the rocker arm
roller in contact with the base radius of the cam profile.
To do this, the flywheel has to be rotated until the pro-
jections (A-B) and (B-C) are exceeded on the eccent-
ric profile connected to the engine brake operation.
This happens by turning the flywheel in the opposite
direction from the operating direction by approxim-
ately 1 and a half turns.
185524 Figure 223

α Camshaft rotation D Cam lift in corres-
angle pondence of 54° be-
Y Cam lift based on the fore the top dead
rotation angle of the centre, 1st cylinder
camshaft end of compression
– P4D32C009E0816
ENGINE ASSEMBLY
100. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
101. Check that the required cam lift values are displayed under the
following conditions:
Code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 224
102. Perform the following if the conditions stated have not been
obtained:
103. Turn the engine flywheel until the required cam lift value ap-
pears on the dial gauge.
104. Loosen the screws (3) securing the gear (1) to the camshaft
(4) and use the slots on the gear (1).
105. Act on the flywheel to obtain the conditions indicated and while
keeping the cam lift value unchanged.
106. Lock the screws (3) and repeat timing check as described
above.
Note While performing this operation recover the clearance
between the camshaft gears.
107. Tighten the screws (3) to the specified torque. 242568 Figure 225
Tightening torque
Camshaft gearing (4 screws 1. Step 1 - Pre-tightening
M14x2x60) (3) 60 N⋅m
Lubrication
Engine oil
60°
108. When adjustment via the slots is not sufficient for recovering
the offset, proceed as follows:
109. Lock the screws (2) and turn the engine flywheel a 1/2 turn in
the opposite direction of the operating direction.
110. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
111. Remove the screws (2) and remove the gear (1) from the
camshaft.
– P4D32C009E0816
ENGINE ASSEMBLY
112. Turn the flywheel (4) again until the following conditions occur:
Code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 226
113. Mount the gear (1) and with the 4 slots and the spacer (2)
centred in relation to the camshaft (4) fastening holes. Lock
the relevant screws (3) to the specified torque.
Tightening torque
Camshaft gearing (4 screws 1. Step 1 - Pre-tightening
M14x2x60) (3) 60 N⋅m
Lubrication
Engine oil
60°
114. Recover the clearance between the timing system gears by

turning the flywheel in the opposite direction to the engine
rotation direction and subsequently turning it in the engine
rotation direction until the dial gauge shows the specific value.
Check the conditions described above. 242568 Figure 227
Technical data
– P4D32C009E0816
ENGINE ASSEMBLY
.541215. Phonic wheel timing

115. Turn the output shaft bringing cylinder piston 1 at compression
stage to T.D.C.; turn the flywheel by about 1/4 turn in opposite
direction than normal direction of rotation.
116. Turn the flywheel again according to normal direction of ro-
tation (anti-clockwise) until the hole marked with the three
notches can be seen through the inspection hole under the fly-
wheel housing (4).
Note If the engine flywheel does not have the three notches,
to identify the reference hole, simply turn the flywheel
in the opposite direction from the operating direction
until reaching the position marked with two notches
(54° before the T.D.C. cyl. 1), then continue to ro-
tate by four holes in the engine operating direction
(remembering that each hole corresponds to a flywheel
rotation of 6°).
117. Install the specific tool (5) in the flywheel sensor seat (6).
Code
118. Insert the specific tool (2), via the seat of the timing sensor,
onto the tooth (↑) obtained on the phonic wheel.
Code
Tool for timing of phonic wheel on timing gear 99360613
119. If it is difficult to fit the tool (2), loosen the screws (3) and
direct the phonic wheel (1) properly to position the tool (2)
correctly on the tooth. Then tighten the screws (3).
Tightening torque
Phonic wheel on timing gear (4 28.5 ±3.5 N⋅m
screws M8x1.25x25) (3)
185254 Figure 228
.771010. High pressure pump assembly

120. Bring the flywheel to 36° before TDC of the first cylinder.
Note This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to
the 30° position marked by THREE notches (4) and continuing to turn the flywheel in the same direction until reach-
ing the next hole (by 6°).
If the engine flywheel does not have the three notches, to identify the reference hole, simply turn the flywheel in the
opposite direction from the operating direction until reaching the position marked with two notches (54° before the
T.D.C. cyl. 1), then continue to rotate by three holes in the engine operating direction (remembering that each hole
corresponds to a flywheel rotation of 6°).
121. Insert the specific tool through the seat of the flywheel sensor in the corresponding flywheel hole.
– P4D32C009E0816
ENGINE ASSEMBLY
122. Mount the HP pump and make sure that the seat of the key (1)
on the pump shaft is facing the pump intakes (2).
187918 Figure 229
123. Position the high pressure pump (2) on the designated seat on
the crankcase (1) and tighten the fastening screws (3).
Tightening torque
High pressure pump to support 37.5 ±2.5 N⋅m
flange (4 screws M10x1.5x35) (3)
242562 Figure 230
124. Fit the pump control gear (2) and tighten the nut (1) to a
torque of:
Tightening torque
High pressure pump control gear (1 275 ±25 N⋅m
nut M24x1.5) (1)
236742 Figure 231
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ENGINE ASSEMBLY

126. Fit the bracket (3) and tighten the fastening screws (1, 2, 4) to
a torque of:
Tightening torque
bracket (1, 2, 4) 32.5 ±2.5 N⋅m
2. (2 screws M10x1.5x20)
47.5 ±2.5 N⋅m
3. (2 screws M8x1.25x20)
25 ±2.5 N⋅m
4. (3 screw M8x1.25x16)
25 ±2.5 N⋅m
242587 Figure 232
.542020. Fitting the high pressure fuel pipes

127. Fit the high pressure fuel delivery pipes (4) and tighten the
fittings ( 3, 5) to a torque of:
Tightening torque
der head (3, 5) 42.5 ±2.5 N⋅m
Note Make sure that the pipe is not damaged after mounting
and that there are no fuel leaks while engine is running.
The HP pipes that are disassembled cannot be used
again and must be replaced.
128. Lock the high pressure fuel delivery pipes (4 )in position using
the retaining clips (1)and tightening the bolts (2) to a torque of:
Tightening torque
242561 Figure 233
Fuel pipe retaining springs between (2 screws M6x1x35 + 2 nuts
pump and cylinder head (2) M6x1)
8 ±2 N⋅m

very carefully.
– P4D32C009E0816
ENGINE ASSEMBLY
187916 Figure 234

– P4D32C009E0816
ENGINE ASSEMBLY

6, 2 - 5 and 3 - 4.
nut (1).
Tool / Material
Box wrench
table.
tion.
Tightening torque
M10x1.25) (1)
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle grade [°]
120
5 2
Angle grade [°]
120
1 6
Angle grade [°]
120
4 3
Angle grade [°]
120
2 5
Angle grade [°]
Conditions
– P4D32C009E0816
ENGINE ASSEMBLY
Code

185252 Figure 236
.540630. installation of head cover

138. Fit the head cover (3) with the relative gasket (4) and tighten
the fastening screws (2) in the order and manner indicated, to
the specified torque.
139. Fit the blow-by pressure sensor (1) on the head cover (3) to a
torque of:
Tightening torque
Blow-by pressure sensor ( 1 fitting 17.5 ±2.5 N⋅m
M10x1) (1)
242573 Figure 237
– P4D32C009E0816
ENGINE ASSEMBLY
236767 Figure 238

140. Position the head cover and insert all the screws.
141. Screw in the screws until making contact with the spacers in the order 1-24 according to the sequence indicated in the figure.
142. Tighten the screws in the order 1-24 in the sequence indicated in the figure to a torque of:
Tightening torque
.540452. Timing gear assembly cover mounting

