WX95 WX125 WSM

EXCAVATOR
WX95
WX125
SERVICE MANUAL
F24062
IMPORTANT:
Data contained in this manual was current at the time of publication. As the Manufacturer improves constantly
his products, some information may result as not updated. If variances are observed, contact your Dealer and
After-Sales Service.
CNH FRANCE S.A. - PRINT 9-91370 EN

December 2004
SECTION 2 F4BE0454 -- F4BE0484
ENGINES F4BE0454B F4BE0484D

F4BE0484E OVERHAUL
INDEX
Engines F4BE0484 . . . . . . . . . . . . . . . . EW--2--3 Checking the eccentric lift and the
Coding of source engines . . . . . . . . . . EW--2--4 pin alignment . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Main engines features . . . . . . . . . . . . . EW--2--5 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--60
Torque and rating features . . . . . . . . . EW--2--7 Replacing the bushings . . . . . . . . . . . . . . EW--2--61
General engines features F4BE0454 EW--2--8 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Assembling engines play F4BE0454 -- Mounting the tappets – Distributing shaft EW--2--61
specifications . . . . . . . . . . . . . . . . . . . . EW--2--10
General engines features F4BE0484 EW--2--16 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Assembling engines play F4BE0484 -- Measuring the journals and crankpins . EW--2--62
specifications . . . . . . . . . . . . . . . . . . . . EW--2--18 Replacing the oil pump drive gears . . . . EW--2--65
Tightening torque . . . . . . . . . . . . . . . . . EW--2--24 Mounting the main bearings . . . . . . . . . . EW--2--65
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25 Measuring the journal assembling play EW--2--65
Graphic indications and symbols . . . EW--2--26 Checking the drive shaft shoulder play . EW--2--66
General remarks . . . . . . . . . . . . . . . . . . EW--2--27 Connecting rod--piston assembly . . . EW--2--67
Description of main mechanic
engine components . . . . . . . . . . . . . . . EW--2--28 Measuring the piston diameter . . . . . . . EW--2--68
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--28 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Conditions for correct pin/piston
Drive shaft seal rings . . . . . . . . . . . . . . . EW--2--29 matching. . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--30 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--31 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--70
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--32 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--71
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--2--33 Checking the connecting rods . . . . . . . . EW--2--71
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Checking the torsion . . . . . . . . . . . . . . . . EW--2--71
Valves and valve seats . . . . . . . . . . . . . . EW--2--35
Checking the flexion . . . . . . . . . . . . . . . . EW--2--71
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--2--36
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--37 Connecting rod--piston match . . . . . . . . EW--2--72
Auxiliary component drive . . . . . . . . . . . EW--2--38 Mounting the piston rings . . . . . . . . . . . . EW--2--72
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Mounting the connecting rod/piston
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--2--40 assemblies in the cylinder liners . . . . . . EW--2--73
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--41 Measuring the crankpin assembling play EW--2--73
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--42 Checking piston protrusion . . . . . . . . . . . EW--2--74
Oil vapour recirculation . . . . . . . . . . . . . . EW--2--43 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--2--74
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--44 Distribution gearbox case . . . . . . . . . . . . EW--2--74
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--2--45 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--75
Mechanic injection feeding system . . . . EW--2--46
Injection pump – 1st phase . . . . . . . . EW--2--76
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--2--46
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--46 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--76
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--2--47 Flywheel cover case . . . . . . . . . . . . . . . EW--2--76
Injection assembly . . . . . . . . . . . . . . . . . . EW--2--48 Mounting the rear seal ring . . . . . . . . . . . EW--2--77
Engine bench--overhaul . . . . . . . . . . . . EW--2--49 Engine flywheel . . . . . . . . . . . . . . . . . . . EW--2--77
Disassembling the engine . . . . . . . . . . . EW--2--49 Replacing the engine flywheel ring gear EW--2--77
Removing the front seal ring . . . . . . . . . EW--2--51 Injection pump – 2nd phase . . . . . . . . EW--2--78
Removing the injection pump . . . . . . . . . EW--2--52 Mounting the injection pump –
Removing the rear seal ring . . . . . . . . . . EW--2--53 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--78
Removing the rocker arm assembly Mounting the oil and water pumps . . EW--2--79
and cylinder head . . . . . . . . . . . . . . . . . . EW--2--55
Monting the front seal ring . . . . . . . . . . . EW--2--79
Repair work on cylinder cluster . . . . . EW--2--57
Checks and measurements . . . . . . . . . . EW--2--57 Mounting the oil sump . . . . . . . . . . . . . EW--2--80
Checking the surface supporting Mounting the water / oil heat
the head on the cylinder cluster . . . . . . . EW--2--58 exchanger . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59 Cylinder head . . . . . . . . . . . . . . . . . . . . . EW--2--81
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--59 Removing the valves . . . . . . . . . . . . . . . . EW--2--81
INDEX
Checking the cylinder head supporting Rocker arm assembly . . . . . . . . . . . . . . . EW--2--87

surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--82
Mounting the injectors . . . . . . . . . . . . . . . EW--2--88
Checking the cylinder head water seal . EW--2--83
Intake manifold unit . . . . . . . . . . . . . . . . . EW--2--89
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--83
Replacing the injectors . . . . . . . . . . . . EW--2--91
Valve descaling, check and grinding . . . EW--2--83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--91
Checking the play between the valve
stem, valve guide and valve centring . . EW--2--84 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--92
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . EW--2--84 Rocker arm removal/reassembling . . EW--2--92

