Engines 1000.3.4 W Euroiii

WORKSHOP MANUAL
1000.3 WT E III
1000.3 WTI E III
1000.4 WTI E III
307.W.M300.en.0.02-Motori EURO I1 1 1/15/2010 8:09:21 PM

307.W.M300.en.0.02-Motori EURO ISec1:2 Sec1:2 1/15/2010 8:09:22 PM
TABLE OF CONTENTS
0 - INTRODUCTION
0.1 - Introduction 0-2
0.1.1 - Safety notes 0-3
0.1.2 - General safety rules 0-4
0.1.3 - Safety precautions for removal and refitting operations 0-6
0.1.4 - Lifting instructions 0-7
0.1.5 - Tightening torques 0-9
0.1.6 - Threadlockers, adhesives, sealants and lubricants 0-13
0.1.7 - Conversion factors 0-15
0.2 - Identification of the engine type and serial number position, Europe version 0-17
0.3 - Identification of the engine type and serial number position, EPA version 0-19
0.4 - Identification of the injection pump type 0-21
0.5 - Identification of the injector type 0-22
0.6 - Injector type identification 0-23
10 - TECHNICAL CHARACTERISTICS
10.1 - Engine 10-2
10.1.1 - Engine block technical data 10-2
10.1.2 - Crankshaft technical data (1000.3 WT E III,1000.3 WTI E III) 10-4
10.1.3 - Crankshaft technical data (1000.4 WTI E III) 10-6
10.1.4 - Piston technical data - Piston rings (1000.3 WT E III) 10-8
10.1.5 - Technical data for pistons - Piston rings (1000.3 WTI E III,1000.4 WTI E III) 10-10
10.1.6 - Connecting rod technical data 10-12
10.1.7 - Camshaft technical data - static advance of 11° (1000.3 WT E III) 10-13
10.1.8 - Camshaft technical data - static advance of 12° (1000.3 WTI E III,1000.4 WTI E III) 10-14
10.1.9 - Timing gears technical data 10-15
10.1.10 - Counter-rotating weights technical data (1000.4 WTI E III) 10-17
10.1.11 - Technical data and dimensions of valves - valve springs (1000.3 WT E III) 10-18
10.1.12 - Technical data and dimensions of valves - valve springs (1000.3 WTI E III) 10-20
10.1.13 - Technical data and dimensions of valves - valve springs (1000.4 WTI E III) 10-22
10.1.14 - Technical data and dimensions of cylinder heads - valve guide - valve seats (1000.3
WT E III) 10-24
10.1.15 - Technical data and dimensions of cylinder heads - valve guide - valve seats (1000.3
WTI E III,1000.4 WTI E III) 10-26
10.1.16 - Technical data and dimensions of rocker arms - rocker shafts - tappets 10-28
10.1.17 - Engine injector technical data (1000.3 WT E III) 10-29
10.1.18 - Engine injectors technical data (1000.3 WTI E III,1000.4 WTI E III) 10-30
10.1.19 - Hydraulic tappets diagram 10-31
20 - METHOD OF INTERVENTION
20.1 - B0 - Engine 20-2
20.1.1 - Operations prior to removal 20-2
20.1.2 - Checking engine block 20-4
20.1.3 - Crankshaft 20-5
20.1.4 - Crankshaft checks 20-12
307.W.M300.en.0.02-Motori EURO II I 1/15/2010 8:09:22 PM

TABLE OF CONTENTS
20.1.5 - Flywheel checks 20-14

20.1.6 - Renewal of crankshaft rear oil seal 20-15
20.1.7 - Pistons and cylinder liners 20-16
20.1.8 - Pistons and rings check 20-20
20.1.9 - Cylinder liners check 20-22
20.1.10 - Check connecting rods - gudgeon pins - rod cap screws 20-23
20.1.11 - Camshaft checks 20-25
20.1.12 - Camshaft 20-26
20.1.13 - Valve timing 20-31
20.1.14 - Timing gear checks 20-33
20.1.15 - Adjusting timing gears backlash 20-35
20.1.16 - Counter-rotating weights (1000.4 WTI E III) 20-37
20.1.17 - Counter-rotating weight checks (1000.4 WTI E III) 20-39
20.1.18 - Overhaul of counter-rotating weights assembly (1000.4 WTI E III) 20-40
20.1.19 - Valves check 20-41
20.1.20 - Valve seats check 20-42
20.1.21 - Valves sealing check 20-43
20.1.22 - Adjusting valve clearance (1000.3 WT E III,1000.3 WTI E III) 20-44
20.1.23 - Adjusting valve clearance (1000.4 WTI E III) 20-45
20.1.24 - Valve guides check and replacement 20-46
20.1.25 - Inspecting the rocker arms and rocker shafts 20-47
20.1.26 - Cylinder heads 20-48
20.1.27 - Calculation of cylinder head gasket thicknesses 20-58
20.1.28 - Valve springs check 20-60
20.1.29 - Heat exchanger removal 20-61
20.1.30 - Lubrication pump 20-62
20.1.31 - Lubrication pump disassembly (1000.3 WT E III,1000.3 WTI E III) 20-64
20.1.32 - Lubrication pump disassembly (1000.4 WTI E III) 20-65
20.1.33 - Oil sump 20-66
20.1.34 - INJECTION PUMPS, GOVERNOR AND FUEL SUPPLY 20-67
20.1.35 - Injection pump timing 20-70
20.1.36 - Injectors assembly 20-75
20.1.37 - Checking injectors protrusion - Renewal of copper bushes 20-76
20.1.38 - Injectors check 20-78
20.1.39 - Injection pumps control rod 20-80
20.1.40 - Mechanical governor overhaul (standard and with L.D.A.) 20-83
20.1.41 - Electronic governor adjustment 20-105
20.1.42 - Installation of electronic governor support 20-107
20.1.43 - Engine coolant pump 20-108
20.1.44 - Engine coolant pump 20-109
20.1.45 - Thermostatic valve 20-111
20.1.46 - Checking the thermostat valve 20-112
20.1.47 - Cooling and intake ducts 20-113
20.1.48 - Final engine checks 20-116
20.1.49 - Final refitting operations 20-119
II
307.W.M300.en.0.02-Motori EURO III II 1/15/2010 8:09:22 PM

0 - INTRODUCTION
307.W.M300.en.0.02-Motori EURO I0-1 0-1 1/15/2010 8:09:23 PM

INTRODUCTION
0.1 - INTRODUCTION
The purpose of this workshop manual is to provide instructions for repair technicians and a practical guide for improvement of the
quality of repairs. This manual enables repair technicians to acquire a thorough knowledge of the engine, indicating the correct
methods for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections of parts subject to repair.
The instructions also indicate the products to use, the tightening torques and the adjustment data. The technical material contained in
this manual is reserved for Authorised Dealers and Service Centres who will be duly informed of any technical changes to the engines
in question through the issue of documents regarding modifications, updates and supplements for optional equipment. All technicians
and their colleagues are expressly forbidden from reproducing any part of this manual in any form or from communicating the
contents to third parties without the express written permission of the Manufacturer, which remains the sole owner of this document
with all rights reserved in accordance with applicable laws.
0-2

INTRODUCTION
0.1.1 - Safety notes

To ensure that engines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very important
that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are safe
and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifically
designed for the intended purpose and may be ordered directly from the Manufacturer. DO NOT USE MAKESHIFT TOOLS; not only
is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous
situations, always give priority to personal safety and take the necessary actions to eliminate the danger
0-3

INTRODUCTION
0.1.2 - General safety rules

● Even if you have a thorough knowledge of the engine as regards its components, operation and controls, always take particular
care when carrying out manoeuvres or movements; Remember that the engine you are working on is in need of repair or
overhaul and consequently may not always behave as expected.
● Before starting work, clean the engine thoroughly to remove all mud, dust and road dirt.
● When carrying out checks and repairs, wear close-fitting clothing, safety goggles and protective gloves that are suitable for
the task (cleaning, draining fluids, repairs). When working near moving parts, long hair should be gathered up and tied back
safely under a cap to prevent the risk of entanglement and severe injury.
● Do not allow anyone who is not directly involved in the work to come near the engine; ensure that they remain at a safe
distance.
● Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a
risk of entanglement, even if protected by safety guards.
● Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations
of toxic gases; always connect suitable fumes extraction equipment to the exhaust pipe.
● Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must
be carried out with the engine stopped.
● Do not top up fuel, oil or coolant levels when the engine is running.
● Never smoke and ensure there are no naked flames nearby when topping up fuel or oil.
● Before checking or removing the battery, stop the engine and remove the key from the starter switch.
● Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0°C.
● When checking or recharging the battery, do not smoke or allow naked flames in the vicinity as the hydrogen gas given off by
the battery is highly explosive.
● The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this
reason, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any
electrolyte accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if
electrolyte comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion
of electrolyte, drink plenty of water, milk or vegetable oil, take antacids such as magnesium, bicarbonate, etc. and seek
medical attention immediately.
● Before working on the electrical systems, always disconnect the battery terminals.
DANGER
Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion
of the work, first connect the positive terminal (+) and then the negative (--).
● No welding is permitted on the engine.

● When topping up lubricants, always wear suitable protective gloves.
● Do not wear clothing contaminated by engine oil or hydraulic oil; prolonged contact with the skin can be harmful and may
cause allergic reactions.
● Used engine oil and hydraulic oil must be disposed of properly; recover used lubricants and dispose of them in accordance
with the applicable regulations.
● Before carrying out any work on the hydraulic or pneumatic systems, discharge all residual pressure from the circuits.
● Before carrying out any work on the hydraulic system or engine, allow the oil and engine coolant to cool down.
● When removing and refitting certain assemblies, it will be necessary to support the engine; use stands, jacks or blocks capable
of supporting the weight and arrange them in a triangular pattern to prevent the engine from overturning.
0-4

INTRODUCTION
● To lift heavy components, use a hoist or crane. Check that wire ropes, chains or fibre slings are not worn and that hooks are
not damaged.
● Always use lifting equipment of suitable capacity for the weight of the components to be removed. Ensure lifting equipment is
attached correctly.
● When lifting or supporting an assembly or component, manoeuvre the parts slowly and carefully to avoid swinging movements
or collision with other components.
● Never work on components suspended from a hoist or crane.
● When removing the retaining bolts of a component that could fall, always leave two opposing bolts in place for safety; before
removing these last two screws, attach the component to suitable lifting equipment or position support blocks.
● Any oil or fuel spilled during removal or dismantling operations should be cleaned up as soon as possible to prevent the risk
of slipping and fire.
● When refitting electrical wiring looms and wires, ensure that they are properly secured with their original retaining straps or
brackets to prevent the possibility of damage caused by vibration.
● Never insert your fingers or hands to check the alignment between fixing holes in components; always use a suitable dowel
of soft material.
● When refitting assemblies or components, always use the specified tightening torques; the tightening torques indicated in the
headings regarding assembly/refitting operations have been determined through experimentation and must be scrupulously
adhered to.
● When refitting parts that are subject to vibration or that rotate at high speed, take particular care when carrying out final
installation checks.
0-5

INTRODUCTION
0.1.3 - Safety precautions for removal and refitting operations

When removing or refitting parts, always take the following safety precautions.
Precautions for removal operations

● After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent ingress of dirt.
● Use containers of sufficient capacity when draining oil, coolant or fuel.
● Before removing a part from the machine, check for alignment markings indicating the correct assembly position. If necessary,
make new markings to ensure correct assembly.
● When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires.
● Where necessary, label wires and pipes before removal to avoid confusion when reconnecting.
● Check the number and thickness of any shims removed and keep them together in a safe place.
● To lift the engine or any of its main components, use lifting equipment of suitable capacity.
● When using eyebolts for lifting components, first check that they are not deformed; screw them fully home and then turn the
bolt so that the eye is aligned with the lifting hook.
● Before removing a part, clean the surrounding area and, after removing the part, cover it to protect it from dirt and dust.
Precautions for refitting operations

● Tighten nuts and screws to the specified tightening torques.
● When refitting flexible pipes and cables, take care not to twist or tangle them.
● Always fit new seals, O-rings, split pins and safety stop rings; make sure that the ends of the split pins are separated and bent
back so that the pin cannot be withdrawn from the hole.
● Ensure that circlips are correctly installed in their grooves.
● When applying threadlocking compound, first clean the part to remove all oil and grease, then cover the thread evenly applying
a few drops of the compound.
● When applying sealant, first clean the surface removing all traces of oil and grease and check for dirt or indentations, then
apply the sealant evenly making sure that it forms a continuous film around any fixing holes.
● Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations.
● Coat all moving parts with a thin film of engine oil.
● When reconnecting electrical wiring connectors, first remove all traces of oil, dust and water from the inside of the connector
and then push the two halves together firmly; connectors with locking tabs should be pushed together until the tab engages
the keeper.
● Bolt down flanged fittings evenly, tightening the screws gradually in a crosswise pattern.
Precautions to be taken on completion of removal/refitting operations

● If coolant has been drained from the engine, refit the drain plug and pour in new coolant to the correct level. Start the engine
to circulate the coolant and then check the level again and top up.
● After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate the oil in the
hydraulic circuits and then recheck the level and top up as necessary.
● After having removed a variable displacement pump, connect the drain pipe and fill the pump casing with oil through the filler
hole provided.
● Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.
0-6

INTRODUCTION
0.1.4 - Lifting instructions

DANGER
Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equipment
with wire rope or polyester slings.
Wire ropes - slings

● Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:
Tab.1
WIRE ROPES (standard twisted “S” or “Z” type) POLYESTER SLINGS (eye-and-eye - simple loop)
Ø rope mm Capacity (kg) Width (mm) Capacity (kg)
60° 90° 60° 90°
8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530
Lifting capacities are calculated with a safety coefficient.
● The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the rope/
sling, this could cause the load to slip during lifting.
● Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
DANGER
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
● Never lift a heavy load when the two legs of the ropes form a wide angle. The permitted load (kg) decreases in inverse
proportion to the angle of suspension; the table below indicates how the permitted load varies according to the angle of
suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.
0-7

INTRODUCTION
2000
1900
Capacità di carico: kg 1700
2000
1400
1000
1000
500
30° 60° 90° 120° 150°

Angolo di sospensione:
Fig.1
0-8

INTRODUCTION
0.1.5 - Tightening torques
Screws and nuts

DANGER
The tightening torques for certain specific components and special tightening methods are indicated in the relative
assembly headings.
The tightening torques indicated below refer to screws and nuts assembled without lubrication and, where applicable, with anaerobic
threadlocking compound. the values apply to tightening on steel or cast iron components; for soft materials such as aluminium,
copper, plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.
Tab.2
SCREW SIZE SCREW CLASS
8.8 10.9 12.9
Nm lb.ft. Nm lb.ft. Nm lb.ft.
M6x1 8.0 - 8.8 5.9 - 6.5 11.8 - 13.0 8.7 - 9.6 13.8 - 15.2 10.2 - 11.2
M8x1.25 19.4 - 21.4 14.3 - 15.8 28.5 - 31.5 21.0 - 23.2 33.3 - 36.9 24.5 - 27.2
M10x1.5 38.4 - 42.4 28.3 - 31.2 56.4 - 62.4 41.6 - 46.0 67.4 - 74.4 49.7 - 54.8
M12x1.75 66-5 - 73-5 49.0 - 54.2 96.9 - 107 71.4 - 78.9 115 - 128 84.8 - 94.3
M14x2 106 - 117 78.1 - 86.2 156 - 172 115.0 - 126.8 184 - 204 135.6 - 150.3
M16x2 164 - 182 120.9 - 134.1 241 - 267 117.6 - 196.8 282 - 312 207.8 - 229.9
M18x2.5 228 - 252 168.0 - 185.7 334 - 370 246.2 - 272.7 391 - 432 288.2 - 318.4
M20x2.5 321 - 355 236.6 - 261.6 472 - 522 347.9 - 384.7 553 - 611 407.6 - 450.3
M22x2.5 441 - 487 325.0 - 358.9 647 - 715 476.8 - 527.0 751 - 830 553.5 - 611.7
M24x3 553 - 611 407.6 - 450.3 812 - 898 598.4 - 661.8 950 - 1050 700.2 - 773.9
M27x3 816 - 902 601.4 - 664.8 1198 - 1324 882.9 - 975.8 1419 - 1569 1045.8 - 1156.4
FINE M8x1 20.8 - 23.0 15.3 - 17.0 30.6 - 33.8 22.6 - 24.9 35.8 - 39.6 26.4 - 29.2
M10x1.25 40.6 - 44.8 29.9 - 33.0 59.7 - 65.9 44.0 - 48.6 71.2 - 78.6 52.5 - 57.9
M12x1.25 72.2 - 79.8 53.2 - 58.8 106 - 118 78.1 - 87.0 126 - 140 92.9 - 103.2
M12x1.5 69.4 - 76.7 51.1 - 56.5 102 - 112 75.2 - 82.5 121 - 134 89.2 - 98.8
M14x1.5 114 - 126 84.0 - 92.9 168 - 186 123.8 - 137.1 199 - 220 146.7 - 162.1
M16x1.5 175 - 194 129 - 143 257 - 285 189.4 - 210.0 301 - 333 221.8 - 245.4
M18x1.5 256 - 282 188.7 - 207.8 375 - 415 276.4 - 305.9 439 - 485 323.5 - 357.4
M20x1.5 355 - 393 261.6 - 289.6 523 - 578 385.5 - 426.0 611 - 676 450.3 - 498.2
M22x1.5 482 - 532 355.2 - 392.1 708 - 782 521.8 - 576.3 821 - 908 605.1 - 669.2
M24x2 602 - 666 443.7 - 490.8 884 - 978 651.5 - 720.8 1035 - 1143 762.8 - 842.4
Fittings
The tightening torques indicated below refer to fittings assembled on any material.
Tab.3
MET- Straight end fittings “T” end fittings “L” end fittings 90° end fittings
RIC
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INTRODUCTION
Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

±10% ±10% ±10% ±10%
M10x1.25 17 14 14 14 14 14 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33x2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250
M48x2 60 305 60 305 60 305 60 305
G 1/8” 17 13 14 13 14 13 14 13
19 13
G 1/4” 19 37 19 37 19 37 19 37
22 37
G 3/8” 24 53 24 53 24 53 24 53
G 1/2” 27 73 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
G 1” 41 160 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305
Plugs
Tab.4
Hex plugs Threaded plugs with hex socket head
Thread Wrench Torque Nm ±10% Wrench Torque Nm ±10%
0-10