143. Fit the gasket (2) on the timing gear cover(1).
181826 Figure 239
– P4D32C009E0816
ENGINE ASSEMBLY
144. Fit the timing gear cover (2) with the gasket (3) and tighten the
fastening screws (1) to a torque of:
Tightening torque
Timing gear cover (20 screws Tightening sequence: 1 - 20
M6x1x25) (1) 10 N⋅m
242564 Figure 240
145. Tightening sequence diagram for timing gear cover fastening

screws.
242602 Figure 241
.540486. Blow-by filter fitting

146. Mount the blow-by case (5) and tighten the screws (4) to the
specified torque.
Tightening torque
M6x1x40)
5 ±0.5 N⋅m
M6x1x40)
15 ±1.5 N⋅m
Tool / Material
LOCTITE 2045
242560 Figure 242

Note Upon assembly, apply LOCTITE 2045 to the screws
(4).
147. Fit the blow-by case (2) and tighten the fastening screws (3) to
a torque of:
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
Blow-by casing (6 screws Tightening sequence: A - F
M6x1x25) (3) 7 ±0.7 N⋅m
148. Diagram of the tightening sequence for the blow-by case fasten-
ing screws.
242601 Figure 243
.543060. Suction strainer installation

149. Overturn the engine.
150. Place a new gasket (3) on the crankcase.
151. Fit the oil intake suction strainer (1) and tighten the fastening
Tightening torque
Oil intake suction strainer in the 20 ±2 N⋅m
sump (2 screws M8x1.25) (2)
242585 Figure 244
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ENGINE ASSEMBLY
152. Fit the supports (2, 4) on the oil recovery pipe (3) and tighten
the fastening screws (1) to a torque of:
Tightening torque
Oil sump recovery pipe bracket (3 24.5 ±2.5 N⋅m
screws M8x1.25x16) (2, 4)
242584 Figure 245
.540430. Oil sump assembly

153. Arrange the gasket (3) on the oil sump (2), fit it onto the
crankcase and tighten the fastening screws (1) to a torque of:
Tightening torque
20 ±2 N⋅m
45 ±4.5 N⋅m
242582 Figure 246
.766161. Fitting the engine management control unit

154. Fit the engine control unit support brackets (1, 3, 4) (6) and
tighten the fastening screws (2, 5) to the specified torque.
Tightening torque
0+0
+0 N⋅m
2. (4 screws ST5.5x1.8x45)
0+0
+0 N⋅m
240873 Figure 247
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ENGINE ASSEMBLY
155. Position the engine management control unit (3) together with
the heat exchanger on the engine crankcase correctly interpos-
ing the spacers (2) and tighten the fastening levers (1, 4).
Tightening torque
exchanger (1, 4) 0+0
+0 N⋅m
2. (1 screw M8x1.25x45)
0+0
+0 N⋅m
156. Position the heat guard (5) on the engine control unit (3) and
tighten the screws (6).
Tightening torque
Control unit heat guard (6) (2 screws) 242555 Figure 248
10 ±2 N⋅m
.542020. Fitting the low-pressure fuel pipes

157. Fit the fuel return pipe (11) from the pump, from the common
rail and from the injectors to the tank and tighten the fittings (1,
10)to the specified torque.
158. Fit the low pressure fuel pipe (6) from the tank to the control
unit heat exchanger and tighten the fittings (5, 7) to the spe-
cified torque.
159. Connect the low pressure fuel pipe (3) to the heat exchanger
of the control unit and to the high pressure pump and tighten
the fittings (2, 4) and the retaining collar screws (8, 9) to a
torque of:
Tightening torque
Fuel pipe between the pump 1. (4 M22x1.5 fittings)
and control unit (1, 2, 4, 5, 50 ±5 N⋅m
7, 8, 9, 10)
236750 Figure 249
2. (4 screw M8x1.25x16)
24.5 ±2.5 N⋅m
3. (2 screws M8x1.25x25)
24.5 ±2.5 N⋅m
37 ±3 N⋅m
37 ±3.7 N⋅m
– P4D32C009E0816
ENGINE ASSEMBLY
.542713. Fitting the oil filler pipe and dipstick

160. Fit the engine oil level dipstick guide pipe (6) and tighten the
fitting (5) to the specified torque.
Tightening torque
Oil dipstick guide tube (5) 1 fitting M18x1.5
0+0
+0 N⋅m
161. Fit the retaining bracket (3) and tighten the screws (2, 4).
Tightening torque
Retaining bracket for dipstick guide 0.0+0
+0 N⋅m
tube base (2 nuts) (4, 6)
162. Introduce the engine oil dipstick (1).
242553 Figure 250
.542014. assembly of the fuel filter mount

163. If removed, fit the spacers (1) on the crankcase and tighten the
to the specified torque.
164. Fit the oil filter support (2) and tighten the fastening screws (4)
to a torque of:
Tightening torque
Fuel filter support (4) 1. (4 spacers M8x1.25)
0+0
+0 N⋅m
2. (4 screw M8x1.25x30)
0+0
+0 N⋅m
165. Fit the fuel temperature (3) and filter clogged (5) sensors onto
the fuel filter support (2).
Tightening torque 240870 Figure 251
Fuel filter sensors (3, 5) 1. Fuel temperature sensor (1 fitting
M12x1.5)
30 ±2 N⋅m
M12x1.5)
30 ±2 N⋅m
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ENGINE ASSEMBLY
.542011. fuel filter assembly

166. Insert the filter cartridge (3) into the filter seat cap (5), position
the O-ring (2) and tighten the filter seat cap (5) onto the rel-
ative support (1) using a suitable wrench and tightening to the
specified torque.
167. Tighten the bleed screw (4) and the breather plug positioned
in the bottom part of the filter seat cap (5) and the top part of
the fuel filter respectively to a torque of:
Tightening torque
32.5 ±2.5 N⋅m
2. Drainage plug.
1.5 ±0.5 N⋅m
242580 Figure 252
.542020. Fitting the low-pressure fuel pipes

168. Connect the low pressure fuel pipes (3, 6) to the high pressure
pump and to the fuel filter and tighten the fittings (1, 4, 5, 7)
to a torque of:
Tightening torque
Fuel pipes between pump 1. (2 M18x1.5 fittings)
and filter (1, 4, 5, 7) 0+0
+0 N⋅m
2. (2 M16x1.5 fittings)
0+0
+0 N⋅m
169. Lock the low pressure fuel pipes (3, 6) using the retaining clips
(2).
236753 Figure 253
.540710. intake manifold assembly

170. Fit the intake manifold (6) together with the heater (3) for
engine start-up and the relative gaskets (2, 7) on the designated
seat on the crankcase (1), then tighten the fastening screws (5)
to a torque of:
Tightening torque
Engine air inlet pipe (5 screws 0+0
+0 N⋅m
M10x1.5x140 + 1 screw
M10x1.5x100) (5)
242558 Figure 254
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ENGINE ASSEMBLY
171. Fit the contactor (5) with the relative support bracket on the
intake manifold (6) and after having placed the spacer (3) in
between, tighten the fastening screws (4) to a torque of:
Tightening torque
Contactor (2 screws M10x140) (4) 0+0
+0 N⋅m
172. If removed, fit the turbocharging air pressure and temperature

sensor (2) housed on the intake manifold (6) and tighten the
fastening screw (1) to a torque of:
Tightening torque
Air temperature and pressure 10 ±2 N⋅m
sensor (1 screw M6x1x20) (1)
242557 Figure 255
.760810. Starter motor assembly

173. If removed, tighten the studs (1) in the flywheel housing (4).
174. Fit the electric starter motor (2) and tighten the fastening nuts
Tightening torque
37.5 ±7.5 N⋅m
2. (3 M12x1.75x12 nuts)
74 ±8 N⋅m
242556 Figure 256
.543110. Heat exchanger assembly

