P1D32C016 11-2014 en

CURSOR 13 TDCV
Technical repair manual

I
Print notes
Product: CURSOR 13 TDCV
Construction
● F3HFE611
Language: ENG
Name: printed P1D32C016E1114 ENG
Publication status: 19.12.2014
FPT Industrial S.p.A.

Via Puglia 15
10156 Torino
Italy
Figures and words: FPT Industrial S.p.A. 2014

All rights reserved.
www.fptindustrial.com
– printed P1D32C016E1114
Contents II
Technical repair manual 1

Principles 2
Operating diagrams 3
Electric/electronic system 4
Scheduled maintenance 5
Scheduled maintenance for
ATS (After Treatment System) 6
General mechanical overhaul 7
technical specifications 8
Equipment 9
safety regulations 10
III Contents
CURSOR 13 TDCV ‒ Technical repair manual
Contents 1
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Contents
INTRODUCTION 3
Contents
Contents
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . 5
SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6
PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . 8
GENERAL WARNINGS REGARDING THE

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 9
Grounding and screening . . . . . . . . . . . . . . . . . . . 10
Optional electrical and mechanical parts

installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conversions between the main units of measurement

of the international system and the most commonly
used derived sizes . . . . . . . . . . . . . . . . . . . . . . . 12
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Revolutions per time unit . . . . . . . . . . . . . . . . 12
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 12
Update data . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 INTRODUCTION
INTRODUCTION 5
SYMBOLS - WARNINGS
INTRODUCTION
This document provides data, specifications, instructions and methods to perform repair interventions on the assembly and its com-
ponents.
Anyhow, this document is addressed to qualified and specialised personnel.
Before performing any intervention, check that the document relating to the vehicle model on which the intervention is being per-
formed is available and also make sure that all accident prevention devices, including but not limited to, goggles, helmet, gloves,
shoes, as well as work equipment, lifting and transport equipment, etc., are available and efficient, and also make sure that the unit is
in safety conditions for intervention.
Carrying out interventions which fully comply with the indications given here, as well as the use of the specific equipment indicated,
ensures repair interventions are carried out correctly, timings are respected and the operator's safety is safeguarded.
Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by
Iveco.
Each intervention on the unit aimed at a modification, alteration or other which has not been authorised by FPT relieves FPT of any
liability, and, in particular, where the assembly is covered by a warranty, each intervention will immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the execution of the interventions and to provide instructions for any
cases and situations not covered in this publication.
The data contained in this issue may not be up-to-date due to possible modifications made by the Manufacturer for technical or
commercial reasons, or to adaptations required by laws in force in different countries.
In the event of discordance between the information in this publication and the actual assembly, please contact the FPT network
before performing any interventions.
The complete or partial reproduction of the text or illustrations herein is forbidden.
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in
the general table of contents.
Sections with mechanical contents include technical data, tightening torque collections, tool lists, overhauls at the bench, diagnostics
and scheduled maintenance
In the electrical/electronic system section there are the descriptions of the electric network and the electronic systems of the as-
sembly, wiring diagrams, electrical characteristics of components and the component codes.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS - WARNINGS
Danger for persons

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

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

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

Pressure
Machined finished product
Oversized
Interference
Greater than ...
Forced assembly
Maximum
Undersized
Thickness
Lesser than ...
Clearance
Minimum
Lubricate Selection
Dampen Classes
Grease Oversizes
Temperature < 0 °C
Sealant
Cold
Glue
Winter
Temperature > 0 °C
Bleeding air Hot
Summer
Replacement
Original spare parts
INTRODUCTION 7
PRODUCT CODE
PRODUCT CODE
AABBCC
● A A B B C C ‒ Product Code
Note The first and second digit identifies the PRODUCT as part of the assembly.
543010 engine
766123 Electric/electronic system
775012 Injection
● A A B B C C ‒ Unit code
Note The third and fourth digit identify the UNIT within the PRODUCT.
543010 lubrication
766123 Control units, resistor and fuses
775012 Injectors
● A A B B C C ‒ Sub-assembly Code
Note The fifth and sixth digit exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.
543010 Oil pump

766123 Fuel pre-heating resistor
775012 Nozzle
8 INTRODUCTION
GENERAL WARNINGS
GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors should be contacted
whenever a dangerous situation that has not been described occurs.
Use the specific and general equipment according to that prescribed in the respective use and maintenance handbooks. Check the working
condition and suitability of tools not subject to periodic review.
Manual handling of loads must be previously appraised regarding the weight, size and path.
Handling with mechanical equipment must be done using appropriate lifts and hoists, in terms of weight, shape and volume. Hoisters, ropes
and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by
authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally
striking workshop personnel.
Shop activities performed by two technicians must always been executed with caution; avoid operations that may be dangerous for any
collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it.
Scrupulously observe all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands and that the
manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific
safety regulations provided.
Remove the expansion tank cap only when the engine is cold, unscrewing it carefully to allow the residual pressure in the system to es-
cape.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point cards of harmful
materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent
sudden fires/explosions. Suitably store flammable, corrosive and pollutant fluids and liquids in accordance with current regulations. Strictly
avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated
with inflammable substances into suitable containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and
oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.
Wear, where required by the operation, garments and protection provided for by accident prevention rules; contact with moving parts can
cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. Wear an appro-
priate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid direct contact with
liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact occurs.
INTRODUCTION 9
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
Before overhauling, clean the assemblies and make sure they are intact and complete. Place in an orderly fashion and in appropriate con-
tainers the parts removed or disassembled with their respective fixing elements (screws, nuts, etc.).
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts with nylon inserts
must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions; FPT's sales and assistance network is available to
provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
● Disconnect all electronic control units and unplug the power cable from the battery's positive terminal (connecting it to the chassis
ground) and connectors.
● Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
● Wait approximately 15 minutes before proceeding with welding.
● Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when
welding.
Should the vehicle be subjected to temperatures exceeding 80 °C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis ground cable
first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery termin-
als.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test lamp to verify circuit continuity, but proper control equipment only.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.)
conform with the FPT system and that they are carefully restored after repair or maintenance work.
Measurements on ECUs, on plug-connectors as well as on electrical connections can be made only on suitable testing lines, by means of
special plugs and plug-type bushes. Do not use in any case inappropriate means as metallic threads, screwdrivers, clips or similar. In addition
to the risk of causing a short circuit, this might damage plug-type connections and this would then give rise to contact problems.
10 INTRODUCTION
Grounding and screening
Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their
destruction.
Disconnect the batteries from the system before recharging them by means of an external unit.
on connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
Key storage procedures are affected by electromagnetic disturbances such as cell phones and the like. Therefore, during key storage:
1. Make sure there are no sources of disturbance near the keys or in the cab.
2. Keys not inserted in the panel must be at least 1 metre away.
Note The connectors are viewed from the cable side. Connector views contained in the manual are representative of cable side.
For fuse identification and rating, comply with the indications present in the vehicle, since their identification or rating may be
subject to changes.
Grounding and screening
185272 Figure 1
The negative conductors connected to a system grounding point must be as short as possible and connected in a "star pattern", as
well as being tightened down correctly and as specified ref. (M).
INTRODUCTION 11
Optional electrical and mechanical parts installations
d
C
d
C
88039 Figure 2
The following precautions must be observed regarding the electronic components:
● electronic control units must be connected to the system ground when equipped with metal housings.
● Electronic control unit negative cables must be connected to a system ground point, such as the dashboard compartment
ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the battery/is.
● Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insula-
tion. Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
● The metal braid of the shielded circuits must be in contact only at the control unit side to which the signal is to be sent.
● In the case of junction connectors the unshielded section (d), near to the latter, must be as short as possible.
● The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Optional electrical and mechanical parts installations

Accessory installation, additions and changes on the vehicle must be carried out in compliance with the FPT assembly directives.
it is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by fitters.
Any exception to the assembly directives must be authorized by FPT.
lack of observance of above described prescriptions involves guarantee lapse.
▶ It is strictly forbidden to carry out any modifications or connections to the electric control unit wiring. In particular,
the data line between the control units (CAN line) is to be considered untouchable.
12 INTRODUCTION
Conversions between the main units of measurement of the international system and the most commonly
Conversions between the main units of measurement of the international system and the most
commonly used derived sizes
Power
1 kW=1.36 HP
1 kW=1.34 HP
1 HP=0.736 kW
1 HP=0.986 HP
1 HP=0.746 kW
1 HP=1.014 HP
Note The HP unit is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 HP
Torque
1 Nm = 0.102 kgm
1 kgm=9.81 Nm
Note Unless there is a specific need for accuracy, the unit Nm is converted into kgm for simplicity according to a ratio of 10:1, or
rather: 1 kgm = 10 Nm.
Revolutions per time unit

1 rad/s = 1 rpm x 0.1047
1 rpm = 1 rad/s x 9.5493
Pressure
1 bar=1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Note The unit bar is converted into kg/cm² for simplicity according to a ratio of 1:1 1 kg/cm² = 1 bar.
Temperature
0 °C = 273.15 K
0 °F = 255 K
1 °C = (1x1.8+32) °F
INTRODUCTION 13
Update data
Update data
Section Section name Description of modification Page Revision date
14 INTRODUCTION
CURSOR 13 TDCV ‒ Principles
Contents 1
Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
2 Contents
GENERAL INFORMATION 3
Contents
Contents
CORRESPONDENCE BETWEEN TECHNICAL

CODES AND COMMERCIAL CODES . . . . . . . . . . . 5
TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 6
LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . 7
RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . 8
FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . 10
TOP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER AND TORQUE CHARACTERISTICS

F3HFE611A . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER AND TORQUE CHARACTERISTICS

F3HFE611B . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REFUELLING . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LUBRICANT NAME . . . . . . . . . . . . . . . . . . . 14
4 GENERAL INFORMATION
CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
GENERAL INFORMATION
CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
Technical codes Commercial Codes
F3HFE611A*C
C13 ENT 6 W
F3HFE611B*C
TECHNICAL NAME
F3HFE611B*C001-XXXXXX
● F3HFE611B*C001 ‒ Engine family indication

● F3HFE611B*C001 ‒ Engine family evolution (also irrespective of the displacement)
● F3HFE611B*C001 ‒ Tier 4/ Euro 6
● F3HFE 611B*C001 ‒ Number of times and cylinder position
E 4 times, vertical with post-treatment
● F3HFE6 11B*C001 ‒ Number of cylinders

● F3HFE61 1B*C001 ‒ Diesel turbocharged, direct injection, intercooled
● F3HFE611 B*C001 ‒ Use (truck)
● F3HFE611B *C001 ‒ Engine torque and power level
A 560 HP/2500 Nm
B 500 HP/2300 Nm
● F3HFE611B*C 001 ‒ Gas emission level given same curves

C Euro 6
● F3HFE611B*C 001 ‒ Variant number in B.O.M.

● F3HFE611B*C001- XXXXXX ‒ Progressive production number
ENGINE VIEWS
5401 ENGINE VIEWS
219024 Figure 1
ENGINE VIEWS
LEFT SIDE VIEW
219027 Figure 2
1 Oil filler cap 7 Turbocharger exhaust gas outlet
2 Head cover 8 Heat exchanger
3 Compressor air intake pipe 9 Turbocharger oil return pipe
4 Engine crankshaft speed sensor 10 Turbocharger
5 Flywheel cover casing 11 Oil filter
6 Turbocharger oil delivery pipe 12 Cooling water inlet pipe
ENGINE VIEWS
RIGHT SIDE VIEW
219028 Figure 3
1 Fuel filter 7 Engine cable
2 Compressor air delivery pipe 8 Starter motor
3 Alternator 9 Air compressor
4 Intake manifold 10 High-pressure fuel pump
5 Oil level control dipstick; 11 Temperature/air pressure sensor
6 EDC control unit
ENGINE VIEWS
FRONT VIEW
219025 Figure 4
1 Engine cable 6 Auxiliary assembly drive belt
2 Thermostat assembly 7 Crankshaft pulley
3 Fan control coupling 8 Automatic belt tensioner
4 Water pump 9 Alternator
5 Oil filter 10 Intake manifold
ENGINE VIEWS
REAR VIEW
219026 Figure 5
1 Gear casing cover 7 Crankshaft speed sensor
2 Blow-by 8 Engine cable
3 Engine flywheel 9 Turbocharger exhaust gas outlet
4 Oil sump 10 Intarder retarder cooling water return pipe
5 Oil drain plug 11 Intarder retarder cooling water delivery pipe
6 Oil filter 12 Lifting eyelet
ENGINE VIEWS
TOP VIEW
219029 Figure 6
1 Camshaft position sensor 5 Compressor air delivery pipe
2 Head cover 6 Intake manifold
3 Turbocharger exhaust gas outlet 7 Control buttons
4 Turbocharger 8 High-pressure fuel pump
POWER AND TORQUE CHARACTERISTICS F3HFE611A
5401 POWER AND TORQUE CHARACTERISTICS F3HFE611A
182452 Figure 7
Torque — Power
Technical data
POWER max. 412 kW (560 HP) at 1900 rpm
Technical data
TORQUE max. 2500 Nm (255 kgm) to 1000 – 1550 rpm
POWER AND TORQUE CHARACTERISTICS F3HFE611B
5401 POWER AND TORQUE CHARACTERISTICS F3HFE611B
182451 Figure 8
Torque — Power
Technical data
POWER max. 368 kW (500 HP) at 1900 rpm
Technical data
TORQUE max. 2300 Nm (234 kgm) to 900 – 1550 rpm
REFUELLING
Quantity
GROUPS PARTS TO BE REFILLED
litres Kg
Engine F3H
Capacity:
● engine sump at minimum level 20 18
● engine sump at maximum level 28 25.2
● first filling 30.5 - 31 25.2 - 26
● oil change with filter change 30.5 - 31 25.2 - 26
Cooling system
Engine F3H – –
* = Protective antifreeze (50% concentration - freezing point -35°C)
REFUELLING
LUBRICANT NAME
Engine oil name
International lubricants and fuels designation Original products