INTRODUCTION
MET- M6x1 10 10 - -
RIC M8x1 13 12 - -
M10x1 13 14 5 14
M10x1.25 13 14 - -
M10x1.5 13 14 - -
M12x1.25 17 30 - -
M12x1.5 17 30 6 30
M12x1.75 17 30 - -
M14x1.5 19 40 6 40
M14x2 19 40 - -
M16x1.5 22 48 8 48
M16x2 22 48 - -
M18x1.5 17 58 10 58
M18x2.5 17 58 - -
M20x1.5 19 65 - -
M22x1.5 - - 12 73
M24x1.5 22 80 12 80
M24x2 22 80 - -
M27x2 22 100 - -
M28x1.5 - - 17 110
M30x1.5 22 130 - -
M32x1.5 - - 19 150
M35x1.5 - - 22 180
M40x1.5 - - 24 225
G 1/8” 14 13 - -
G 1/4” 19 37 - -
G 3/8” 22 53 - -
G 1/2” 19 73 - -
G 5/8” 22 85 - -
G 3/4” 22 100 - -
G 1” 22 160 - -
Fittings with seal at 37°

Tab.5
Thread Wrench Torque Nm ±10%

7/16” - 20 14 13
1/2” - 20 16 19
9/16” - 18 17 28
3/4” - 16 22 47
7/8” - 14 27 76
1 1/16” - 12 32 110
36 110
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INTRODUCTION
1 3/16” - 12 36 138
1 5/16” - 12 38 155
1 5/8” - 12 50 215
1 7/8” - 12 60 290
2 1/2” - 12 75 345
Fittings for pipes with banjo union

These tightening torques refer to tightening the fitting with new copper sealing washers.
Tab.6
Unions for one-way fittings Unions for three-way fittings Unions for four-way fittings
Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

±10% ±10% ±10%
M8x1 - 12 14 - -
M8x1.25 13 14
M10x1 - - 14 20 14 20
M10x1.25 13 20 - - - -
M12x1.25 17 30 - - - -
M12x1.5 - - 17 30 17 30
M14x1.5 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48
M18x1.5 22 58 24 58 24 58
M20x1.5 27 65 - - - -
M22x1.5 – – 27 73 27 73
M24x1.5 32 80 – – – –
M26x1.5 – – 32 95 32 95
M28x1.5 36 110 – – – –
M30x1.5 – – 36 130 36 130
M35x2 41 180 – – – –
M38x1.5 – – 46 200 46 200
M42x2 50 250 – – – –
M45x1.5 – – 55 280 55 280
M50x2 60 320 – – – –
M52x1.5 – – 60 320 60 320
M65x2 – – 75 450 75 450
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INTRODUCTION
0.1.6 - Threadlockers, adhesives, sealants and lubricants

Tab.7
FUNCTION NAME DESCRIPTION
THREADLOCKER Loctite 222 Colour: opaque fluorescent purple Anaerobic product suitable for low-strength locking of retaining,
adjustment and precision fasteners. All traces of lubricant must first be
removed using the specific activator.
Loctite 242 Colour: fluorescent blue Anaerobic product that prevents loosening of all types of nut and bolt;
used in place of conventional mechanical locking systems. Used for
medium-strength locking. All traces of lubricant must first be removed
using the specific activator.
Loctite 243 Colour: opaque fluorescent blue Alternative product to 242 ; oil tolerant and so can be used on lightly
lubricated surfaces without prior use of activator.
Loctite 270 Colour: fluorescent green Anaerobic product for high-strength locking of bolts and studs that do
not normally require disassembly. Parts must be heated to approxi-
mately 80°C for removal. All traces of lubricant must first be removed
using the specific activator.
DEGREASERS AND Loctite 703 Product used for degreasing and cleaning parts prior to application of
ACTIVATORS Loctite anaerobic products; after drying, promotes uniform curing of
threadlockers
Loctite 747 Product used specifically for treatment of passive metals prior to use of
slow-cure anaerobic threadlockers (series 5 and 6). Can also be used
to increase cure speed at low temperatures or in applications where
there are large gaps between the parts.
SEALANTS (for faces Loctite 510 Colour: red Super-rapid anaerobic sealant for sealing between rigid metal faces;
and fittings) can eliminate the need for conventional gaskets as it can fill gaps up
to 0.4 mm. Does not shrink and therefore fasteners do not need re-
tightening to specified torque values after curing.
Loctite 542 Colour: brown Anaerobic product used as a liquid sealant for threaded fittings up to
3/4” gas; rapid curing and parts may be disassembled with ordinary
tools.
Loctite 554 Colour: red Anaerobic sealant and locking compound used for sealing cooling and
industrial fluid circuits. Slow curing, also suitable for use on non-fer-
rous alloys
Loctite 572 Colour: white Anaerobic sealant and locking compound used for sealing pipes and
threaded fittings up to 2” in diameter. Very slow curing on most metal
surfaces.
Loctite 573 Colour: green Thixotropic anaerobic product used for sealing joints between metal
faces. Ensures total contact between surfaces with maximum toler-
ance of 0.10 mm, filling microvoids caused by flatness errors. Very
slow curing on most metal surfaces and requires prior application of an
activator.
Loctite 576 Colour: brown Anaerobic product used as a liquid thread sealant for large diameter
threaded fittings (up to 2”). Very slow curing; also suitable for non-fer-
rous alloys and parts requiring subsequent removal.
INSTANT ADHE- Loctite 401 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a wide range of
SIVES acidic and porous materials including, ceramics, wood, rubber and
plastic (excluding polyolefin). Curing takes place in a few seconds
as an effect of the condensed humidity present on the surfaces to be
bonded, and is independent of environmental conditions.
Loctite 495 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics
and metal in any combination.
0-13

INTRODUCTION
SILICONE SEAL- Silastic 738 (Dow Corning) Colour: milky white One-part silicone adhesive/sealant, non shrinking, ready for use.
ANTS Cures on exposure to air to form a rubbery solid and obviates the need
for conventional seals on flexible joints, filling gaps of up to 1 mm or
more.
Dirko Transparent Colour: transparent One-part silicone adhesive/sealant, shrinking, ready for use. Cures
rapidly when exposed to humidity in the air to form a rubbery solid;
resistant to high temperatures.
POLYURETHANE Betaseal HV3 (Gurit Essex) Colour: black Polyurethane prepolymer based adhesive/sealant, high viscosity, suit-
SEALANTS able for permanent, high-strength flexible bonding. Slow curing, used
for bonding glass to frames, wire mesh, metal plates, etc. surfaces
must be degreased with primer.
RETAINING COM- Loctite 601 Colour: fluorescent green Anaerobic, fast-curing, high-strength adhesive. Suitable for sealing
POUNDS and retaining cylindrical assemblies with gap clearances of up to 0.10
mm; used for retaining rotors, gears, bearings, pulleys, bushes etc. on
shafts.
Loctite 638 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, very high strength; suit-
able for bonding cylindrical parts in non-ferrous alloys.
Loctite 648 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, high-strength; suitable
for bonding cylindrical parts, permanent retention of threaded parts,
sealing of refrigeration systems, retention of bearings, etc. Alternative
to Loctite 601 in high-temperature applications.
Loctite 986/AVX Colour: fluorescent red Anaerobic sealant/retaining compound for metal cylindrical parts.
Slow-curing, high-strength, heat-resistant and resistant to chemical
attack. Parts must be first treated with an activator.
LUBRICANTS Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose Lithium grease used for lubrication of seals, to prevent
oxidation and to facilitate assembly operations.
Molikote (Dow Corning) Anti-wear compound, contains Molybdenum bisulphate, used neat or
diluted with engine oil for assembly of main engine bearings.
Vaseline Neutral pH compound used to protect battery terminals against oxidi-
zation and corrosion.
Engine oil 10W - 30 Used to dilute Molikote anti-wear lubricant during assembly of main
engine bearings.
0-14

INTRODUCTION
0.1.7 - Conversion factors

Conversion from British to metric units
Tab.8
inch x 25.40 = mm
foot x 0.305 =m
yard x 0.914
Brit.miles x 1.609 = km
Sq.in. x 6.452 = cm²
Sq.ft. x 0.093 = m²
Sq.yard x 0.835
Cu.in. x 16.39 = cm³
Cu.ft. x 28.36 = m³
Cu.yard x 0.763
Imp.gall. x 4.547 = litres
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785 = ,/min
oz. x 0.028 = kg
lb. x 0.454
lb.ft. x 0.139 = kgm
lb.in. x 17.87 = kg/m
psi x 0.070 = kg/cm²
lb./Imp.gall x 0.100 = kg/,
lb./US.gall x 0.120
lb./cu.ft. x 16.21 = kg/m³
lb.ft. x 1.356 = Nm
psi x 1.379 = bar
Conversion from British to metric units

Tab.9
mm x 0.0394 = inch
m x 3.281 = foot
m x 1.094 = yard
km x 0.622 = Eng.miles
cm² x 0.155 = Sq.in.
m² x 10.77 = Sq.ft.
m² x 1.197 = Sq.yard
cm³ x 0.061 = Cu.in.
m³ x 0.035 = Cu.ft
m³ x 1.311 = Cu.yard
litres x 0.220 = Imp.gall.
litres x 0.264 = US gall.
litres x 1.762 = pint
litres x 0.880 = quart
,/min x 0.2642 = US.gpm
kg x 35.25 = oz.
kg x 2.203 = lb.
kgm x 7.233 = lb.ft.
0-15

INTRODUCTION
kg/m x 0.056 = lb.in.

kg/cm² x 14.22 = psi
kg/, x 10.00 = lb./Imp.gal.
kg/, x 8.333 = lb./US.gal.
kg/m³ x 0.062 = lb./cu.ft.
Nm x 0.737 = lb.ft.
bar x 14.503 = psi
0-16

INTRODUCTION
0.2 - IDENTIFICATION OF THE ENGINE TYPE AND SERIAL NUMBER POSITION,

EUROPE VERSION
NOTE
The expressions RIGHT-HAND and LEFT-HAND are referred to the engine viewed from the timing side.
The engine type and serial number (included between the symbols *) are punched on the identification plate fixed to the right-hand
side of the crankcase next to the starter motor.
The identification plate shows, in addition to the Constructor’s logo:
1. Engine type
2. Serial number (always included between the symbols*)
3. Approval number
4. Injection advance
5. Constructor
6. Serial number
The engine’s serial number (always included between the symbols*) is also punched on the left-hand side of the crankcase.
Fig.2 - Identification plate
0-17

INTRODUCTION
5 1 2
6
Fig.3 - Serial number
0-18

INTRODUCTION
0.3 - IDENTIFICATION OF THE ENGINE TYPE AND SERIAL NUMBER POSITION,

EPA VERSION
For Countries that call for EPA approval, a plate is affixed to the engine showing, in addition to the Constructor, the following
information:
1. Engine type
2. Month and year of engine manufacture
3. U.S. EPA regulation number with which the engine complies
4. Engine displacement (cm³)
5. Stated power (kW)
6. Engine idling speed (n/1’)
7. Injection advance (degrees)
8. Type of fuel to use
9. Designation of the relevant group in the EP regulation (the first digit denotes the year of construction)
10. Constructor
11. Serial number
The serial number (always included between the symbols *) for these engines is punched only on the left-hand side of the crankcase,
while the identification plate is fixed to the right-hand side of the crankcase next to the starter motor.
NOTE
The injection advance value (BTDC) is also punched on the left-hand side of the crankcase, outside of the identification
data.
NOTE
The expressions RIGHT-HAND and LEFT-HAND are referred to the engine viewed from the timing side.
0-19

INTRODUCTION
6 8 4 7 5 9 3 1 2
Made by - IMPORTANT ENGINE INFORM ATION - 1000 . 6 W

For engine tuneup and adjustments :
SAME - Trasmission in neutral position :
- Accessories not operatin g
DEUTZ-FAHR - Date of manufacture :
GROUP S.p.A. - Diese l fue l
This engine conforms t o U.S. E PA regulation s
Iarge nonroad compression-ignition engines .
TREVIGLIO I TALY E PA family designatio n 1 FG XLO6 .OWO O
2, 9929 , 685 , 0/5 0
Fig.4 - Identification plate
10 1 2
11
Fig.5 - Serial number
0-20

INTRODUCTION
0.4 - IDENTIFICATION OF THE INJECTION PUMP TYPE

Tab.10
IDENTIFICATION PUMP TYPE (BOSCH) PUMP PART NUMBER (BOSCH) PUMP ASSEMBLY ORDER CODE
PLATE COLOUR
Black PFM1A 90S 2505 0 414 396 006 2.4619.280.0
Make a note of the pump type and BOSCH code marked on the
identification plate.
1
NOTE
2
If necessary, strop the paint with solvent.
NOTE
Always specify the data indicated above when 3

ordering.
0-21

INTRODUCTION
0.5 - IDENTIFICATION OF THE INJECTOR TYPE

Read the distinctive numbers on the injector nozzle representing the
end part of the BOSCH code.
Find the various injectors shown in the “Technical characteristics” and
the corresponding order codes in the table below.
Tab.11
END OF BOSCH INJECTOR NOZZLE PART NUMBER INJECTOR NOZZLE ORDER CODE INJECTOR ASSEMBLY PART
CODE (BOSCH) (1) NUMBER
1352 DLLA 150P 1352 2.4729.630.0 2.4719.640.0
0-22

INTRODUCTION
0.6 - INJECTOR TYPE IDENTIFICATION

Read the distinctive numbers on the injector nozzle representing the
final part of the BOSCH code.
Find the various injectors shown in the “Technical characteristics” and
the corresponding order codes in the table below.
Tab.12
END OF BOSCH INJECTOR NOZZLE PART NUMBER INJECTOR NOZZLE ORDER CODE INJECTOR ASSEMBLY PART
CODE (BOSCH) (1) NUMBER
2159 DLLA 150P 2159 2.4729.650.0 2.4719.650.0
0-23

INTRODUCTION
PAGE LEFT INTENTIONALLY BLANK
0-24

10 - TECHNICAL CHARACTERISTICS

TECHNICAL CHARACTERISTICS
10.1 - ENGINE
10.1.1 - Engine block technical data

2
3 1
*
5
4
Fig.6 - Engine block - cylinders
* Selection class
NOTE
Always check the cylinder class
Tab.13
POS. ITEMS TO BE CHECKED NORMAL MEAS- MAXIMUM TOLER- NOTES
UREMENT ANCE LIMIT
1 Cylinder diameter Class A 105,000 (4.1370) 105,100 -
(distance from liner 105,022 (4.1379) (4.1410)
top: A= 70 mm (2.758 Class B -
in.))
Cylinder ovality 0,020 (0.0008) Max. 0,080 -
(Max. 0.0032)
2 Protrusion from crankcase 0,020 - 0,090 - -
(0.0008 - 0.0035)
3 Lapping intersection angle 40 - 50° 40 - 50° With surface rough-
ness Ra 0.2- 0.6 μm
10-2

POS. ITEMS TO BE CHECKED NORMAL MEAS- MAXIMUM TOLER- NOTES

UREMENT ANCE LIMIT
4 Main bearings diameter 70,018 - 70,068 70,130 -
(2.7587 - 2.7607) (2.7631)
1st undersize (grinding) 69,768 - 69,818 69,880
(2.7488 - 2.7508) (2.7139)
2nd undersize (grinding) 69,518 - 69,568 69,650
(2.7390 - 2.7410) (2.7442)
5 Camshaft bearings diameter 55,060 - 55,090 55,180 -
(2.1694 - 2.1705) (2.1741)
Tolerance between bearing and camshaft 0,060 - 0,120 (0.0024 - 0.0047) -
Unit of measure: mm (in.)
10-3

10.1.2 - Crankshaft technical data (1000.3 WT E III,1000.3 WTI E III)

n°1 n°2 n°3
1
4 1 1 1
2 2 3
Fig.7 - Crankshaft - 3-cylinder version
Tab.14
POS. ITEMS TO BE CHECKED NORMAL MEASURE- TOLERANCE LIMIT
MENT
1 Main bearing journals diameter 69,98 - 69,96 (2.7572 69,90 (2.7541)
- 2.7564)
1st undersize (grinding) 69,73 - 69,71 (2.7474 69,65 (2.7442)
- 2.7466)
2nd undersize (grinding) 69,48 - 69,46 (2.7375 69,40 (2.7344)
- 2.7367)
Permitted taper Max. 0.030 (Max. 0.0012) 0,050 (0.002)
Out of round Max. 0.005 (Max. 0.0002) 0,050 (0.002)
2 Crankpins diameter 63,50 - 63,48 (2.5019 63,40 (2.4980)
- 2.5011)
- 2.4913)
- 2.4814)
3 Crankshaft end float 0.105...0.300 (0.0041 0,500 (0.020)
- 0.0118)
Half thrust washers 1st assembly - -
1st oversize +0.250 (+0,01) -
2nd oversize +0,500 (+0.02) -
4 Crankshaft pulley screw tightening torque See “ENGINE ASSEMBLY”
Notes for grinding

1 Before grinding the crankshaft, check for the presence of cracks with penetrating liquids.
In the presence of cracks, even slight, the crankshaft must be rejected.
2 Grinding with the permitted undersizes does not call for regrinding of the crankpin fillets.
10-4

NOTE
Do not alter the existing fillet radii.
3 When grinding, the crankshaft must rotate preferably in the opposite direction to that of operation; it is however permissible for
the crankshaft to turn in the operating direction.
4 During the polishing stage the crankshaft must rotate exclusively in the operating direction.
5 The surfaces of the main journals and crankpins must be completely free of scoring (Ra=0.25 mμ).
10-5