175. Position the O-rings (1), fit the internal plate element of the
heat exchanger (2) on the exchanger body (3),and tighten the
fastening screws (4) to the specified torque.
Tightening torque
Heat exchanger elements (4 screws 19 ±3.8 N⋅m
M8x1.25x45) (4)
240863 Figure 257
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ENGINE ASSEMBLY
176. Position the gasket (3), fit the heat exchanger body (4) com-
plete with the internal plate element (1) in the designated seat
on the crankcase (2) and tighten the fastening screws (5, 6) in
the order indicated below to a torque of:
Tightening torque
Oil heat exchanger (5, 6) 1. Step 1 - Pre-tightening (17
M8x1.25x55)
11.5 ±3.5 N⋅m
M8x1.25x55) 242550 Figure 258
24.5 ±2.5 N⋅m
177. Diagram of tightening sequence for lubricant oil heat exchanger

fastening screws.
180274 Figure 259
.543070. oil filter assembly

178. Fit the oil filter support (1) interposing the gasket on the heat
exchanger (2) and tighten the fastening screws (3, 4) to a
torque of:
Tightening torque
Oil filter support (3, 4) 1. Step I (5 screws M8x1.25x65 + 1
screw M8x1.25x40 )
11.5 ±3.5 N⋅m
2. Step II (5 screws M8x1.25x65 + 1
screw M8x1.25x40 )
24.5 ±2.5 N⋅m
242549 Figure 260
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ENGINE ASSEMBLY
179. Diagram of tightening sequence for oil filter support fastening

screws.
242603 Figure 261
180. Moisten the O-ring (2) with a thin layer of oil and place it in its
seat on the oil filter tank(3).
181. Insert the filtering cartridge (3)into the oil filter tank (5).
182. Manually screw the oil filter tank (3) onto the filter body (1)
until the O-ring (2) adheres fully.
183. Tighten the oil filter tank (3) further to a torque of:
Tightening torque
60 ±5 N⋅m
2. Bleed plug
6.5 ±1.5 N⋅m
184. Close the bleed plug (4). 242548 Figure 262
.540720. exhaust manifold assembly

185. Screw the threaded bar (4) onto the cylinder head (1).
186. Position the exhaust manifold (3) on the threaded bar and after
interposing the relative gaskets (2), rest the exhaust manifold
(3) on the cylinder head (1).
240937 Figure 263
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ENGINE ASSEMBLY
187. Fit the exhaust manifold (4) in position together with the new
gaskets (7) on the cylinder head (1) and tighten the fasten-
ing screws (6) together with the spacers (2) and the fastening
screws (4) of the V collars (5) to the specified torque, follow-
ing the tightening order and methods shown in the following
figure.
Tightening torque
Exhaust manifold (6) 1. Step 1 - Pre-tightening (24 screws
M10x1.5x70)
30 ±5 N⋅m
M10x1.5x70)
60 ±5 N⋅m 242545 Figure 264
8 ±0.5 N⋅m
188. Place the pre-assembled exhaust manifold on the cylinder head

using the specific tool fitted in the positions3b-2c.
189. Lubricate the fastening screws with graphitised oil before fitting
the exhaust manifold.
190. Tighten the fastening screws to a torque of 30 Nm in the order: 240863 Figure 265
8a-7a-6a-5a-1a-4a-2a-3a; 8b-2b-6b-5b-3b-4b-1b; 8c-7c-3c-5c-
1c-2c-4c.
191. Remove the specific tool and tighten the fastening screws in the
positions 6c-7b.
192. Tighten the fastening screws to a torque of 30 Nm in the order:
7b-6c.
193. Tighten the fastening screws to a torque of 60 Nm in the order:
8a-7a-6a-5a-1a-4a-2a-3a; 8b-7b-6b-5b-1b-2b-3b-4b; 8c-7c-6c-
5c-1c-2c-3c-4c.
.542410. turbocharger assembly

194. If necessary, tighten the studs (2) on the exhaust manifold (1).
195. Place the turbocharger(5) gasket(3) on the exhaust manifold
(1).
196. Fit the turbocharger (5) together with the Wastegate valve and
tighten the fastening nuts (4)to a torque of::
Tightening torque
manifold (2, 4) 50 ±20 N⋅m
2. (4 M12x1.75x30 studs)
0+0
+0 N⋅m
240858 Figure 266
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ENGINE ASSEMBLY
197. Fit the lubricant oil delivery pipe (1) to the turbocharger and
tighten the fitting (5) on the heat exchanger and the screws (2)
on the turbocharger (3) to the specified torque.
198. Tighten the screw (6) of the retaining clamp of the lubricant oil
delivery pipe (1) to the turbocharger to a torque of:
Tightening torque
turbocharger ( 3, 5, 6) 50 ±2.5 N⋅m
2. (2 screws M8x1.25x35)
24.5 ±2.5 N⋅m
3. (1 M10x1.5x14 screw)
24.5 ±2.5 N⋅m
240857 Figure 267
199. Fit the oil lubricant return pipe (3) in the crankcase (4) and
200. Secure the lubricant oil return pipe (3) to the heat exchanger
using the screw (6).
201. Position the relative gasket and tighten the screws (1) securing
the lubricant oil return pipe (3) to the lower part of the tur-
bocharger (2) to a torque of:
Tightening torque
Turbocharger lubricant return pipe 24.5 ±2.5 N⋅m
(4 M8x1.25x25 screws) (1, 2)
240856 Figure 268
.543251. Thermostat case assembly

202. Position the thermostat (3) inside the thermostat seat (2), lay
the water outlet pipe (5) over it, interposing the gasket (1) and
tighten the screws (4).
240852 Figure 269
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ENGINE ASSEMBLY
203. Place a new gasket (5) on the cylinder head and fit the thermo-
stat body (1), complete with the engine coolant delivery pipe to
the radiator.
204. Tighten the fastening screws (2, 3, 4), following the tightening
order shown in the figure below and to a torque of:
Tightening torque
4- 5
30 ±3 N⋅m
2. Step 1 - (2 screws M8x1.25x50)
4- 5 240908 Figure 270
30 ±3 N⋅m
3. Step 1 - (1 screw M8x1.25x140)
4- 5
30 ±3 N⋅m
4. Step 2 - (4 screws M8x1.25x100)
12- 13- 14
30 ±3 N⋅m
5. Step 2 - (2 screws M8x1.25x50)
12- 13- 14
30 ±3 N⋅m
6. Step 2 - (1 screw M8x1.25x140)
12- 13- 14
30 ±3 N⋅m
205. Diagram of the tightening sequence for thermostat body fasten-

ing screws.
237204 Figure 271
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ENGINE ASSEMBLY
.505712. Fitting the rear suspension mounts

206. Fit the rear engine mount (2) on the flywheel housing (3) and
Tightening torque
Rear right engine suspensions 1. Step 1 - Pre-tightening
(4 screws M16x2x60) (1) 120 ±12 N⋅m
50°
242559 Figure 272
207. Fit the rear engine mount (2) on the flywheel housing and
Tightening torque
Rear left engine suspension 1. Step 1 - Pre-tightening
(4 screws M16x2x60) (3) 120 ±12 N⋅m
50°
208. Fit the camshaft incremental sensor (2) and tighten the screw
(6) to the prescribed torque.
Tightening torque
Camshaft timing sensor (1 nut 8 ±2 N⋅m
M6x1x12) (6) 242552 Figure 273
.544011. Alternator support assembly