Engine oil
Meets specifications:
ACEA E6 completely synthetic SAE 5W30 Urania FE (1)
Mineral based ACEA E9, API CJ-4 SAE 10W40 Urania LD9 10W40
(1) FPT recommends the use of these types of oil in order to obtain advantages in terms of "fuel economy". FPT supplies the new assembly already with
these types of lubricants (also suitable for cold climates, with minimum temperatures of -30ºC).
WARNING
● It is strictly prohibited to top up the engine oil with lubricants other than those already present in the sump. Lubricant 10W40 can only be used when
a complete engine oil change is being carried out. If there is no label providing the engine oil characteristics, it is to be understood that 5W30 is used.
● FPT ensures optimal engine performance when original lubricants are used. If non-original products are used, lubricants with minimum ACEA per-
formance are acceptable for the Diesel engines given in the table. Using products with inferior characteristics to these ACEA specifications could cause
engine damage not covered by warranty.
CURSOR 13 TDCV ‒ Operating diagrams
Contents 1
Contents
OPERATING DIAGRAMS . . . . . . . . . . . . . . . . . . . 3
SCRT (Selective Catalytic Reduction Technology)

exhaust gas post-treatment system . . . . . . . . . . . . . 35
2 Contents
OPERATING DIAGRAMS 3
Contents
Contents TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . 27
Turbocharging diagram . . . . . . . . . . . . . . . . . . 27
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine fuel supply diagram . . . . . . . . . . . . . . . . . 6 GT 4502 V turbocharger . . . . . . . . . . . . . . . . . . . 28
E-VGT turbocharger operation . . . . . . . . . . . . . 28
CPN 5.2 high pressure pump . . . . . . . . . . . . . . . . . 6
High pressure pump section . . . . . . . . . . . . . . . . 8 Exhaust flap (engine brake throttle valve) . . . . . . . . . 32
Rail (pressure accumulator) . . . . . . . . . . . . . . . . . . 8
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . . 10
operation . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication circuit . . . . . . . . . . . . . . . . . . . . . 13
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil pump cross-section . . . . . . . . . . . . . . . . . . 14
Overpressure valve . . . . . . . . . . . . . . . . . . . . . . 15
Main data to check the overpressure valve
spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pressure regulator valve . . . . . . . . . . . . . . . . . 15
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . . 18
Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 19
Valve integrated in piston cooling nozzle . . . . . . . . . 20
Oil vapour recirculation (Blow-by) . . . . . . . . . . . . . 20
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Description . . . . . . . . . . . . . . . . . . . . . . . . . 22
operation . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electromagnetic coupling . . . . . . . . . . . . . . . . . . . 23
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section on water pump . . . . . . . . . . . . . . . . . . 24
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Water circulating in the engine . . . . . . . . . . . . . 25
Water leaving the thermostat . . . . . . . . . . . . . . 25
4 OPERATING DIAGRAMS
POWER SUPPLY
OPERATING DIAGRAMS
5420 POWER SUPPLY
The Common Rail fuel system has a special pump that continuously keeps fuel at high pressure, independently from the stroke and
the cylinder which is to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from the rail takes
place in the corresponding cylinder.
180251 Figure 1
A Fuel supply system B Tank return circuit
CPN 5.2 high pressure pump
Engine fuel supply diagram
210171 Figure 2
A High pressure B Low pressure
1 High-pressure pump 6 Electric injectors

2 Fuel filter 7 overpressure valve
3 Tank 8 Rail pressure accumulator
4 Fuel pre-filter 9 Pressure sensor
5 Engine control unit
771010 CPN 5.2 high pressure pump

It is a pump, equipped with two plungers, that takes drive from the distribution gear. The gear supply pump is installed on the same
control shaft.
CPN 5.2 high pressure pump
Pump connections
180252 Figure 3
1 Fuel delivery to rail 4 Fuel delivery to filter
2 Fuel supply from filter 5 Plug
3 Fuel supply from tank 6 Fuel return to tank
Technical data
Pump characteristics
Transmission ratio 1:1
Number of cam plungers / lobes 2/3
Incoming fuel temperature (gear pump) - 40 ± 80°C (90° max 100h)
Maximum 280 Nm at maximum flow
Max torque at nominal speed
Average 80 Nm at maximum flow
Average power required 18 kW
Weight 15.3 kg
Maximum speed in overspeed (250 h) 2625 rpm
Nominal speed 2100 rpm
Overspeed (1h) 3150 rpm
Maximum pressure at gear pump output 13 bar abs
Maximum pressure at gear pump intake 0.35 ± 1 bar abs
Rail (pressure accumulator)
High pressure pump section
180253 Figure 4
1 Plungers (2x) 3 Flow regulator
2 CP5 gear plungers
774510 Rail (pressure accumulator)
180254 Figure 5
1 Pressure sensor 4 Fuel return
2 Rail 5 Overpressure valve
3 Pipes to injectors 6 Intake from the high-pressure fuel pump
The rail volume is of reduced size to allow a quick pressurisation at start-up, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump
operation.
This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.
Some calibrated holes have been made in the fittings of the high pressure pipes, with the function of damping the oscillations in
pressure generated by the opening of the injectors and the plungers of the high pressure pump.
A fuel pressure sensor (1) is screwed to the rail.
Rail (pressure accumulator)
The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is
checked and, if necessary, corrected.
Characteristics
Technical data
Nominal rail volume 28.6 cm³
Inner diameter 9 mm
Nominal pressure 2,200 bar
operating temperature −40 ℃ to140 ℃
Electro-injectors
775010 Electro-injectors
180255 Figure 6
1 Electric connection 6 Vaporiser nozzle
2 Coil 7 Fuel return hole
3 High-pressure fuel inlet fitting 8 IQA codes
4 Injector closing force 9 Production code
5 Nozzle
The electro-injectors are mounted on the cylinder head and operated by the engine control unit. They are supplied by a HP fuel
line and connected to a return line at atmospheric pressure required for operation of the pilot valve.
Electro-injectors
operation
CRIN 3.3 injector section
181583 Figure 7
1 Coil 6 Nozzle
2 High-pressure fuel inlet fitting 7 Pressure chamber
3 filter 8 Fuel return
4 Pressure rod 9 Control volume
5 Needle 10 Pilot valve shutter
The electro-injector may be considered as mainly made up of two parts:

- actuator spray nozzle consisting of a pressure rod (4), needle (5) and jet(6).
- control solenoid valve made up of coil (1) and pilot valve.
Electro-injector operation is divided into three phases:
1st Phase - Resting position
The coil (1) is cut off and the shutter (10) of the pilot valve is in the closed position.
In this condition the opening force is balanced by the closing force, because the pressure of the fuel in the control volume (9) is the
same in the pressure chamber (7).
2nd Phase- Injection start
The coil (1) is energized and causes the shutter to rise (10).
The control volume fuel (9) flows back towards the return manifold (8), causing a drop in pressure
At the same time, in the pressure chamber (7) the pressure line exerts an opening force that causes the needle (5) to rise, with
the consequent introduction of fuel into the cylinders.
3rd Phase - End of injection
The coil (1) is cut off and causes the shutter (10) to return to the closed position, recreating a balance of forces, bringing the
needle (5) back to the closed position and consequently ending injection.
Fuel filter
542010 Fuel filter
191090 Figure 8
1 Fuel filter 4 Fitting for bleeding
2 Fuel temperature sensor 5 Drain valve
3 Clogged filter sensor
Technical data
Maximum load 750 ℓ/h
Nominal pressure < 13 bar
operating temperature −40 ℃ to120 ℃
Pressure drop with new filter <0.5 bar
Pressure drop with filter at end of life >2 bar
Capacity ≈1.7 l
Oil filter tightening torques

TORQUE
DETAIL
Nm kgm
1 Fuel filter 32.5 ± 2.5 3.25 ± 0.25
2 Fuel temperature sensor 30 ± 2 3 ± 0.2
3 Clogged filter sensor 30 ± 2 3 ± 0.2
4 Fitting for bleeding 18 ± 2 1.8 ± 0.2
5 Drain valve 1.5 ± 0.5 0.15 ± 0.05
LUBRICATION
5430 LUBRICATION
The engine is lubricated by a gear pump driven via gears by the crankshaft.
A heat exchanger governs the temperature of the lubricating oil.
It houses the oil filter, indicator sensors and safety valves.
Lubrication circuit
180256 Figure 9
A Engine brake solenoid valve detail D Oil dropping
B Oil to brake cylinders E Oil under pressure
C To engine brake cylinder 6
Oil pump
543010 Oil pump

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

Main data to check the overpressure valve spring
073540 Figure 12
543075 Oil pressure regulator valve

The oil pressure relief valve is located on the left-hand side of the
crankcase.
Start of opening pressure 5 bar.
161256 Figure 13
Oil pressure regulator valve
Main data to check the oil pressure adjustment valve spring
161269 Figure 14
A Start opening B Opening end
Heat exchanger
543110 Heat exchanger
180296 Figure 15
1 By-pass valve 3 Oil filter support seat
2 Heat exchanger
Technical data
By-pass valve opening pressure 2.5 ±0.3 bar
Filter by-pass valve
543077 Filter by-pass valve

The valve quickly opens at a pressure of: 3.4 ± 0.3 bar.
073545 Figure 16
Engine oil filter
543070 Engine oil filter
180257 Figure 17
1 Oil filter support 4 Cartridge
2 Cap O-ring 5 Closing cap
3 Cartridge O-ring 6 Drainage plug
Technical data
Maximum operating pressure 13 bar
Operating temperature −30 ℃ to120 ℃
By-pass valve opening pressure 3.4 ±0.3 bar
Tightening torque
Oil filter retainer at the support base 60 ±5 N⋅m
Drain plug on the engine oil filter 6.5 ±1.5 N⋅m
Valve integrated in piston cooling nozzle
540414 Valve integrated in piston cooling nozzle

The valve allows oil to enter and thus lubrication of pistons only
above the pressure value shown below.
Technical data
Valve opening pressure 1.7 ±0.2 bar
This permits filling the circuit and therefore lubricating the most
stressed parts even when working at lower pressures.
109080 Figure 18
540480 Oil vapour recirculation (Blow-by)

Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and sent into the air intake circuit.
The device is essentially composed of a rotary filter (3) fitted to the high pressure pump/camshaft control shaft (4) and a rear
cover (2) housing the normally closed valves (1) that manage the flow of the mixture.
A pressure sensor that detects the clogging of the Blow-by filter is located on the rocker arm cover.
By measuring the pressure under the rocker arm cover, it is also able to detect the presence of fuel in oil.
Oil vapour recirculation (Blow-by)
Oil vapour recirculation (Blow-by) diagram
180258 Figure 19
A Oil vapour flow
1 Vapour breather valve 3 Blow-by filter

2 Blow-by box 4 High pressure pump drive gear
COOLING
5432 COOLING
Description
183671 Figure 20
A Water leaving the thermostat C Pump inlet water
B Water circulating in the engine
The engine cooling system is a closed circuit forced circulation system and can be connected to an additional heater (if any) and to
the Intarder heat exchanger.
It consists mainly of the following components:
● An expansion tank and plug (1) with two built-in valves: an outlet and an inlet, which regulate the pressure of the system.
● A coolant level sensor placed at the bottom of the expansion tank with two coupling points.
● An engine cooling unit to dissipate the heat taken by the coolant from the engine through the intercooler.
● A heat exchanger to cool the lubricating oil.
● A centrifugal water pump incorporated in the crankcase.
● An electric fan consisting of a two-speed electro-magnetic coupling. A hub turning idly on the coupling's shaft is fitted with a
metal plate moving along the axis, on which the fan is installed.
● A 3-way thermostat regulating the circulation of the coolant
Electromagnetic coupling
operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylin-
der head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is
channelled from here to the radiator and cooled by the fan.
The pressure inside the system depending on the temperature variation is controlled by the discharge and charge valves incorpor-
ated in the expansion reservoir filling plug (1).
The discharge valve has a double function:
● keep the system under light pressure in order to raise the coolant boiling point;
● discharge into the atmosphere the pressure surplus produced in case of high coolant temperatures.
The function of the inlet valve is to permit the transfer of coolant from the expansion tank to the radiator when a low pressure is
generated inside the system due to coolant volume reduction as a result of lowering of temperature.
543422 Electromagnetic coupling