Valve seat reconditioning -- replacement EW--2--84 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--92
Valve springs . . . . . . . . . . . . . . . . . . . . . . EW--2--86 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--92
Mounting the cylinder head . . . . . . . . EW--2--86 Adjusting the tappets . . . . . . . . . . . . . . EW--2--93
Reattaching the cylinder head . . . . . . . . EW--2--87 Valve timing . . . . . . . . . . . . . . . . . . . . . . EW--2--93
EW--2--3
ENGINES F4BE0454 - F4BE0484 OVERHAUL
ENGINES F4BE0484E
Figure 1
84235
.
EW--2--4
CODING OF SOURCE ENGINES
F 4 B E 0 4 8 4 E * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern:
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 4 = 4--cylinder
Group
Engines
8 = Direct injection turbo

diesel with intercooler
5 = Direct injection turbo
diesel
4 = Earthmovers
X Y Y Y Y Y Y Y Y
X = 6 rotary, 2--valve injection pump Manufacturing sequence number

Y = Engine model
EW--2--5
MAIN ENGINES FEATURES
A WX90
B F4BE0454B F4BE0484D
C *D602 *D601 *D608
E 3922 cm3
74kW 88 kW
F 2100 min--1 2200 min--1
G Direct injection
H Rotary injection pump
T.C. T.A.A.
I
(Boosted) (Boosted by intercooler)
A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6
MAIN ENGINES FEATURES
A WX125
B F4BE0484E
C *D605 *D601 *D607
E 3922 cm3
83 kW
F 2000 min--1
G Direct injection
H Rotary injection pump
T.A.A.
I (Boosted by intercooler)
A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--7
TORQUE AND RATING FEATURES
Figure 2
Torque - Nm
Rating - kW
Torque Rating
84279
EW--2--8
GENERAL ENGINES FEATURES F4BE0454

F4BE0454B
Type
*D601 *D602
Cycle 4--stroke diesel engine

Feeding Boosted
Injection Direct
Number of cylinders 4 in--line
Bore mm 102
Stroke mm 120
Total displacement cm3 3922
Compression ratio 17.5 : 1
Max. rating kW 74
min --1 2100
Max. torque Nm 390

min --1 1400
No--load idle rpm min --1 800
No--load peak rpm min --1 2300
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX25W
Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--2--9
F4BE0454B
Type
*D601 *D602
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
Ambra Master gold HSP REFUELLING

15W40
10W30 -- engine sump + filter litres 12.5
FEEDING
Bosch--type injection VE4 / 12 F 1100 L
Pump setting 0° ± 0°.5
Start of delivery mm 1
Type of nozzle DSLA 145 P603
Injection sequence 1 -- 3 -- 4 -- 2
Injection pressure (bar) 245 bar

EW--2--10
ASSEMBLING ENGINES PLAY F4BE0454 -- SPECIFICATIONS

F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners ∅1 102.01 to 102.03
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 101.757 to 01.775
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253
Piston diameter ∅1 0.5
Position of pistons from crankcase X 0.28 to 0.52
Gudgeon pin ∅3 39.9938 to 40.0002
Gudgeon pin -- Pin seat 0.0058 to 0.0182
Type of piston X1* 2.69

Piston ring slots X2 2.425 to 2.445
X3 4.040 to 4.060
* measured on ∅ of 99 mm
S1* 2.310 to 2.340
Piston rings S2 2.560 to 2.605
S3 3.975 to 4.000
1 0.082 to 0.133
Piston rings – Slots 2 0.135 to 0.180
3 0.040 to 0.085
Piston rings 0.5

EW--2--11
F4BE0454B
Type
*D601 *D602
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Connecting rod small--end

bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 73.013
Connecting rod small--end bushing

diameter 43.279 to 43.553
Outer ∅4 40.019 to 40.033
Inner ∅3 1.63 to 1.76
Connecting rod small--end bushing –

seat 0.266 to 0.566
Gudgeon pin – Bushing 0.0158 to 0.0362
Measurement dimension X --
Max. error on connecting rod axis

parallelism = --
Journals ∅1 82.99 to 83.01

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

no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
EW--2--12
F4BE0454B
Type
*D601 *D602
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.068 to 0.410

EW--2--13
F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
Valve stem and respective guide 0.052 to 0.092
Seat on head for valve seat:

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

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

seat and the head
0.050 to 0.102
Valve seats --
EW--2--14
F4BE0454B
Type
*D601 *D602
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for distributing shaft bushings

--
no. 1--5
--
Distributing shaft seats no. 2--3--4
Distributing shaft support pins:

1⇒5 ∅ 53.995 to 54.045
Bushing outer diameter for

distributing shaft: ∅ --
Bushing inner diameter ∅ 54.083 to 54.147
Bushings and seats in crankcase --
Bushings and support pins 0.038 to 0.162

Eccentric working lift:
6.045
7.239
EW--2--15
F4BE0454B
Type
*D601 *D602
∅1 Seat for tappet

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

∅2
Between the rocker arm and the
0.025 to 0.063
shaft
EW--2--16
GENERAL ENGINES FEATURES F4BE0484

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Cyicle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct
Number of cylinders 4 in--line
Bore mm 102
Stroke mm 120
Total displacement cm3 3922
Compression ratio 17,5 : 1
Max. rating kW 83 88
min --1 2000 2200
Max. torque Nm 450 500

min --1 1400 1400
No--load idle rpm min --1 800 850
No--load peak rpm min --1 2200 2400
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX35W
Forced by means of gear pump, pres-

LUBRIFICATION
sure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1,2
at peak rpm bar 3,8
EW--2--17
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
Ambra Master gold HSP REFUELLING
15W40
-- engine sump + filter litres 12 5
12.5
10W30
FEEDING
VE4 / 12 F 1100 L
Bosch--type injection
Pump setting 0° ± 0°≥5
Start of delivery mm 1
Type of nozzle DSLA 145 P603
Injection sequence 1 -- 3 -- 4 -- 2
Injection pressure (bar) 245 bar

EW--2--18
ASSEMBLING ENGINES PLAY F4BE0484 -- SPECIFICATIONS

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Cylinder liners ∅1 102.01 to 102.03
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 101.757 to 101.775
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253
Piston diameter ∅1 0.5
Position of pistons
0.28 to 0.52
from crankcase X
Gudgeon pin ∅3 39.9938 to 40.0002
Gudgeon pin -- Pin seat 0.0058 to 0.0182
Type of piston X1* 2.69