209. Position the top alternator support (1) and tighten the fastening
Tightening torque
Top alternator support (2) (2 screws M8x1.25x30)
0+0
+0 N⋅m
210. Position the bottom alternator support (4) so that the ref-
erence grub screws coincide with the engine crankcase and
Tightening torque
Lower alternator support (3) (3 screws M10x1.5x80)
0+0
+0 N⋅m
240905 Figure 274
– P4D32C009E0816
ENGINE ASSEMBLY
.540821. assembly of the crankshaft pulley

Code
71702 Figure 275
212. Key (1) the crankshaft pulley (2) onto the crankshaft and
tighten the fastening screws (3) in two steps:
Tightening torque
M16x2x80) (3) 120 N⋅m
2. Angle tightening
60°
240909 Figure 276
.543210. water pump assembly

213. Apply a new sealing ring (1) to the water pump (2).
214. Fit the water pump (2)in its seat and tighten the fastening
Tightening torque
Water pump (4 screws 24.5 ±2.5 N⋅m
M8x1.25x20) (3)
240906 Figure 277
– P4D32C009E0816
ENGINE ASSEMBLY
215. Diagram of tightening sequence for water pump fastening

screws.
237228 Figure 278
.760310. alternator assembly

216. Position the alternator (1) on its supports, insert the spacer (3)
and tighten the fastening screws (2, 4) to a torque of:
Tightening torque
0+0
+0 N⋅m
2. (1 M10x1.5x110 screw)
0+0
+0 N⋅m
240904 Figure 279
.543417. Automatic belt tensioner assembly

217. Fit the automatic belt tensioner (1) on the support (3)and
tighten the fastening screw (2) to a torque of:
Tightening torque
Automatic belt tensioner (1 screw 66 ±4 N⋅m
M10x1.5x70) (2)
240903 Figure 280
– P4D32C009E0816
ENGINE ASSEMBLY
.543411. Ancillary belt assembly

into position.
242546 Figure 281
damper (4) and the pulleys (3, 6).
belt has settled.
240902 Figure 282
.540860. Damper flywheel installation

221. Fit the damper flywheel (2) on the crankshaft pulley (1).
222. Fit the fan drive pulley (3) and tighten the fastening screws (4)
to a torque of:
Tightening torque
Damper flywheel (6 screws 190 ±20 N⋅m
M14x100) (4)

Code
Engine oil
Torque wrench
square heads
240901 Figure 283
Note Before installing, lubricate the screw thread (2) with
engine oil.
Note Use specific tool for angle tightening.
– P4D32C009E0816
ENGINE ASSEMBLY
.540110. Removing the engine from the stand

Caution!
Engine lifting Lift the engine only by using the specific tool for engine removal and refitting and the specific lifting eye-
lets.
▶ The only method recommended for lifting the engine consists in using the specific tool for engine removal and re-
fitting and the specific lifting eyelets.. As the tool is adjustable, make sure that the lifting points keep the engine bal-
anced, as shown in the figure. Use a hoist to lift the engine slowly with a longitudinal load, as an angular load consid-
erably reduces the lifting capacity.
▶ Handle all the parts with great care. Never place hands or fingers between parts. Wear suitable personal protective
equipment such as a visor, gloves and safety shoes.
242605 Figure 284

223. unscrew the fastening screws of the brackets (1, 2, 3, 5) on the rotating stand (4).
224. Lift the engine from the rotating stand (4) using the lifting hooks and with the help of a specific balance and hoist.
225. Unscrew the screws and remove the brackets (1, 2, 3, 5) from the engine.
226. tighten the lubricant drain plug housed in the lower part of the oil sump and tighten it to a torque of:
– P4D32C009E0816
ENGINE ASSEMBLY
Tightening torque
227. Through the oil filler hole and filler pipe, fill with the quantity and quality of engine lubricant oil as specified in the REFILLING
table.
.543075. Oil pressure adjustment valve assembly

228. Fit the oil pressure adjustment valve (4) interposing the gasket
(5) and tighten the fastening screws (3) to the specified torque.
Tightening torque
Oil pressure relief valve (2 screws 0+0
+0 N⋅m
M8x1.25x20) (3)
229. Position the engine oil pressure and temperature sensor (1)
and tighten the fastening screws(2).
242551 Figure 285
.505711. Fitting the front suspension mounts

230. Fit the front engine mount (2) on the engine crankcase (1)
(turbocharger side) and tighten the screws (3) to the specified
torque.
Tightening torque
Front left engine suspension (4 0+0
+0 N⋅m
screws M14x35) (3)
240893 Figure 286
231. Fit the front engine mount (2) (intake manifold side) and
tighten the screws (1) to the specified torque.
Tightening torque
Front right engine suspension (4 0+0
+0 N⋅m
screws M14x35) (1)
240896 Figure 287
– P4D32C009E0816
ENGINE ASSEMBLY
.790510. Air compressor assembly

232. If removed, screw the studs (5) into the flywheel housing.
233. Position the air compressor (2) together with the gear (1),
interposing the relative gasket (4) in the designated seat on the
gear casing.
234. Screw the nuts (3) onto the relative studs (5).
Tightening torque
Air compressor (3 nuts 170 ±10 N⋅m
M12x1.75) (3)
240895 Figure 288
235. Position the water delivery pipe (2) to the compressor (6) and
connect the fittings (1, 3).
236. Position the water delivery pipe (5) to the compressor (6) and
connect the fittings (4).
240894 Figure 289
.540110. Assembly of Power Generation outfitting

237. Correctly position the gas outlet pipe from the turbocharger
(2) on the turbocharger (1) and tighten the screw (3) of the
relative collar to the specified torque.
Tightening torque
M6x1x50) (3) 7 ±1 N⋅m
247682 Figure 290
– P4D32C009E0816
ENGINE ASSEMBLY
238. Correctly position the air delivery pipe to the air intake mani-
fold (3) on the intake manifold (2) and tighten the screw (1) of
the relative collar to the specified torque.
Tightening torque
Intake air delivery pipe collar (1 0+0
+0 N⋅m
screw M6x1) (1)
247722 Figure 291
239. Correctly position the radiator suspensions (1, 2) on the crank-

case and tighten the screws (3, 4) to the specified torque.
Tightening torque
screws M16x2x60) (3, 4) 100 ±10 N⋅m
60°
247693 Figure 292
240. Correctly position the radiator supports (3, 4) on the en-

gine suspensions and tighten the screws (1, 2) to the specified
torque.
Tightening torque
Radiator supports (4 screws 80 ±8 N⋅m
M12x1.75x30) (1, 2)
247723 Figure 293
241. Lastly, carry out the following: Radiator guards installation ( ➠ Page 6) Radiator pipes installation ( ➠ Page 9) Radiator belts
installation ( ➠ Page 7) Air filter pipe installation ( ➠ Page 13) Air filter installation ( ➠ Page 16).
– P4D32C009E0816
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Technical specifications
Contents 1
Contents
Technical specifications . . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
Contents
Contents
DATA - INSTALLATION CLEARANCES . . . . . . . . . 5

Cylinder assembly and crank gears . . . . . . . . . . . . 5
Cylinder head - Timing system . . . . . . . . . . . . . . 8
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 10
TIGHTENING TORQUES . . . . . . . . . . . . . . . . 10
– P4D32C009E0816
4 Technical specifications
– P4D32C009E0816
DATA - INSTALLATION CLEARANCES
Cylinder assembly and crank gears
F3JFA615A*D001
Type
F3JFA615B*D001
CYLINDER ASSEMBLY AND CRANK GEARS mm
Cylinder liner housing:
Top 156.000 - 156.025