10.1.3 - Crankshaft technical data (1000.4 WTI E III)

n°1
n°2 n°3 n°4
1
4 1 1 1 1
2 2
3
2 2
Fig.8 - Crankshaft - 4-cylinder version
Tab.15
POS. ITEMS TO BE CHECKED NORMAL MEASURE- TOLERANCE LIMIT
MENT
1 Main bearing journals diameter 69,98 - 69,96 (2.7572 69,90 (2.7541)
- 2.7564)
- 2.7466)
- 2.7367)
2 Crankpins diameter 63,50 - 63,48 (2.5019 63,40 (2.4980)
- 2.5011)
- 2.4913)
- 2.4814)
3 Crankshaft end float 0.105...0.300 (0.0041... 0.500 (0.020)
0.0118)
Half thrust washers 1st assembly - -
1st oversize +0,250 (+0.01) -
2nd oversize +0,500 (+0.02) -
4 Crankshaft pulley screw tightening torque See “ENGINE ASSEMBLY”
Notes for grinding

1 Before grinding the crankshaft, check for cracks with penetrating liquids.
In the presence of cracks, even slight, the crankshaft must be rejected.
2 Grinding with the permitted undersizes does not call for regrinding of the crankpin fillets.
10-6

NOTE
Do not alter the existing fillet radii.
3 When grinding, the crankshaft must rotate preferably in the opposite direction to that of operation; it is however permissible for
the crankshaft to turn in the operating direction.
4 During the polishing stage the crankshaft must rotate exclusively in the operating direction.
5 The surfaces of the main journals and crankpins must be completely free of scoring (Ra=0.25 mμ).
10-7

10.1.4 - Piston technical data - Piston rings (1000.3 WT E III)
TOP
1
2
TOP
3
5
4
H1
** 2-3-4
*
20
Fig.9 - 3-cyinder WT pistons

Tab.16
POS. ITEMS TO BE CHECKED NORMAL MEASUREMENT TOLERANCE NOTES
LIMIT
1 Piston external Class A H= 104,890 (4.1326) 104,680 -
diameter (Position 104,902 (4.1331) (4.1244)
from edge: H = 9 H1 = 104,765 (4.1277) 104,600
mm (0.3546 in.) 104,777 (4.1282) (4.1212)
H1 = 58.3 mm
Class B H= 104,900 (4.1330) 104,680
(2.297 in.)
104,912 (4.1335) (4.1244)
H1 = 104,630 (4.1224) 104,600
104,642 (4.1228) (4.1212)
10-8


LIMIT
2-3-4 Clearance 1st ring 0.110 ... 0.145 - Chrome plated
between rings and (0.0043 ... 0.0057) and convex
piston seat 2nd ring 0.050 ... 0.082 0,150 Tapered face, 90°
(0.0020 ... 0.0032) (0.006)
Wiper ring 0,030 (0.0012) 0,150 Chromium plated
0,065 (0.0026) (0.006)
Piston rings gap 1st ring 0.40 ... 0.65 1,5 -
(0.016 ... 0.026) (0.06)
2nd ring 0.40 ... 0.65 1,5
(0.016 ... 0.026) (0.06)
Wiper ring 0.30 ... 0.60 1,5
(0.012 ... 0.024) (0.06)
5 Gudgeon pin outside diameter 34.99 ... 34.984 34,960 -
(1.3786 ... 1.3784) (1.3774)
Gudgeon pin bore diameter 35,012 (1.3795) 35,020
35,006 (1.3792) (1.3798)
10-9

10.1.5 - Technical data for pistons - Piston rings (1000.3 WTI E III,1000.4 WTI E III)
TOP
1
2
TOP
3
5
4
H1
** 2-3-4
*
20
Fig.10 - 3-cyinder WT pistons

Tab.17
LIMIT
1 Piston external Class A H= 104,890 (4.1326) 104,680 -
diameter (Position 104,902 (4.1331) (4.1244)
from edge: H = 9 H1 = 104,765 (4.1277) 104,600
mm (0.3546 in.) 104,777 (4.1282) (4.1212)
H1 = 58.3 mm
Class B H= 104,900 (4.1330) 104,680
(2.297 in.)
104,912 (4.1335) (4.1244)
H1 = 104,630 (4.1224) 104,600
104,642 (4.1228) (4.1212)
10-10


LIMIT
2-3-4 Clearance 1st ring 0.110 ... 0.145 - Chrome plated
between rings and (0.0043 ... 0.0057) and convex
piston seat 2nd ring 0.050 ... 0.082 0,150 Tapered face, 90°
(0.0020 ... 0.0032) (0.006)
Wiper ring 0,030 (0.0012) 0,150 Chromium plated
0,065 (0.0026) (0.006)
Piston rings gap 1st ring 0.40 ... 0.65 1,5 -
(0.016 ... 0.026) (0.06)
2nd ring 0.40 ... 0.65 1,5
(0.016 ... 0.026) (0.06)
Wiper ring 0.30 ... 0.60 1,5
(0.012 ... 0.024) (0.06)
5 Gudgeon pin outside diameter 34.99 ... 34.984 34,960 -
(1.3786 ... 1.3784) (1.3774)
Gudgeon pin bore diameter 35,012 (1.3795) 35,020
35,006 (1.3792) (1.3798)
10-11

10.1.6 - Connecting rod technical data
1 124,4 20°
2 4
Fig.11 - Connecting rods for pistons

Tab.18
POS. ITEMS TO BE CHECKED NORMAL MEASUREMENT TOLERANCE LIMIT
1 Bush inside diameter 35,015 (1.3796) 35,060
35,025 (1.3800) (1.3814)
2 Connecting rod bush inside 63,535 (2.5033) 63,620
diameter 65,575 (2.5836) (2.5066)
1st undersize (grinding) 63,285 (2.49349) 63,370
63,325 (2.4950) (2.4968)
2nd undersize (grinding) 63,035 (2.4836) 63,120
63,075 (2.4851) (2.4870)
3 Connecting rod axes parallelism - Max. 0,05
(measured at 142,4 mm from con (Max. 0.0020)
rod axis)
4 Difference between diameters in - Max. 0,1
segment A of screws (Max. 0.004)
5 Weight difference between all - Max. 20 g
connecting rods
10-12

10.1.7 - Camshaft technical data - static advance of 11° (1000.3 WT E III)
2 1 1 1 1
n°1 n°2 n°3
Fig.12 - 3-cylinder
NOTE
The presence of part “A” indicates a static advance of 11°

Tab.19
POS. ITEMS TO BE CHECKED NORMAL MEASUREMENT MAXIMUM TOLERANCE LIMIT
1 Camshaft bearings 54,970 - 55,000 55,950
(2.1658 - 2.1670) (2.2044)
2 End float 0,08 - 0,206 Max. 0,25
(0.0032 - 0.0081) (Max. 0.001)
10-13

10.1.8 - Camshaft technical data - static advance of 12° (1000.3 WTI E III,1000.4 WTI E
III)
2 1 1 1 1
n°1 n°2 n°3
Fig.13 - 3-cylinder
2 1 1 1 1 1
n°1 n°2 n°3 n°4
Fig.14 - 4-cylinder
Tab.20
POS. ITEMS TO BE CHECKED NORMAL MEASUREMENT MAXIMUM TOLERANCE LIMIT
1 Camshaft bearing journal 54,970 - 55,000 55,950
(2.1658 - 2.1670) (2.2044)
2 End float 0,08 - 0,206 Max. 0,25
(0.0032 - 0.0081) (Max. 0.001)
10-14

10.1.9 - Timing gears technical data
5 6
4 2
Fig.15 - Timing gears

NOTE
Apply Loctite 542 to part A.

Tab.21
POS. ITEMS TO BE CHECKED NORMAL MEAS- TOLERANCE LIMIT NOTES
UREMENT
1 Intermediate gear bush inside diameter 40,025 (1.5770) 40,125 -
40,064 (1.5785) (1.581)
2 Intermediate gear support shaft outside 39,975 (1.5750) 39,950 -
diameter 40,000 (1.5760) (1.574)
3 Intermediate gear end float 0,13 - 0,53 Max. 0,80 -
(0.0051 - 0.0208) (Max. 0.0315)
4 Backlash between teeth of crankshaft gear 0.05...0.10 Max. 0,10 -
- intermediate gear (0.0019...0.0039) (Max. 0.0039)
5 Backlash between teeth of intermediate gear 0.05...0.10 Max. 0,10 -
and camshaft gear (0.0019...0.0039) (Max. 0.0039)
10-15


UREMENT
6 Intermediate gear Base Red dot for backlash
of 0.05...0.10
(0.0019...0.0039)
1st oversize Yellow dot for backlash
of 0.11...0.13
(0.0043...0.0051)
2nd oversize Green dot for backlash above
0.13 (0.0051)
10-16

10.1.10 - Counter-rotating weights technical data (1000.4 WTI E III)

Counter-rotating weights
45 45
1 1
Gears backlash

Tab.22
POS. ITEMS TO BE CHECKED NORMAL MEASUREMENT TOLERANCE LIMIT
1 Bushes inside diameter 26.050...26.075 26,150
Shafts outside diameter (45 mm) 25.087...26.000 -
2 Counter-rotating weights end float 0.10...0.43 -
3 Gear backlash 0.10...0.20 0,20
10-17

10.1.11 - Technical data and dimensions of valves - valve springs (1000.3 WT E III)
Valve - valve spring
4
2
3
DANGER
The spring should be positioned so that the end with the more tightly-packed coils is contact with the cylinder head.
NOTE
The identification mark is shown in yellow under the valve crown
10-18

Tab.23
UREMENT
1 Stem diameter Intake 8,972 (0.3535) - Renew when the
8,958 (0.3527) valve stem to guide
Exhaust 8.972 (0.3532) - clearance exceeds
8,987 (0.3540) 0.1 mm (0.004 in.)
2 Valve diameter Intake 39.3 ... 39.5 - -
(1.547 ... 1.555)
Exhaust 43.9 ... 44.1 -
(1.728 ... 1.736)
3 Valve angle Intake 91° 15’±15’ - -
Exhaust 140° 30’±141°
4 Free spring length Intake - - -
Exhaust -
Inclination Intake - - No deviation from
Exhaust - perpendicular permit-
ted
10-19

10.1.12 - Technical data and dimensions of valves - valve springs (1000.3 WTI E III)
4
2
3
DANGER

Tab.24
UREMENT
8,987 (0.3540) 0.1 mm (0.004 in.)
(1.547 ... 1.555)
Exhaust 43.9 ... 44.1 -
(1.728 ... 1.736)
10-20


UREMENT
Exhaust 140° 30’±141°
Exhaust -
ted
10-21

10.1.13 - Technical data and dimensions of valves - valve springs (1000.4 WTI E III)
4
2
3
DANGER
NOTE
The identification mark is shown in yellow under the valve crown
10-22

Tab.25
UREMENT
8,987 (0.3540) 0.1 mm (0.004 in.)
(1.547 ... 1.555)
Exhaust 43.9 ... 44.1 -
(1.728 ... 1.736)
Exhaust 140° 30’±141°
Exhaust -
ted
10-23

10.1.14 - Technical data and dimensions of cylinder heads - valve guide - valve seats
(1000.3 WT E III)
Fig.16 - Heads - valve guide - valve seats

Tab.26
UREMENT
1 Valves recess Intake 0.7-1.3 1,8 -
(0.028 - 0.051) (0.0709)
Exhaust 0.9-1.5 2,0
(0.035 - 0.060) (0.0788)
2 Valve seats angle Intake 120° - -
Exhaust 90° -
3 Width of valve contact Intake 2,10 - -
area with seat (0.083)
Exhaust 2,21 -
(0.087)
4 Valve guides inside diameter 9,025 (0.364) - Renew when the
clearance exceeds
0.1 mm (0.004 in.)
10-24


UREMENT
5 Protrusion of valve Intake 14,3 - 14,7 - -
guides from spring Exhaust (0.563 - 0.579)
locating surface
6 Injector nozzle guide length 19,28 - 19,18 - -
(0.760 - 0.752)
7 Injector nozzle guide bore 7,3 - 7,4 - -
(0.288 - 0.292)
8 Copper bushes bore 17,9 - 18 - -
(0.705 - 0.709)
9 Injector protrusion 2,383 - 3,095 - -
(0.094 - 0.122)
10-25

10.1.15 - Technical data and dimensions of cylinder heads - valve guide - valve seats
(1000.3 WTI E III,1000.4 WTI E III)
Fig.17 - Heads - valve guide - valve seats

● A = Washer “A” (drwng. n° 2.1499.224.0) is located between the injector and the copper bush.

Tab.27
UREMENT
1 Valves recess Intake 0.7-1.3 1,8 -
(0.028 - 0.051) (0.0709)
Exhaust 0.9-1.5 2,0
(0.035 - 0.060) (0.0788)
2 Valve seats angle Intake 120° - -
Exhaust 90° -
3 Width of valve contact Intake 2,10 - -
area with seat (0.083)
Exhaust 2,21 -
(0.087)
10-26


UREMENT
4 Valve guides inside diameter 9,025 (0.364) - Renew when the
clearance exceeds
0.1 mm (0.004 in.)
5 Protrusion of valve Intake 14,3 - 14,7 - -
guides from spring Exhaust (0.563 - 0.579)
locating surface
6 Injector nozzle guide length 19,28 - 19,18 - -
(0.760 - 0.752)
7 Injector nozzle guide bore 7,3 - 7,4 - -
(0.288 - 0.292)
8 Copper bush bore 17,9 - 18 - -
(0.705 - 0.709)
9 Injector protrusion 1,844 - 2,734 - -
2,65 (-0.267; +0.445)
10-27

10.1.16 - Technical data and dimensions of rocker arms - rocker shafts - tappets
3
2
1
Fig.18 - Rocker arms - rocker shafts - tappets

Tab.28
POS. ITEMS TO BE CHECKED NORMAL MEASURE- TOLERANCE LIMIT NOTES
MENT
1 Rocker arm bush inside 19,015 (0.749) - Renew when the rocker
diameter 19,025 (0.746) shaft clearance exceeds
0.08 mm (0.0031 in.)
2 Intake valve clearances 0,20 (0.008) - -
0,25 (0.001)
Exhaust valve clearances 0,15 (0.006) - -
0,25 (0.001)
3 Diameter of rocker shafts 19...18.987 - -
(0.749 - 0.748)
4 Tappets outside diameter 15,984 (0.630) - -
15.966 (0,629)
5 Flexure of pushrods - Max. 0,3 -
(Max. 0.012)
10-28

10.1.17 - Engine injector technical data (1000.3 WT E III)

Injector type: P/N 2.4719.620.0
Calibration pressure: 180 ... 188 bar (2610.5 ... 2726.5 psi)
Max. injection pressure: 1200 bar (17403 psi)
Injector nozzle: P/N 2.4729.630.0, end of Bosch code 1352
Injector nozzle holder: type D.17 - P/N 2.4719.590.0
10-29

10.1.18 - Engine injectors technical data (1000.3 WTI E III,1000.4 WTI E III)
Calibration pressure: 180 ... 188 bar (2610.5 ... 2726.5 psi)
Max. injection pressure: 1200 bar (17403 psi)
Injector nozzle: P/N 2.4729.650.0
Injector nozzle holder: P/N 2.4719.650.0; end of Bosch code 2159
10-30

10.1.19 - Hydraulic tappets diagram
Fig.19
Diagram showing hydraulic tappets operated
10-31

Fig.20
Diagram showing hydraulic tappets diagram not operated
10-32

20 - METHOD OF INTERVENTION

METHOD OF INTERVENTION
20.1 - B0 - ENGINE
20.1.1 - Operations prior to removal

1 During disassembly remove from the engine:
● Disconnect the accelerator and engine stop cables of the mechanical governor, the fuel supply and return pipes;
● starter motor;
● cooling fan and relative belt;
● alternator, oil filters and auxiliary PTO, if present;
● air conditioning compressor, if present, and relative drivebelt;
● trailer air braking compressor, if present;
● clutch;
● flywheel;
● engine mounting flange.
Removal of blow-by assembly

1 DANGER 15 15
The blow-by unit is one of the solutions adopted;

for other models the solution may be different,
but the operations to be performed are identical.
Loosen the clamps and disconnect oil recovery pipes (15).
NOTE
Renew the oil seal on reassembly.
2 Remove nuts (16) and remove blow-by assembly (17) complete

with pipes.
17
16
20-2

3 Loosen screws with washer (18) and remove filler (19).

18 19
18
4 Remove union (20).

21
NOTE
21
Renew oil seal (21) on reassembly.
20 21
20-3

20.1.2 - Checking engine block

1 Mount main bearing caps complete with main bearing shells or main bearings on the block.
NOTE
Position the main bearing caps and main bearing shells according to the punched numbers and the marks
executed on disassembly.
Fix the main bearing caps with the screws.