Using a feeler gauge, check the gap between the anchor assembly (2)
and the pulley (1); it must not exceed the value shown below.
Technical data
Thickness of the gap between the anchor as- 0.5 mm to1.2 mm
sembly and the pulley
The electro-magnetic coupling operation depends on:
● coolant temperature;
● the climate control system fluid pressure (if any);
● the slowing down action of Intarder turned on (if any).
Neutral condition:
● water temperature is lower than 93 °C and both the Intarder

and the climate control system - if any - are OFF;
● coolant temperature is lower than 85°C and the climate control
system is ON at pressure inside the circuit lower than 18 bar;
● coolant temperature is lower than 85°C and the Intarder is ON
with its braking power lower than 41% of its maximum power.
The low speed activates when:
● coolant temperature reaches 85°C and the Intarder is ON with

its braking power greater than 41% of its maximum power.
● coolant temperature reaches 85°C and the climate control
system is ON at pressure of the circuit higher than 18 bar.
77469 Figure 21
The second speed activates when:
● coolant temperature reaches 93°C, and the Intarder is either

OFF or ON with its braking power lower than 41% (speed
deactivates when temperature falls down to 88°C);
Water pump
● coolant temperature reaches 85°C, the Intarder is ON with its

braking power greater than 41% of its maximum power, or the
climate control system is ON and the pressure inside the circuit
is 22 bar.
When second speed actuation is required, the system will drive the
fan for 5 seconds at low speed and then engages the second speed.
This will increase belt and fan component wear over time.
When the fan first speed is actuated longer than one minute, the
system activates the second speed until control parameters fall under
the operation levels.
77469 Figure 21
543210 Water pump

Section on water pump
The water pump is composed of: rotor, bearing, gasket and drive
pulley.
Note Check that the pump casing shows no sign of cracking or

water leakage; replace the water pump assembly if it does.
60631 Figure 22
Thermostat
543250 Thermostat
Water circulating in the engine
60747 Figure 23
Water leaving the thermostat
60748 Figure 24
Check that the thermostat works properly, replace it if there is any doubt.
Thermostat technical data

Technical data
Start of stroke temperature 84 ±2 ℃
Minimum stroke temperature (15 mm) 94 ±2 ℃
Thermostat
Cold operation with thermostat closed
72675 Figure 25
A Water circulating in the engine and the Intarder. B To water pump.
Hot operation with thermostat open
72676 Figure 26
A Water circulating in the engine and the Intarder. C To radiator.
B From radiator to water pump.
TURBOCHARGING
5424 TURBOCHARGING
The turbocharging system is composed of:
● an air filter;
● an E-VGT turbocharger;
● an "intercooler" radiator.
Turbocharging diagram
180289 Figure 27
A Engine exhaust gas C Compressed air (hot)
B Intake air D Compressed air cooled
GT 4502 V turbocharger
542410 GT 4502 V turbocharger
180290 Figure 28
542410 E-VGT turbocharger operation

Main components
185512 Figure 29
1 Turbine volute 4 Compressor volute
2 Turbine rotor 5 Electric actuator
3 Central body 6 Blade direction variation device
Operation at low speed
62870
62870 Figure 30
The variable geometry turbocharger (E-VGT) consists of a centrifugal compressor and a turbine equipped with a mobile blade
device that can change the direction and section of passage of the exhaust gases going to the turbine.
Thanks to this solution it is possible to keep the speed of the gas and turbine high even when the engine is running at low speed.
In this condition, the mobile blades (2) are in the maximum closed position and the reduced passage sections between the blades
increase the speed with which the exhaust gases run into the turbine rotor. As a result, this increases the speed of the turbine (1),
thus building turbocharging pressure.
Operation at high engine rpm
62872
62872 Figure 31
As the engine speed increases, the flow of the exhaust gas increases.
By means of the actuator (3), the ECU manoeuvres the opening of the mobile blades (2) by moving them in order to reach the
maximum open position.
62872
62872 Figure 31
The larger aperture in the blade through-sections thus produces a decrease in the speed of exhaust gas flow through the turbine
(1) with speeds equal to or lower than those of the low rpm condition.
The engine control unit regulating the orientation of the mobile blades is able to regulate the turbocharging pressure in any condi-
tion.
Turbine actuator
185513 Figure 32
The E-VGT turbines have an electric actuator. This solution has a series of advantages:
● The mechanic connection between the geometry variation device and the actuator allows for a mechanically defined position
unlike what happens with the pneumatic VGT actuators where the position of the geometry variation device depends on the
balance of pressure that is created.
● To have feedback on the position of a pneumatic actuator, it is necessary to mount a position sensor on the actuator, while on
the E-VGT actuators it is not necessary because the sensor is already integrated internally.
Each time the engine starts, the actuator performs a stroke to reach mechanical stop (A). Here the position control system is
reset and all the following positions that the actuator assumes will be referred to this point.
● In case of failure of the actuator, there is a spring that keeps the mobile blades in a fixed intermediate position and allows the
engine to operate with limited performance.
Exhaust flap (engine brake throttle valve)
543760 Exhaust flap (engine brake throttle valve)
180291 Figure 33
1 Throttle valve (flap) 3 Coolant inlet/outlet couplings
2 Electric actuator
A throttle valve (1) operated by an electric actuator (2) is introduced into the exhaust pipe downstream of the turbine.
The main function is that of an engine brake: when the throttle valve closes, it blocks the exhaust gas outlet; this causes an increase
in pressure upstream of the engine break, which exerts a resistance on the up stroke of the pistons. This resistance extends
throughout the entire kinematic chain, applying a braking effect on the driving wheels.
The main novelty of this type of engine brake, compared to the previous ones, is the electric actuator that makes it possible to
choke the exhaust gas outlet to increase its output temperature.
This possibility is used to:
Exhaust flap (engine brake throttle valve)
● rapidly bring the SCRT catalytic converter to its thermal operating condition (reduction of cold engine emissions);
● regenerate the DPF filter inside the SCRT catalytic converter (avoid post-injection with a positive effect on consumption and
problems connected to the dilution of oil that afflict DPF-equipped engines).
The electric actuator (2) is connected to the engine cooling circuit by means of pipes (3).
34 SCRT (Selective Catalytic Reduction Technology) exhaust gas post-treatment system
SCRT (Selective Catalytic Reduction Technology) exhaust gas post-treatment system 35
Contents
Contents
SCRT (Selective Catalytic Reduction

Technology) . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Schematic diagram (demonstrative) . . . . . . . . . . 37
MAIN COMPONENTS OF THE SYSTEM . . . . . . . . 41

Diverter valve . . . . . . . . . . . . . . . . . . . . . . . 41
AdBlue pump module . . . . . . . . . . . . . . . . . . . 41
Dosing module . . . . . . . . . . . . . . . . . . . . . . . 42
Catalytic converter . . . . . . . . . . . . . . . . . . . . 43
NH3 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 45
NH3 control unit . . . . . . . . . . . . . . . . . . . . . . 45
Particulate trap pressure sensor (Δp) . . . . . . . . . 46
Nitrogen oxides detecting sensor . . . . . . . . . . . 46
Exhaust gas temperature sensor . . . . . . . . . . . . 47
Humidity detecting sensor . . . . . . . . . . . . . . . . 47
SCRT (Selective Catalytic Reduction Technology) exhaust gas post-treatment system

5074 SCRT (Selective Catalytic Reduction Technology)
Schematic diagram (demonstrative)
180400 Figure 34
A AdBlue pump module supply line C AdBlue heating system line
B AdBlue to tank return line D AdBlue to dosing module delivery line
To keep the valuesof the exhaust emission limits required by the regulations Euro VI, it was necessary to adopt the SCRT treat-
ment system of the exhaust gases that combines two devices:
● a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide) and
the particulate;
● the DeNOx 2.2 device for treating NOx (nitrogen oxides).
The SCRT system is essentially composed of:
● a DOC oxidizing catalytic converter (6);

● a DPF particulate filter catalytic converter (5);
● a pressure difference sensor (11) that measures pressure difference between particulate filter intake and outlet;
● a tank (8) of reagent solution (water-urea: AdBlue) with level indicator (7);
● One H2O (9) diverter valve;
● one pump module (10);
● one metering and injection module (12);
● an SCR catalytic converter (2);
● three exhaust gas temperature sensors (1): one at the DOC catalytic converter (6) inlet, one after the DPF catalytic con-
verter (5) and the other on the exhaust gas outlet pipe from the catalytic converter (2);
● one humidity detection sensor fitted on the engine air inlet pipe downstream of the air filter;
● two sensors (3) to detect the amount of nitrogen oxide (NOx) that are up/down stream of the catalytic converter;
● a sensor (4) that detects NH3 (ammonia) at exhaust gas outlet.
ATS (After Treatment System) system schematic diagram
180401 Figure 35
1 NOx sensor upstream of the catalytic converter 7 SCR catalytic converter
2 Differential pressure sensor 8 SCR catalytic converter intake temperature sensor
3 Dosing module 9 DPF catalytic converter
4 NOx sensor downstream of the catalytic converter 10 DOC catalytic converter
5 NH3 Sensor 11 DPF catalytic converter inlet temperature sensor
6 SCR catalytic converter outlet temperature sensor
In the first stage the exhaust gases leaving the turbine encounter in their path the DOC (10) oxidation catalytic converter in which
the hydrocarbons (HC) and carbon monoxide (CO) present are transformed, through the reactions of oxidation, into carbon
dioxide (CO2) and water (H2O).
Subsequently, the exhaust gases pass through the DPF particulate filter (9) in which are retained the carbonaceous particles form-
ing the particulate.
To maintain efficiency the system needs to be regenerated, for this purpose there is a differential pressure sensor (2) which, by
detecting the difference in pressure between intake and outlet, provides a filter clog intensity signal to the ECU.
The particulate filter is regenerated by using the Exhaust Flap device to choke the exhaust gas outlet section from the turbine, cre-
ating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature and the particulate particles
burn keeping the filter clean.
In the second phase the metering module (3) introduces in the exhaust gases, through an injector placed in the exhaust pipe up-
stream of the SCR catalytic converter (7), a solution of water and urea (AdBlue).
In the first part of the SCR catalytic converter, the reagent solution evaporates instantly due to the exhaust gas temperature and
is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2), and at the same time, solution evaporation lowers the exhaust gas
temperature to levels close to the optimal temperature required for the process.
At the reaction temperature, the exhaust gases with added ammonia are introduced into the SCR catalytic converter (7) where
the second stage of the process takes place: the ammonia reacting with the oxygen in the exhaust gas is converted into free nitro-
gen (N2) and water vapour (H2O).
The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to oxidise the excess urea produced by the
engine in the transient operating phases.
The amount of AdBlue injected is controlled through a NH3 (5) sensor, mounted on the outlet pipe of the silencer which detects
the presence of ammonia in the exhaust gas and sends a signal to the ECU thereby providing a feedback signal.
The engine ECU as a function of the number of engine revolutions, torque, exhaust gas temperature, intake air humidity, amount
of nitrogen oxides and the amount of urea present in the exhaust gases, detected by the respective sensors, regulates the flow rate
of the solution AdBlue to be injected into the system.
AdBlue heating circuit schematic diagram (demonstrative)
180402 Figure 36
A Engine coolant C AdBlue (high pressure)
B AdBlue (low pressure)
1 engine 4 Pump module

2 Diverter valve 5 Metering module
3 AdBlue tank
The system must be equipped with an electric heating circuit to adjust the temperature of the AdBlue and prevent it from freezing
(AdBlue freezes at -11 °C).
For this purpose we have a diverter valve (2) which allows passage of part of the engine coolant to the cooling system (for ex-
ample, in the coil inside the tank) (3) and then to the pumping module (4).
When the AdBlue in the tank reaches working temperature, the diverter solenoid valve (2) is actuated and the coolant is supplied
to the metering module (5).
When starting the engine, the system heats the pipes and the tank; the system only activates AdBlue metering when the system is
free of ice.
The dosing module, given the mounting position unfavourable from the cooling point of view, and given the high temperatures that
the exhaust gas downstream of the DPF catalytic converter reached, is connected to the engine cooling circuit and continuously
cooled.
SCRT system sensors
215314 Figure 37
SCRT tightening torque sensors
Torque
Part
Nm Kgm
1 Differential pressure sensor fixing screws 6 ± 0.9 0.6
2 Sensor detecting incoming nitrogen oxide (NOx) to the catalytic converter 52 ± 8 5.2 ± 0.8
3 Catalytic converter intake exhaust gas temperature sensor 45 ± 4.5 4.5 ± 0.5
Exhaust gas temperature sensor for gas coming out of the particulate filter and up-
4 45 ± 4.5 4.5 ± 0.5
stream of the SCR catalytic converter
5 Exhaust gas temperature sensor downstream of the catalytic converter 45 ± 4.5 4.5 ± 0.5
6 NH3 Sensor 50 ± 10 5±1
7 Sensor detecting outgoing nitrogen oxide (NOx) from the catalytic converter 52 ± 8 5.2 ± 0.8
8 Metering module fixing screws 8±2 0.8 ± 0.2
– NH3 control unit fixing screws 11.5 ± 1.5 1.15 ± 0.15
MAIN COMPONENTS OF THE SYSTEM
5074 MAIN COMPONENTS OF THE SYSTEM