Piston ring slots X2 2.74
X3 4.040 to 4.060
S1* 2.567 to 2.618
Piston rings S2 2.560 to 2.605
S3 3.975 to 4.000
1 0.082 to 0.133
Piston rings – Slots 2 0.135 to 0.180
3 0.040 to 0.085
Piston rings 0.5

EW--2--19
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Connecting rod small--end

bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 7.013

diameter
Outer ∅4 43.279 to 43.553
Inner ∅3 40.019 to 40.033

– seat 0.266 to 0.566
Gudgeon pin – Bushing 0.0158 to 0.0362
Measurement dimension X --
Max. error on connecting rod axis

parallelism = --
Journals ∅1 82.99 to 83.01

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

no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
EW--2--20
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.068 to 0.410

EW--2--21
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
Valvese:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
Valve stem and respective guide 0.052 to 0.092
Seat on head for valve seat:

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

inclination of valve seats
on cylinder head:
∅2 47,063 ÷ 47,089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 0.356 to 1.102
X 0.104 to 0.840
Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102
Valve seats --
EW--2--22
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for distributing shaft

bushings no. 1--5 --
Distributing shaft seats no. 2--3--4 --
Distributing shaft support pins:

1⇒5 ∅ 53.995 to 54.045
Bushing outer diameter for

distributing shaft: ∅ --
Bushing inner diameter ∅ 54.083 to 54.147
Bushings and seats in crankcase --
Bushings and support pins Bushings and support pins

Eccentric working lift:
6.045
7.239
EW--2--23
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030
∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Between the tappets and the

seats 0.020 to 0.065
Tappets --
∅1
Rocker arm shaft ∅1 18.963 to 18.975
Rocker arms ∅2 19.000 to 19.026

∅2
Between the rocker arm and the
shaft 0.025 to 0.063
EW--2--24
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st phase
p 50 ± 6 (5 ± 0.6)
2nd p
phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90°
Connecting g rod cap
p fastening
g screws 1st p
phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
-- Lubrication with oil

EW--2--25
TOOLS
380000144 Engine flywheel retaining tool
380000216 Swing bar for engine detachment and reattachment
380000220 Band for inserting the piston into the cylinder liner (60--125 mm)
380000221 Pliers for removing and reassembling the piston rings (65--110 mm)
380000228 Comparator (0--5 mm)
380000301 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000302 Tool for removing and reassembling the engine valves
380000304 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380000322 Extractor for the gear linking the injection pump to the engine
380000362 Drive shaft lifting tool
380000364 Comparator holder base for miscellaneous measurements (to be used with 380000228)
380000661 Brackets for fastening the engine to the rotary stand 380000301
380000663 Tool for removing the drive shaft rear gasket
380000664 Coupler for mounting the drive shaft rear gasket
380000665 Tool for removing the drive shaft front gasket
380000666 Coupler for mounting the drive shaft front gasket
380000667 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000668)
380000668 Handle for interchangeable beaters
380000669 Gasket extracting tool
380000670 Cartridge filter removing tool
380000671 Injector extracting tool
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000988 Tool for rotating the engine flywheel
380001003 Full square for connecting rod squaring check
380001005 Comparator (0--10 mm)
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380000228)
EW--2--26
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

α
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
EW--2--27
GENERAL REMARKS
Figure 3
84236
1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump drive belt – 6. Automatic belt stretcher – 7. Fixed guide pulley – 8. Fixed guide pulley – 9. Fan
pulley – 10. In--line injection pump – 11. Cold start air heater – 12. Blow--by
Figure 3bis
Aspiration manifold part for applications without

intercooler: F4BE0454.
88233
EW--2--28
DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.
Figure 4
2
7 3
86605
EW--2--29
Drive shaft
It is made of steel and rests on five induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
Inside the drive shaft are the lubricating oil ducts.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
The second main half bearing is equipped with a
flywheel and auxiliary component drive pulley.
shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 5
84207
1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear
Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000665 and 380000663, and mounted by means of tools 380000666 and 380000664.
EW--2--30
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 6
84038
EW--2--31
Pistons
Figure 7
84039
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1 and 2, trapezoidal in shape and with ce-
Three slots (piston ring seats) are provided: the first ramic chrome coating.
one and the second one are obtained from a cast-- Ring 3, with double scraper ring shoe with inner
iron insert with trapezoidal section. spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 8
84040
EW--2--32
Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.
Figure 9
70164
84238
EW--2--33
Valve control
Figure 10
84239
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--34
Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);
Figure 11
84240
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--35
Valves and valve seats
Figure 12
S 1
84241
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side.
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 13
84242
Figure 13 shows the oil seals mounted on valve

stems.
EW--2--36
Valve guides
Figure 14
INTAKE EXHAUST
84046
DETAIL OF VALVE GUIDES AND SEATS

EW--2--37
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 15
84048
EW--2--38
Auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft The belt is stretched by means of automatic belt
(5) to water pump (1), alternator (2) and fan (6). stretcher (3).
Figure 16
84243
1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
EW--2--39
Lubrication
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the crank-
lowing components: case, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure control valve built into the oil filter
case front part, controlled by the straight--tooth adapter;
gear force--fitted on the drive shaft shank; - by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.
Figure 17
84244
Oil return drop--type path Oil supply
Pressure oil path

EW--2--40
Heat exchanger
Figure 18
84051
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter
EW--2--41
Oil pump
Figure 19
84052
Figure 20
70150
1. Drive shaft with oil pump drive gear

EW--2--42
Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2) (fitted onto the oil
case by means of an aluminium plate (3), Figure 21. sump leading profile) enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 21
84245
Figure 22
84246
The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--2--43
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
Figure 23
84056
EW--2--44
Cooling
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.
Figure 24
84247
Water flowing out of the thermostat Water flowing into the pump
Water recirculating in the engine

EW--2--45
Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 25
84058
Figure 26
84059
EW--2--46
Mechanic injection feeding system