Screws: 92 Nm (67.8 lb.ft.)
2 Check the main bearings diameter and out of round with an
internal dial gauge.
NOTE
Make a note of the values read for each main

bearing and renew the bearing if the diameters
exceed the tolerance limits specified in
“TECHNICAL DATA AND DIMENSIONS”.
NOTE
The main bearings must be replaced with

undersize main bearings whenever the crankshaft
is reground.
3 Check the crankshaft main bearings diameter with an internal

dial gauge.
NOTE
If the bearings exceed the permissible tolerance

values specified in “TECHNICAL DATA AND
DIMENSIONS” they must be replaced, and the
new bearings must be bored after assembly.
NOTE
To facilitate removal of the worn main bearings

and boring of the new main bearings, remove the
plug on the flywheel side. When this procedure
has been carried out, refit a new plug smeared
with sealant.
Plug: Loctite 554
20-4

20.1.3 - Crankshaft
1 Position a dial gauge on a magnetic stand “A” and preload the
gauge by about 3 mm (0.118 in.) on the head of crankshaft A
(1). Using lever “B”, pry the crankshaft axially in one of the two
directions; set the dial gauge to zero and move the crankshaft in
the opposite direction to check if the end float reading is within
the permissible range of values. If the end float is not within the 1
specified limits, replace the thrust washers with oversize versions
(see “Technical data checks”).
2 Remove the screws and remove connecting rod caps (2)

complete with main bearing shells (3). 2
NOTE
Label the main bearing shells and connecting

rod for the following dimensional check.
3
NOTE
Note the connecting rod cap and relative

connecting rod are marked with punched
numbers facing the injection pumps side.
NOTE
Mark the assembly position of each connecting

rod. Do not switch positions unless a general
overhaul is to be carried out.
3 Remove the screws and remove central main bearings (4) 2

complete with the main bearing shells. 2
NOTE
1
Label the main bearing shells and main bearings
1
for the following dimensional check. 4
A
NOTE
Note that the central main bearings have the

same numerical punch marking shown on the
engine block and that orientation is defined by
the smaller diameter spot facings “A” facing the
injection pump side.
20-5

4 Remove the screws and remove front main bearing (5) complete
with main bearing shell (6).
5
6
NOTE
Label the main bearing shell and front main

bearing for the following dimensional check.
NOTE
When removing the bearing remove also the

triangular seals and be sure to renew them at the
time of reassembly.
5 Remove the screws and remove rear main bearing (7) complete
7A
with main bearing shell and crankshaft half thrust washers (8).
NOTE
8
Label the main bearing shell and rear main
bearing for the following dimensional check.
NOTE
Note the direction of installation of the half thrust

washers, the oil grooves of which must face the
crankshaft are installed.
NOTE
When removing the bearing remove also the

triangular seals and be sure to renew them at the
time of reassembly.
6 Attach crankshaft (1) to a hoist with soft belt and lift it clear of
the engine.
1
20-6

7 Remove lower half thrust washers (9) and main bearing shells
(10).
NOTE 10
Label the positions of the main bearing shells for

the following dimensional check.
8 Remove tappets (11) from the block.
NOTES
Carefully check that the contact surface of each 11 11

tappet with the cam is perfectly smooth. Renew
any tappets showing signs of a pitted or rough
surface.
9 Remove nut (12) and remove washer jets (13) and relative
14
seals.
NOTE
Only if necessary: remove union (14). 12
13
Installing crankshaft
1 Position main bearing shells (7), with the lubrication hole, in block
(6) with the lubrication hole. 8
NOTE
Take care to align the tabs of the shells (7) in

6
their locations in the block (6).
7
2 Position the two lower half thrust washers (8).
20-7

NOTE
The oil grooves must be facing outwards.
NOTE
To hold the half thrust washers in place, smear grease on their seats.
3 Lubricate main bearings (7) and half thrust washers (8) liberally
and fit crankshaft (9).
9
Main bearings and half thrust washers: Engine oil
4 Lubricate crankshaft (9) liberally and fit central main bearing

shells and main bearings (10).
Crankshaft: Engine oil 10
1
NOTE 1
9
Carefully check correct orientation of main A
bearings (10); smaller diameter spot facing “A”
must be on the injection pump side. The main
bearings are numbered and must be fitted
according to the punch markings on the block.
5 Fit the upper half thrust washers (8) and triangular gaskets (12)
11
for the lateral seals, in the rear main bearing (11).
12
NOTE
Smear grease on the half thrust washers and

gaskets to hold them in position; apply grease
also to the exterior surface of the gaskets. 8 A
Equip the engine block with two installation guide plates “A”
(thickness. 0.3 mm (0.012 in) made of soft metal, and install the
rear bearing.
20-8

6 Fix rear main bearing (11) with the screws tightened manually
to hold the position; remove guide plates “A” by pulling them 11
sideways with respect to the gasket.
A
7 Install the front main bearing (13) by means of the same

procedure utilised for the rear main bearing. 12
A 13
8 Tighten the 5 screws (14) of main bearings (15) to the 1st torque
stage with a torque wrench.
Screws: 1st stage = 10 Nm (7.4 lb.ft.)
15 14
Using a torque wrench, tighten the main bearing screws to the
specified pre-torque value.
Screws pre-torque: 40 Nm (29.5 lb.ft.) 15
DANGER
Before proceeding, check that end float is within

tolerance limits given in “Technical data and
dimensions (For the procedures, see “Removing
the crankshaft”).
9 Using the same torque wrench and angular tightening protractor

T17 (code 5.9030.640.0), tighten main bearing screws (11) and
(13).
T17
Screws: Angle-tighten through 55°±1°
Check that the crankshaft rotates freely with no points of
stiffness.
11
20-9

10 Trim off the protruding part of the triangular gaskets (12) for
lateral sealing of the front and rear main bearings. Ensure that 12
the gasket protrusion is no more than 0.2 mm (0.008 in.).
12
11 Fit bearing half-shells (19) in connecting rods (18).
NOTE
Take care to align the tabs of bearing half-shells

(19) in their locations in connecting rod (18). 19
Lubricate the bearing half-shells and engage the connecting rods

on the crankshaft.
18
● Bearing half-shells: Engine oil.
F0012200
NOTE
Take care to install the connecting rods the right

way round; the side marked with the punched
number must face the injection pump side.
12 Lubricate the crankshaft and fit the big-end bearing caps (20)
complete with half shells.
Hand tighten the screws of the big-end bearing caps (20). 20
20
F001 1270
13 Using a torque wrench, tighten screws (21) of the big-end bearing

caps (20) to Stage 1 torque.
● Screws: 10 Nm (7.4 lb.ft.)
Still with a torque wrench, tighten screws (21) to Stage 2 torque.
20
● Screws pre-torque: 30 Nm (22.1 lb.ft.) 21
21
F001 1280
20-10

14 Using the same torque wrench and angular tightening protractor

T17 (code 5.9030.640.0), fully tighten connecting rod screws
T17
(21).
● Screws: Angle-tighten through 90±1°
Check that the crankshaft rotates freely with no points of 21
stiffness. 21
NOTE
Check during crankshaft rotation that the cooling

oil spray is perfectly aligned with the hole of the F001 1291
piston chamber.
20-11

20.1.4 - Crankshaft checks

1 Check the diameter of the main bearing journals and crankpins
with the micrometer gauge.
NOTE
Check at various points and all around the

circumference to detect also taper and out of
round.
2 If dimensional and geometrical errors exceed the tolerances

specified in “TECHNICAL DATA AND DIMENSIONS” (even on
a single crankpin or main journal), grind the entire crankshaft,
reducing the diameters of the main journals and crankpins to one
of the possible undersize diameters indicated.
NOTE
If the crankshaft is reground, the main bearings

and crank bushes must be replaced.
3 Only if necessary
Using puller T12 (P/N 5.9030.008.4/10) to remove timing gear (1)
1 T12
from the crankshaft.
Heat the new gear on a thermostatic hotplate to approx. 100°C
and fit it to the crankshaft, making sure that it is located fully
home against the thrust washer.
NOTE
Check the condition of the key.
4 6-cylinder version
If necessary, renew the lubrication oil pump drive gear.
2 T12
Using puller T12 (P/N 5.9030.008.4/10), remove oil pump drive
gear (2).
NOTE
Remove sealant residues from the crankshaft.
20-12

5 Heat the new gear on a thermostatic hotplate to a temperature A 2 3

approx. 100°C above the crankshaft temperature. 3
Apply sealant to the area of the crankshaft that will receive the
gear. 2
Crankshaft: Loctite 648
Fit gear (2) on crankshaft (3) at distance “A” from crankshaft
thrust surface (3).
NOTE
A = 0.2...0.5 mm (0.079...0.197 in.).
6 After cooling the gear, remove excess sealant and check that
lateral oscillation of the gear does not exceed 0.1 mm (0.004 in.)
at a the height of the 116 mm diameter (4.56 in.).
NOTE
If lateral oscillation exceeds 0.1 mm (0.004

in.), use a punch made of soft metal (copper,
aluminium, brass) to return the gear to within
tolerance.
20-13

20.1.5 - Flywheel checks

1 The checks relative to the flywheel are as follows:
● Visual inspection of ring gear conditions.
● Check radial runout (post-assembly check).
● Check face runout (post-assembly check).
2 If the ring gear is damaged, remove it using a puller.
NOTE
Tap the ring gear all the way around until

removing it.
NOTE
Note the direction of assembly of the ring

gear; The bevelled side of the teeth must face
outwards.
3 Clean the seat with care, heat the new ring gear on a thermostatic
hotplate to approx. 100°C and then fit it to the flywheel, making
sure that it is fully seated.
4 After having fitted the flywheel to the crankshaft and tightened

down the retaining bolts, use a dial gauge with magnetic stand to
check the radial and face runout.
NOTE
The max. permissible error is 0.10 mm (0.004

in.).
NOTE
For the tightening torque, see “ENGINE

ASSEMBLY”.
20-14

20.1.6 - Renewal of crankshaft rear oil seal

1 Remove rear oil seal (2) from crankcase (1) using a punch.
NOTE
Note which way round the oil seal is installed and

2
note the position.
DANGER 1
On first fitting, oil seal (2) is fitted fully into the

location in the crankcase. At each replacement,
oil seal (2) must be installed with displacement
towards the exterior of 2.5 mm (0.098 in.).
2 Tab.29
A B C
ORIGINAL 1st OVERHAUL 2nd OVERHAUL
A B C
X= 0 mm (0 in.) X= 2.5 mm (0.098 X= 5 mm (0.197 in.)
in.)
X X X
3 Using a press and suitable tool, install new oil seal (2) on
crankcase (1) in the position determined by the overhaul.
20-15

20.1.7 - Pistons and cylinder liners
Disassembly
1 Using a plastic drift and mallet, free and remove cylinder liner (1)
and pistons and connecting rods at the same time.
2 Remove piston-connecting rod assembly (2) from the lower part

of cylinder liner (1).
Remove O-rings (3) from cylinder liner (1). 1
2
NOTE
3
Renew the O-rings on reassembly.
3 Remove circlip (5) from piston (4).

Withdraw pin (6) and remove connecting rod (7).
7
NOTE
5 4
Note the arrow on the piston crown is opposite to 6
the number on the connecting rod.
4 Using piston ring pliers, remove first and second rings (8) and (9)
from piston (4). 8
NOTE
Note that the word TOP is inscribed on the upper

face of the piston rings.
8
9
20-16

5 Remove wiper ring (10).
10
6 Remove spring (11) of wiper ring (10).
11
Installation
1 Position O-rings (2) on perfectly clean and degreased cylinder
liner (1).
1
DANGER
The O-rings are specially treated and once

removed from their packaging, they must not be
exposed to the air for more than 48 hours.
2
NOTE
Do not lubricate O-rings (2).
2 Using piston ring pliers, fit rings (4) and (5) on piston (3) .
3 4
DANGER
The upper rings must be installed with the word

TOP towards the piston crown.
4
5
20-17

3 Upend piston (3) and fit spring (6) and wiper ring (7).
NOTE 3 3
The wiper ring gap must be located at 180° with

respect to the join of the spring.
7
6
4 Upend cylinder liner (1), lightly lubricate the interior and partially
fit piston assembly (3).
Position the gaps in the piston rings as described in “TECHNICAL
DATA AND DIMENSIONS” and use a ring compressor T15 (P/N 3
5.9030.654.0/10) and a driving tool made of soft material, insert
piston (3) fully into liner (1).
T15
1
5 Slide piston (3) so that pin seat (8) is beyond the rim of liner (1).
Lubricate pin seats (8) and fit connecting rod (9) and circlips 9
(10). 10
8
3 3
DANGER
The connecting rod must be installed with the

number (referred to the connecting rod cap)
facing the side opposite the arrow on the piston.
1 1
6 Apply a continuous film of sealant around the flange of liner (1)

and fit the assembly in the corresponding bore in the block.
Liner: Loctite 986 AVX
1
NOTE
Ensure that the sealant film is continuous and

avoid contact with the O-rings.
20-18

7 Apply constant and forceful hand pressure on the liner to ensure

that the O-rings engage the sealing surfaces of the block bore.
NOTE
Do not use the mallet at this stage

1 T16
Once the second O-ring has seated in the sealing surface of the
bore, drive liner (1) home using a plastic-faced mallet.
Fit diagonally opposed clamping blocks T16 (P/N
5.9030.631.4/10) and leave in position until Loctite is completely
cured (approximately 4 hours).
Assembly of piston cooling washer jets (only if removed)

1 Apply sealant to the base of fittings (1), screw the fittings into the
block and then tighten them. 1
Fittings: Loctite 242

Fittings: 30...35 Nm (22.1...25.8 lb.ft.)
2 Turn the block and fit the specific tool for the engine on overhaul
on the 1st cylinder; fit the first copper seal (2), washer jet (3),
second seal (4) and nut (5) in sequence. 5
With the washer jet inserted in tool T14, tighten nut (5). 4
T14
For pistons without cooling chamber: tool (P/N 5.9030.731.4)
For pistons with cooling chamber: tool (P/N 5.9030.732.4) 2
3
Nut: 25...29 Nm (18.4...21.3 lb.ft.)
Repeat these operations for all cylinders. 5
20-19

20.1.8 - Pistons and rings check

1 CAUTION
1 - Pistons and cylinder liners are divided into

selection classes (A white - B red) to check
that they are exactly matched. 2 - If pistons B
and cylinder liners are renewed, make sure all A
assemblies (pistons+liners) belong to the same
selection class. 3 - Class identification marks are
stamped on pistons and liners in the positions
indicated in “Technical data and dimensions”.
After removal of carbon deposits and careful cleaning, check the

pistons outside diameter with a dial gauge.
The measurement must be mad in two positions “A” and “B”
starting from the base of the skirt and at 90° with respect to the
gudgeon pin axis.
● A = 9 mm (0.354 in)
● B = 58.3 mm (2.295 in)
Renew the pistons if the value is not within the limits indicated in
“Technical data and dimensions”.
2 Check the height of the second ring and wiper ring grooves.
For this check, use a feeler gauge and a new piston ring as
shown.
NOTE
The first piston ring groove cannot be checked

because it has a conical section.
If the height of the grooves of the second piston ring and the
wiper ring exceed the heights indicated in “Technical data and
dimensions”, renew the pistons.
3 Remove carbon deposits from the upper part of the cylinder
liners; place the piston rings and wiper ring one at a time in the
lower part of the cylinder liner and use a feeler gauge to check
the ring gaps.
20 mm
NOTE (0.788 in.)
Insert the rings about 20 mm (0.788 in.) and

keep them parallel to the cylinder head surface.
If the measured distances fail to fall within the
tolerance values specified in “Technical data and
dimensions”, renew the compression rings and
oil wiper.
20-20

4 Use a dial bore gauge to check the diameter of the gudgeon pin
bore.
20-21

20.1.9 - Cylinder liners check

1 Clean carefully and remove carbon deposits. Check the cylinder
liner inside diameter with a dial bore gauge. 70 mm
(2.758 in.)
The measurements must be performed at a depth of 70 mm
(2.758 in.) from the head of the cylinder liner and must be made
at an angle of 90° from one to the next.
NOTE
Renew the cylinder liners if the diameter exceeds

the tolerance limits indicated in “TECHNICAL
DATA AND DIMENSIONS”.
2 DANGER
Carefully check that the new liners are all of the

same selection class as the pistons (class A or
B).
The class is stamped on the liner base as shown alongside and

in “TECHNICAL DATA AND DIMENSIONS”.
3 If piston rings and wiper ring are replaced, visually inspect the
cylinder liner for the presence of traces of lapping; if no lapping
marks are found (even partial marks), take the liners to an
authorised service centre to recreate the required level of surface
roughness as indicated by a cross hatch applied using tool T13
(P/N 5.9030.349.0.01).
4 Before completely fitting the new cylinder liners into the cylinder
block, remove all traces of sealant, install the liners without O-
rings and secure with blocks T16 (P/N 5.9030.631.4/10).
Check with tool T1 (P/N 5.9030.433.0) that liner protrusion T1
from the block is as specified in “TECHNICAL DATA AND
DIMENSIONS”.
DANGER
To fit the liners into the cylinder block, follow

the instructions given in the section “ENGINE T16
ASSEMBLY”.
20-22

20.1.10 - Check connecting rods - gudgeon pins - rod cap screws

1 Check parallelism between the small end and big end axes of
the connecting rod using tool T11 (P/N 5.9030.651.4) and a dial
gauge resting on the gudgeon pin.
Proceed as follows: T11
● Prepare the connecting rod with the corresponding cap

and gudgeon pin assembled.
● Position the rod on the tool, and rotate in both directions;
preload the dial gauge and set to zero in the maximum
radius point.
● Overturn the rod and repeat the measurement. The
reading difference gives the value of the axes parallelism
error which, if it is greater than the permissible value given
in “TECHNICAL DATA AND DIMENSIONS” must lead to
replacement of the defective connecting rod.
2 DANGER
Renewal of one or more rods also calls for

the weight of the replaced rods to be checked T11
against the weight of the re-utilised rods; the
max. permitted weight difference between the
lightest and the heaviest rod is 20 g.
3 Use a dial bore gauge to check the diameter of the connecting

rod big end bush. Renew the bush if its wear exceeds the limit
indicated in “TECHNICAL DATA AND DIMENSIONS”.
20-23

4 Use a dial bore gauge to check the diameter of the rod small
end bush; Renew the bush if wear exceeds the limit indicated in
“TECHNICAL DATA AND DIMENSIONS”.
DANGER
When fitting the new bushes, carefully check the

orientation of the oil groove and position of the
split in the bush.
5 Check the diameter of the gudgeon pins with a micrometer;

Renew the gudgeon pins if the value is not within the limits
indicated in “TECHNICAL DATA AND DIMENSIONS”.
Check rod cap screws

1 Use a precision gauge or micrometer to check the diameter of
the screws around the central recessed section; the difference
between maximum and minimum diameter indicates screw metal
fatigue during previous tightenings.
Renew the screws if the difference between maximum and
minimum diameter exceeds that indicated in “TECHNICAL DATA
AND DIMENSIONS”.
20-24

20.1.11 - Camshaft checks

1 Carefully check the condition of the surfaces of the cams; the cam surfaces must be perfectly smooth and free of any form of
distortion (flattening, pitting, seizure).
Renew the camshaft at the first sign of degradation of the smooth surfaces of the cams.
2 Check the bearing journals diameter and out of round with a dial
gauge.
If even one single camshaft journal is not within the tolerance
limits given in “TECHNICAL DATA AND DIMENSIONS”, renew
the camshaft.
20-25

20.1.12 - Camshaft
Removal
1 Only if fitted: remove the screw and remove engine speed sensor
(1) and spacer (2), if present. 1
Remove cover (3). 3
NOTE
This operation should not be done if the engine is

equipped with the trailer air braking compressor
or auxiliary PTO. 2
2 Undo retaining nut (4), remove washer (5) and remove crankshaft
pulley (6).
4
5
3 Remove screws (7) and remove cover (24).