507433 Diverter valve
Main components
180580 Figure 38
1 Electric connection 3 Metering module coolant pipe
2 AdBlue tank heating liquid pipe 4 Coolant from engine pipe
The diverter valve is a 2 position/3-way solenoid valve that allows heating of AdBlue tank and pipes with the engine coolant.
In function of the temperature measured by the NTC temperature sensor controls the diverter valve that, based on the temperat-
ure, closes or opens the flow of the hot engine cooling liquid in the AdBlue tank heating coil.
The cooling circuit of the dosing module is always open.
507410 AdBlue pump module

Main components
181585 Figure 39
1 Main filter 5 Pump module heating liquid intake pipe
2 Electrical connector 6 AdBlue liquid return pipe to tank
3 Pressure compensation diaphragm. 7 Pump module heating liquid outlet pipe
4 Tank supply pipe 8 Delivery pipe to metering module
The AdBlue pump module consists essentially of a diaphragm pump that draws the AdBlue from the tank and sends it to the
metering module.
It is equipped with a circuit connected to the engine cooling system that, in case of low temperatures, prevents the freezing of
AdBlue.
The amount of AdBlue sent to the metering module and the injection pressure are controlled by the engine control unit and de-
pend on the operating conditions of the engine and the signals sent by the sensors.
To avoid damage to the pump and metering module, the pump module contains an internal filter that cleans the AdBlue from any
impurities.
507431 Dosing module

Main connections
181584 Figure 40
1 Electric connection 3 Coolant
2 AdBlue intake
The metering module is controlled by the engine ECU and its function is dosing the AdBlue solution to be injected into the exhaust
pipe upstream of the SCR catalytic converter.
It is mounted on the catalytic converter during its operation and is constantly subjected to high temperature, for this reason it is
connected to the engine cooling circuit via pipes (3).
AdBlue maximum injection pressure: 9 bar.
507130 Catalytic converter

Main components
180406 Figure 41
1 Temperature sensors 2 Differential pressure sensor pressure point fittings
180406 Figure 41
3 APU Exhaust 7 NOx sensor
4 SCR Catalytic converters 8 NH3 Sensor
5 Particulate filter (DPF) 9 AdBlue metering module
6 Oxidizing catalytic converter (DOC)
The catalytic converter comprises two main parts:
● the first stage consists of a DOC catalytic converter (6) followed by a DPF catalytic converter (7) in which the exhaust gases
are scrubbed for HC (uncombusted hydrocarbons), CO (carbon monoxide) and particulate matter;
● the second stage consists of 3 SCR catalytic converters (4) mounted in parallel, upstream of which is located the AdBlue
metering module;(1); the NOx (nitrogen oxide) reduction reactions occur there.
507437 NH3 Sensor

The NH3 sensor is connected to the NH3 control unit and detects
the presence of ammonia (NH3) in the exhaust gas exiting the cata-
lytic converter, making it possible to optimally regulate the quantity of
AdBlue to be injected.
181586 Figure 42
5074 NH3 control unit

The NH3 control unit measures the quantity of ammonia contained
in the exhaust gas by means of the NH 3 sensor and sends this value
to the engine control unit via the CAN network.
181586 Figure 43
507134 Particulate trap pressure sensor (Δp)

The pressure sensor measures the difference (Δp) between the
pressure of the exhaust gas inlet and outlet of the SCRT filter thus
determining its efficiency and the state of clogging.
186663 Figure 44
Vo Outlet voltage ΔpDifference between
the outlet and inlet
voltage in the CRT
507435 Nitrogen oxides detecting sensor

The nitrogen oxides detection sensor detects the amount of nitrogen
oxides present in the exhaust gases in and out of the catalytic con-
verter.
On the basis of this information the engine control unit adjusts the
amount of AdBlue injected and is also able to measure the efficiency
of the catalytic converter.
125530 Figure 45
507434 Exhaust gas temperature sensor
102303 Figure 46
The exhaust gas temperature sensor has the function of sending information to the control unit regarding the temperature of the
exhaust gas entering and exiting the catalytic converter that is necessary for calculating the amount of AdBlue to inject in the sys-
tem.
507436 Humidity detecting sensor

Humidity detecting sensor components details
102311 Figure 47
1 Temperature 3 Percent of Humidity
2 Ground 4 Supply
The humidity detection sensor, placed on the outlet from the air filter upstream of the turbocharger, has the function of sending
the percentage of moisture in the intake air to the ECU, which is necessary for the calculation of the amount of AdBlue to be injec-
ted into the system.
CURSOR 13 TDCV ‒ Electric/electronic system
Contents 1
Contents
ELECTRIC/ELECTRONIC SYSTEM . . . . . . . . . . . . . 3
Exhaust gas post-treatment system . . . . . . . . . . . . 45
2 Contents
ELECTRIC/ELECTRONIC SYSTEM 3
Contents
Contents Alternator 120A . . . . . . . . . . . . . . . . . . . . . . . . 38

Alternator current delivery curve . . . . . . . . . . . 38
ARRANGEMENT OF ENGINE ELECTRICAL
Perspective view . . . . . . . . . . . . . . . . . . . . . . 38
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 5
TECHNICAL view (rear side) . . . . . . . . . . . . . . 40
Arrangement of electrical components on engine
1/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER MOTOR "NIPPONDENSO" 24V - 5.5KW
Arrangement of electrical components on engine STARTER MOTOR - [08000] . . . . . . . . . . . . . . . . 40
2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical view . . . . . . . . . . . . . . . . . . . . . . . 40
Arrangement of electrical components on engine
Characteristic curves . . . . . . . . . . . . . . . . . . . 41
3/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 41
EDC17CV41 control unit . . . . . . . . . . . . . . . . . . . 8 Perspective view with matching electrical
connections . . . . . . . . . . . . . . . . . . . . . . . . . 42
EDC (ECM) SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
EDC SYSTEM OPERATION EDC CONTROL
UNIT - [85150] . . . . . . . . . . . . . . . . . . . . . . . 9
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . 18
Cable on engine . . . . . . . . . . . . . . . . . . . . . . 19
Rail pressure sensor (RPS) PRESSURE
ADJUSTMENT SENSOR - [85157] . . . . . . . . . . 20
Fuel metering valve PRESSURE REGULATOR
SOLENOID VALVE - [78013] . . . . . . . . . . . . . . 21
Fuel temperature sensor FUEL TEMPERATURE
SENSOR - [47042] . . . . . . . . . . . . . . . . . . . . 22
Engine coolant temperature / engine fan sensor
COOLANT TEMPERATURE SENSOR FOR EDC -
[85153] . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flywheel pulse transmitter ENGINE RPM SENSOR
- [48035] . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Timing system pulse transmitter ENGINE SPEED
SENSOR ON TIMING SYSTEM - [48042] . . . . . . 27
Pre/post heating element RESISTOR FOR ENGINE
PREHEATING - [61121] . . . . . . . . . . . . . . . . . 29
Air temperature and pressure sensor TURBO
BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156] . . . . . . . . . . . . . . 30
Oil pressure and temperature sensor
TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER
SIGNALLING THE ENGINE OIL TEMPERATURE
- [42030/47032] . . . . . . . . . . . . . . . . . . . . . . 32
CPS pressure sensor . . . . . . . . . . . . . . . . . . . 34
Turbocharging . . . . . . . . . . . . . . . . . . . . . . . 35
Exhaust flap actuator (engine brake throttle
valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 ELECTRIC/ELECTRONIC SYSTEM
ARRANGEMENT OF ENGINE ELECTRICAL COMPONENTS
ELECTRIC/ELECTRONIC SYSTEM
5401 ARRANGEMENT OF ENGINE ELECTRICAL COMPONENTS
Arrangement of electrical components on engine 1/3
219042 Figure 1
Component
Ref. Description
code
1 Turbocharger speed sensor 48043
2 Electromechanical actuator for VGT EVGT
3 Electromechanical actuator for engine brake on exhaust ExFLp
4 Transmitter for engine oil pressure gauge 42030
5 Engine rpm sensor 48035
6 Transmitter for engine oil temperature signalling thermometer 47032
7 Engine coolant temperature sensor (EDC) 85153
219043 Figure 2
Component
Ref. Description
code
1 Exhaust brake control solenoid valve 70050
2 Fuel temperature sensor 47042
3 Pressure adjustment sensor 85157
4 Electronic injection solenoid valve 78247
219044 Figure 3
Component
Ref. Description
code
1 Contactor for thermostarter activation consent 25222
2 Turbo blower air pressure and temperature sensor for EDC 85156
3 Pressure sensor on crankcase CPS
4 Pressure regulator solenoid valve 78013
5 Engine speed sensor on timing system 48042
EDC17CV41 control unit
178240 Figure 4
1 Chassis side connector (connector 1) 2 Engine side connector (connector 2)
EDC (ECM) SYSTEM
76 EDC (ECM) SYSTEM

System components
766161 EDC SYSTEM OPERATION EDC CONTROL UNIT - [85150]

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

When it is cold, the engine encounters greater resistance to its action: the mechanical friction is high, the oil is still very viscous, the
various clearances are not yet optimum.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
De-rating
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the tem-
perature reached by the coolant.
Turbine speed
Turbine speed is adjusted continuously and corrected if needed through geometry variation.
Injection advance electronic control

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

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

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

During the first few turns of the engine, the timing and cylinder no. 1 recognition signals (flywheel sensor and camshaft sensor) are
synchronised. When the engine starts, the accelerator pedal signal received via CAN is ignored. The fuel feed for starting the en-
gine is based on just the water temperature using specific engine mapping. When the control unit detects enough engine revs and
crankshaft acceleration to consider the engine as started and no longer being turned over by the starter motor, it enables signals
from the accelerator pedal.
EDC (ECM) SYSTEM
Run Up
Upon activation of the key contact, the control unit transfers the information stored during the last engine stop to the main
memory (see: After run), and runs system diagnostics.
After run
Each time the engine is turned off with the key, the control unit continues to operate for a few seconds thanks to the internal
MAIN RELAY.
This allows the microprocessor to transfer data from the main memory (volatile) to a non-volatile, erasable, rewritable memory
(EEPROM) to make it available for the next start (see: Run Up).
The data mainly consists of:
● various settings (engine idling, etc.);

● calibration of certain components;
● faults memory.
This procedure lasts a few seconds, typically from 2 to 7 (depending on the quantity of data to save), after which the ECU deactiv-
ates the main power supply.
If this happens, system functionality remains guaranteed until the fifth time it is turned off incorrectly (also non consecutively) after
which an error is stored in the faults memory and upon the following engine start-up, the engine will function with reduced per-
formance while the EDC warning light remains on.
Repeated interruptions of the procedure could in fact lead to damage to the control unit.
Cut - off
This function cuts off fuel feed during deceleration and during engine braking etc.
Cylinder Balancing
This function permits individual, customised control over the delivery of fuel and the start of delivery for each cylinder, which can
even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.
The difference in fuel feed to each cylinder is not signalled by the ECU but by an instrument.
Synchronisation Search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with
the sequence already synchronized.
If this occurs when the engine is off, the ECU energises a single solenoid valve. Within a maximum of 2 revolutions of the crank-
shaft, injection will take place in that cylinder, so the ECU simply needs to synchronise with the firing sequence and to start up the
engine.
To reduce the number of connections, the length of the connection cables with the injectors and, as a result, disturbances in the
transmitted signal, the control unit is mounted directly on the engine by means of a heat exchanger that cools it, using elastic dowels
which reduce the vibrations transmitted by the engine.
Internally, there is an ambient pressure sensor that is used to further improve injection system management.
EDC (ECM) SYSTEM
178240 Figure 5
1 Chassis side connector (connector 1) 2 Engine side connector (connector 2)
In order to be able to detect the Euro 6 emissions, the Stralis engine is equipped with:
● low pressure diesel pump outside fuel tank;

● water in fuel pre-filter signalling sensor;
● contactor for pre-filter heating control.
EDC17 control unit pin-out
EDC (ECM) SYSTEM
Chassis side connector (Connector 1)