Ø1
Lower 154.480 - 154.550
Cylinder liners:
outer diameter
Top 155.961 - 155.986
Ø2
Lower 154.390 - 154.415
length L 268.5
Cylinder liners - crankcase Top 0.014 - 0.064
seat Lower 0.065 - 0.160
Cylinder liners:
Inner diameter Ø3 141.000 - 141.024
Protrusion X* –
* Below a load of 8,000 kg
Pistons:
Measuring point X 50
Outer diameter Ø1 140.758 - 140.995
Pin housing Ø2 62.089 - 62.109
Piston - cylinder liners 0.005 - 0.226
Protrusion of pistons from

X –
crankcase
Piston pin Ø3 61.992 - 62.000
Piston pin - pin seat 0.089 - 0.117
X 1* 2.480 - 2.510
Piston ring slots X2 2.508 - 2.511
X3 3.550 - 3.580
* measured on Ø of 130 mm
– P4D32C009E0816
F3JFA615A*D001
Type
F3JFA615B*D001

S 1** 2.296 - 2.340
Piston rings S2 2.470 - 2.500
S3 3.470 - 3.490
**measured at 2.5 mm from the outer Ø
1 0.140 - 0.214
Piston rings - slots 2 0.008 - 0.140
3 0.060 - 0.110
Piston rings –
Piston ring end gap in cylinder liner:

X1 0.35 - 0.45
X2 0.700 - 0.850
X3 0.400 - 0.600
Connecting rod small end bush seat
Ø1 67.000 - 67.030
Big-end bearing seat
Ø2 109.987 - 110.013
1 109.987 - 109.996
classes 2 109.997 - 110.005
3 110.006 - 110.013
Connecting rod small end bush diameter
External Ø4 67.120 - 67.160

Internal Ø3 62.072 - 62.087
S STD
Red 2.453 - 2.463
Big end half-bearings
Green 2.463 - 2.473
Yellow 2.473 - 2.483
Connecting rod small end bush - housing 0.090 - 0.160
Piston pin - bushing 0.060 - 0.082
Connecting rod weight g

A (yellow) 6763 - 6893
classes B (green) 6840 - 6915
C (Blue) 6916 - 6991
Main journals Ø1 119.970 - 120.000
1 119.970 - 119.979
classes 2 119.980 - 119.989
3 119.990 - 120.000
Crankpins Ø2 104.970 - 105.000
1 104.970 - 104.979
classes 2 104.980 - 104.989
3 104.989 - 105.000
– P4D32C009E0816
F3JFA615A*D001
Type
F3JFA615B*D001

S1 STD
Red
2.955 - 2.965
Main half-bearings Green
2.965 - 2.975
Yellow
2.975 - 2.985
Black
S2 STD
Red 2.453 - 2.463
Big end half-bearings
Green 2.463 - 2.473
Yellow 2.473 - 2.483
Main journals Ø3 126.000 - 126.030
A
126.000 - 126.009
B
Selection classes 126.010 - 126.019
C
126.020 - 126.030
D
Half-bearings - main journals 0.090 - 0.130
Half-bearings - crankpins 0.060 - 0.110
Main half-bearings 0.127*; 0.254; 0.508
Big end half-bearings 0.127*; 0.254; 0.508
* Fitted in production only and not supplied as spares.
Thrust main journal no. 7 X1 47.95 - 48.00
Thrust main bearing X2 40.94 - 40.99
Thrust half rings X3 3.350 - 3.400
Crankshaft thrust 0.160 - 0.360
Concentricity 1 0.040
Ovalization 1-2 ≤ 0.010
Taper – –
– P4D32C009E0816
Cylinder head - Timing system
F3JFA615A*D001
Type
F3JFA615B*D001
CYLINDER HEAD - TIMING SYSTEM mm
Valve guide housing on

Ø1 15.980 - 15.997
cylinder head
Ø2 10.015 - 10.030
Valve guide:
Ø3 16.012 - 16.025
Valve guides and seats on the head 0.015 - 0.045
Valve guides 0.2 – 0.4
Valves:
Ø4 9.960 - 9.975
α 60° 30' ± 7' 30″
Ø4 9.960 - 9.975
α 60° 30' ± 7' 30″
Valve stem and related guide 0.040 - 0.070
Valve seat on head
Ø1 49.185 - 49.220
Ø1 46.985 - 47.020
Valve seat outside diameter; valve seat

angle on cylinder head:
Ø2 49.260 - 49.275
α 18° ± 1°
Ø2 47.060 - 47.075
α 60° ± 1°
Valve seats 0.2
0.54 - 0.86
Sinking X
1.74 - 2.06
– P4D32C009E0816
F3JFA615A*D001
Type
F3JFA615B*D001
Between valve seat and

0.040 - 0.090
cylinder head
Valve spring height: –

free spring H 76
under a load of:
660 ± 33 N H1 59
1140 ± 57 N H2 46
Injector protrusion X 1.6
Seat for camshaft bushing Ø1→7 88.000- 88.030
Camshaft journals: Ø1→7 82.950 - 82.968
Camshaft bushing outer

Ø 88.153 - 88.183
diameter:
Camshaft bushing inner

Ø 83.018 - 83.085
diameter:
Bushes and seats on cylinder head 0.123 - 0.183
Bushing and support pins 0.050 - 0.135
Useful cam height:
9,2310
H
9.5607
Rocker-arm shaft Ø1 41.984 - 42.000
– P4D32C009E0816
TIGHTENING TORQUES
F3JFA615A*D001
Type
F3JFA615B*D001
42.045 - 42.061
Rocker arms Ø
59.000 - 59.019
Rocker arm bush outer –

diameter: 59.070 - 59.110
Rocker arm bush inner –

diameter: 56.045 - 56.064
Bushings and rocker arm –

seats 0.051 - 0.110
Engine brake control lever

Eccentric pin outer dia-
meter Ø2 55.981 - 56.000
Rocker arm shaft seat Ø1 42.025 - 42.041
Rocker arm bushes and
0.045 - 0.077
rocker arm shaft
Rocker arms and engine
0.045 - 0.083
brake control lever pin
Rocker arm shaft and seat
on engine brake control 0.025 - 0.057
lever
TIGHTENING TORQUES
540110 TIGHTENING TORQUES
Tightening torque
Camshaft timing sensor (1 screw M6x1x12) 8 ±2 N⋅m
Engine oil temperature and pressure sensor (2 M6x1x20 screws) 10 ±2 N⋅m
Fuel temperature and pressure sensor (2 M6x1x20 screws) 10 ±2 N⋅m
Water temperature sensor (1 fitting M12x1.5) 25 N⋅m
Fuel filter clogged sensor (1 sensor M14x1.5) 30 ±2 N⋅m
Fuel temperature sensor (1 M12x1.5 sensor) 30 ±2 N⋅m
Pressure sensor on rail RPS4-22uc (1 sensor M18x1.5) 140 ±7 N⋅m
Lower crankcase (14 internal screws M18x2x208) 1. Step 1 - Pre-tightening
160 N⋅m
90°
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Lower crankcase (14 internal screws M18x2x208) 3. Phase 3 - Tightening to angle
60°
Lower crankcase (25 external screws M12x1.75x130 + 1 ex- 1. Step 1 - Pre-tightening
ternal screw M12x1.75x58) 30 N⋅m
60°
Big-end bearing caps (24 screws M12x1.25x70) 1. Step 1 - Tightening
12 ±0.6 N⋅m
40 ±2 N⋅m
90°
Cylinder head (6 screws M18x2x175 + 20 screws M18x2x196) 1. Step 1 - Pre-tightening
75 N⋅m
150 N⋅m
Cylinder head (6 screws M18x2x175 + 20 screws M18x2x196) 1. Phase 3 - Tightening to angle
90°
90°
Oil recovery pump 1. (2 screws M8x1.25x70)
24.5 ±2.5 N⋅m
2. (1 M8x1.25x35 screw)
24.5 ±2.5 N⋅m
+0 N⋅m
Flywheel housing 1. Step 1 - (12 screws M12x1.75x100)