24
20-26

4 Using a puller, remove pulse wheel (12).
12
5 Loosen clamps (25) and remove cooling line (26) from pump to
heat exchanger.
25
25
26
6 Undo union (27) and disconnect diesel fuel pipeline.
NOTE 27
Always renew the copper gaskets.
7 Undo the screws and spacers and remove timing cover (13).
13 14
NOTE
Gasket (14) remains in place, but must be

renewed on reassembly.
NOTE
If the crankshaft oil seal is to be renewed, see

“Renewal of crankshaft rear oil seal”.
20-27

8 Unscrew and remove washer jet (28), check that it is not clogged,
and then refit.
28
Washer jet: Loctite 243
9 Remove self-locking screws (15) and remove timing gear (16).
NOTE 15
Renew screws (15) on reassembly.
16
10 Position a dial gauge on a magnetic stand “B” and preload the

gauge by about 3 mm (0.118 in.) on the head of the camshaft.
B
Pry the camshaft axially in one of the two directions; set the dial
gauge to zero and move the camshaft in the opposite direction to
check if end float is within the permissible range of values (see
“Checks and technical data”). If end float is outside the specified
limits, replace clearance yoke (17).
17
11 Loosen and remove the retaining screw and remove spring

assembly (18) contrasting the injection pump control rod.
18
20-28

12 Remove the screws and washers and clearance yoke (17) of

camshaft (19).
19
17
13 Remove circlip (20) and remove clearance washer (21) and the
bronze thrust washer (22) of intermediate gear (23).
22
21
20
23
14 Remove intermediate gear (23) and thrust washer (22).

23
22
15 Overturn the engine and remove camshaft (19).
NOTE
Exert constant axial traction and rotate the

camshaft to and fro to facilitate removal. 19
NOTE
Take care not to damage the main bearings with

the crest of the cams.
20-29

Installation
1 Lubricate the seats and fit tappets (1).
Tappet seats: Engine oil
1 1
2 Lubricate bushes (2) and fit camshaft (3).

Bushes: Engine oil
2
NOTE
Take care not to damage the bearings with the

cam lobes.
3 Fit clearance yoke (4) and secure it with screws (5) and
5 4
washers.
Lubricate the camshaft in the groove engaged with the yoke and
try turning it. rotation should be free with no signs of sticking.
NOTE
Check also that end float is within the tolerance

limits indicated in “Technical data and
dimensions”.
20-30

20.1.13 - Valve timing

1 Timing operations must be carried out on cylinder N° 1.
If removed, refit the crankshaft, tappets and camshaft.
Fit the timing drive gear on the crankshaft.
Secure camshaft end float control plate (1).
If removed, fit centring bush (2) on the camshaft.
2 Fit timing gear (3) and fasten fixing screws (4).
3 Position a dial gauge on a magnetic stand on the block.

3 5
Bring the first piston to top dead centre (T.D.C.).
Preload the dial gauge by 20 mm (0.788 in.) on the piston.
Turn the crankshaft clockwise by 40°; the piston stroke must be
of 17.273 ± 0.04 mm (0.6806 ± 0.0016 in.).
DANGER
The prescribed stroke must be obtained

exclusively with clockwise rotation. If the descent
value is surpassed, return to T.D.C. and repeat 6
the procedure.
Install intermediate gear (5) matching the timing punch marks of

timing gear (3) and crankshaft gear (6).
20-31

4 Fit bronze thrust washer (7), clearance ring (8) and circlip (9).
8 9
NOTE
Ensure the thrust washer oil grooves (4) are

facing the intermediate gear.
7
9
Check
1 The following check can be performed for verification purposes.
Bring the first piston to top dead centre (T.D.C.) and set dial
gauge (A) to zero.
A
PM S
2 Turn the crankshaft clockwise by 40°; the first piston stroke must
be of 17.273 ± 0.04 mm (0.6806 ± 0.0016 in.).
17.273 mm A
(0.6806 in.)
17.273 mm
(0.6806 in.)
20-32

20.1.14 - Timing gear checks

1 Use a dial bore gauge to check the diameter of the intermediate
gear bush (1).
Renew the bush if its wear exceeds the limit permitted by
“Technical data and dimensions”.
2 Use a dial gauge to check the diameter of intermediate gear

shaft (2).
2
If the measurement is less than the permissible value given in
“Technical data and dimensions”, renew the shaft.
NOTE
The shaft must always be renewed if it presents

signs of seizure.
3 Before timing the camshaft, check the backlash between the timing gears to reduce noise levels.
Permitted backlash:
0.05 ... 0.1 mm (0.0019 ... 0.0039 in.)
The correct backlash is obtained by fitting the intermediate gear chosen from among the three available sizes, each identified
by a coloured dot:
Unit of measure:mm (in.)
Tab.30
MEASURED BACKLASH GEAR TO BE INSTALLED NOTES
0.05...0.10 (0.0019 -- 0.0039) Red dot Standard gear
0.11...0.13 (0.0043 -- 0.0051) Yellow dot 1st oversize gear *
above 0.13 (above 0.0051) Green dot 2nd oversize gear *
* The oversize concerns the tooth width on the reference diameter.
20-33

Removing the shaft

1 To remove the shaft fit a bolt with a long nut and force between
the shaft and internal wall.
Before fitting the new shaft, clean the lubrication hole carefully;
after installing the shaft in the engine block, close the oilway with
the plug coated with sealant.
Plug: Loctite 242
The gear shaft must be fitted in the engine block exclusively
using the method of prior cooling in liquid nitrogen.
NOTE
DO NOT use hammers, mallets or hydraulic

jacks
20-34

20.1.15 - Adjusting timing gears backlash

1 NOTE 4
Timing operations must be carried out on cylinder 1 2

N° 1.
Temporarily install intermediate gear (1) complete with thrust

bushes (2), thrust washer (3) and circlip (4).
3
2 8
2 Position a dial gauge “B” on a magnetic stand with the contact

point perpendicular to a tooth of the intermediate gear; preload 1
4
the dial gauge by about 2 mm. (0.079 in.).
Turn intermediate gear (1) two and fro to check backlash between
teeth.
NOTE
B
Make a note of the backlash value before

proceeding with the following check.
3 Fit camshaft gear (5), flange (6) and new screws (7).
7 6
NOTE
Tighten the screws to a minimum torque of 10

Nm (7.4 lb.ft.) to ensure that the gear is pressed
fully home onto the camshaft.
Tighten pulse wheel retaining screw (8) on the crankshaft. 5
NOTE
This screw is utilised to engage the wrench for

subsequent precision rotations.
4 Position dial gauge “B” with the contact point perpendicular to a

tooth of the camshaft gear. B
Drive intermediate gear (1) fully home and move camshaft timing
gear (5) to and fro to check the backlash between the teeth.
NOTE
5
Make a note of the backlash.
1
20-35

5 Check the two backlash values measured against the permissible values given in “TECHNICAL DATA AND DIMENSIONS”
and, if the measured values are not within the permissible limits, renew the intermediate gear with a replacement part that is
capable of producing the optimal backlash values.
NOTE
The gears available for adjusting play are shown in “TECHNICAL DATA AND DIMENSIONS”.
6 Remove intermediate gear (1) used for checking and leave inner
thrust bush (2) in place.
NOTE 5
2
Ensure the thrust bush oil grooves are facing the
gear.
Tighten gear (5) with screws (7) working in an alternate cross- 1

wise sequence.
Screws: 50 4.5 Nm (36.8 3.3 lb.ft.).
7
20-36

20.1.16 - Counter-rotating weights (1000.4 WTI E III)
Removal of counter-rotating weights (4-cylinder version and if installed)

1 Loosen and remove screws (1) retaining counter-rotating weights
assembly (2). 1 2 1
NOTE
Loosen the screws in a crosswise and alternate

sequence.
2 Remove counter-rotating weights assembly (2).

2
NOTE
Recover shims, if any.
Counter-rotating weights assembly

1 Mount the weights assembly after aligning the oilway pin.
3
Raise the assembly from the gear side; turn crankshaft (1) and
balance shaft (2) of counter-rotating weights until matching the
reference notches of the respective gears.
Secure the assembly with screws (3).
2 Position a dial gauge with contact point T8 (P/N 5.9030.888.0)

installed on tool T18 (P/N 5.9030.886.0) resting alongside drive T18
gear (2) and preload the gauge by about 2 mm.
T8
20-37

3 Manually turn driven gear (4) in both directions to check if

backlash between teeth corresponds to the value indicated in 5
“TECHNICAL DATA”.
If necessary, add shims between the surface of the engine block
and the 4 surfaces of the weights assembly (5) until the backlash
is within the permissible range of tolerance.
Remove screws (3) securing the assembly, apply sealant and
secure to the prescribed torque.
Screws: Loctite 242
4A
NOTE
Tighten alternate screws gradually in a cross-

wise sequence.
20-38

20.1.17 - Counter-rotating weight checks (1000.4 WTI E III)

1 With a dial gauge, check the diameter of shafts (1) in the areas in
which the counter-rotating weight bearings rotate.
1
If the values are lower than those indicated in “TECHNICAL
DATA”, renew the shafts.
45
m
m
2 With a dial bore gauge, check the diameter of counter-rotating

weight bearings (2).
2
3 If wear exceeds the tolerance limits indicated in “TECHNICAL

DATA”, renew the bushes.
4 After assembling the counter-rotating weights unit and before

securing the shafts, check that counter-rotating weights end float
is within the tolerance limits indicated in “TECHNICAL DATA”.
3
If the end float exceeds the limit, renew thrust washers (3).
20-39

20.1.18 - Overhaul of counter-rotating weights assembly (1000.4 WTI E III)
Disassembly
1 Using a pin punch, remove spring pins (1) securing shafts (2)
and (3).
2 1
2 Use a soft metal drift (aluminium, copper, etc.) to remove weights

support shafts (2) and (3). 2
3 Remove counter-rotating shafts (2) and (3) and recover front and
rear clearance washers (4). 5 3
Remove circlip (5) and remove gear (6) from driven shaft (2).
2
NOTE
Note that the reference of driven gear (2) is

located between the marked teeth of the drive
gear (3). 6 4
Installation
To assemble, follow the disassembly steps in reverse order.
Shafts (2) and (3): Molikote
NOTE
Check assembly timing between the drive gear and the driven gear.
20-40

20.1.19 - Valves check

1 Measure the diameter of the valve stem with a micrometer
gauge
NOTE
Measure the stem in several points and with

readings taken at positions that are 90° apart.
NOTE
If the diameter is not within the prescribed

tolerance limits, renew the valves. See
“TECHNICAL DATA AND DIMENSIONS” for the
tolerance values.
20-41

20.1.20 - Valve seats check

1 Using tool T1 (P/N 5.9030.433.0) and a dial gauge, check the
recess of the valves with respect to the surface of the cylinder
head. T1
If the recess of even a single valve is outside the tolerance values
given in “TECHNICAL DATA AND DIMENSIONS”, the valve seats
and valves must be renewed by an authorised service centre.
2 Check that valve seats and valves are in perfect condition and free of any dips or pitting in the sealing area.
If the valve seats show signs of defects that cannot be removed by grinding, have the valve seats changed by an authorised
service centre.
NOTE
The new valve seats are supplied already pre-machined; they do not require any form of operation after
installation, which must be carried out only after cooling the seats in liquid nitrogen.
NOTE
For the valves recess values and checking of the valve seat angles, refer to “TECHNICAL DATA AND
DIMENSIONS”.
20-42

20.1.21 - Valves sealing check

1 After cleaning the head entirely, lubricate the stems and fit the
valves, springs and plates.
Check valve sealing by pouring drops of solvent through intake
and exhaust pipes; valves that have been ground should not
allow the solvent to leak, while slight leakage is permissible for
new valves and seats.
NOTE
The valve seats will adapt automatically after a

short period of engine operation.
20-43

20.1.22 - Adjusting valve clearance (1000.3 WT E III,1000.3 WTI E III)
Adjusting valve clearance

1 Using feeler gauge (1) between valve and rocker arm, measure
1 3
the valve clearance .
Valve clearances (intake and exhaust valves): 0.20 mm (0.008
in).
To set the valve clearance loosen nut (2) and turn set screw (3).
When the adjustment is completed, tighten nut (2).
Valve clearance check

1 Number the rocker arms (from 1 to 6) starting from the rocker
6 5 4 3 2 1
arm on the crankshaft pulley side.
Turn the crankshaft clockwise and bring rocker arms (1) and (4)
to the maximum height position of the relative valves.
Check the clearance and adjust the valves of rocker arms (3), (5)
and (6), if necessary.
Turn the crankshaft clockwise by 1 complete revolution and
check the clearance and adjust the valves of rocker arms (1) and
(4), if necessary.
Turn the crankshaft clockwise and bring rocker arm (3) to the
maximum height position of the relative valve and check the
clearance and adjust the valve of rocker arm (2).
20-44

20.1.23 - Adjusting valve clearance (1000.4 WTI E III)
Adjusting valve clearance

1 Using feeler gauge (1) between valve and rocker arm, measure
1 3
the valve clearance .
Valve clearances (intake and exhaust valves): 0.20 mm (0.008
in).
To set the valve clearance loosen nut (2) and adjust set screw
(3).
When the adjustment is completed, tighten nut (2).
Valve clearance check

1 Number the rocker arms (from 1 to 8) starting from the rocker
arm on the crankshaft pulley side. 8 7 6 5 4 3 2 1
Turn the crankshaft clockwise and bring rocker arms (1) and (4)
to the maximum height position of the relative valves.
Check the valve clearance and adjust rocker arms (3), (5), (6),
(7) and (8), if necessary.
Turn the crankshaft clockwise by 1 complete revolution and bring
rocker arms (6) and (7) to the maximum height position of the
relative valves and check the valve clearance and adjust rocker
arms (1), (2) and (4), if necessary.
20-45

20.1.24 - Valve guides check and replacement
Valve guides check

1 Check the valve guides for possible signs of seizure.
Check the diameter with plug gauge T3 (P/N 5.9030.020.0); if
the NP side of the gauge is able to enter the guides, renew the T3
valve guides.
Replacing the valve guides

1 Position the head under a press on a perforated plate; use driving
tool T9 (P/N 5.9030.850.0) to remove the valve guides. T9
2 Clean the valve guide seats carefully, lubricate the guide

external surfaces and fit the guides using driving tool T10 (P/N
5.9030.852.0). T10
Valve guide: engine oil
NOTE
The insertion measurement is provided by

the pusher at its full stroke position. (See
“TECHNICAL DATA AND DIMENSIONS”).
20-46

20.1.25 - Inspecting the rocker arms and rocker shafts

Measure the inside diameters of the rocker bushes and the diameters of the rocker shafts.
Use a dial bore gauge and a micrometer.
If the wear exceeds the tolerance limits indicated in “TECHNICAL DATA AND DIMENSIONS”, renew the bushes and shafts.
NOTE
When renewing rocker bushes, take great care to ensure that oil holes and grooves are correctly oriented (see
“TECHNICAL DATA AND DIMENSIONS”).
20-47

20.1.26 - Cylinder heads
Removing the cylinder heads

1 Remove screws (1) and remove valve covers (2).
NOTE 1
2 1
Inspect the O-rings carefully.
2 Remove gasket (3) and discard.
3 Undo bolt (4) and remove clamp (5).
5 4
20-48

4 Undo unions (6) and (7) and remove the turbocharger oil delivery
8 7
pipe.
NOTE
Renew copper washers (9) on reassembly.
5 Unscrew union (10).

10 11 12
Slacken off strap (11).
Disconnect and remove turbocharger return pipe (12).
6 Undo the four nuts (13) and remove turbocharger (14).

14
13
7 Remove gasket (15).

15
20-49

8 Undo the locknuts and remove exhaust manifold (16).

Remove seals (17).
NOTE
17
Renew gaskets (17) on reassembly.
16
9 Loosen the clamp and disconnect pipe (18) from the water
pump.
18
10 Undo fixing screws (19) and remove manifold (20) from the
cooling circuit, complete with thermostatic valve. 19
NOTE
Renew the gaskets on reassembly.
20
11 Remove anti-vibration clamps (35).
35
35
20-50

12 Remove fuel delivery pipes (36) to the injectors.

36 36
NOTE
Holding the pump union loosen the pipe union.
13 Remove nuts (37) and conical washers (38).

Remove injector retaining bracket (39).
37
38
39
14 Extract out injectors (40) and O-rings (41).
NOTE 40
Renew the O-rings on reassembly.
NOTE 41
Note which way round the injectors are installed.
DANGER
Plug the delivery bore and injector nozzle to

prevent the ingress of contaminants.
20-51

15 Mark the cylinder heads (42) with respect to the engine block.
42
NOTE
Start numbering from cylinder 1 (side opposite

flywheel).
16 Loosen nuts (43) of rollers (44) and unscrew the rollers to free
the rocker arms.
43
44
17 Remove nuts (45) and remove rocker arm supports assembly

(47).
45
46
18 Remove rocker arm pushrods (47).
47
20-52

19 Unscrew and remove screws (48) responsible for fastening

cylinder heads (42).
Remove complete cylinder heads (42).
42
48
42
20 Remove cylinder head gaskets (49).

49
NOTE
When the heads are to be refitted without

renewing cylinder liners, make a note of the type
of gasket installed under each head. The gaskets
feature different thicknesses identified by the
presence or absence of identification holes on
the side with the centring hole on the oilway and
the holes for the push rods.
21 Before proceeding with the disassembly, clean the surfaces of

the heads and the valves.
Check with tool T1 (P/N 5.9030.433.0) and a dial gauge that the T1
recess of the intake and exhaust valves is within the range of
permissible values (see “CHECKS AND TECHNICAL DATA”).
22 If the valves recess is within the limits, before removing the valves
mark the positions with respect to the cylinder head so that, if
undamaged, they can be refitted in their original positions.
A1 A1
Example: Head 1 - A1 - S1, 2 - A2 - S2
S1 S1
20-53

23 Using tool T2 (P/N 5.9030.012.0), compress springs (50) and

remove valve retaining half cones (51). T2
52 52
Release and remove springs (50) and plates (52).
51
52 50
50
24 Remove valves (53) and (54).
A1
S1 A1
53
S1
54
25 Using a screwdriver or a lever, remove valve O-rings (55).
55
26 Remove circlips (56).