Fuel prefilter
The filter support (1) incorporates manual priming

pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 27
84060
Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.
Figure 28
84248
EW--2--47
Mechanic fuel pump

Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.
Figure 29
84249
1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank
Figure 30
84250
1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--48
Injection assembly
Figure 31
84251
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KKSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--49
ENGINE BENCH--OVERHAUL Figure 34

Disassembling the engine
Figure 32
84252 84254
Drain the engine oil by taking the cap off the sump - disconnect the engine oil vapour recovery pipe
and the oil filling cap off the head cover. from blow--by (1);
Remove the fan unit from the fan pulley. - take off tappet covers (4);
In order to be able to fit bracket 380000661 (which - disconnect electric wiring (8);
fastens the engine to the overhaul stand) to the - take off fuel filter (9);
crankcase, it is necessary to:
- take off intake manifold (3);
- remove electric wiring (1).
- take off container (2);
- take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
Figure 33
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 35;
- take off fuel filter support (6).
Figure 35
84253
In order to be able to fit bracket 380000661 to the
crankcase on the right side, it is necessary to re-
move:
- the starter motor (3);
- the bracket (2) fastening the oil return pipe (1);
- the oil return piping (1) relative to turbine;
- oil pipes (4) and (5) from heat exchanger unit
(6). 70126
Secure the engine to rotary stand 380000301. Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
- take off turbine lubrication delivery pipe (7);
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--50
Figure 36 Figure 39
84255
- Remove injector (5) feed pipes (5) from injection 84082
pump (6); remove the rackets fastening the pipe

Take out injectors (2) by means of tool (1) 380000671.
unit (1), (2) and (3) on the cylinder head.
- Remove the priming pump (4).
Figure 37
Figure 40
84256
- Remove the feed pipe unit from injectors (1).

- Remove fuel drain pipe (2) from injectors by re-
moving the screw (4) and the seal (3).
Figure 38
84258
- Remove the belt tightener (4).

- Remove the auxiliary component belt (6) operat-
ing the alternator fastening bracket (1).
87005 - Remove the alternator (2), the water pump (5),
- Remove the screws (3) and then remove the tur- the fan pulley (8) and the guide pulleys (7).
bine (1).
- Remove the pulley support (9).
- Remove the exhaust manifold (2).
- Remove the engine cooling system connection
- Remove water temperature sensor (4). (3) from the cylinder block.
EW--2--51
Figure 41 Removing the front seal ring

Figure 43
84068
Apply tool 380000144 (1) to the flywheel housing to

78256
stop flywheel rotation.
Apply tool 380000665 (4) on drive shaft front shank

(2).
Drill inner seal ring (1), through tool 380000665 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000665 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).
Figure 42 Figure 44
84259 78257
Unscrew fastening screws (1) from pulley (2). Apply the proper tension rod (3) of tool 380000669 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
EW--2--52
Figure 45 Figure 47
84260
84237 To correctly preset the injection pump prior to remov-

ing it, loosen screw (2) and remove L--shaped spacer
(1).
Remove gear oil pump (1).
Fasten again screw (2) to its abutting end.
IMPORTANT -- Oil pump (1) cannot be recondi- IMPORTANT -- Carefully store the L--shaped
tioned. spacer with the pump body.
Removing the injection pump Figure 48

Figure 46
84073
84071
Prior to removing the injection pump, take off the fly- - Remove cover (1) from gear covering case (2).
wheel locking tool described in Figure 41.
- Lock the engine flywheel as described in
Rotate the drive shaft until it reaches the condition of Figure 41.
1° cylinder at top dead centre.
- Loosen nut (3) securing the injection pump drive
Such condition is obtained when, by pushing pin (1) gear (4).
shown by the arrow, it is housed in its own seat ob-
tained on distributing shaft drive gear (2).
EW--2--53
Figure 49 Figure 51
84261
84076
Loosen the three nuts (2) (4) (5) securing the injection Screw two pins (2) of adequate length into drive shaft
pump (1) to the flywheel covering case (3), then take holes (3).
the pump out of its housing by means of tool
380000322 through proper application to gear (4) in Remove tool 380000144 (2).
Figure 48B.
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
Removing the rear seal ring
Figure 50 Figure 52
84075 78258
Remove screws (3) securing engine flywheel (4) to the Apply tool 380000663 (3) on drive shaft rear shank
drive shaft. (5).
Drill inner seal ring (1), through tool 380000663 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000663 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2).
EW--2--54
Figure 53 Figure 56
78257
Apply the proper torsion bar (3) of tool 380000669 to

86601
outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever APPLICATION WITH ROSE PIPE IN FRONT
(4). POSITION
Figure 57
Figure 54
84077
86470
Remove screws (2) and take off rear cover (1). APPLICATION WITH ROSE PIPE IN REAR
POSITION
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. Remove screws (1) and (4) and take off oil suction
strainer (5).
Remove screws (2) and take off stiffening plate (3).
Figure 55 Figure 58
84278 70156
Turn the engine upside down, remove screws (2), Remove screws (1) and take off gear (3) from distrib-
take off both plate (3) and oil sump (1). uting shaft (2).
EW--2--55
Removing the rocker arm assembly and Figure 62

cylinder head
Figure 59
84085
84081 Remove screws (2) and take off timing gear case (1).
For each cylinder, remove rocker arm assembly (1),
loosen adjusting nuts (3), unscrew registers (2) and
remove screws (4).
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter.
Figure 60
87006 Figure 63
Remove screws (1) securing the head to the crank-
case.
Figure 61
70158
Remove connecting rod cap (2) fastening screws (1),

then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part.
87007
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
EW--2--56
Figure 64 Figure 67
70159
Remove screws (1) and take off bed caps (2). 70162
Take off main half bearings (1).