20 ±2 N⋅m
2. Step 2 - (12 screws M12x1.75x100)
63 ±7 N⋅m
3. Step 1 - (4 screws M12x1.75x35)
20 ±2 N⋅m
4. Step 2 - (4 screws M12x1.75x35)
63 ±7 N⋅m
5. Step 1 - (2 screws M12x1.75x193)
20 ±2 N⋅m
6. Step 2 - (2 screws M12x1.75x193)
63 ±7 N⋅m
7. Step 1 - (2 screws M12x1.75x70)
20 ±2 N⋅m
8. Step 2 - (2 screws M12x1.75x70)
63 ±7 N⋅m
9. Step 1 - (2 screws M10x1.5x25)
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Flywheel housing 9. 20 ±2 N⋅m
10. Step 2 - (2 screws M10x1.5x25)
44 ±4 N⋅m
Engine flywheel (10 screws M19x1.5x75) 1. Step 1 - Tightening
180 ±9 N⋅m
120°
Thrust plate (5 screws M8x1.25x25) 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
20 ±2 N⋅m
idler gear (3 screws M12x1.75x110) 1. Step 1 - Pre-tightening
30 N⋅m
90°
+0 N⋅m

Common rail 1. (3 screw M8x1.25x45)
24.5 ±2.5 N⋅m
2. (1 M8x1.25 nut)
24.5 ±2.5 N⋅m
High pressure fuel pipes from the cylinder head to the rail (4 fittings 42 ±2 N⋅m
M16x1.5)
High pressure fuel pipes from the rail to the electro-injectors (16 fittings 42 ±2 N⋅m
M16x1.5)
Head connector (5 screws M6x1x12) 0+0
+0 N⋅m

Rocker arm shaft (7 screws M16x1.5x76) 1. Step 1 - Pre-tightening
25 N⋅m
60 N⋅m
80 N⋅m
60°
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Camshaft gearing (4 screws M14x2x60) 1. Step 1 - Pre-tightening
Lubrication 60 N⋅m
Engine oil 2. Phase 2 - Tightening to angle
60°
High-pressure pump support bracket 1. (2 screws M12x1.75x30)
32.5 ±2.5 N⋅m
2. (2 screws M10x1.5x20)
47.5 ±2.5 N⋅m
3. (2 screws M8x1.25x20)
25 ±2.5 N⋅m
4. (3 screw M8x1.25x16)
25 ±2.5 N⋅m
Fuel pipe retaining springs between pump and cylinder head (2 screws M6x1x35 + 2 nuts M6x1)
8 ±2 N⋅m
Fuel pipes between pump and cylinder head (4 M16x1.5 fittings)
42.5 ±2.5 N⋅m
Blow-by filter 1. Step 1 - Pre-tightening (3 screws M6x1x40)
5 ±0.5 N⋅m
2. Step 2 - Tightening (3 screws M6x1x40)
15 ±1.5 N⋅m
Blow-by casing (6 screws M6x1x25) Tightening sequence: A - F
7 ±0.7 N⋅m
Oil intake suction strainer in the sump (2 screws M8x1.25) 20 ±2 N⋅m
Engine oil sump (16 M10x1.5x80 screws) 1. Step 1 - Pre-tightening
20 ±2 N⋅m
45 ±4.5 N⋅m
+0 N⋅m
Dipstick guide tube support bracket (1 fitting M8x1.25) 0+0

+0 N⋅m
Oil dipstick guide tube 1 fitting M18x1.5

0+0
+0 N⋅m
Control unit with fuel heat exchanger 1. (2 screws M8x1.25x60)

0+0
+0 N⋅m
2. (1 screw M8x1.25x45)
0+0
+0 N⋅m
Control unit supports 1. (2 M6x1x30 screws)

0+0
+0 N⋅m
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Control unit supports 2. (4 screws ST5.5x1.8x45)
0+0
+0 N⋅m
Control unit heat guard (2 screws)

10 ±2 N⋅m
Fuel filter support 1. (4 spacers M8x1.25)
0+0
+0 N⋅m
2. (4 screw M8x1.25x30)
0+0
+0 N⋅m
Fuel filter 1. Filter seat cap (0 wrench 50)

32.5 ±2.5 N⋅m
2. Drainage plug.
1.5 ±0.5 N⋅m
Fuel pipes between pump and filter 1. (2 M18x1.5 fittings)
0+0
+0 N⋅m
2. (2 M16x1.5 fittings)
0+0
+0 N⋅m
Fuel pipe between pump and control unit 1. (2 fitting M18x1.5)

0+0
+0 N⋅m
0+0
+0 N⋅m
Lubricant delivery pipe to turbocharger 1. (1 fitting M18x1.5)

50 ±2.5 N⋅m
2. (2 screws M8x1.25x35)
24.5 ±2.5 N⋅m
3. (1 M10x1.5x14 screw)
24.5 ±2.5 N⋅m
Turbocharger on the exhaust manifold 1. (4 M12x1.75 nuts)
50 ±20 N⋅m
2. (4 M12x1.75x30 studs)
0+0
+0 N⋅m
Exhaust manifold 1. Step 1 - Pre-tightening (24 screws M10x1.5x70)

30 ±5 N⋅m
2. Step 2 - Tightening (24 screws M10x1.5x70)
60 ±5 N⋅m
8 ±0.5 N⋅m
+0 N⋅m

+0 N⋅m
Starter motor 1. (3 M12x1.75x30 studs)

37.5 ±7.5 N⋅m
2. (3 M12x1.75x12 nuts)
74 ±8 N⋅m
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Oil heat exchanger 1. Step 1 - Pre-tightening (17 screws M8x1.25x40 +1 screw M8x1.25x55)
11.5 ±3.5 N⋅m
2. Step 2 - Tightening (17 screws M8x1.25x40 + 1 screw M8x1.25x55)
24.5 ±2.5 N⋅m
Oil filter support 1. Step I (5 screws M8x1.25x65 + 1 screw M8x1.25x40 )
11.5 ±3.5 N⋅m
2. Step II (5 screws M8x1.25x65 + 1 screw M8x1.25x40 )
24.5 ±2.5 N⋅m
Oil filter 1. Oil filter tank
60 ±5 N⋅m
2. Bleed plug
6.5 ±1.5 N⋅m
Rear left engine suspension (4 screws M16x2x60) 1. Step 1 - Pre-tightening
120 ±12 N⋅m
50°
Rear right engine suspensions (4 screws M16x2x60) 1. Step 1 - Pre-tightening
120 ±12 N⋅m
50°
Top alternator support (2 screws M8x1.25x30)
0+0
+0 N⋅m
Lower alternator support (3 screws M10x1.5x80)

0+0
+0 N⋅m
Crankshaft pulley (6 screws M16x2x80) 1. Pre-tightening

120 N⋅m
2. Angle tightening
60°
Thermostat body/Coolant output pipe 1. Step 1 - (4 screws M8x1.25x100)
Tightening sequence: 1- 3- 2- 6- 7- 4- 5
30 ±3 N⋅m
2. Step 1 - (2 screws M8x1.25x50)
30 ±3 N⋅m
3. Step 1 - (1 screw M8x1.25x140)
30 ±3 N⋅m
4. Step 2 - (4 screws M8x1.25x100)
30 ±3 N⋅m
5. Step 2 - (2 screws M8x1.25x50)
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Thermostat body/Coolant output pipe 5. Tightening sequence: 8- 9- 10- 11- 12- 13- 14
30 ±3 N⋅m
6. Step 2 - (1 screw M8x1.25x140)
30 ±3 N⋅m
Fan pulley mount (5 screws M12x1.75x30)
105 ±10 N⋅m
Alternator 1. (1 M8x1.25x30 screw)
0+0
+0 N⋅m
2. (1 M10x1.5x110 screw)
0+0
+0 N⋅m
Guide pulley (2 screws M12x1.75) 60 ±8 N⋅m