57
Remove thrust washers (57) and remove rocker arms (58).
56
58
20-54

Installing the heads

1 Fit heads (1) complete with valves on the relative cylinders.
NOTE
Fit the valves by performing the removal steps in

reverse sequence.
NOTE
Do not change or mismatch the head positions. 1
2 Lubricate screws (2) responsible for fixing cylinder heads (1) and
screw them in by hand.
2
Screws: Engine oil
1
Check that the mating surfaces are clean and temporarily
fit exhaust manifolds (3); secure them with the relative nuts
tightened to a torque of about 15 Nm (11 lb.ft.).
NOTE
3
This operation serves to keep the head surfaces
in line with manifold surfaces: do not fit the
gaskets of the manifolds.
3 Tighten head fixing screws (2) to the 1st torque stage with a
torque wrench. 1 3
Screws: 50 Nm (37 lb.ft.)
4 2
2
NOTE
Tighten the screws following the sequence

indicated.
4 Using the same torque wrench and an angular tightening

goniometer T17 (P/N 5.9030.640.0) fully tighten head screws 1 3
(2).
4 2 T17
Screws: Rotation 50 ± 3° + 50 ± 3°
NOTE 2
Tighten the screws following the sequence

indicated.
20-55

5 Remove exhaust manifolds (3).
6 Fit rocker arm pushrods (4).
Completion of cylinder heads installation

1 Install the rocker arm assemblies by fitting rocker arms (2), thrust
washers (3) and circlips (4) on support (1).
3
Fully loosen valve clearance set screws (5). 4
1 5
2 Lubricate pivot pins and fit rocker arm supports assembly (1).
Lock the supports with nuts (6). 6
Nuts: 39 Nm (28.7 lb.ft.). 1
20-56

3 Fit new injector O-rings (7) in the cylinder heads.

Adjust valve clearance following the procedure described below.
7
20-57

20.1.27 - Calculation of cylinder head gasket thicknesses

1 DANGER
This procedure must be carried out for each

cylinder.
Once the 4 hours required for polymerisation have elapsed,

remove clamping blocks T16 (P/N 5.9030.631.4/10) applied for T16
insertion of the cylinder liners.
Remove carefully sealant residues from all the surfaces.
2 Bring piston (1) of the cylinder in question to TDC, checking

the position using tool T5 (P/N 5.9030.967.0) and a dial gauge
preloaded by about 4 mm on the piston; reset the gauge at
TDC.
NOTE
The tool must be positioned in the middle of the

piston parallel to the gudgeon pin axis.
Move the tool aside and check distance “X” between piston
crown (1) and the gasket mating surface on liner (2).
3 depending on measurement reading “X”, select the gasket from among the available thicknesses.
Tab.31
MEASURED VALUE “X” MM GASKET THICKNESS MM GASKET COLOUR NUMBER OF HOLES
(IN.) (IN.)
0.15...0.40 1,2 (0.0472) Red -
(0.0059 - 0.0157)
0.41...0.60 1,4 (0.0551) Black 2
(0.0161 - 0.0236)
0.61...0.80 1,6 (0.0630) Green 1
(0.0240 - 0.0315)
4 NOTE 4
The holes that identify the thickness of the

gaskets are the ones shown in the figure.
NOTE
Position the gasket of each cylinder and check

to ensure O-rings (3) and (4) are present. The
gaskets have an obligatory direction of assembly: A
check that the gasket code and flame guard ring A A 3
“A” are facing upwards.
20-58

5 DANGER 4
The gaskets must not be degreased.
A A A 3
20-59

20.1.28 - Valve springs check

1 Rest valve springs (1) on a reference surface and check
perpendicularity with a set square.
2 Check the length of valve springs (1).

If either of the two parameters checked is not within the values
indicated in “TECHNICAL DATA AND DIMENSIONS”, renew the
springs.
1
NOTE
The springs must be changed also when the

coils show signs of rust pitting.
20-60

20.1.29 - Heat exchanger removal

1 Unscrew oil filter (1) and remove it.
NOTE
When installing, lubricate the gasket with engine

oil.
2 Loosen coolant pipe clamps (2).
3 Unscrew union (3) and remove heat exchanger (4).

4
NOTE
When installing, lubricate the gasket with engine

oil.
20-61

20.1.30 - Lubrication pump
Removal
1 Remove screws (10) and pump (11).
10
11
2 Remove drive coupling (14) and shaft (15).
14
15
Assembly
1 Lubricate pump drive shaft (1) and drive coupling (2) and fit into
block (3).
2
2 Fit pump (4) and secure with screws (5).

5
20-62

3 Fit suction rose (6) and secure with nut (7) and screw (8).
6
8
20-63

20.1.31 - Lubrication pump disassembly (1000.3 WT E III,1000.3 WTI E III)

1 NOTE
Dismantle the pump only for a visual inspection; renew the entire unit in the presence of anomalous wear.
Disassembly of the pressure limiting valve must be carried out when, on checking the pump delivery pressure,
the values specified in “Checks and technical data” cannot be reached.
2 Loosen and remove screw (1) and nut (2).

4
Remove pump cover (3) and remove pressure limiting valve (4).
1
3
2
3 Drive out spring pin (5) and remove the valve assembly,
withdrawing end cap (6), spring (7) and piston (8).
8
Clean carefully and refit the valve checking that piston (8) slides 7
freely. 6
NOTE
Valve calibration: 4.9...5.9 bar (71.07...85.57 5

psi)
4 Check wear of gears (9) and the pump body to decide whether or
not to replace the entire assembly.
9
NOTE
On refitting, lubricate the gears and drive gear

shaft liberally.
Gears: gearbox oil

Screws: 20.4 Nm (15 lb.ft.)
Tab.32
Mini- 700 rpm 2400 rpm
mum litres bar psi litres bar psi
flow
rate
11 7-22 38 51-65
20-64

20.1.32 - Lubrication pump disassembly (1000.4 WTI E III)

1 NOTE 4
Dismantle the pump only for a visual inspection; 1
renew the entire unit in the presence of anomalous
wear. Disassembly of the pressure limiting valve
must be carried out when, on checking the pump
delivery pressure, the values specified in “Checks
and technical data” cannot be reached.
Loosen and remove screw (1) and nut (2).

3
Remove pump cover (3) and remove pressure limiting valve (4). 2
2 Drive out spring pin (5) and remove the valve assembly,
withdrawing end cap (6), spring (7) and piston (8).
8
Clean carefully and refit the valve checking that piston (8) slides 7
freely. 6
NOTE
Valve calibration: 4.9...5.9 bar (71.07...85.57 5

psi)
3 Check wear of gears (9) and the pump body to decide whether or
not to replace the entire assembly.
9
NOTE
On refitting, lubricate the gears and drive gear

shaft liberally.
Gears: gearbox oil

Tab.33
Mini- 700 rpm 2400 rpm
mum litres bar psi litres bar psi
flow
rate
16 7-22 48 51-65
20-65

20.1.33 - Oil sump
Removal
1 Unscrew and remove screws (1) securing oil sump (2).
1 2
NOTE
Make a note of the positions of the washers and

spacers.
1
1
2 Attach oil sump (2) to a hoist and remove it.
NOTE 2
To remove the oil sump tap gently and evenly
with a rubber mallet.
NOTE 3
Renew gasket (3) on reassembly.
Installation
1 Coat the sump mating surfaces in correspondence with the front
and rear main bearings oil seals with sealant.
19
Seal area: Silastic 738
Position gasket (18), install sump (19) so that the rear face of
sump (19) is aligned with the rear face of the engine block as
shown by the arrows; fix the sump with the screws.
18
NOTE
Fit the washers and spacers under the screws as

noted on disassembly.
Screws: 30...35 Nm (22.1...24.8 lb.ft.)
20-66

20.1.34 - INJECTION PUMPS, GOVERNOR AND FUEL SUPPLY

1 Remove the fuel filter.
NOTE
Plug the pipes to prevent the ingress of dirt.
2 Remove oil filler cap (1).
NOTE
Inspect the O-ring carefully; if in the least doubt

about its condition, fit a new seal. 1
3 Remove screws (2) securing governor drive unit (3).
NOTE
On 3/4-cylinder versions, this unit also drives the

oil pump.
3
4 Only if necessary
See para. 20.1.42 - Installation of e... - Page 20-107
5 Remove fuel delivery pipes (6) to the injectors.
(For details, see “REMOVING HEADS”). 6
DANGER 6
Plug the pump unions immediately after having

removed the fuel delivery pipes.
20-67

6 Undo unions (7) and remove fuel supply pipe (8) to the injection
pumps.
8
NOTE
Renew the bronze seals of the unions on

reassembly. Use original parts only.
NOTE
Carefully inspect the threads of the unions; if 7

damaged, renew the union using original parts
only.
DANGER
Plug the pump ports with unions (7) immediately

to prevent the ingress of contaminants.
7 Remove unions (9) and fuel return pipe (10).

9
NOTE
Renew the seals of the unions on reassembly.

Use original parts only.
NOTE 10
Carefully inspect the threads of the unions; if
damaged, renew the union using original parts
only.
DANGER
Plug the pump ports with unions (9) immediately

to prevent the ingress of contaminants.
8 Record the positions of injection pumps (11) and relative shims

(12) to avoid confusion during re-assembly. 11 11 11
3 2 1
3 2 1
12 12 12
20-68

9 Gradually loosen and remove locknuts (13) and flange (14) of

the injectors.
14
13
13
10 Manually move the control rod to around the mid-point of its

stroke, remove the nuts and washers and remove injection
11
pumps (11) and shim pack (12).
NOTE
Note that if the shims or the pumps are mixed

up and not refitted in their original positions,
then it will be necessary to carry out the timing
procedure on all the pumps. 12
11 Remove the roller tappets (15).
15
12 Remove the nuts and remove fuel pump (16).
NOTE
Carefully check the condition of gasket (17).
16
17
20-69

20.1.35 - Injection pump timing

1 DANGER
The operations are described for cylinder N° 1,

but they must be carried out for all cylinders.
These operations must be carried out each time
a new camshaft is fitted and whenever the valve
timing is adjusted, whenever a new pump control
rod or cam follower roller is fitted.
Remove the governor, if not previously removed.

Lubricate the exterior and insert in the crankcase all the roller
tappets (1) responsible for operating the injection pumps.
NOTE
Lubricate the rollers with engine oil
NOTE
Check that pins (2) are located in their seats and

rollers (1) are in contact with the cams.
2 Bring piston N° 1 to TDC and turn the crankshaft until the piston performs a stroke corresponding to the static advance position
shown in the table.
3 NOTE
The required position can be obtained by surpassing the precise dimension point turning the crankshaft
counter-clockwise and then reaching the exact value with a clockwise rotation in order to recover backlash.
Tab.34
PISTON STROKE MM (IN.) STATIC ADVANCE ANGLE
1,39 (0.0547) 11°
1,65 (0.065) 12°
4 Measure the distance between the injection pumps mating

surface on the engine block and the relative tappet.
Measure with tool (P/N 0.015.2474.4)
The instrument shows difference “X” (in 1/10 mm) between the
nominal dimension fixed at 46.60 mm (check gauge drwng.
0.015.2477.0) and the effective distance between pump mating
surface and tappet.
Dimension “X” will be a whole number (round to the closest whole
number value) and must always be > 0.
NOTE
Make a note of dimension X.
20-70

Repeat these measurements for all cylinders.
5 Fit the injection pump control rod:

See para. 20.1.39 - Injection pumps c... - Page 20-80
6 Form the shim pack of thickness “X” (5) to be installed.
Apply a thin layer of sealant between shims (5), pump (6) and
engine block (7) and install the parts on engine block (7).
NOTE
Apply sealant LOXEAL 08-07 to the shims.
7 Install rod centring tool (A) and secure it.

A
NOTE
The tool serves to hold the pump control rod in

position.
8 Move pump control pin (7) to its mid-stroke position.
20-71

9 Fit pumps (6), positioning them so that the pin of the pump control
lever locates in the slot in the control rod.
6
10 Turn the crankshaft clockwise to bring the roller to the dead race
of the cam.
NOTE
Interruption of downward movement of the pump

indicates that the race has been reached.
Fit the washers and nuts (8); tighten them gradually in a crosswise
sequence to seat the pump against the crankcase.
Tighten the nuts to a starting torque of 5 Nm (3.68 lb.ft.).
NOTE
While tightening the nuts, gently rotate the pump

in a clockwise direction in order to ensure that it
stays in contact with the control rod.
Repeat the steps described for all the pumps.

11 Remove tool (A) and check that the control rod slides freely
without sticking. A
20-72

12 Fit new gasket (9) and governor drive relay (10).
NOTE
Apply sealant LOXEAL 08-07.
10
13 Position a dial gauge with a magnetic stand on the crankcase

with the contact point resting on pump control rod (11).
11
14 Turn all the pumps slightly clockwise and set the dial gauge to
zero.
Starting with pump N° 1, turn it clockwise until you see the needle
on the dial gauge move.
NOTE
This procedure serves to achieve an initial

balancing of the injection pumps; on completion
of the procedure it is not essential that the 8
movement of the pump control rod relative to
TDC is less than 0.05 mm.
Using a torque wrench, tighten the nuts (8) alternately in two

stages.
Tightening torque (stage 1): 10 Nm (7.37 lb.ft.)
Tightening torque (stage 2): 16...20 Nm (11.8...14.8 lb.ft.)
15 Remove special screw T27 (P/N 0.015.2495.4) and replace
screw (3) removed previously.
NOTE
Renew the copper washer.
20-73

NOTE
To avoid bending the pump control rod, move the

rod in the direction of the flywheel and tighten
screw (3) by hand.
Removing and refitting an injection pump for bench testing.

1 DANGER
This procedure only applies in cases when no components are renewed and the calibration is not altered.
2 Remove pump (1) leaving the shim pack in position.

After testing. apply sealant to the underside of pump (1). Fit the
1
pump and tighten down with the retaining nuts.
Pump: LOXEAL 08-07
Nuts: 16 4 Nm (11.8 3 lb.ft.)
Renewing an injection pump

DANGER
Fit exclusively pumps of the same type (see “TECHNICAL DATA”).
Proceed as indicated above, using the shims of the old pump.
Removing and installing a pump after the renewal of parts or a calibration adjustment.
The injection pump that has been overhauled and checked on the test bench must be installed as illustrated above.
20-74

20.1.36 - Injectors assembly

1 Fit injector (1), retaining bracket (2), conical washer (3) and nut
(4). 4
NOTE A
1
2 A
Surface “A” of the injector must face the retaining
bracket.
3
Tighten nut (4) securing bracket (2).
Nut: 39 Nm (28.7 lb.ft.)
20-75

20.1.37 - Checking injectors protrusion - Renewal of copper bushes
Injectors protrusion check

1 Fit injector (1) into the head and secure it with retaining bracket
(2), conical washer (3) and nut (4).
2 4
1
Nut: 39 Nm (28.8 lb.ft.)
2 Using a gauge check injector protrusion “A” from surface of

cylinder head (5).
● Renew the copper bush if the protrusion value is outside
A
the limits indicated in “Technical data and dimensions”.
Renewal of the copper bushes

1 NOTE
These operations must be carried out exclusively

by a specialised service centre.
Ream out the old bush mechanically using a system with swarf
extraction; remove enough material from the inside diameter so
that the bush can be easily deformed and thus withdrawn.
Remove all traces of old sealant and metal particles from groove
“C”.
NOTE
Take care not to damage the bush seating bore.
Carefully degrease the bush seating bore and the bush to be

fitted.
Apply silicone sealant to groove “C”.
Sealant: DIRKO TRASPARENT/OXIM
20-76

NOTE
Once the sealant has been applied, the new bush

must be installed within 10-15 minutes; once this
time interval has elapsed, remove the sealant
and repeat application.
Insert the bush in its bore in the cylinder head and press it fully
home in seat “D”.
While maintaining the pressure, widen the bush by roll forming to
improve the axial seal up to a depth “A”.
Calibrate the nozzle seat using a ball calibration tool.
NOTE
Calibration tool: Ø 7.3 mm (0,288 in.)
Check that injector protrusion “B” is as specified in “TECHNICAL

DATA AND DIMENSIONS”.
20-77

20.1.38 - Injectors check

1 NOTE
Checks are relative to fuel atomisation efficiency

and injection start pressure.
2
Unscrew injection nozzle holder (1), remove injection nozzle 1
assembly (2), the direction plate and drain the injection assembly
of residual fuel.
NOTE
The check cannot be performed if the residual

fuel is not discharged.
NOTE
Renew the copper gasket.
2 Refit plug (1) and connect the injector to the injector test pump.
Pump several times to expel air from the circuit and fill the
injector.
Activate pump slowly and check injection start pressure on the
pressure gauge.
Repeat the procedure several times and check that injection
pressure is uniform.
NOTE
Use this method to check also that fuel

atomisation is uniform; the fuel must be delivered
with a number of jets equivalent to the number
of injector nozzle orifices and each jet must be
finely atomised and identical to the others. If
injection start pressure does not correspond to
the value indicated in “TECHNICAL DATA AND
DIMENSIONS”, have the calibration carried out
by a specialised service centre.
20-78

3 Also check the seal between nozzle seat and needle valve. To do
this, operate the pump to build up pressure to approx. 10% lower
than opening pressure.
Maintain pressure and check that no fuel leaks from the nozzle.
If leakage occurs, the entire injector assembly must be
renewed.
20-79

20.1.39 - Injection pumps control rod
Removal
1 Unscrew and remove retaining plug (1)
NOTE
Remove all traces of sealant from the thread.
2 Unscrew and remove stop pin (6) of rod (2).

6 7
NOTE
Renew copper washer (7) on reassembly.
3 Remove rod (2).

4 Recover rod (2) driver plate (3).
NOTE
Take care not to drop plate (3) into the engine

block.
2
3
5 NOTE
The rod contrast spring is fitted on the other side of the engine. To remove this spring refer to “Timing gear
disassembly”.
20-80

6 Remove the screws and remove rod driver assemblies 4).
NOTE
Renew O-rings (5) and remove all traces of 4

sealant
Installation
1 Fit the contrast spring assembly (1) for the pump control rod in
the crankcase and secure with the screw.
2 Fit O-rings (3) on rod drivers (2) .