Figure 65
Remove screws (2) and take off oil nozzles (3).
Figure 68
70160
The penultimate bed cap (1) and its respective sup-

port have half bearing (2) provided with shoulder.
70163
Remove screws (1) and take off distributing shaft (3)

IMPORTANT -- Take note of the mounting position retaining plate (2).
of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in IMPORTANT -- Take note of plate (2) mounting
the same position they had prior to being taken off. position.
Figure 66
Figure 69
70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000362(1) and a hoist. crankcase.
EW--2--57
Figure 70 Figure 71
70165 70166
Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
NOTE – If no ring gauge is available, use a micro-

meter to perform reset.
Repair work on cylinder cluster Figure 72

Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
70167
Measurements must be taken for each single cylin-

der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
EW--2--58
Figure 73 Checking the surface supporting the head on

the cylinder cluster
Figure 74
70170
Verify that the head supporting plane on the cylinder

cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
70168 The flatness error must not be greater than 0.075 mm.
IMPORTANT -- In case of reconditioning, all the

liners must be machined to the same increase (0.5
mm).
NOTE -- Crankcase flattening may be carried out
Check the main bearing seats as follows: only after making sure, when the repair work has
- mount the bed caps on the supports without bear- been completed, that the protrusion of the piston
ings; from the cylinder liner is not greater than the speci-
fied value.
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com- Check the condition of cylinder cluster working caps
parator, that the seat diameter is the same as the (1); they must be replaced if they are rusty or their
specified value. sealing properties are in doubt.
If a greater value is found, replace the crankcase. After flattening, restore the cylinder liner countersink,
as shown in Figure 73.
EW--2--59
Valve gear
Distributing shaft
Figure 75
70169
MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins
The shaft support pin and eccentric surfaces must be Figure 76

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm for ex-
haust eccentrics and 6.045 mm for intake eccentrics;
if different values are found, replace the shaft.
70171
Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--2--60
Bushings Figure 77
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.
70172
Figure 78
sec. A-A
70173
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
EW--2--61
Replacing the bushings Mounting the tappets – Distributing shaft

Figure 79 Figure 81
70174 70176
To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000667 (2) and handle 380000668 (3) to remove seats of the crankcase.
and reassemble the bushings.
IMPORTANT -- Bushings (1) must, upon mount-

ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.
Tappets
Figure 80 Figure 82
84053 70164
MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
EW--2--62
Figure 83 Figure 85
70238 70180
Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.
Drive shaft
Measuring the journals and crankpins
Figure 86
Figure 84
70182
If traces of excessive seizing, scoring or out--of--

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

values on a table.
See Figure 87.
70179
Check the distributing shaft end play (1).

EW--2--63
Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crank-
pins must be marked with a special stamping
made on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
Figure 87
70181
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--64
Figure 88
70183
MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES
TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY
Figure 89
BEARINGS ON TIMING INTERMEDIATE FIRST

SIDE BEARINGS BEARING ON
UPPER SIDE
84275
EW--2--65
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 90 Figure 93
70184 70161
Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
Mounting the main bearings

Figure 91 Figure 92
70185 70186
Check the play between the drive shaft journals and

IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
EW--2--66
Figure 94 Figure 96
70187 70189
Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
Checking the drive shaft shoulder play

Figure 95 Figure 97
70188 70190
- 3rd phase with tool 380000304 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60° ± 5°. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--67
Connecting rod--piston assembly
Figure 98
70191
PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing
NOTE -- Pistons are supplied as spares increased by 0.5 mm.
Figure 99 Figure 100
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000221 (3). moved by means of a mark scraper (3).
EW--2--68
Figure 101
84095
MAIN DATA ABOUT PISTON IN APPLICATION WITH INTERCOOLER
86471
MAIN DATA ABOUT PISTON IN APPLICATION WITHOUT INTERCOOLER
Measuring the piston diameter
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 61 mm far
from the piston skirt base.
EW--2--69
Gudgeon pins Figure 107

Figure 104
84097 84100
Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 105
Figure 108
84098
Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 106
84101
SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
EW--2--70
CONNECTING ROD BODY
CONNECT--
70194 ING ROD
WEIGHT
NO.
Measuring the play between the ends of piston rings

(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).
Connecting rods
Figure 110
CONNECTING ROD CAP
CONNECTING ROD YEAR DAY

NO.
70196
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
86472 ment, it is therefore necessary to number the
MAIN DATA OF CONNECTING ROD, GUDGEON new connecting rod with the same number as
PIN BUSHING AND HALF BEARINGS the replaced one.
* Dimension of inner diameter to be obtained after - By a letter (on the connecting rod body) which
driving into the connecting rod small--end and refacing indicates the weight class of the factory--as-
by means of a reamer. sembled connecting rod:
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure
better match. Material removal is not permitted.
Therefore, it is recommended not to remove
knurls.
EW--2--71
Bushings Checking the torsion

Figure 113
Verify that the bushing in the connecting rod small--
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 112
61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ∼ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.
Checking the flexion

Figure 114
61696
Check the parallelism of connecting rod axes (1) by
means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--72
Connecting rod--piston match Mounting the piston rings

Figure 118
Figure 115
84103 84093
The following reference data are engraved on the pis- Use pliers 380000221 (3) to fit piston rings (1) on pis-
ton crown: ton (2).
1. Spare part number and design modification The rings must be mounted with the writing “TOP”
number; facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
2. Date of manufacture;
by 120°.
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin- IMPORTANT -- Spare piston rings are supplied in
der liner. the following dimensions:
Figure 116 -- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;
Figure 119
84104
Connect piston (2) to connecting rod (4) by means of
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5)
stamped on connecting rod (4) can be seen as shown
in the figure.
Figure 117
70200
Mount half bearings (1) both on the connecting rod
and the cap.
IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
EW--2--73
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 122
Figure 120
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000220 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 123
Figure 121
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 124
84040
SCHEME FOR MOUNTING THE CONNECTING

ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the writing stamped on the piston crown faces the 70205
crankcase front side, or the notch obtained on the - Apply tool 380000304 (1) on the compass
piston skirt corresponds to the position of oil nozz- wrench, then tighten screws (2) further in a criss--
les. cross sequence.
EW--2--74
Figure 125 Checking piston protrusion