Pin Description cable code
1 Positive +30 7151
2 Spare –
3 Earth 0000
4 Spare –
5 Earth 0000
6 Spare –
7 Urea pressure signal 6550
8 Signal of urea tank temperature 6542
9 Catalytic converter outlet temperature signal 6541
10 Ground for catalytic converter upstream and downstream temperature 0540
11 Signal from the engine compartment stop switch 0151
12 Spare –
13 Water in fuel filter signal 5530
14 Spare –
15 R.H. fuel supply air signal 5173
16 Temperature upstream of the catalytic converter sensor positive 6449
17 Spare –
18 Spare –
19 Spare –
20 To pin 86 of contactor for terminal 15 8775
21 Spare –
22 Spare –
23 Metering module solenoid valve with SCR supply Red
24 Spare –
25 Positive +30 7151
Positive for engine fan solenoid valve 7545
27
Free (FEP) −
28 Earth 0000
29 Spare –
30 Spare –
31 Urea level in the tank signal 6543
32 Intake catalytic converter temperature signal 6544
33 Spare –
34 Engine rpm signal for body builder connectors 5587
35 Spare –
36 Spare –
37 Spare –
38 Signal from the engine compartment start switch 8892
39 Ground for urea tank level and temperature sensor 0543
40 Combustion air temperature signal 5174
41 Spare –
EDC (ECM) SYSTEM

42 Spare –
43 Ground for combustion air humidity and temperature sensor / ΔP 0173
"EDC" system fault warning light 5535
44
Free (FEP) −
45 To pin 85 of contactor for terminal 15 0775
46 ECB can network WS/BI
47 ECB can network GN/VE
48 Spare –
Positive for engine water flow solenoid valve for urea tank heater (78267) / urea to tank return valve [85140] /
50 7542
urea module electro pump
51 Spare –
52 Earth 0152
53 Spare –
54 Spare –
55 ΔP signal 5284
56 Spare –
57 Spare –
58 Spare –
59 Spare –
60 Spare –
61 Spare –
Engine fan solenoid valve negative signal 0986
62
Free (FEP) −
63 Spare –
Spare –
64
Signal for engine fan rpm sensor (FEP) 9744
Spare –
65
Ground for engine fan rpm sensor (FEP) 0744
66 Spare –
Spare –
67
Power supply for engine fan rpm sensor (FEP) 7744
68 Urea pressure sensor positive 7537
69 User positive under key (+15) 8150
70 Engine ECU diagnostic line pin 7 ODB connector 2298
71 Spare –
72 Ground for engine water circulation solenoid valve control for urea tank heating (78267) 9542
74 Control signal for thermostarter activation consent contactor 7545
75 Earth 0000
76 Spare –
77 Spare –
78 Spare –
79 Spare –
EDC (ECM) SYSTEM

80 Spare –
81 Spare –
82 Spare –
83 Contactor for thermostarter activation consent ground 0094
84 Ground for urea module electropump control 9549
85 Urea to tank return valve (85140) 0539
86 Spare –
Negative control signal for engine fan engagement consent (Baruffaldi) 0014
87
Negative signal for engine fan engagement control (FEP) 0745
88 Spare –
89 Ground for urea module electropump 0549
90 Power supply for combustion air humidity and temperature sensor / ΔP 8173
91 Spare –
92 Spare –
93 Spare –
94 Spare –
95 Spare –
96 Ground for metering module solenoid valve control Yellow
Engine side connector (Connector 2)

1 Cylinder electro-injectors 4 –
4 Spare –
5 Spare –
6 Ground for oil pressure/temperature sensor –
7 Power supply for turbocharger air pressure and temperature sensor for EDC. –
8 Spare –
9 Spare –
10 Spare –
11 Diesel (RPS) pin 3 pressure signal –
12 Diesel temperature sensor –
13 Oil temperature signal –
14 Spare –
15 Spare –
16 Spare –
17 CAN-H line (ECB2) White
18 CAN-L line (ECB2) Green
19 Spare –
20 Spare –
21 Spare –
22 Spare –
EDC (ECM) SYSTEM

23 Spare –
24 Spare –
25 Electro-injector cylinder 4 –
28 Spare –
29 Spare –
30 Spare –
31 Power supply for oil pressure/temperature sensor –
32 Crankcase pressure sensor power supply –
33 Spare –
34 Spare –
35 Oil pressure signal –
36 Diesel (RPS) pin 2 pressure sensor ground –
37 Turbocharger air temperature sensor for EDC. –
38 Spare –
39 Engine coolant temperature sensor –
40 Spare –
41 Spare –
42 Crankcase pressure sensor ground –
43 Spare –
44 Spare –
45 Spare –
46 Spare –
47 Spare –
48 Spare –
52 Spare –
53 Spare –
54 Spare –
55 Spare –
56 Spare –
57 Spare –
58 Fuel metering valve to 78013 pin 1 –
59 Engine coolant and fuel temperature sensor ground –
60 Diesel (RPS) pin 1 pressure sensor power supply –
61 Crankcase pressure sensor signal –
62 Spare –
63 Spare –
64 Spare –
65 Camshaft Engine rpm sensor pin 1 –
EDC (ECM) SYSTEM

66 Camshaft Engine rpm sensor pin 2 –
67 Engine speed sensor pin 2 –
68 Engine speed sensor pin 1 –
69 Timing system and engine speed sensor ground –
70 Engine brake solenoid valve pin 1 –
71 Spare –
72 Spare –
76 Spare –
77 Spare –
78 Spare –
79 Spare –
80 Spare –
81 Spare –
82 Spare –
83 Fuel metering valve to 78013 pin 2 –
84 Spare –
85 Spare –
86 EDC turbocharger air pressure sensor –
87 Spare –
88 Spare –
89 Spare –
90 Ground for turbocharger air pressure and temperature sensor for EDC. –
91 Spare –
92 Spare –
93 Turbocharger speed sensor –
94 Turbocharger speed sensor –
95 Engine brake solenoid valve pin 2 –
96 Spare –
EDC (ECM) SYSTEM
775010 Electro-injectors
178241 Figure 6
1 Electrical connections 2 Electromagnet assembly
Characteristics
Technical data
Maximum working pressure 1,800 bar
Minimum working pressure 250 bar
Tightening torque
Electrical connection M4 nut 1.5 ±0.25 N⋅m
operation
This is an N.O. solenoid valve.
They are connected to the EDC ECU on connector 2.
The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm.
The electro-injector essentially consists of two parts:
● actuator - spray nozzle consisting of a pressure rod, a needle and a jet

● control solenoid valve made up of coil and pilot valve
The solenoid valve checks the lift of the nozzle needle.

BEGINNING OF INJECTION
Upon being supplied with power, the coil moves up the shutter. The fuel in the control volume flows back towards the return duct
resulting in a pressure drop in control volume.
At the same time, the fuel pressure in the pressure chamber moves up the needle resulting into the fuel being injected into the
cylinder.
END OF INJECTION
EDC (ECM) SYSTEM
When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its
closed position and stops the injection process.
7691 Cable on engine
178249 Figure 7
1 Connector ST-E 6 Injector 4
2 Injector 1 7 Injector 5
3 Rail pressure sensor 8 Exhaust brake control solenoid valve
4 Injector 2 9 Injector 6
5 Injector 3
Connector ST-E Pin Out

Pin Function Cable
1 Injector 1 V
2 Injector 2 L
3 Injector 3 V
4 Injector 1 B
5 Injector 2 V
6 Injector 3 R
7 Spare –
8 Injector 4 V
9 Injector 5 V
10 Injector 6 Z
11 Spare –
12 Exhaust brake control solenoid valve V
13 Injector 4 C
14 Injector 5 H
15 Injector 6 V
16 Exhaust brake control solenoid valve Z
17 Rail pressure sensor G
18 Rail pressure sensor N
19 Rail pressure sensor S
EDC (ECM) SYSTEM
774511 Rail pressure sensor (RPS) PRESSURE ADJUSTMENT SENSOR - [85157]

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
196904 Figure 8
A Technical view C Recommended assembly position
B Perspective view
technical specifications
Supplier: BOSCH
Technical data
Pressure range 0 bar to2,400 bar
RPS sensor power supply 5V
Tightening torque
RPS sensor 140 N⋅m
Pin - out
Pin Function Cable colour
1 Pressure sensor power supply on rail (+5V) from pin 60 of EDC control unit −
2 Pressure signal on rail to pin 36 of the EDC control unit −
3 Ground to pin 11 of the EDC control unit −
EDC (ECM) SYSTEM
771034 Fuel metering valve PRESSURE REGULATOR SOLENOID VALVE - [78013]
178247 Figure 9
1 Fuel metering valve
Situated at the inlet of the high pressure pump, on the low pressure system, this device adjusts the quantity of fuel reaching the high
pressure pump in accordance with the commands received from the control unit.
It mainly consists of the following parts:
● tapered shutter
● valve control pin
● Pre-load spring
● Coil
In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery
mode.
The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high
pressure pump.
The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system that is managed
by the EDC.
Pin - out
1 Power supply from pin 58 of EDC control unit Pink
2 Ground to pin 83 of the EDC control unit Green
EDC (ECM) SYSTEM
772656 Fuel temperature sensor FUEL TEMPERATURE SENSOR - [47042]

It is a N.T.C. sensor located on the fuel filter at the engine left side.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.
Sensor
196902 Figure 10
A Technical view C Wiring Diagram
B Perspective view
EDC (ECM) SYSTEM
Supplier: BOSCH
Tightening torque
maximum tightening torque 25 N⋅m
Pin - out
1 Fuel temperature signal to pin 12 of EDC control unit Grey
2 Ground to pin 59 of the EDC control unit Blue
764274 Engine coolant temperature / engine fan sensor COOLANT TEMPERATURE SENSOR FOR EDC -
[85153]
It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the
need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
The coolant temperature signal is used to be displayed on the Cluster and to control the fan.
EDC (ECM) SYSTEM
Sensor
196902 Figure 11
B Perspective view
EDC (ECM) SYSTEM
Supplier: BOSCH
Tightening torque
maximum tightening torque 25 N⋅m
Pin - out
1 Engine coolant temperature signal from pin 39 of the EDC control unit Grey
764263 Flywheel pulse transmitter ENGINE RPM SENSOR - [48035]

This sensor is an inductive one and is located on the flywheel.
It generates signals obtained from the magnetic flow lines, which close through the holes obtained on the flywheel.
The electronic control unit uses this signal to detect the various engine ratings and to control the electronic rev counter.
If this signal fails the rev counter will not work.
The sensor gap is NOT ADJUSTABLE.
EDC (ECM) SYSTEM
Sensor
191894 Figure 12
B Perspective view D Connector
Characteristics:
Supplier: BOSCH
Tightening torque
tightening torque 8 ±2 N⋅m
Technical data
resistance 774 Ω to956 Ω
EDC (ECM) SYSTEM
Pin - out
1 Engine rpm signal from pin 67 of the EDC control unit Black
2 Ground from pin 68 of the EDC control unit White
764264 Timing system pulse transmitter ENGINE SPEED SENSOR ON TIMING SYSTEM - [48042]
This inductive sensor is located on the camshaft.
It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to the
crankshaft.
The signal generated by this sensor is used by the control unit as the injection timing signal.
The sensor gap is NOT ADJUSTABLE.
Sensor
191894 Figure 13
A Technical view B Perspective view
EDC (ECM) SYSTEM
191894 Figure 13
C Wiring Diagram D Connector
Characteristics
Supplier: BOSCH
Tightening torque
tightening torque 8 ±2 N⋅m
Technical data
resistance 774 Ω to956 Ω
Pin - out
1 Engine rpm signal on timing system from pin 66 of the EDC control unit White
2 Ground to pin 65 of the EDC control unit Black
EDC (ECM) SYSTEM
766123 Pre/post heating element RESISTOR FOR ENGINE PREHEATING - [61121]