Coat the cylindrical part next to the flange with sealant and fit the
rod guides (3), orienting the fixing hole.
2
Rod guide: Loctite 510
3 Partially tighten the fixing screws and fit control rod (4) complete
with spring guide, spring and driver plate (5).
NOTE
To prevent driver plate (5) from falling apply

grease to the mating surface of rod (4).
4
NOTE
5
Secure rod guides (2) and check that the control
rod slides freely.
20-81

4 Secure tool (9) to the crankcase, engaging yoke (10) on rod

control pin (11).
11
9 10
5 Manually snug stroke limit pin (7) of rod (4), moving the rod and
8 7
aligning it in its seat.
NOTE
Renew copper washer (8) on reassembly.
6 Partially tighten rod retaining plug (6).

Smear sealant on plug (6).
Plug: Loctite 542 6
Screw plug (6) down until it is recessed by 0.5 mm with respect
to the crankcase surface.
20-82

20.1.40 - Mechanical governor overhaul (standard and with L.D.A.)

1 DANGER
1 - The overhaul should be carried out on the governor disassembled from the engine and installed on tool T4
(P/N 5.9030.665.0). 2 - General adjustments that affect operation of the governor must be carried out on the
workbench. 3 - Adjustments impacting on operation of the engine must be carried out with governor installed.
4 - Remove only the parts indicated in this section; the parts that are not mentioned must be left in place
because their position is factory set and must remain unchanged for the entire lifetime of the governor and
the engine. 5 - If the parts indicated are disassembled by mistake, ship the entire governor to the factory for
all-round calibration and overhaul.
Standard governor disassembly
Separation of lower housing from upper housing

1 Fit governor (1) on tool T4 (P/N 5.9030.665.0) held in a vice.
1 3
Loosen and remove fixing screws (2) of upper housing (3).
T4
2 Remove upper housing (3) and gasket (4). 3

5
NOTE
Renew the gasket at each disassembly. 4
Remove spring (5).
3 Remove circlip (6) and washer (7) connecting the levers to

control sleeve (8). 7 8
20-83

4 Remove circlip (9) and washer (10) of pivot pin (11).

11
10
5 Loosen and partially unscrew nut (12) of pivot pin (11).
12
11
6 Unscrew pivot pin (11) from the exterior until releasing lever
(13). 11 12
13
NOTE
Recover nut (12) and washer (14).
NOTE
14
Renew the copper gasket.
7 Turn control sleeve (8) to detach it from the levers and remove.
Remove thrust sleeve (15) complete with bearing (16). 8 16
15
20-84

8 Remove lower housing (17) from tool T4 (P/N 5.9030.665.0) and

remove lever assembly (13). 13
17
9 Carefully check pin (A) of sleeve (8) and slot (B) of lever (13).
8
If the pin is worn and the slot has a concave profile, renew the
parts.
13
NO SI
NOTE
A
Remove any burr that has formed on the slot
profile.
NO SI
10 Loosen and remove nut (18) and the relative washer.

Remove spring pivot pin (19), bush (20) and spring (21)
18
simultaneously. 21
NOTE
19
Renew the O ring.
20
11 Relieve the staking on lock washer (22) and loosen shaft locking
ringnut (23).
23
22
20-85

12 Remove ringnut (23) and lock washer (22) and withdraw lower
23 17
housing (17) from shaft (24).
22
24
13 Using a pin punch, remove pivot pins (25) and remove weights
27
(26).
NOTE
Note the orientation of the contrast blocks (27). 25
26
14 Using a pin punch of suitable diameter, drive out spring pin (28)
securing weights support (29).
28
29
15 Using a soft mallet (aluminium or copper), drive shaft (24) out of

support (29).
24
29
20-86

16 Remove circlip (30) and remove bearing (31) from lower housing
(17).
17
31
30
17 Loosen and remove nut (32), the relative washer and engine 33
stop and automatic fuel boost lever (33).
32
18 Remove engine stop control lever (34) and relative spring (35).
34
NOTE
Renew the O-ring.
35
NOTE
Make a note of the engagement positions of the

ends of the spring.
19 Using a pusher tool calibrated on the bearing inner diameter,

remove thrust bush (15) from bearing (16).
NOTE
Recover shims, if any, adjusting axial play of the

bearing. 15
16
20-87

20 Using a suitable tool, remove bushes (36) from levers control

sleeve (8).
NOTE
36
Make sure the bushes are flush with the sleeve.
Lower housing assembly

1 To assemble, follow the disassembly steps in reverse order.
27
● Stake lock ringnut (23).
● Apply Loctite 270 on spring pin (28).
● Apply Loctite 601 on shaft (24) and support (29).
Calculate the thickness of the shim pack to be installed under the
bearing using the following procedure:
1. Install thrust sleeve (15) and, keeping it pressed against 15
contrast blocks (27) measure the distance between the
bearing shoulders. Example: measured value 60.5 mm
(2.384 in.)
2. Subtract the calculated value from the design fixed value.
Resulting value “S” is the shim to be added under the
bearing.
NOTE
Fixed value: 61±0.1 (2.403±0.0039 in.), S =

61±0.1 - 60.5 = 0.4...0.6 mm
Bush height adjustment

1 Position governor lower housing on tool T4 (P/N 5.9030.665.0).
Position a dial gauge on tool T1 (P/N 5.9030.433.0) and install
the assembly on the stud; restrain it (with light clamping force) by
means of a nut.
Preload the dial gauge by about 5-6 mm (0.197-0.236 in.) on
governor lower housing surface (17) and set it to zero.
20-88

2 Loosen cap nut (37).

Turn the dial gauge tool holder to bring the gauge anvil into
contact with the bush surface (8).
Adjust cam (38) until reaching the design value.
37 38 38
NOTE
Measured value 4.5...5.5 mm (0.177...0.216 in.) 37
8
NOTE
Make sure that the cam is facing upwards.
3 Holding the cam (38), tighten cap nut (37) fully down.
Repeat the check and, if necessary, repeat steps 6 and 7 to 8
return to within the permissible range of values.
4.5 +0 1m m
0
(0.177 + 0.0394 in.)
Upper housing disassembly

1 After removing anti-tamper protections, loosen and remove safety
cap (39) for the stroke adjustment screw of injectors control rod.
Remove also the copper gasket. 39
2 Using a gauge, measure the protrusion of screw (40) with respect

to locking nut (41).
NOTE 40
Make a note of the measurement. During

fitting, this value must be restored to keep the
engine running. The final measurement must be
established with the governor installed and the 41
engine running. (for details see “Calibration of
mechanical governors”).
20-89

3 Remove cap (42) of the anti-hunting device and the relative

copper gasket.
Loosen nut (43) and remove anti-hunting device (44). 42
44
43
4 Loosen and remove the nut securing the rod stroke adjustment
and remove mushroom head screw (45).
45
45
5 Push lever (46) outwards and remove compression bush (47)

and spring (48).
For versions with LDA only: recover washer (49) on which the
anti-hunting device spring is located. 49 47
48
46
NOTE
Note the bush lower diameter rests on the

spring.
6 Loosen lever pivot pin (50) fully.

50
NOTE
Renew the O-ring.
20-90

7 Remove the pivot pin and remove lever (46) and the two thrust
washers (51). 46
NOTE 51
Note the thrust washers are installed on both

sides of the lever pivot pin.
NOTE
Check that the lever pins are perfectly cylindrical;

renew them at the first sign of ovality.
8 Remove spring guide bush (52).
52
9 Remove grub screw (53) and drive out accelerator lever (54).
53
NOTE
Renew the O-rings.
54
10 Remove yoke (55) and the relative two thrust washers.
NOTE 55
Note the thrust washers are installed on both

sides of the yoke.
20-91

11 NOTE
All the operations indicated below must be performed: 1 - On renewing the counterweights shaft. 2 - When the
bush and shaft are worn. 3 - When sleeve and spring guide are worn or seized. 4 - When the accelerator lever
bushes are worn. 5 - Renew the oil seal on reassembly also if the upper bush remains installed.
12 Loosen and remove nut (56) securing shaft upper guide bush
(57).
57
56
13 Using a suitable tool, remove guide bush (57).
NOTE 57
Always renew the O-ring.

57
14 Renew bushes (58) and (59) of the accelerator lever pin.
59
58
20-92

Upper housing assembly

D
After the final calibrations carried out on the engine apply the
anti-tamper protections “C” and a drop of light coloured enamel
paint “D” for the adjuster nuts.
2 NOTE
Restore the protrusion dimension of the rod stroke limiting screw.
Apply Loctite 242 on pin (50).

Apply Loctite 601 to guide bush (57).
Apply Loctite 601 to bushes (58) and (59) .
NOTE
Position the bushes flush with the governor housing inner surface.
3 Screw mushroom head screw (45) into the upper housing

until obtaining a measurement of approximately 1 mm (0.0394
in.) between the surface of the housing and the screw head
surface.
45
1m m
(0 .0394 in.)
Governor housing assembly

1 Lubricate all pivot pins of the levers and weights accommodated
in the lower housing with engine oil.
Lubricate the counterweights shaft, bushes and all sliding parts 3
with Molikote.
Position gasket (4) on lower housing (17) and fit upper housing
(3).
2
Fasten housings together with screws (2). 4
17
20-93

NOTE
Tighten the screws gradually in an alternate 3

sequence.
2
4
17
Disassembly of governor with L.D.A. valve

DANGER
1 - This section contains and shows only steps different from those illustrated for the standard governor. 2 - The
construction difference of certain parts does not affect the adjustments and descriptions concerning adjustments of
the standard model.
Separation of lower housing from upper housing

1 Using the specific tool, remove clamps (60) securing rubber
protection (61).
61
60
2 Free protection (61) from bush (62) and push it downwards.
62
61
20-94

3 Remove circlip (63) and remove pin (64).
63
64
Diaphragm renewal
1 Unscrew and remove screws (65); remove valve cover (66).
65 67
66
2 DANGER
Do not remove grub screw (67). Adjust, if necessary, when calibrating the governor. (for details see “Diaphragm
excursion adjustment”).
3 Remove diaphragm assembly (68) and spring (69).

68
NOTE
69
Check for the presence of shims under the spring
and recover them if found.
20-95

4 Hold the diaphragm assembly in a vice, loosen and remove nut

(70) and upper plate (71).
70
71
5 Remove diaphragm (72).
NOTE
72 73
Note which way round the diaphragm is fitted.
Raise guide plate (73) and tighten nut (74) by 2 turns.

74
6 DANGER
This operation should be carried out only when it is necessary to revise or check centring of the diaphragm
stroke; for replacement only this operation can be eliminated provided the position of lower nut (74) is not
altered.
Completion of disassembly
1 For the renewal of diaphragm guide bush or valve body only:
measure distance “C” between disc supporting surface and the
surface of spring support bush (62).
C
62
2 DANGER
Make a note of the measurement. During fitting, this value must be restored.
20-96

3 For the renewal of the valve body only: mark the position of the
L.D.A. valve body on the governor upper housing and remove
76
screws (75) and valve body (76). 75
NOTE 76
Only if present: mark the position of the shims

installed between the valve body and governor
housing to avoid confusion on reassembly.
4 Remove the rubber bellows (61).
NOTE
61
Take care not to damage tie rod (77) for reduction
of injection pump control rod stroke.
77
5 Unscrew and remove diaphragm connection yoke (78).
78
77
6 After removing anti-tamper protections, loosen and remove safety

cap (39) for the stroke adjustment screw of injectors control rod.
Remove also the copper gasket. 39
20-97

7 Using a gauge, measure the protrusion of screw (40) with respect

to locking nut (41).
40
NOTE
Make a note of the measurement. During fitting,

this value must be restored to keep the engine
running. The measurement must be made with
the governor installed and the engine running. (for
41
details see “CALIBRATION OF MECHANICAL
GOVERNORS”).
After the measurement remove nut (41).

8 Loosen and remove connecting screws (2) of governor upper
housing (3) and lower housing (17). 3
Remove upper housing assembly (3) and gasket (4). 3
NOTE
Renew the gasket at each disassembly.

4 17
2
9 Recover washer (49) on which the anti-hunting device spring

49
rests.
10 Remove circlip (79) securing lever (80) for reduction of the pumps
control rod stroke. 80
Remove lever assembly (80).

Perform disassembly operations of upper and lower housing as
described for standard governor. (For details, see “Mechanical
governor overhaul”).
79
20-98

Assembly of governor with L.D.A. valve

Restore measurement “C” between the surface of the guide plate
and the surface of bushing (62) on which the spring rests before
C
fitting any shims that might be necessary.
62
2 Perform valve body centring procedure as follows:

Fit anti-hunting device bush (81) and secure by tightening nut
(82) slightly.
76
Fit the L.D.A. valve body on governor upper housing (76) inserting
previously removed shims, if any; gently secure the valve body
with relative screws and washers (75). 81
75
82
3 Fit tool T6 (P/N 5.9030.885.0) into the bore of diaphragm stem

guide bush (62) and anti-hunting bush (81) and further tighten
screws (75). T6
Check that the tool slides freely and tighten the screws in
75 62
crosswise sequence.
81
4 Assemble upper housing to lower housing and tighten yoke (78)

fully onto rod (77).
78
77
20-99

Inspection
1 Temporarily install the diaphragm assembly and connect rod (77)
to yoke (78) with pin (64).
Raise the diaphragm and check that the movement is constant
and without undue friction throughout the entire stroke. If 64
necessary, adjust the valve body position to eliminate any rod
friction. 78
Disconnect the rod and perform the adjustments on the
workbench and once assembly has been completed. 77
(For details see next heading).
2 Make sure that yoke (78) is screwed down until locating on spring pin.
Restore the protrusion value of screw (40) with respect to nut (41).
Smear the washer with grease to hold it in position.
Workbench adjustments for the L.D.A. valve
Tie rod length adjustment

1 Before applying the upper cover, loosen and remove nut (70),
diaphragm (72) and the two plates (71), (73).
70 71
Tighten lower nut (74) on the guide stem by a few turns; reposition
plates, diaphragm and nut (70). 72
74 73
2 Pull diaphragm assembly (68) upwards until you feel pin (83) 80
engage with lever (80). 68 83
Tighten nut (70) until lower plate (73) rests on valve body (76).
76
20-100

3 Remove pin (84) and withdraw the diaphragm assembly without

moving nut (74).
70
Screw nut (74) to lower plate (73) then back it off by half a turn.
Holding lower nut (74) in position, secure nut (70).
84
74
Spring force adjustment

1 Loosen ringnut (85) and unscrew bush (62) until it locates against
the valve body.
Tighten bush (62) by 3/4 of a turn and secure with ringnut (85).
Complete valve and governor assembly. 85
62
Adjustment of diaphragm excursion

1 When the valve is fully installed, tighten adjuster grub screw (67)
until the lower guide plate is located on the valve body.
Loosen grub screw (67) by 2 and a 1/4 turns and secure this 67
position with nut (86).
86
Final adjustments
DANGER
1 - If the engine is installed on a tractor, these operations must be carried out in safety conditions, on level ground
and with the parking brake engaged. 2 - Adjustments described in this heading must be carried out with the governor
installed on the engine, and with all the external controls connected and adjusted (for mechanical governor). 3 -
Make the final adjustments after having started the engine and allowed it to idle until brining the oil temperature to at
least 80 °C (176 °F) 4 - The adjustments must be carried out with the engine in no load conditions, i.e. with the air
conditioning, heating, lights and directional control valves either off or not activated.
20-101

Fuel flow rate control

1 With the engine at operating temperature, use the hand throttle
to bring it to calibration speed.
NOTE
Calibration speed: see table.
40
Loosen nut (40) securing power adjuster screw (41); back off the
screw until the engine is running smoothly at a speed close to 41
stopping (300...500 rpm).
Tighten screw (41) about 3 turns and wait until engine speed
stabilises.
Slacken screw (41) by two turns and then proceed in steps of
approximately 30° waiting for approximately 5 seconds between
each step.
Continue with the adjustment until the engine stops.
With the engine stopped, tighten power adjuster screw (41) by
the value shown in the table, selecting the engine type stamped
on the engine identification plate.
Example: engine type shown on the engine identification plate:
1000.3 AT2 Screw turns: n° 6.25
NOTE
Screw turns are shown in complete turns and

quarter turns.
CALIBRATION FOR MECHANICAL GOVERNORS

1 Tab.35
Engine type Rated power kW Engine speed Fuel screw

(HP) Minimum n/1’±20 Maximum (no load) Speed at max. no. of screw turns at
n/1’ (±) power n/1’ ±5 2100 n/1’ ±10
2 While holding screw (41) in position, tighten locknut (40)

Fit safety cap (39) and secure with nut (40).
39
40
20-102

Top speed adjustment

1 Loosen nut (87) and use screw (88) to set the maximum speed
according to the calibration table.
NOTE
Check the speed with a precision rev counter. 88
While holding screw (88) in position, tighten locknut (87).