Figure 127
70206 70208
- Take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380000364 (1) equipped with base 380000228 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
70207
If the measured play is different from the specified 84105

one, replace half bearings and repeat the check.
SCHEME FOR SEALANT LOCTITE 5999
Once the specified play has been obtained, lubricate APPLICATION AREA
the connecting rod half bearings and mount them defi- Clean thoroughly distribution gearbox case (1) and
nitely by tightening the connecting rod cap fastening the engine crankcase.
screws as described. Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case so as to
IMPORTANT -- Prior to mounting the connecting make a bead with a diameter of a few millimetres.
rod cap fastening screws definitely, verify that the The bead must be smooth (no lumps) and free from
diameter of the same (as measured at the middle air bubbles, thin areas or gaps.
of the thread length) is not smaller than 0.1 mm of Any defect must be corrected as soon as practicable.
the diameter measured at about 10 mm from the Avoid using excess material to seal the joint.
screw end. An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
Check manually that connecting rods (1) run axially After completing sealant application, the joints must
on the drive shaft pins, and that the end play of the be mounted immediately (within 10 -- 20 minutes).
same (as measured by means of a thickness gauge
(2) is 0.10 to 0.33 mm.
EW--2--75
84106 84107
SCHEME FOR REAR GEARBOX CASE FASTEN- Turn drive shaft (4) and distributing shaft (2) in such
ING SCREW TIGHTENING SEQUENCE a direction that when mounting driven gear (1) on the
Reassemble case to the crankcase. distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.
Valve timing
70211 70213
Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--76
Injection pump – 1st phase Figure 135

Timing
Figure 133
84108
Force--fit gear (1) transmitting the motion to the pump,
then fasten nut (2) by hand.
84071
Flywheel cover case
Bring cylinder 1 to the top dead centre. This condition
occurs when pin (1) (shown by an arrow) is housed in Figure 136
the seat available on the distributing shaft drive gear
(2).
84109
SCHEME FOR SEALANT LOCTITE 5999 AP-

PLICATION AREA
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox.
Figure 134
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case (1) so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
84273
Mount the injection pump body (1) in the gearbox seat
(2), then secure it by means of screws (3).
EW--2--77
Figure 137 Engine flywheel

Figure 139
84110 84111
SCHEME FOR FLYWHEEL COVER CASE Check the clutch disc supporting surface and turn it if
FASTENING SCREW TIGHTENING SEQUENCE scoring is detected.
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
taken off, then fasten them to the specified torque. NOTE -- The rated thickness of the engine flywheel
is 51 mm.
Screws:
- M12 x 1.75 x 100 80 ± 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 ± 20 Nm Check the condition of ring gear (2) teeth. If breaks or
- M16 x 1.50 x 100 200 ± 20 Nm excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 139) by using a
- M12 x 1.75 x 78 80 ± 10 Nm normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.
Mounting the rear seal ring
70216 84076
Apply part (5) of tool 380000666 on drive shaft rear Screw down two pins (2) of adequate length into the
shank (6), secure it by means of screws (4) and force-- shaft holes (3), then remove the engine flywheel (1)
fit the new seal ring (3) on the same. by means of suitable harnesses and a hoist.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--78
Figure 141 Injection pump – 2nd phase

Mounting the injection pump – 2nd phase
Figure 143
84075 84115
Apply tool 380000144 (2) to the flywheel cover case Torque--tighten nut (1) by means of torque wrench (2).
(1) to stop engine flywheel (4) rotation.
Tighten screws (3) fastening engine flywheel (4) to the
Figure 144
drive shaft.
Figure 142
α 84116
Apply sealant (1) as shown in the figure, then put on

small cover (2).
Figure 145
84114
Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: tighten to an angle of 60° ± 5°. 84260
Remove plug (1) from the distribution gear seat

Figure 46.
IMPORTANT -- Angle tightening is carried out by
means of tool 380000304. Remove presetting screw (2) and insert L--shaped
spacer (1). Fasten again the screw to its abutting end.
EW--2--79
Mounting the oil and water pumps Figure 149
Figure 146
70223
Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5999 onto the same.
70220
Figure 150
Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 147
70224
Clean thoroughly the surface of front cover (2) attach-

ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
70221
Mounting the front seal ring
Apply a new seal ring (2) onto water pump (1).
Figure 151
Figure 148
70225
Apply part (5) of tool 380000660 on drive shaft front

70222
shank (6), secure it by means of screws (4) and force--
Mount water pump (1). fit the new seal ring (3) on the same.
Fasten screws (2) and tighten them to the specified Position part (1) on part (5), then screw nut (2) to fully
torque. mount seal ring (3) in front cover (7).
EW--2--80
Mounting the oil sump Figure 155

Figure 152
84278
86601
Mount oil sump (1) and apply plate (3) on the same.
APPLICATION WITH ROSE PIPE IN FRONT
POSITION Fasten screws (2) and tighten them to the specified
torque.
Figure 153 Screws:
- M10 x 1.50 x 70 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 100 70 ± 5 Nm
- M10 x 1.50 x 90 70 ± 5 Nm
NOTE -- The application relative to excavator E165

and E195 Evolution requires that the sump is
mounted in a position rotated by 180° relative to the
figure.
86470
APPLICATION WITH ROSE PIPE IN REAR

POSITION
Mount plate (3) and strainer (5), then screw down
fastening screws (2, 4 and 1) and tighten them to the Figure 156
specified torque.
Figure 154
84280
70227
Force--fit pulley (1) complete with spacer (2) onto the
Place gasket (1) on oil sump (2). drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380000304.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (4) to the front cover by means
of screws (3).
EW--2--81
Mounting the water / oil heat exchanger Figure 160

Figure 157
84175 84281
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support (3).
gasket (1), heat exchanger (2), a new gasket (3), and
Fasten screws (2) without torque--tightening them.
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Figure 158
84176
Lubricate seal ring (1) with engine oil, then position it Cylinder head
on oil pipe coupling (2).
Removing the valves
Fit oil pipe coupling (2) to support (4).
Figure 161
Place a new seal ring (3) in the crankcase housing.
Figure 159
84179
Valves can be removed by means of tool 380000302