+0 N⋅m

+0 N⋅m

+0 N⋅m

Radiator supports 1. (4 screws M12x1.75x30)
80 ±8 N⋅m
2. (4 screw M10x1.5x25)
45.5 ±4.5 N⋅m
Radiator tie-rod (4 nuts M12x1.75x10 41.5 ±4.5 N⋅m
Radiator suspensions (6 screws M16x2x60) 1. Step I - Tightening to torque
100 ±10 N⋅m
60°
+0 N⋅m

+0 N⋅m

+0 N⋅m
Air filter pipe (2 screws M8x1x18 23 ±2 N⋅m

gas exhaust pipe collar (1 screw M6x1x50) (1 fitting M18x1.5)
7 ±1 N⋅m
Air filter (4 nuts M10x1.5) 45.5 ±4.5 N⋅m
Air filter bracket 1. (2 M8x1x20 screws)
23 ±2 N⋅m
23 ±2 N⋅m
Interface housing support (2 screws M16x2x45) 115 ±15 N⋅m
Engine breather external pipe 1. (1 M8x1x20 screws)
23 ±2 N⋅m
– P4D32C009E0816
TIGHTENING TORQUES
Tightening torque
Engine breather external pipe 2. (1 screw M10x1.5x20)
41.5 ±4.5 N⋅m
20.5 ±2.5 N⋅m
Interface housing (4 nuts M6x1x8 9 ±1 N⋅m
– P4D32C009E0816
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Equipment
Contents 1
Contents
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
TOOLS 3
Contents
Contents
FPT DIAGNOSTICS EQUIPMENT . . . . . . . . . . . . . . 5
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– P4D32C009E0816
4 TOOLS
– P4D32C009E0816
TOOLS 5
FPT DIAGNOSTICS EQUIPMENT
TOOLS
Diagnostics interface with the prepaid card (99327282)
The kit consists of:
● 1 HW PT-box.
● 1 Cable 30 Pin.
● 1 USB Cable 1.8 m
● 1 USB Cable 4.5 m
● 1 Plug
● 1 additional PT-box
● 1 Pre-paid card for activation 99327301
● 1 Adapter from 30 to 19 pins 99368555
● Case
● SW installation CD
Diagnostics tool PT-Plus (I) (99327210)

● 1 Panasonic Toughbook.
● 1 Additional connector for PtBox.
● 1 Italian version of the pre-installed SW.
Diagnostics tool PT-Plus (E) (99327220)

● 1 Spanish version of the pre-installed SW.
Diagnostics tool PT-Plus (UK) (99327230)

● 1 English version of the pre-installed SW.
– P4D32C009E0816
6 TOOLS
Diagnostics tool PT-Plus (F) (99327240)

● 1 French version of the pre-installed SW.
Diagnostics tool PT-Plus (D) (99327250)

● 1 German version of the pre-installed SW.
Prepaid card (99327301)

● 1 Prepaid card for the Teleservices (Remote pro- Included in the kit 99327282.
gramming of the Electronic Control Unit)
30 to 19 pole adaptor (component of 99327282) (99368555)