The resistance is located between the cylinder head and the intake manifold used to heat the air in pre - post heating operations.
When the key switch is actuated, if even only one of the temperature sensors (water, air, diesel) detects less than 10 °C, the elec-
tronic control unit activates pre/post-heating and turns on the relevant dashboard warning light for a time depending on the tem-
perature.
Once this time expires, the warning light starts flashing, thus telling the driver that he can now start the engine.
The warning light goes off after engine start while the resistance continues to be supplied for a variable period of time performing
post - heating.
If the engine is not started within 20 to 25 seconds after the warning light starts flashing, the operation is cancelled so as to prevent
battery discharge.
When reference temperature is above 10°C, actuating the ignition key makes the warning light go on for approximately 2 seconds
to complete the test and then turns it off to indicate the engine can be started.
resistance
196907 Figure 14
EDC (ECM) SYSTEM
Supplier: BERU
Technical data
Rated voltage 24 V
Pick-up current 160 A to290 A
Constant current 120 A to150 A
Insulating resistance 1 MΩ
540752 Air temperature and pressure sensor TURBO BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156]
This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
EDC (ECM) SYSTEM
Sensor
196905 Figure 15
A Technical view D Wiring Diagram
B Perspective view E Connector
C Recommended assembly position
EDC (ECM) SYSTEM
Supplier: BOSCH
Technical data
Sensor power supply 5V
Storage temperature −40 to130
Pin - out
1 Ground to pin 90 of the EDC control unit Yellow
2 Air temperature signal to pin 37 of the EDC control unit Red
3 Sensor power supply (+5V) to pin 7 of the EDC control unit Green
4 Air pressure signal to pin 86 of the EDC control unit Purple
764251 Oil pressure and temperature sensor TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER SIGNALLING THE ENGINE OIL TEMPERAT-
URE - [42030/47032]
This component incorporates a temperature sensor and a pressure sensor.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low pres-
sure warning light).
The engine oil temperature is used by the EDC control unit only.
EDC (ECM) SYSTEM
Sensor
196906 Figure 16
A Technical view D Wiring Diagram
B Perspective view E Connector
C Recommended assembly position
EDC (ECM) SYSTEM
Supplier: BOSCH
Technical data
Sensor power supply 5V
Pin - out
1 Ground to pin 6 of the EDC control unit Yellow
2 Oil temperature signal to pin 13 of the EDC control unit Green
3 Sensor power supply (+5V) to pin 31 of the EDC control unit Red
4 Oil pressure signal to pin 35 of the EDC control unit Purple
7642 CPS pressure sensor
178245 Figure 17
It is a pressure sensor fit on the engine head.
Supplier: KAVLICO
Technical data
Storage temperature −40 to125
Pin - out
1 Power supply from pin 32 of the EDC control unit Blue
2 Ground to pin 42 of the EDC control unit Purple
3 Pressure signal to pin 61 of the EDC control unit Yellow
EDC (ECM) SYSTEM
5424 Turbocharging
Components
542410 EVGT actuator

The EVGT actuator is electromechanical and serves to vary turbine geometry.
178242 Figure 18
1 EVGT actuator
This solution enables keeping gas and turbine rates high even when the engine is operating at low speed. By making the gases pass
through small cross-sections, they flow faster, so that the turbine turns faster as well.
Exhaust gas section with engine under load.
EDC (ECM) SYSTEM
106992 Figure 19
The device is in the condition of being fully closed at low speeds.
At high engine speeds the electronic control system intervenes and increases the cross-section of the flow to allow the incoming
gases to pass without increasing their speed.
EVGT actuator pin-out

Pin Function Cable colour code
1 CAN - H line White
2 CAN - L line Green
3 Earth 0000
4 power supply +30 8940
542456 Turbine speed sensor TURBOCHARGER SPEED SENSOR - [48043]
106996 Figure 20
This is an inductive sensor positioned on the impeller shaft.
It generates signals obtained from the magnetic flow lines, which close through a notch obtained on the shaft itself.
The signal generated by this sensor is used by the control unit to verify that the turbine revs number does not exceed the max-
imum value.
The ECU adjusts the speed by changing the variable geometry.
If the revs number keeps on increasing until it reaches excessive r.p.m. values, the electronic control unit will detect an anomaly.
The gap is NOT ADJUSTABLE.
EDC (ECM) SYSTEM
Pin - out
1 Turbine rpm signal to pin 93 of the EDC control unit Yellow
3 Spare −
5437 Exhaust flap actuator (engine brake throttle valve)

ExFlp actuator
178244 Figure 21
It is an electromechanical actuator that moves the throttle valve on the exhaust manifold.
For a description of its operation, see SECTION 2 - Engines
ExFlp actuator pin-out

Pin Function Cable colour code
1 power supply +30 8940
2 Earth 0000
3 CAN - L line Green
4 CAN - H line White
Alternator 120A
760310 Alternator 120A

Characteristics
Supplier MITSUBISHI
Rated voltage 28.3 ± 0.5 V (20ºC)
Nominal supply current 120A
Operating speed 5000 rpm
Belt tension 730 N
Direction of rotation clockwise, viewed from pulley
Weight 7 kg
Tightening torque on terminal B+ 12.5 ± 2 Nm
Alternator current delivery curve
132919 Figure 22
Perspective view
132920 Figure 23
Alternator 120A
Alternator wiring diagram
132921 Figure 24
L no battery charging signal R voltage regulator
B+ battery power IG alternator activation
B- ground S battery voltage sensor
STARTER MOTOR "NIPPONDENSO" 24V - 5.5KW STARTER MOTOR - [08000]
TECHNICAL view (rear side)
132922 Figure 25
760810 STARTER MOTOR "NIPPONDENSO" 24V - 5.5KW STARTER MOTOR - [08000]

Technical view
4956 Figure 26
Characteristic curves
137660 Figure 27
Wiring Diagram
4958 Figure 28
Perspective view with matching electrical connections
6658 Figure 29
Connector Function Cable colour code

+30 Positive +30 for starter motor power supply from battery positive terminal (via the T.G.C.) 7777
+30 Positive +30 to the alternator 7777
+30 Positive +30 to contactor for engine preheat activation consent 7777
+50 Positive +50 from key switch 8888
Version
Characteristics
5.5 kW
Nominal power 5.5 kW
Rated voltage 24 V
Coupling system Positive approach control
Adjusted time 30 s
Version
Characteristics
5.5 kW
Direction of rotation Clockwise seen from pinion end
16 V
Operating voltage
MAX
Weight ≈ 10.5 kg
17.6 N⋅m to24.5 N⋅m
Tightening torque for terminal +30
(M10X1.5)
2.6 N⋅m to4.6 N⋅m
Tightening torque for terminal +50
(M5X0.8)
Specific power
Version
Load 5.5 kW
Test conditions Characteristics
120 A
No load 23 V MAX
(3,100 rpm)
690 A
16 V
Load MAX
(49 N⋅m)
(900 rpm)
1,260 A
Stall 6V MAX
(73.5 N⋅m)
44 Exhaust gas post-treatment system
Exhaust gas post-treatment system 45
Contents
Contents
SCR SYSTEM (SELECTIVE CATALYTIC

REDUCTION) - DeNOx 2.2 . . . . . . . . . . . . . . . . 47
Main functions . . . . . . . . . . . . . . . . . . . . . . . 47
Exhaust gas after-treatment system (ATS) . . . . . . 47
Layout and diagram of the ATS (After Treatment
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
AdBlue Pump Module . . . . . . . . . . . . . . . . . . . 49
Pin out connector . . . . . . . . . . . . . . . . . . . . . 50
Electrical components inside the pump
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Denox2 Injector . . . . . . . . . . . . . . . . . . . . . . 53
AdBlue heating system . . . . . . . . . . . . . . . . . . . . 54

AdBlue heating system diagram
(demonstrative) . . . . . . . . . . . . . . . . . . . . . . 54
Water pipes for AdBlue heating system . . . . . . . . 54
AdBlue heating system valve . . . . . . . . . . . . . . . 55
Exhaust gas temperature sensor . . . . . . . . . . . . 55
Ammonia detection sensor (NH3) . . . . . . . . . . . . . 57

Technical specifications . . . . . . . . . . . . . . . . . . 58
NH3 ammonia sensor . . . . . . . . . . . . . . . . . . . . . 59

Particulate trap pressure sensor (Δp) . . . . . . . . . . . 60
Nitrogen oxide detecting sensor (NOx) . . . . . . . . . 61

NOx control unit . . . . . . . . . . . . . . . . . . . . . 62
NOx Sensor . . . . . . . . . . . . . . . . . . . . . . . . 63
Temperature and humidity sensor . . . . . . . . . . . . . 64
SCR SYSTEM (SELECTIVE CATALYTIC REDUCTION) - DeNOx 2.2
Exhaust gas post-treatment system

5074 SCR SYSTEM (SELECTIVE CATALYTIC REDUCTION) - DeNOx 2.2
Main functions
A supply module takes the AdBlue from the tank and brings it to a pressure of 9 bar by means of a membrane pump.
The control system and heating strategies are managed by a software module inside the engine control unit (EDC17); this module
takes into account the different input signals such as NOx emissions and engine load.
The metering strategy calculates the amount of AdBlue to inject and transforms it into a PWM signal to control the metering mod-
ule.
The system for controlling the AdBlue injection can adjust its operating parameters to adapt to the actual situation.
AdBlue freezes at -11 ° C for this reason, the engine switches off the system empties the AdBlue bringing the liquid in the tank.
When starting the engine, the system heats the pipes and the tank; the system only activates metering when the system is free of
ice.
For more details, the operation of this system is described in the "Engine" section of this manual.
Exhaust gas after-treatment system (ATS)
178262 Figure 30
1 Urea level and temperature sensor. 7 Dosing module (AdBlue injector)
2 Humidity sensor 8 DeltaP sensor of DPF
3 NH3 sensor (ammonia) 9 Temperature sensor before catalytic converter
4 NOx sensor downstream of the catalytic converter 10 NOx sensor before catalytic converter
5 Temperature sensor after catalytic converter 11 AdBlue temperature sensor
6 Temperature sensor before SCR 12 AdBlue pressure sensor
Layout and diagram of the ATS (After Treatment System)
180401 Figure 31
1 NOx sensor before catalytic converter 5 NH3 sensor (ammonia)
2 DeltaP sensor of DPF 6 Temperature sensor after catalytic converter
3 Dosing module (AdBlue injector) 7 Temperature sensor before SCR
4 NOx sensor after catalytic converter 8 Temperature sensor before catalytic converter
507410 AdBlue Pump Module
180404 Figure 32
1 Main filter 5 AdBlue tank inlet
2 Electrical connector 6 Return to AdBlue tank
3 Pressure compensation diaphragm. 7 Pump module heater manifold
4 Pump module heater manifold 8 AdBlue outlet to injector
It serves to pressurise the AdBlue fluid to approx. 9 bar.
507410 Pin out connector
178259 Figure 33
Cable diameter
Pin Function
(mm²)
1 — −
2 Power supply (+5V) for pressure sensor 0.75
3 Pressure sensor signal 0.75
4 GND pressure sensor ground 0.75
5 — −
6 — −
7 — −
8 GND Diaphragm pump ground 1.5
9 Diaphragm pump power supply (+BAT) 1.5
10 PWM Diaphragm pump signal 0.75
11 Reverse solenoid valve 1.5
12 Reverse solenoid valve 1.5
507410 Electrical components inside the pump module
178260 Figure 34
1 Reverse valve 4 Electrical connector
2 Pressure sensor 5 Diaphragm pump
3 Temperature sensor
Component characteristics
Diaphragm pump
Technical data
Diaphragm pump power draw 400 ±200 mA
Note The values are to be intended in case of 28.5 V battery and AdBlue pressure equal to 900kPa.
Pressure sensor
Technical data
Pressure sensor power supply 5 ±0.25 V
Note With AdBlue pressure at 900 Kpa, supply the sensor with 5 V at 18 ÷ 28°C, The value measured must be equal to 3.357 V
with a tolerance of ± 0.05V
Reverse valve
Technical data
Reverse valve coil resistance 21.10 ±3 Ω
Note The value is correct for temperatures between 18 ÷ 28°C
507432 Denox2 Injector
180405 Figure 35
1 Electrical connector 3 Coolant
2 AdBlue intake
Its function is dosing the AdBlue solution to be sent into the exhaust pipe upstream of the catalytic converter.
AdBlue heating system
5074 AdBlue heating system

AdBlue heating system diagram (demonstrative)
178262 Figure 36
1 AdBlue intake line 5 AdBlue tank level sensor
2 Pump module 6 Dosing module
3 Pressurised AdBlue line 7 AdBlue tank
4 AdBlue return line 8 AdBlue heating system valve
Water pipes for AdBlue heating system
1 Pipe isolation 3 Engine cooling line

2 AdBlue line
178263 Figure 37
507433 AdBlue heating system valve
178243 Figure 38
1 Coolant from engine intake 3 AdBlue tank and pump module heating
2 Electrical connector 4 Dosing module cooling
Characteristics
Technical data
Rated voltage 24 V
Technical data
Current absorption 0.75 A
507434 Exhaust gas temperature sensor
178264 Figure 39
178265 Figure 40
Sensor characteristics
T °C RS (Ω) V0 (V)
−40 170.2 0.727
−20 185.6 0.783
0 201.1 0.837
25 220.1 0.902
50 239.0 0.964
100 276.4 1.083
150 313.2 1.193
200 349.5 1.295
250 385.1 1.390
300 420.2 1.479
350 454.7 1.563
400 488.6 1.641
450 521.9 1.715
500 554.6 1.784
600 618.3 1.910
700 679.7 2.023
800 738.7 2.124
900 795.4 2.215
1,000 849.7 2.297
Ammonia detection sensor (NH3)
5074 Ammonia detection sensor (NH3)