(1) by pressing slightly on collar (3) so that lock cones
84177
(2) can be removed by compressing springs (4). Then
Position alternator support (1) in such a way that pins
remove collar (3) and springs (4).
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified Repeat the procedure on all valves.
torque.
EW--2--82
84282 87008
Take off oil seals (1) fitted to the valve stems. Remove the thermostat unit (2) and brackets (1) and
(4).
To remove the valves, properly turn the head upside
down. Remove the cover (3) of the intake manifold.
IMPORTANT -- Mark the exhaust and intake

valves prior to removing them.
Checking the cylinder head supporting surface
INTAKE EXHAUST
84181 84183
In addition to the head dimensions, the exhaust The plane of the supporting surface of head (1) to cyl-
valves differ from intake valves in that they are inder cluster is checked by means of a ruler (2) and
equipped with a supplementary notch (1) obtained on a thickness gauge (3).
the stem for intake valves. The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
EW--2--83
Checking the cylinder head water seal Valves

Check the water seal by means of suitable equipment. Figure 167
Use a pump to feed water heated to ∼ 90 °C at a pres- EXHAUST INTAKE
sure of 2 to 3 bar. VALVE VALVE
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.
IMPORTANT -- Prior to mounting the caps, apply

water--repellent sealant on the sealing surface of
the same.
If leaks are detected from the cylinder head, the latter

must be replaced. 84185
MAIN DATA OF INTAKE AND EXHAUST VALVES
Valve descaling, check and grinding

Figure 166
Figure 168
84284
Nominal thickness A of the cylinder head is 95 ± 0.25

84186
mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm. Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
IMPORTANT -- After regrinding, check valve sink- crimping or burns.
ing and regrind valve seats if required, to obtain
the required value. Reface, if necessary, the valve seats by means of a
grinder 380000975, by removing as less material as
possible.
EW--2--84
Figure 169 Valve guide

Figure 171
84187
Use a micrometer (2) to measure valve stem (1),

which must be equal to 7.96 to 7.98. INTAKE EXHAUST
84046
Use a bore gauge to measure the valve guide inner

diameter, which must be equal to the value shown in
the figure.
Checking the play between the valve stem, Valve seats

valve guide and valve centring
Valve seat reconditioning -- replacement
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). If slight burns or scoring are
parator (1) placed as shown. Assembling play must found, proceed with reconditioning by means of tool
be equal to 0.039 to 0.079 mm. 380000975 (1) according to the inclination values
shown in Figure 173.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
EW--2--85
Figure 173
EXHAUST INTAKE
87009
VALVE SEAT DIMENSIONS
Figure 174
EXHAUST INTAKE
87010
VALVE SEAT HOUSING DIMENSIONS
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 172) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 173.
EW--2--86
Figure 175 MOUNTING THE CYLINDER HEAD

Figure 177
87008
84192
Apply sealant LOCTITE 5999 between cover (3) and
cylinder head, then tighten the screws to the specified
After the reconditioning operations, verify, by means torque.
of base 380000364 (2) and comparator 380000228 Mounting the thermostat unit (2) and brackets (1) and
(1), that valve hollow (3) corresponds to the specified (4), then tighten the screws to the specified torque.
value.
Figure 178
Valve springs
Figure 176
84282
Lubricate the valve stem and insert into the respective
valve guide according to the position marked upon
disassembling.
Mount seal rings (1) onto the valve guide.
84193
Figure 179
MAIN DATA FOR INTAKE AND EXHAUST VALVE
SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of tool 380000976. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.
Height Under a load of

mm N
84179
H(Free) 63.50 No load
Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000302 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).
EW--2--87
Reattaching the cylinder head Figure 182

Figure 180
84113 84209
Verify that the cylinder head attaching plane and the Prior to inserting the pushrods, verify their state of
crankcase attaching plane are both clean. preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
Do not spoil the cylinder head gasket. not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
IMPORTANT -- Prior to reusing the cylinder head they are interchangeable.
fastening screws, verify that they do not show Rocker arm assembly
traces of wear or deformations; otherwise, replace
them. Figure 183
84195
PARTS MAKING UP THE ROCKER ARM

ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
87006 84196
Mount the cylinder head on the crankcase by fastening MAIN DATA OF ARBOUR--ROCKER ARM
screws (1) without torque--tightening them. Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--88
84197
Verify that the tappet adjusters are unscrewed to pre- 87037

vent the latter from crawling on the rods when the Ad just the play between the rocker arms and the
rocker arm assembly (1) is mounted. valves by means of an Allen wrench (2), box wrench
Mount the rocker arm assembly made up of the ar- (3) and thickness gauge (1).
bours and rocker arm support, then secure them to
the head without torque--tightening screws (2) and The operation play is:
(3). -- intake valves: 0.25 ± 0.05 mm
Figure 186 -- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
FIRING ORDER 1--3--4--2
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
of cylinder valve no.
Mounting the injectors

Figure 189
87036
Fasten the head screws according to the instructions

given in Figure 187.
Figure 187
84285
Scheme of cylinder head fastening screw tightening
sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201
screw M12 x 1.75 x 70 [ ]50 Nm ± 5 Nm;

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; Mount a new seal ring (2) lubricated with petrolatum
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; and a new seal washer (3) on injector (1).
- 2nd phase: angle tightening: 90° Mount the injectors on their seats on the cylinder
- 3rd phase: angle tightening only for screws 140 head, then tighten them by means of a torque wrench.
and 180 mm long: 90°.
EW--2--89
Intake manifold unit Figure 192