● 1 connector Included in the kit 99327282.
– P4D32C009E0816
TOOLS 7
TOOLS
TOOLS
Rotary telescopic stand(range 2000 daN, torque 375 daNm) (99322230)
Extraction tool for injectors (99342157)
Key to fit crankshaft front gasket (99346250)
Key to fit crankshaft rear gasket (99346266)
Box wrench for block junction bolts to the lower crankcase (99350072)
– P4D32C009E0816
8 TOOLS
TOOLS
Punch for valve guide removal (99360143)
Pliers for removing/refitting piston rings (105 -160 mm) (99360184)
Tool to remove and refit engine valves (to be used with special plates) (99360259)
Tool for engine valves removal and refitting (use with 99360259) (99360263)
Tool for valve guide refitting (use with 99360143) (99360296)
– P4D32C009E0816
TOOLS 9
TOOLS
Tool for rotating the flywheel (99360321)
Spacer (to be used with 99360321) (99360325)
Adjuster for gasket assembly on valve guide (99360329)
Cylinder liner protrusion gauge (to be used with 99370415-99395603 and special plates)
(99360334)
Spacer (to be used with 99360334) (99360336)
– P4D32C009E0816
10 TOOLS
TOOLS
Tool for cylinder liners compression (use with 99360334 -99360336) (99360338)
Tool for retaining the flywheel (99360351)
Drift to take down and fit back camshaft bushes (99360499)
Crankshaft lifting tool (99360500)
Bracket for removing and refitting engine flywheel (99360551)
– P4D32C009E0816
TOOLS 11
TOOLS
Tool for rocker arm shaft assembly and fitting (99360553)
Arm for engine removal and refitting (99360585)
Clamp for fitting piston into cylinder liner (90 - 175 mm) (99360603)
Tool for engine T.D.C. positioning (99360612)
Tool for timing of phonic wheel on timing gear (99360613)
– P4D32C009E0816
12 TOOLS
TOOLS
Tool for cylinder liner fastening (99360703)
Tool to extract cylinder liners (use with special rings) (99360706)
Ring (135 mm) (to be used with 99360706) (99360728)
Brackets for fastening engine to 99322230 rotary stand (99361036)
Tool for removing the high pressure pump gear (99366198)
– P4D32C009E0816
TOOLS 13
TOOLS
Tool to check timing (use with 99395606) (99370400)
Dial gauge base to adjust lay shaft bearings (use with 99395603) (99370415)
Torque wrench (20-120 Nm) with 1/2" square head (99389813)
9X12 coupling torque wrench (5-60 Nm) (99389829)
14X18 coupling torque wrench (20-120 Nm) (99389833)
– P4D32C009E0816
14 TOOLS
TOOLS
Torque screwdriver (1-6 Nm) for adjusting the locking nut of the injector solenoid valve
connectors (99389834)
Sleeker for valve guide (99390330)
Pair of gauges for angular tightening with 1/2" and 3/4" square heads (99395216)
Gauge to determine centre distance between camshaft and high pressure pump
(99395226)
– P4D32C009E0816
TOOLS 15
TOOLS
Gauge for defining the distance between the centres of camshaft and transfer case gear
(99395228)
Dial gauge (0-5 mm) (99395603)
Dial gauge (0-30 mm) (99395606)
Centring ring of crankshaft front gasket cover (99396035)
– P4D32C009E0816
16 TOOLS
– P4D32C009E0816
CURSOR 16 Not emissioned. ‒ Safety regulations
Contents 1
Contents
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . 3
– P4D32C009E0816
2 Contents
– P4D32C009E0816
SAFETY REGULATIONS 3
Contents
Contents
Standard safety precautions . . . . . . . . . . . . . . . . . . 5
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . 5
During maintenance . . . . . . . . . . . . . . . . . . . . . . . 5
Protection of the environment . . . . . . . . . . . . . . . . 6
– P4D32C009E0816
4 SAFETY REGULATIONS
– P4D32C009E0816
SAFETY REGULATIONS 5
Standard safety precautions
SAFETY REGULATIONS
Standard safety precautions
We direct your attention on some precautions that must be necessarily followed in a regular work environment and, in case of
non-compliance, any other precaution will not be sufficient to protect the safety of the staff in charge of maintenance.
● Please obtain information and inform the staff on applicable laws on safety, making the informative material available for con-
sultation.
● Please keep the rooms as clean as possible and properly ventilated.
● Equip the rooms with specific, well-visible first-aid boxes, always stocked up with suitable medical aids.
● Be equipped with suitable fire extinguishing devices, properly signalled and never obstructed. Check their operation on a regu-
lar basis and train the staff on the intervention priorities and methods.
● Arrange gathering points for the evacuation of the rooms, properly signalling the exit routes.
● Absolutely prohibit smoking in the areas where the works subject to fire hazard are carried out.
● Draw the attention on prohibitions and indications with suitable signs, which are immediately comprehensible always in case of
emergency.
Accident prevention
● Do not wear cloths with loose edges, rings and chains, while working near engines and moving organs.
● Use protective gloves and glasses when: - filling up inhibitors or antifreeze; - replacing or filling up lubricant; - using air or li-
quids under pressure (permitted pressure ≤ 2 bar).
● Wear a protective helmet if working in an area with suspended loads or overhead systems.
● Always wear safety shoes and cloths fitted to the body, better if equipped with rubber bands at the edges.
● Use protective creams for hands.
● Change wet clothes as soon as possible.
● In the presence of voltage higher than 48-60V, check the effectiveness of the ground electric connections. Make sure your
hands and feet are dry and perform the work standing on insulating platforms. Do not proceed if not qualified!
● Do not smoke or spark free flames near batteries and any combustible material.
● Return oily rags or solvents to fire-proof containers.
● Do not perform operations without the necessary instructions.
● Do not use equipment to perform works other than those for which they have been designed, you may sustain accidents,
even of serious type.
● In case of checks or calibrations that require the engine to be on, make sure that the room is properly ventilated and use
proper fans to remove exhaust gases: intoxication and death hazard.
During maintenance
● Never open the filling cap of the cooling circuit when the engine is hot. The operating pressure will spill the high temperature
liquid with serious risk of burns. Wait until the temperature drops below 50 °C.
● Never add coolant to an overheated engine and only use appropriate fluids.
● Always operate with engine off: in case particular circumstances require maintenance with the engine on, consider all the risks
involved in these operations.
● Use adequate and safe containers for draining the engine fluids and exhaust oil.
● Preserve the engine clean from oil, gas oil stains and/or chemical solvents.
● The use of solvents or detergents during maintenance may develop toxic vapours. Always ventilate the work rooms. Use
safety masks when required.
● Do not leave cloths soaked with flammable substances near the engine.
● When starting up the engine after a repair operation, foresee suitable measures to stop air suction in case of over-revving.
● Do not use quick screwers.
● Do not disconnect the batteries whilst the engine is running.
– P4D32C009E0816
6 SAFETY REGULATIONS
Protection of the environment
● Before any interventions involving the electrical circuits, disconnect the batteries.
● Disconnect the batteries from the on-board network while charging.
● After each intervention, make sure the polarity of the battery's terminals is respected and the latter are well tightened and
protected against accidental short circuits and oxidation phenomena.
● Do not disconnect and connect the electric connections when power is on.
● Before carrying out removal operations on pipes (pneumatic, hydraulic or fuel pipes), check the possible presence of fluid or
air under pressure. Adopt the necessary precautions, exhausting the residual pressures or closing the shut-off valves. Always
wear suitable masks or protective glasses. Failure to follow these rules may cause serious accidents and intoxication.
● Avoid improper tightening operations or out of torque. The engine's components may be damaged also seriously, thus preju-
dicing their life cycle.
● Avoid draughts from fuel tanks in copper alloy and/or pipes without filters.
● Do not apply changes to the cabling, their length must not be modified.
● Do not connect any utility to the engine's electric equipment, unless specifically approved.
● Do not modify the fuel or hydraulic systems without authorization. Any unforeseen change will void the warranty and may
prejudice the engine's duration and life cycle.
For engines equipped with electronic units:
● Do not carry out any arch welding without previously removing the electronic units.
● Remove the electronic control units in case of interventions in which the temperatures will exceed 80 °C.
● Do not paint the electronic components and connections.
● Do not modify or alter the data contained in the engine management electronic control unit. Any manipulation or alteration of
the electronic components will invalidate the service warranty of the engine and may also affect its operation and duration.
Protection of the environment

● Allows prioritise protection of the environment implementing all necessary precautions to protect the safety and health of
staff.
● Make sure you and all staff are fully aware of current standards for the treatment and disposal of fluids and engine oils. Set up
adequate signage and specific courses to ensure a full understanding of the rules and the basic prevention measures.
● Collect used oil in suitable containers with water tight seals also providing storage in areas which are adequately
marked,ventilated, away from sources of heat and present no fire hazard.
● Handle batteries with care in well ventilated areas and in antacid containers. Beware of fumes coming from the batteries: they
may pose a serious risk of poisoning and contamination of the environment.
– P4D32C009E0816

CURSOR 16 Not Emissioned

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Technical repair manual

FPT Industrial S.p.A.

Figures and words: FPT Industrial S.p.A. 2016

Technical repair manual 1

SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6

GENERAL WARNINGS REGARDING THE

Grounding and screening . . . . . . . . . . . . . . . . . . . . 9

Optional electrical and mechanical parts

Conversions between the main units of measurement

Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

SYMBOLS - SERVICE OPERATIONS

Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Grounding and screening

Optional electrical and mechanical parts installations

Revolutions per time unit

CORRESPONDENCE BETWEEN TECHNICAL

● CR16TE1W ENGINE FAMILY IDENTIFICATION (CR = CURSOR)

● CR16TE1W DISPLACEMENT: 16 = 16,000 c.c. NOMINAL

● CR16T E1W - FUEL SUPPLY: T = TURBOCHARGED WITH AIR / AIR INTERCOOLER

● CR16TE1W - INJECTION: E = ELECTRONIC MANAGEMENT / with E.C.U.)

● CR16TE1W - LEVEL OF POWER

● CR16TE1W - ENGINE CONTROL UNIT: W = EDC17CV41

● F3JFA615A*D001 - ENGINE FAMILY IDENTIFICATION

● F3JFA615A*D001 - PRODUCT EVOLUTION CURSOR 16

● F3JFA615A*D001 - ENGINE WITH HW

● F3JFA615A*D001 - CYLINDER CONFIGURATION (A = 4 stroke, vertical)

● F3JFA615A*D001 - NUMBER OF CYLINDERS

● F3JFA615A*D001 - APPLICATION (5 = G-Drive)

● F3JFA615A*D001 - TORQUE LEVEL OR ENGINE POWER

● F3JFA615A*D 001 - EMISSION LEVEL (D = Non emissionato)

54 CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES

540110 ISOMETRIC VIEW

540110 ENGINE VIEWS

RIGHT SIDE VIEW

Number of cylinders 6 in line

Total displacement cm3 15926

compression ratio 16.5:1

POWER kW 570 600

First kWm 505 523

Stand-by kWm 557 578

Revs. rpm 1500 1800

start before T.D.C. A = 19°

end after B.D.C. B = 31°

start before B.D.C. D = 50°

end after T.D.C. C = 9°

For timing check

Electro-injectors type CRIN 3-22

Firing order 1–4–2–6–3–5

Injection pressure bar 2200

Turbocharger type: HTT Wastegate turbocharger (WG)

Forced by gear pump, pressure relief valve, oil

– Through centrifugal water pump (fixed speed),

Total capacity (3)

SUPPLY SYSTEM COMPONENTS . . . . . . . . . . . . . . 6

LUBRICATION CIRCUIT COMPONENTS . . . . . . . 15

COOLING CIRCUIT COMPONENTS . . . . . . . . . . 23