The sensor detects the presence of ammonia (NH3) in the exhaust gas exiting the catalytic converter and sends this signal to the
NH3 control unit.
This information that the NH3 control unit transmits to the engine control unit via the CAN line permits a more precise adjust-
ment of the AdBlue quantity to be injected.
NH3 control unit
A B
191881 Figure 41
Ammonia detection sensor (NH3)
Recommended assembly position
A B
191882 Figure 42
A Control unit in a horizontal position 1 Recommended position
B Control unit in a vertical position
Technical specifications
Supplier: DELPHI
Technical data
Operating voltage 10 V to32 V
Rated voltage 24 V
Average absorbed current 1.2 A
Maximum current absorbed 4A
Working temperature −40 ℃ to105 ℃
Storage temperature −40 ℃ to125 ℃
Pin - out
J1 J2
191883 Figure 43
J1 Vehicle connectors J2 Sensor connector
Connector J1
Pin Description Cable
1 Positive +15 8540
2 CAN H network White
3 CAN L network Green
NH3 ammonia sensor
Pin Description Cable

4 Ground 0000
Connector J2
Pin Description
1 Heater
2 Adjustment resistance
3 Adjustment resistance ground
4 EMF_2
5 Heater
6 Temperature signal
7 Ground signal
8 EMF_1
5074 NH3 ammonia sensor

NH3 sensor
191887 Figure 44
A Technical view 2 Vertical exhaust pipe position
B Recommended assembly position 3 Horizontal exhaust pipe position
1 Connector connecting with the NH3 control unit
Particulate trap pressure sensor (Δp)
Supplier: DELPHI
Technical data
Maximum operating temperature (exhaust gas) Less700 ℃
507134 Particulate trap pressure sensor (Δp)

Measures the difference (Δp) between the pressure of the exhaust gas inlet and outlet of the SCRT filter thus determining its effi-
ciency and the state of clogging.
Converts the Δp value into a voltage Vo which is sent to the control unit EDC according to the following chart
Vo characteristic in function of Δp
Vo Outlet voltage Δp Difference between the
outlet and inlet voltage in
the CRT
186663 Figure 45
Sensor pin-out
1 Supply voltage (5V) 3 Output voltage signal (Vo)
2 ground
186662 Figure 46
Nitrogen oxide detecting sensor (NOx)
507435 Nitrogen oxide detecting sensor (NOx)

Its function is to inform the EDC control unit about the AdBlue liquid metering and the catalytic converter efficiency.
The NOx sensor comprises a ceramic sensor and an electronic control unit, connected with a special cable as shown in the figure.
The electronic unit transforms the analogue signal into a digital signal to be sent directly to the CAN network.
191893 Figure 47
NOx control unit
A B
191884 Figure 48
A Technical view C Recommended assembly position
B Perspective view 1 Horizontal position
Supplier: CONTINENTAL
Technical data
Standard supply voltage 28.5 V
Average supply current 0.6 A
Peak current at activation 12 A
Maximum power absorbed 20 W
Technical data
Working temperature −40 ℃ to105 ℃
Storage temperature −40 ℃ to120 ℃
Pin - out
191886 Figure 49
Vehicle connectors
Pin Function Cable code
1 Supply 8540
2 Ground 0000
3 CAN L line (ECB) Green
4 CAN H line (ECB) White
5 – –
NOx Sensor
191885 Figure 50
A Technical view 2 Vertical exhaust pipe position
B Recommended assembly position 3 Horizontal exhaust pipe position
1 NOx Sensor
Temperature and humidity sensor
Supplier: CONTINENTAL
Technical data
Maximum operating temperature (exhaust gas) Less800 ℃
507436 Temperature and humidity sensor

It is located after the air filter on the intake manifold.
The sensor, provides the EDC control unit with the percentage of humidity and the temperature of the combustion air necessary
for the control unit to inject the correct amount of AdBlue within the catalytic converter.
182296 Figure 51
182297 Figure 52
Pin out
Pin Description
1 Vcc (+5V)
2 Humidity signal
3 Ground
4 Temperature signal
Humidity and temperature sensor temperature characteristic charts

% moisture Rated voltage (mV)
10 1,205
15 1,355
25 1,500
30 1,640
30 1,770
35 1,905
40 2,030
45 2,155
50 2,275
55 2,400
60 2,520
65 2,640
70 2,770
75 2,895
80 3,020
85 3,150
90 3,285
95 3,410
Humidity and temperature sensor temperature characteristic charts

°C Resistance (Ω)
−40 42,172
−30 24,760
−20 14,995
°C Resistance (Ω)
−10 9,348
0 5,988
10 3,933
20 2,644
30 1,817
40 1,274
50 910
60 662
70 489
80 367
90 279
CURSOR 13 TDCV ‒ Scheduled maintenance
Contents 1
Contents
SCHEDULED MAINTENANCE FOR CURSOR 13

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Contents
SCHEDULED MAINTENANCE FOR CURSOR 13 ENGINE 3
Contents
Contents
Maintenance services schedule . . . . . . . . . . . . . . . . 5
STANDARD SERVICES . . . . . . . . . . . . . . . . . . . . . 6
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of the engine oil filter . . . . . . . . . . . 6
Fuel filter replacement . . . . . . . . . . . . . . . . . . . 7
Check water pump and alternator drive belt . . . . . 8
Replacing the Blow-by filter . . . . . . . . . . . . . . . . 9
Replacing water pump and alternator drive
belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXTRA PLAN OPERATIONS . . . . . . . . . . . . . . . . 10

Check valve clearance and adjust if necessary . . . . 10
Replacement of the automatic belt tensioner . . . . 12
TIMED OPERATIONS . . . . . . . . . . . . . . . . . . . . 13
Checking the antifreeze concentration in the
engine coolant . . . . . . . . . . . . . . . . . . . . . . . 13
Change the engine coolant . . . . . . . . . . . . . . . . 14
4 SCHEDULED MAINTENANCE FOR CURSOR 13 ENGINE
Maintenance services schedule
SCHEDULED MAINTENANCE FOR CURSOR 13 ENGINE

M Maintenance services schedule
Scheduled Maintenance consists of "Standard" services, plus a series of operations called "Non-scheduled" and others called
"Timed". Differentiated plans are normally not prescribed in relation to use of vehicles. In cases where there is a differentiation in
terms of the "mission" there are as many plans as there are missions. The systematic use of recommended lubricants allows longer
replacement intervals at relatively low costs.
To minimize the number of downtimes for maintenance, it is advisable to plan the downtimes, based on the annual average dis-
tance, making them coincide, to the extent possible with the predefined kilometric intervals.
To schedule the work, observe the following chart:
STANDARD SERVICES FREQUENCY

Change engine oil (2) (3) (4) (5) Every 150,000 km or 3,000 hours
Change engine oil filter (2) (3) Every 150,000 km or 3,000 hours
Replacement of the fuel filter cartridge Every 150,000 km or 3,000 hours
Replacing (1)
fuel pre-filter cartridge Every 150,000 km or 3,000 hours
Check water pump and alternator drive belt Every 150,000 km or 3,000 hours
Check fan electromagnetic connector clutch wear Every 150,000 km or 3,000 hours
Replacement of the engine blow-by filter Every 150,000 km or 3,000 hours
Replacing water pump and alternator drive belt Every 300,000 km or 6,000 hours
1. Not supplied by FPT.
2. If ACEA E9 lubricant is used, the engine oil and filter must be changed every 80,000 km.
3. In case of very low annual mileage of less than 100,000 km/year (municipal use, concrete mixers, etc.), the engine oil and filters must be changed every 12
months.
4. It is absolutely forbidden to top up engine oil with a lubricant other than that already present in the sump. 10W40 lubricant may be used only when completely
changing the engine oil.
5. URANIA FE LS. FPT recommends the use of these oils to obtain benefits in terms of "fuel economy". The new engine is already equipped by FPT with these
types of lubricants, also suitable for cold climates (minimum temperatures to -30°). The replacement intervals of the lubricants declared in this document regard
the use of these types of oil.
EXTRA PLAN OPERATIONS FREQUENCY

First intervention at 150,000 km or 3,000 hours
Check valve clearance and adjust if necessary
Then every 300,000 km or 6,000 hours
Replacement of the automatic belt tensioner Every 600,000 km or 12,000 hours
TIMED OPERATIONS FREQUENCY

Air dryer replacement (1)
Every year
Engine coolant density check Every year (before winter)
Change engine coolant Every two years
1. Not supplied by FPT
In order to observe the specified servicing intervals please ensure that the lubricants recommended by FTP in the fol-
lowing section are used.
STANDARD SERVICES
STANDARD SERVICES
.543070. Engine oil change
Tightening torques
Oil drain plug 95 ±10 N⋅m
Main action
1. Take out the oil level dipstick (1).
2. Unscrew the plug (2) from the oil sump and drain the engine
oil off into a specific container.
3. Screw the plug (2) back on under the sump and tighten it to
the specified torque.
Tightening torque
Oil drain plug 95 ±10 N⋅m
219050 Figure 1
4. Fill in with the prescribed oil quantity and quality from the filler
(1).
219052 Figure 2
.543070. Replacement of the engine oil filter

Tightening torques
Engine oil filter 60 ±5 N⋅m
Main action
Caution!
Filter replacement Precautions
▶ The oil filter contains approximately 2.5 l of engine oil inside.
▶ Position a suitable container to collect the oil.
▶ Avoid skin contact with the engine oil: in case of contact, wash thoroughly with water.
▶ The engine oil is highly pollutant: it must be disposed of according to applicable laws.
STANDARD SERVICES
1. Unscrew the drain plug (2) and drain the engine oil contained in
the filter.
2. Unscrew the body (1) completely and replace the cartridge.
3. Insert the cartridge into the body and fit the centring flanges on
the top cap with the relative seats.
4. Oil and fit new seals.
5. Screw the filter (1) until the seals come in contact with the
resting bases.
6. Tighten the filter to the specified torque.
Tightening torque
Engine oil filter 60 ±5 N⋅m
7. Tighten the drain plug (2) in the cartridge body.

Tightening torque 219049 Figure 3
.542011. Fuel filter replacement

Tightening torques
Fuel filter 32.5 ±2.5 N⋅m
Drain valve 1.5 ±0.5 N⋅m
Fitting for bleeding 18 ±2 N⋅m
STANDARD SERVICES
Main action
1. Position a collection container under the vehicle.
2. Unscrew the lower filter plug (1).
3. Loosen the breather (2) and drain the diesel contained in the
filter.
4. Unscrew the fuel filter container (3) using a suitable wrench
and remove the cartridge (4).
5. Before refitting the new cartridge (4), moisten the gasket with
diesel or engine oil.
6. Manually screw on the filter, being careful not to pinch the
gasket, until it comes into contact with the support and then
tighten it to the required tightening torque.
Tightening torque
Fuel filter 32.5 ±2.5 N⋅m
Drain valve 1.5 ±0.5 N⋅m
Fitting for bleeding 18 ±2 N⋅m
7. Bleed air from the fuel system.

Note Make absolutely sure that the fuel does not soil the
drive belt: alternator, water pump, etc.
193329 Figure 4
.543411. Check water pump and alternator drive belt
Main action
▶ Visually check that the belt is not worn or deteriorated; if so,
replace it as described in the relative chapter Replacing water
pump and alternator drive belt ( ➠ Page 10).
191908 Figure 5
STANDARD SERVICES
.540486. Replacing the Blow-by filter

Consumables
LOCTITE 243
Tightening torques
Blow-by filter fixing screws 1. Pre-tightening Tightening sequence: 1 - 2 - 3
LOCTITE 243 5 N⋅m
2. Tightening Tightening sequence: 4 - 5 - 6
15 N⋅m
Blow-by cover fixing screws 7 ±1 N⋅m
Preliminary actions
Introduction
Caution!
Engine compartment wash-out Precautions for electrical components
▶ If washing the engine compartment, protect the electric/electrical components and their connections appropriately.
1. Wash the engine, if necessary.
Main action
1. To replace the blow-by filter, remove the pipe (1), unscrew the
peripheral screws on the cover (2).
2. Unscrew the screws (4) and remove the filter.
3. Carefully clean the seating of the filter and the cover.
4. Fit the new filter (3).
5. Apply specific threadlock on the screws (4) and tighten them to
the specific torque.
Tightening torque
Blow-by filter fixing 1. Pre-tightening
screws (4) Tightening sequence: 1 - 2 - 3
Fixing
5 N⋅m
LOCTITE 243
2. Tightening
Tightening sequence: 4 - 5 - 6
15 N⋅m
Tool / Material
LOCTITE 243
6. Position the cover (2) and tighten the screws to the required
torque.
Tightening torque
Blow-by cover fixing screws 7 ±1 N⋅m
191323 Figure 6
EXTRA PLAN OPERATIONS
.543411. Replacing water pump and alternator drive belt

Main action
1. Using a suitable tool (3) act in the direction shown by the ar-
row on the automatic belt tensioner (2) and remove the belt
(1) controlling the water pump and alternator.
2. Act on the automatic belt tensioner (2) and fit the new altern-
ator/water pump drive belt (1).
Note The belt tensioner (2) is automatic therefore, no fur-
ther adjustments are to be made after fitting.
191063 Figure 7