Figure 190
87012
- Mount exhaust manifold (2).
- Mount turbine (1) by means of screws (3).
- Mount water temperature sensor (4).
86604
The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5999 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
87011
84255
Mount the injector feeding pipe assembly (1). Mount Mount the injection pump (6) injector feeding pipes
the pipes for fuel discharge (2) from injectors, by using (5), then secure brackets (1), (2) and (3) fastening the
gaskets (3) and by tightening screws (4). pipe assembly onto the cylinder head.
Mount priming pump (4).
EW--2--90
84253
87038
- Mount tappet covers (1).
- Mount the starter motor (3).
- Mount container control unit (2).
- Mount turbine lubricating oil return piping (1) with
- Mount fuel filter support (3). its respective fastening bracket (2).
- Mount fuel filter (7). - Mount turbine lubricating oil delivery pipe (7) and
- Attach quick coupling pipes (4), (8) and (10) by fol- engine oil pipes (4) and (5) to water / oil heat ex-
lowing the indications given in Figure 195. changer unit (6).
- Mount electric wiring (5) and (6).
- Mount L.D.A. system piping (9).
- Connect the engine oil vapour recovery pipe to
blow--by (11).
87013
- Mount fan pulley support (3) on head (1) by

torque--tightening screws (2).
70126
Press clip (1) in the direction of the arrow (detail B),

then connect the piping. Bring the clip back to the in-
itial locking position (detail A).
EW--2--91
Figure 198 REPLACING THE INJECTORS

Removal
Figure 200
84288
Mount fan pulley (2) on support (1) by torque--tighten-

ing screws (3).
84289
Place the vehicle in safe conditions.

Lift the engine compartment cover, disconnect the
battery cables and proceed as follows:
- disconnect engine oil vapour recovery pipe (2)
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
84258
84082
Mount Poli--V belt (5) on pulley (7), drive shaft pulley,
guide pulleys (6), water pump (4) and on alternator
(2); then, stretch the belt by acting on automatic belt Remove injectors (2) by means of tool 380000671 (1)
stretcher (3). and take them off the cylinder head.
EW--2--92
Reassembling Rocker arm removal/reassembling

Figure 202 Removal
Figure 204
84081
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2).
84201
Remove screws (4) and dismount rocker arm assem-
bly (1) made up of the rocker arm support and ar-
Mount a new seal ring (2) lubricated with petrolatum bours, then take off valves.
and a new seal washer (3) on injector (1). Reassembling
Mount the injectors on their seats on the cylinder Verify that the tappet adjusters are unscrewed to pre-
head, then tighten them by means of a torque wrench. vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
torque of 36 Nm.
Ad just the tappets as described above.
Figure 203
84290
Mount new seal rings (1) on fuel manifolds (2).

Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
blow--by.
EW--2--93
Adjusting the tappets

Figure 205
84200
Ad just the play between the rocker arms and the FIRING ORDER 1--3--4--2
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
Adjusting cylinder
1 3 4 2
The operation play is: valve no.
Adjusting clearance
-- ± 0.05 mm of cylinder valve no.
4 2 1 3
– intake valves: 0.25 ± 0.05 mm
-- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
Valve timing
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 206
84210

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EXCAVATOR

CNH FRANCE S.A. - PRINT 9-91370 EN

ENGINES F4BE0454B F4BE0484D

Checking the cylinder head supporting Rocker arm assembly . . . . . . . . . . . . . . . EW--2--87

Valve guide . . . . . . . . . . . . . . . . . . . . . . . . EW--2--84 Rocker arm removal/reassembling . . EW--2--92

ENGINES F4BE0454 - F4BE0484 OVERHAUL

ENGINES F4BE0454 - F4BE0484 OVERHAUL

CODING OF SOURCE ENGINES

8 = Direct injection turbo

X = 6 rotary, 2--valve injection pump Manufacturing sequence number

ENGINES F4BE0454 - F4BE0484 OVERHAUL

MAIN ENGINES FEATURES

C *D602 *D601 *D608

H Rotary injection pump

ENGINES F4BE0454 - F4BE0484 OVERHAUL

MAIN ENGINES FEATURES

C *D605 *D601 *D607

H Rotary injection pump

ENGINES F4BE0454 - F4BE0484 OVERHAUL

TORQUE AND RATING FEATURES

ENGINES F4BE0454 - F4BE0484 OVERHAUL

GENERAL ENGINES FEATURES F4BE0454

Cycle 4--stroke diesel engine

Number of cylinders 4 in--line

Total displacement cm3 3922

Compression ratio 17.5 : 1

Max. torque Nm 390

No--load idle rpm min --1 800

No--load peak rpm min --1 2300

BOOSTING With intercooler

Forced by means of gear pump,

ENGINES F4BE0454 - F4BE0484 OVERHAUL

Ambra Master gold HSP REFUELLING

Pump setting 0° ± 0°.5

Type of nozzle DSLA 145 P603

Injection pressure (bar) 245 bar

ENGINES F4BE0454 - F4BE0484 OVERHAUL

ASSEMBLING ENGINES PLAY F4BE0454 -- SPECIFICATIONS

Cylinder liners ∅1 102.01 to 102.03

Pistons: supplied with standard

Piston diameter ∅1 0.5

Position of pistons from crankcase X 0.28 to 0.52

Gudgeon pin ∅3 39.9938 to 40.0002

Gudgeon pin -- Pin seat 0.0058 to 0.0182

Type of piston X1* 2.69

Piston rings 0.5

ENGINES F4BE0454 - F4BE0484 OVERHAUL

Connecting rod small--end

Connecting rod small--end bushing

Connecting rod small--end bushing –

Max. error on connecting rod axis

Journals ∅1 82.99 to 83.01

Bed supports no.:

ENGINES F4BE0454 - F4BE0484 OVERHAUL

Shoulder journal X1 37.475 to 37.545

Shoulder bed support X2 25.98 to 26.48

Shoulder half rings X3 37.28 to 37.38

Drive shaft shoulder 0.068 to 0.410

ENGINES F4BE0454 - F4BE0484 OVERHAUL

Valve guide seats on

Valve stem and respective guide 0.052 to 0.092

Seat on head for valve seat:

C D602 D601 *D608

C D605 D601 *D607