Refit the anti-tamper protection. 87
Hunting adjustment
1 Only for standard governor: remove safety cap (42).
Only for standard governor: loosen nut (43) and slacken grub
screw (44) by several turns.
43 44
42
2 For governors with LDA only: remove clamp (60) and raise rubber
cover (61).
Loosen nut (82) and slacken off ringnut (81) several turns.
61 60
82
81
3 Start the engine and bring the revs up to maximum with no load.
Slowly tighten bush (81) or grub screw (44) until attenuation of
the hunting phenomenon.
While holding bush (81) or grub screw (44) in position, tighten 44
43 61 60
nut (43) or (82).
Stop the engine and fit the safety cap. 82
81
NOTE
For governor with L.D.A., reposition rubber cover

(61) and apply retaining clamp (60).
20-103

4 DANGER
1 - The adjustment is unable to completely eliminate the hunting phenomenon - it can only minimise it. 2 -
Adjustment of the device must not affect maximum engine speed by more than 20 rpm. 3 - Check the change
in engine speed with a precision rev counter.
Idle speed adjustment

1 Loosen nut (89) and slacken off control screw (90) few turns.
Start the engine and bring the revs up to 750 rpm with the hand
throttle.
90
Tighten control screw (90) until you feel it engages the inner 89
lever.
Return the hand throttle to minimum, unscrew control screw
(90) gradually and check the engine speed with a precision rev
counter; stop the adjustment at the rpm value shown in the table.
See Fuel flow rate adjustment.
While holding screw (90) in position, tighten locknut (89).
Governor sealing
1 After having checked that the governor is functioning correctly
D
and checked the tightness of safety caps and adjuster screw
nuts, fit anti-tamper protection “C” connecting the components
through the hole provided install a lead seal.
To seal the adjuster nuts, apply a spot of light coloured enamel
paint “D”. C
20-104

20.1.41 - Electronic governor adjustment

1 NOTE 1 2
Adjustments must be carried out in safety

conditions and with no load on the engine.
2 After renewing electronic governor (1), remove cap (2) providing

3
access to set screw (3).
Start the engine and leave it running until it reaches normal
operating temperature.
Using the hand throttle set the revs to 2100±10 rpm.
3 Slowly loosen screw (3) until you notice the engine speed
decrease.
NOTE
2 3
This manoeuvre serves to reduce the fuel flow
rate; wait for a few seconds for the fuel flow rate
to stabilise in this condition.
Slacken off screw (3) through a few degrees and wait for the flow
rate to stabilise again.
Using the procedure described above, undo screw (3) gradually
in several steps of a few degrees each until the engine stops.
Once the engine has stopped, slowly tighten screw (3) by the
number of turns indicated in the table.
NOTE
Adhere strictly to the values of screw turns

indicated.
4 Apply a small quantity of weak threadlocker to plug (2) and screw the plug into the seat of the actuator until it locates against
screw (3).
20-105

NOTE
Use only low-strength threadlocker for precision fixing.
NOTE
Do not force plug (2) onto screw (3).
Tab.36
CALIBRATION FOR ELECTRONIC GOVERNORS
Engine type Rated power kW Engine speed Fuel screw
(HP) Minimum n/1’±20 Maximum (no load) Speed at max. no. of screw turns at
n/1’ (±) power n/1’ ±5 2100 n/1’ ±10
5 Fit anti-tamper protection “A”.
20-106

20.1.42 - Installation of electronic governor support

1 Fit gasket (1) and fit relay (2) centring the oil pump drive shaft.
2
NOTE
Oil the relay gears and relative shaft.
Relay: engine oil
2 Fix relay (2) with screws (3).

2
Lubricate the gears and bearings by pouring about 30 cm³ of oil
into the flange hole.
Gears: engine oil
20-107

20.1.43 - Engine coolant pump

1 3-4 cylinder versions
Loosen the clamps and disconnect hoses (1) and (2) from the 2
pump.
Remove alternator support (3).
1
3
2 Unscrew and remove screws (8); remove pump (9) and relative
10
gasket (10).
NOTE
Renew the gasket every time the pump is 8

removed.
3 6-cylinder version
7
Loosen the clamps and remove hoses (4), (5), (6) and remove
pump (7) and the relative gasket.
4
NOTE
Renew the gasket every time the pump is

removed.
6
5
20-108

20.1.44 - Engine coolant pump

1 If the coolant line was not previously removed, loosen clamps (1)
1
and disconnect hose (2).
2 Loosen the clamps and disconnect hoses (3).

5 4
Loosen screw (4) and remove alternator support (5).
3 Unscrew screw (6) and remove pipe (7).

8
NOTE
Renew oil seal (8) on reassembly.
20-109

4 Loosen and remove the four screws (9) with washer then remove
9
engine coolant pump (10).
10
5 Remove gasket (11).

11
NOTE
Renew gasket (11) after every removal.
20-110

20.1.45 - Thermostatic valve
Removal
1 Loosen clamps (1), undo screw (2) and remove pipe (3).
3
2 Loosen and remove screws (4) and remove cover (5) and gasket
5 6
(6).
NOTE
Renew the gasket at each disassembly.
3 Remove thermostatic valve (7).

7
20-111

20.1.46 - Checking the thermostat valve

1 Fully immerse the thermostatic valve in a pan “A” of coolant.
B
Heat the coolant, while checking the temperature with a
thermometer “B”.
Make sure that the thermostat valve opening is 0.1 mm (0.004
in.) when coolant temperature is 79±2 °C (174.2±35.6 °F) and A
the opening is 7 mm (0.276 in.) when temperature reaches 94
°C (201.2 °F).
2 DANGER
If the values found differ from the those indicated above, fit new thermostatic valve (6). Do not attempt to adjust
valve calibration.
20-112

20.1.47 - Cooling and intake ducts

1 Loosen screw (1) and clamp (2); remove radiator connection
3
pipe (3).
1 2
2 Loosen and remove unions (4) and remove pipe (5).

4
3 Loosen clamps (6), undo screws (7) and remove pipe (8).
8
6 7 7 6
20-113

4 Undo screw (9) and slide out fuel filter (10) and relative supporting
10 9
bracket.
5 Loosen clamp (11), undo union (12), disconnect pipes (13) and
11 12
remove fuel filter (10) complete with supporting bracket.
13
6 Undo screws (14) and remove blow-by support bracket (15).

14 15
14
7 Remove the three spacers (16) and undo the five fixing screws
16 17
(17).
Remove intake manifold (18).
NOTE
Renew the gaskets on reassembly.
18
20-114

Heating element
1 Undo nut (19), loosen nut (20) and move bracket (21) aside.
20 21 19
Unscrew the two flange fixing nuts (22).
22
2 Remove flange (23).

23
3 Remove heating element (24) and gaskets (25).

24
25
20-115

20.1.48 - Final engine checks

These checks are necessary for the final setup of the fuel injection system and to check the efficiency of the engine lubrication
system. The tests are to be carried out after the engine has been installed on the tractor and after all the liquid levels have been
restored (engine oil, coolant, fuel and recharging of the air conditioning system).
Initial start-up and oil pressure check

1 Check that the battery is fully charged and then connect the
terminals.
+
NOTE
--
First connect the positive terminal (+) and then
the negative (-).
2 Remove the engine oil pressure sensor and connect a 10 bar

pressure gauge “A” to pressure test fitting “B”.
A
NOTE
Note that in this condition, the oil pressure warning

light will not illuminate when the electrical circuits
are powered on.
3 Loosen the drain plug on the fuel filter and operate the fuel lift pump until the fuel flowing out of the drain hole is free of air
bubbles. Tighten the plug.
NOTE
If no resistance is encountered when operating the lever of the fuel lift pump and no fuel flow is obtained, turn
the starter key briefly back and forth until the fuel starts to flow.
Run the engine at idle speed and check that pressure gauge (fitted in step 2) shows a reading of 0.5 ... 1.5 bar (7.25 ... 21.75
psi).
4 Leave the engine idling for about 5 minutes, and then, using the hand throttle, set an engine speed of about 1200 rpm to bring
the engine up to its normal operating temperature (engine oil temperature above 65°C).
5 Return the engine to idle speed and check that the oil pressure indicated on the pressure gauge is greater than 0.5 bar.
6 Stop the engine, remove the pressure gauge and carry out the procedure to synchronize the injection pumps.
20-116

Synchronizing the injection pumps

1 This procedure should be carried out:
2
● After the removal of one or more pumps for testing,
overhaul or renewal.
1
● When the engine runs unevenly and the engine parameters
have already been checked using the All Round Tester or
(for industrial engines) the electronic control unit.
DANGER
All checks described below must be performed in T24

a well-ventilated area and with the exhaust pipe
connected to a fumes extraction system.
Inspection
1 Start the engine and leave it running at around 1200 rpm until it reaches normal operating temperature (engine oil temperature
above 65°C).
2 When the engine oil temperature exceeds 65°C, unplug the wiring connector of the solenoid valve that controls the hydraulic
tappets to ensure that the latter are not operated.
3 Remove plugs (1) on the exhaust manifold (2).
4 Insert digital temperature probe T24 (P/N 5.9030.667.4) in hole in the manifold corresponding to cylinder 1; allow the
temperature reading to stabilise, then note down the temperature value.
5 Repeat these operations for all cylinders.
6 Check the temperature difference between all the cylinders; if the temperature difference is not within the optimum range of
±15°C (±59°F), it will be necessary to adjust the angular position of the injection pumps.
Pump adjustment
1 With the engine running at idle speed, slightly loosen retaining nuts (1) of injection pump (2) to be adjusted.
NOTE
The nuts should be loosened sufficiently to eliminate the tightening torque but so that the pump is still held
firmly.
2 Rotate the pump.
NOTE
Rotate the pump CLOCKWISE to INCREASE the temperature of the exhaust gases. Rotate the pump
COUNTER-CLOCKWISE to DECREASE the temperature of the exhaust gases.
IMPORTANT
Adjust the pump corresponding to the cylinder with the lowest temperature reading by rotating it clockwise.
20-117

NOTE
After adjusting the angular position of one pump. it will be necessary to re-check the exhaust gas temperature
for all the cylinders.
3 Using a torque wrench, gradually tighten retaining nuts (1) of pump (2) alternately to the prescribed final torque.
Nuts: 16...20 Nm (11.8...12.1 lb.ft.)
20-118

20.1.49 - Final refitting operations

1 Position valve covers gasket (1).
2 Fit single valve covers (3) and secure with screws (2).
Screws: 5 Nm (3.7 lb.ft.) 2
NOTE 3
4
Check the condition of fixing screw O-rings (4).
3 Fit fuel delivery pipes (5) to the injectors complete with anti-
vibration clamp.
NOTE
Holding the pump union tighten the pipe union.
5 5
Pipe union: 20...25 Nm (14.7...18.4 lb.ft.)
4 Secure anti-vibration clamps (6).
6
6
20-119

5 Fit blow-by device union (7) for oil discharge.
6 Fit fuel pump (10) and secure with nuts (11).
NOTE
Check the presence and condition of O-ring

(12).
10
11
12
7 Apply Loxeal 08-07 sealant to the surfaces of gasket (15).

Position the gasket and fit actuator (16). 16
DANGER
With a screwdriver inserted through window “A”

move the control rod until engaging the driveshaft
in the drive plate.
15
8 Secure actuator (16) tightening the screws gradually in alternate

sequence. 16
Screws: 20 Nm (14.7 Ib.ft.)
20-120

9 Fit oil filler neck (17) or the sight glass cover; secure with screws
18
(18).
NOTE
Check the presence and condition of O-ring (19)

on the oil filler or the gasket on the cover.
17 19
10 See para. 20.1.45 - Thermostatic valve - Page 20-111

20
11 Fit gasket (21) and cover (22) and secure with screws (23).
21 22
23
12 Position the new gasket “A” and install coolant pump (24).
Pump fixing screws: 49...54 Nm (36...40 lb.ft.)
A
NOTE
If the pump is renewed, the alignment between

the engine pulley and pump pulley must be
checked. (For details, see the engine workshop
manual).
24
20-121

13 Fit the new gaskets, install manifolds (25) complete with

thermostatic valve and secure with screws (26).
26
Manifold fixing screws: 30...35 Nm (22.1...25.8 lb.ft.)
25
14 Fit new gaskets (34) and install exhaust manifold (35).
34
35
15 Fit turbocharger gasket (40) on the exhaust manifold.

40
16 Fit turbocharger (41) and tighten the four nuts (42).

41
42
20-122

17 Fit the turbocharger return pipe and tighten filler (43).

43
Connect the exhaust pipe and tighten clamp (44).
44
18 Fit the turbocharger oil delivery pipe and tighten unions (45).
45
NOTE
Renew copper washers (46) on reassembly.
46
45
19 Secure the pipes with suitable clamp (47) and the relative bolt.
47
20 Fit injection pumps fuel return pipe (49) and secure with unions
50
(50) and the relative gaskets.
DANGER
Renew the gaskets on reassembly. Use original

parts only.
Unions: 20 4 Nm (14.74 3 lb.ft.)
49
20-123

21 Fit injection pumps fuel supply pipe (51) and secure with unions
51
(52) and the relative gaskets.
DANGER
Renew the gaskets on reassembly. Use original

parts only.
DANGER
Renew the unions, if damaged, using original

parts only.
52
Unions: 20...24 Nm (14.74...17.74 lb.ft.)
22 Fit heating element (24) and relative gaskets (25).
24
25
23 Fit flange (23) and tighten locknuts (22).

20 21 19
Fit bracket (21) in place and tighten locknuts (19) and (20).
23
22
20-124

24 Fit intake manifold (18) and tighten the five fixing screws (17).
16 17
Install spacers (16).
18
25 Fit blow-by support bracket (15) and tighten down fixing screws
14 15
(14).
14
26 Connect fuel filter pipes (23) and tighten clamp (11) and union
11 12
(12).
13
27 Fit fuel filter (10) complete with bracket and tighten fixing screws
10 9
(9).
20-125

28 Fit pipe (8) and secure with clamps (6) and screws (7).
8
6 7 7 6
29 Fit pipe (5) and tighten unions (4).

4
30 Apply Silastic 738 sealant to mating faces “H” of the timing

cover.
31 Position new gasket (58) and fit timing cover (59) holding it in
place with the relative fixing screws and washers.
NOTE
Do not tighten the screws at this stage.
58
59
20-126

32 Lubricate the lips of the oil seal and fit spacer (60).
NOTE
60
Use two screws “A” to drive it fully home.
33 Temporarily fit crankshaft pulley (63) and secure it with screw 63

(64) and washer (65) tightened to a torque of approximately 30
Nm (22.1 lb.ft.).
NOTE
Do not fit the key.
65 64
34 Fit tool T23 (P/N 5.9030.634.0) between timing cover (59) and
59
engine block; tighten the tool fixing screws to align the surfaces.
T23
35 Tighten screws A-B-C. in a sequence.

A
T23
Tighten the other screws in a crosswise sequence to the same
tightening torque.
Remove tool T23 (P/N 5.9030.634.0) and trim any excess gasket
interfering with timing gear housing.
C B
20-127

36 Remove the pulse wheel or pulley and fit cover (66).
66
37 Fit the drive key

62 63
Refit pulley (63) and secure with screw (62) and the washer.
NOTE
Lubricate the screw, washer and crankshaft bore

with engine oil.
NOTE
Tighten the screws in two stages:
1st tightening: 60...70 Nm (44.2-51.6 lb.ft.)

2nd tightening: 326...350 Nm (240-258 lb.ft.)
38 Fit engine speed sensor (71) and secure with screw (72), circlip
72
and plain washer.
Screw: Loctite 242
Screw: 6 Nm (4.4 lb.ft.)
71
73
NOTE
Check that the distance between sensor and

pulse wheel is 0.35...0.75 mm (0.014 ... 0.029
in.). If the distance between sensor and wheel
does not correspond to the values indicated,
add shims (73) between cover and sensor to the
permitted value.
39 Fix oil recovery flange (20).
NOTE
Fit the new O-ring.
22
Connect vapour recovery pipes (21) and (22) and secure with
clamps. 21
20
20-128

40 On reconnection, install on the engine:

● engine mounting flange;
● flywheel;
● clutch;
● trailer air braking compressor, if present;
● air conditioning compressor, if present, and relative drivebelt;
● alternator, oil filters and auxiliary PTO, if present;
● cooling fan and relative belt;
● starter motor;
● connect the accelerator cables, fuel supply and return pipes.
20-129

PAGE LEFT INTENTIONALLY BLANK
20-130

307.W.M300.en.0.02-Motori EURO I1 1 1/15/2010 8:11:23 PM
*307.W.M300.en.0.02*
SAME DEUTZ-FAHR ITALIA S.p.A.

Viale F. Cassani, 15 • 24047 Treviglio (BG) • Italy • Phone + 39.0363.4211 • Fax + 39.0363.421638
www.samedeutz-fahr.com
307.W.M300.en.0.02-Motori EURO ISec1:2 Sec1:2 1/15/2010 8:11:23 PM

Engines 1000.3.4 W Euroiii

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Engines 1000.3.4 W Euroiii

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WORKSHOP MANUAL

307.W.M300.en.0.02-Motori EURO I1 1 1/15/2010 8:09:21 PM

307.W.M300.en.0.02-Motori EURO II I 1/15/2010 8:09:22 PM

20.1.5 - Flywheel checks 20-14

307.W.M300.en.0.02-Motori EURO III II 1/15/2010 8:09:22 PM

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307.W.M300.en.0.02-Motori EURO I0-2 0-2 1/15/2010 8:09:23 PM

0.1.1 - Safety notes

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0.1.2 - General safety rules

● No welding is permitted on the engine.

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307.W.M300.en.0.02-Motori EURO I0-5 0-5 1/15/2010 8:09:23 PM

0.1.3 - Safety precautions for removal and refitting operations

Precautions for removal operations

Precautions for refitting operations

Precautions to be taken on completion of removal/refitting operations

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0.1.4 - Lifting instructions

Wire ropes - slings

60° 90° 60° 90°

8 650 620 500 25 500 400 860 700

Lifting capacities are calculated with a safety coefficient.

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30° 60° 90° 120° 150°

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0.1.5 - Tightening torques

Screws and nuts

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Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

Thread Wrench Torque Nm ±10% Wrench Torque Nm ±10%

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Fittings with seal at 37°

Thread Wrench Torque Nm ±10%

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Fittings for pipes with banjo union

Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

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0.1.6 - Threadlockers, adhesives, sealants and lubricants

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0.1.7 - Conversion factors

Conversion from British to metric units

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kg/m x 0.056 = lb.in.

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0.2 - IDENTIFICATION OF THE ENGINE TYPE AND SERIAL NUMBER POSITION,

Fig.2 - Identification plate

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Fig.3 - Serial number

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0.3 - IDENTIFICATION OF THE ENGINE TYPE AND SERIAL NUMBER POSITION,

307.W.M300.en.0.02-Motori EURO I0-19 0-19 1/15/2010 8:09:27 PM

Made by - IMPORTANT ENGINE INFORM ATION - 1000 . 6 W

Fig.4 - Identification plate

Fig.5 - Serial number

307.W.M300.en.0.02-Motori EURO I0-20 0-20 1/15/2010 8:09:27 PM

0.4 - IDENTIFICATION OF THE INJECTION PUMP TYPE

Always specify the data indicated above when 3

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0.5 - IDENTIFICATION OF THE INJECTOR TYPE

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0.6 - INJECTOR TYPE IDENTIFICATION