.541230. Check valve clearance and adjust if necessary
Work material
Tool for engine T.D.C. positioning 99360612
Box wrench
Note The adjustment of clearance between the rocker arms and bridges controlling the intake and exhaust valves must be done
very carefully.
Main action
187916 Figure 8
A Hole on flywheel with reference mark, corresponding D Flywheel hole with two notches corresponding to
to the TDC of pistons 1-6 position 54° before TDC of pistons 1-6 (camshaft
B Hole on flywheel with reference mark, corresponding timing reference);
to the TDC of pistons 2-5 E Flywheel hole with three notches corresponding to
C Hole on flywheel with reference mark, corresponding position 30° before TDC of pistons 1-6 (reference to
to the TDC of pistons 3-4 HP fuel pump and timing system phonic wheel timing).
1. In order to perform adjustments correctly, during each rotation phase check the positioning accuracy using the specific pin,
inserting it into the hole marked with a notch on the flywheel corresponding to piston position.
Tool / Material Product code
2. Take the cylinder in which the clearance must be adjusted to

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

erating clearance shown in the "Characteristics and data" 114287 Figure 9
table.
6. Screw or unscrew the adjustment screw of the rocker arm (2)
with the appropriate wrench.
7. Check that the feeler gauge blade (3) can slide with slight fric-
tion.
8. Lock the nut (1) by stopping the adjustment screw.
9. To carry out the adjustments stated above, the sequence shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]
Note Check during each rotation phase, the accuracy of the position by using the specific pin and inserting it into the hole
marked with a notch on the flywheel corresponding to piston position.
.543417. Replacement of the automatic belt tensioner

Tightening torques
Screw fixing the automatic belt tensioner 50 ±5 N⋅m
TIMED OPERATIONS
Main action
1. Cut the belt (2) and remove it from its seat.
2. Use the appropriate wrench (1) to remove the adjustable belt
tensioner (3) by acting on the retaining screw.
3. Fit a new belt tensioner and tighten the retaining screw to the
specified torque.
Tightening torque
Screw fixing the automatic belt 50 ±5 N⋅m
tensioner
191601 Figure 10
TIMED OPERATIONS
.506010. Checking the antifreeze concentration in the engine coolant
Work material
Hydrometer (densimeter) for checking density of anti- 99395858
freeze liquid
Main action
Caution!
High engine temperature Precautions when checking coolants
▶ Given the high temperatures which are reached inside the engine, do not carry out operations immediately after the
engine has stopped but wait until the temperature has fallen.
▶ Protect eyes and skin from any unexpected high pressure jets of coolant.
1. Using a densimeter, take a sample of the coolant.

Hydrometer (densimeter) for checking density of antifreeze liquid 99395858
2. Depending on the temperature of the fluid, check the percentage of antifreeze in the fluid on the reading scale of the instru-
ment.
Note The percentage should be higher than 40% and must not exceed 50%.
3. If necessary, restore the percentage of antifreeze.
TIMED OPERATIONS
.506010. Change the engine coolant

Main action
Caution!
High engine temperature Precautions when checking coolants
▶ Given the high temperatures which are reached inside the engine, do not carry out operations immediately after the
engine has stopped but wait until the temperature has fallen.
▶ Protect eyes and skin from any unexpected high pressure jets of coolant.
1. Only proceed when the engine is not turning over.
Caution!
Engine fluid at high pressure Precautions when checking coolants
▶ When the engine is hot, a pressure is stabilised in the cooling circuits which is able to eject the hot liquid in a very
violent manner, resulting in a risk of burns.
2. Use suitable containers to ensure that the coolant is not dispersed in the environment.
3. Loosen the retaining elements and remove the sleeves that couple the engine circuit with the heat exchanger and wait for
them to empty completely. Once emptied, restore the condition of the circuit, ensuring the sleeves are perfectly sealed.
4. Refill the circuit.
5. Refill the engine and the exchanger until the exchanger is completely full.
6. With the filler plug open, start the engine and idle it for approximately 1 minute. This phase helps to completely bleed the air
contained in the cooling circuit.
7. Stop the engine and then top up with the amount which is still needed.
Note After having refilled, proceed with the de-aeration of the system with the breathers on the engine. The missing sys-
tem de-aeration could cause serious damage to the engine because of air pockets in the engine head.
CURSOR 13 TDCV ‒ Scheduled maintenance for ATS (After
Contents 1
Contents
SCHEDULED MAINTENANCE FOR ATS

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Contents
SCHEDULED MAINTENANCE FOR ATS SYSTEM 3
Contents
Contents
Maintenance services schedule for ATS system . . . . . . 5
TIMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacing the AdBlue filter . . . . . . . . . . . . . . . . . 5
Replacing the DPF (Diesel Particulate Filter) catalytic
converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 SCHEDULED MAINTENANCE FOR ATS SYSTEM
Maintenance services schedule for ATS system
SCHEDULED MAINTENANCE FOR ATS SYSTEM

M Maintenance services schedule for ATS system
Scheduled Maintenance consists of operations that must be performed on the components of the ATS system within the set time
range.
Also, in the case of evident system malfunction, it is necessary to adopted timely measures to verify the cause of the defect.
To schedule the work, observe the following chart:
COMPONENT FREQUENCY
Tank pre-filter (100 μm) No maintenance anticipated (clean if necessary)
Clean every 160,000 km or 3,200 hours or 2
Supply module pre-filter (100 μm)
years
AdBlue inlet filter to supply module (100 μm) No maintenance envisaged (replace if necessary)
AdBlue filter supply module (1)
Replace every 300,000 km
AdBlue return filter from supply module to tank (100 μm) No maintenance envisaged (replace if necessary)
Dosing module filter (36 μm) No maintenance anticipated
Replace every 240,000 km or every 4 years of
DPF (Diesel Particulate Filter) catalytic converter
every 3,200 hours
Replace every 300,000 km or every 800 hours or
every year (1)
AdBlue system control with diagnostic tools
Replace every 60,000 km (2)
Replace every 80,000 km (3)
Catalytic converter Replace only if damaged
1. Frequency valid for heavy duty vehicles (urban utility applications)
2. Frequency valid for vehicles meant for short-medium range transport (regional or interregional)
3. Frequency valid for vehicles meant for long range transport (national or interregional, mainly on the motorway)
TIMED
.507413. Replacing the AdBlue filter
Tightening torques
AdBlue filter plug 20 ±5 N⋅m
Main action
Conditions
● Operate on the pump module.
TIMED
▶ Unscrew the cover (1), and remove the element (2).
194410 Figure 1
▶ Insert the specified extraction tool (3) in the filter as

shown in the figure. If the filter is green the direction of
insertion is (2); if the filter is black it should be inserted in
the direction (1).
Note The tool (3) must be inserted until a click is heard,
which indicates it is correctly positioned.
191094 Figure 2
▶ Pull in the indicated direction (→) and extract the AdBlue

filter from its seat.
Note Protect the AdBlue filter seat from the possible
entry of particles.
191095 Figure 3
TIMED
▶ Oil the gaskets and install the new filter (2) in the seat.
▶ Insert the element (1) in the filter (2).
Note Make sure there are no cracks or breaks in the
plug and in the filter seat.
▶ Tighten the plug to the prescribed torque.
Tightening torque
AdBlue filter plug 20 ±5 N⋅m
▶ Refit the AdBlue pump module guards that were previ-

ously removed.
191092 Figure 4
.507130. Replacing the DPF (Diesel Particulate Filter) catalytic converter
Tightening torques
DPF catalytic converter fastening collar 1. Pre-tightening Tightening sequence: 1-2
8 N⋅m
2. Torque tightening Tightening sequence: 1-2
12 ±1 N⋅m
DPF catalytic converter clamp fastening collar 1. Pre-tightening Tightening sequence: 3-4
25 N⋅m
2. Pre-tightening Tightening sequence: 3-4
35 N⋅m
3. Torque tightening Tightening sequence: 3-4
42.5 ±2.5 N⋅m
Cover fixing screws on the silencer 10.3 ±0.8 N⋅m
Guard fixing screws on the silencer 14 ±1.4 N⋅m
Note If the Δp sensor is replaced, it is necessary to use the diagnostic tool to reprogram the control unit by following the re-
placement procedure of the component in question.
TIMED
Main action
.507130. Removing the DPF catalytic converter
1. Unscrew the screws (1) and remove the guards that are on the
catalytic converter.
192990 Figure 5
2. Unscrew the screws (1) and remove the cover (2).
191099 Figure 6
TIMED
3. Loosen the collar (2) by turning the screws (1) and (3) at the
same time and remove it.
Note Once the collar (2) has been removed it must not be
reused but replaced.
191100 Figure 7
4. Loosen the screws (2) and move the collar (1) approx. 60 mm
in the direction indicated by the arrow (→).
Note Once the collar (1) has been removed it must not be
reused but replaced.
191902 Figure 8
TIMED
5. Remove the DPF catalytic converter (1) from its seat using a
suitable lifting device.
191903 Figure 9
6. Remove the 2 pressure rings (1) from the catalytic converter

and DPF.
Note The pressure rings may be reused when refitting after
they have been cleaned.
7. Remove the metal gasket.
191904 Figure 10
TIMED
.507130. Refitting the DPF catalytic converter

8. Fit a new metal gasket. The one previously removed may not be
reused.
9. Clean and install the pressure rings (1) that were previously
removed in their seats on the catalytic converter and on the
DPF.
191904 Figure 11
10. Insert a new collar (1) on the DPF catalytic converter (2).
191905 Figure 12
TIMED
11. Position the new DPF catalytic converter (1) in its seat.
191903 Figure 13
12. Push the collar (1) in the direction indicated by the arrow (→)
until it reaches its correct position.
191906 Figure 14
TIMED
13. Install a new collar (5) and tighten the fixing screws (1) and (2)
to the required torque.
Tightening torque
DPF catalytic converter 1. Pre-tightening
fastening collar Tightening sequence: 1-2
8 N⋅m
2. Torque tightening
Tightening sequence: 1-2
12 ±1 N⋅m
14. Tighten the screws (3) and (4) to the required torque.
Tightening torque
DPF catalytic converter clamp 1. Pre-tightening
fastening collar Tightening sequence: 3-4
25 N⋅m
2. Pre-tightening
Tightening sequence: 3-4 191907 Figure 15
35 N⋅m
3. Torque tightening
Tightening sequence: 3-4
42.5 ±2.5 N⋅m
15. Refit the cover (2) and tighten the screws (1) to the required
torque.
Tightening torque
Cover fixing screws on the silencer 10.3 ±0.8 N⋅m
191099 Figure 16
TIMED
16. Refit the guards on the silencer and tighten the fixing screws
(1) to the required torque.
Tightening torque
Guard fixing screws on the silencer 14 ±1.4 N⋅m
192990 Figure 17
17. Conclude the replacement procedure by following the instructions provided by the diagnostic tool.
CURSOR 13 TDCV ‒ General mechanical overhaul
Contents 1
Contents
GENERAL MECHANICAL OVERHAUL . . . . . . . . . . 3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 111
2 Contents
GENERAL MECHANICAL OVERHAUL 3
Contents
Contents
ENGINE DISASSEMBLING . . . . . . . . . . . . . . . . . . 5
COMPREHENSIVE CRANKCASE CHECKS . . . . . . . 25
OVERHAULING THE CONNECTING ROD-PISTON

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . 53
COMPLETE TIMING SYSTEM OVERHAUL . . . . . . . 61
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 70
4 GENERAL MECHANICAL OVERHAUL
ENGINE DISASSEMBLING
GENERAL MECHANICAL OVERHAUL

.540110. ENGINE DISASSEMBLING
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Extraction tool for injectors 99342157
Tool for retaining the flywheel 99360351
Crankshaft lifting tool 99360500
Tool for rocker arm shaft assembly and fitting 99360553
Brackets for fastening engine to 99322230 rotary stand 99361036
Tool for removing the high pressure pump gear 99366198
Socket threaded wrench
Metal ropes
Main action
1. Before mounting the engine on the specified rotating stand, remove the following parts that may interfere with mounting the
brackets.
2. Disconnect the engine cable from the electrical components and remove it from the engine.
.790510. Air compressor removal

3. Disconnect the water pipes (2).
4. Disconnect the air pipes (1) and (5).
5. Unscrew the screws (4) and remove the air compressor (3).
219030 Figure 1
.543075. Oil pressure adjustment valve removal

6. Remove the oil pressure adjustment valve (1).
60486 Figure 2
.543211. Removing the water inlet pipe

7. Loosen the clips securing the sleeve (3) to the thermostat as-
sembly (4).
8. Loosen the screws (2) and remove the water inlet pipe (1)
together with the sleeve (3).
219037 Figure 3
191076 Figure 4
9. Fasten the engine to the specified rotating stand by means of dedicated brackets (1).
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230
.540860. Damper flywheel removal

10. Lock the flywheel using the specified tool (1).
Tool / Material Product
code
71702 Figure 5
11. Remove the damper flywheel (2) turning the screws (1).
181788 Figure 6
.543411. Coolant pump alternator drive belt disassembly

12. Using an appropriate tool (1) turn it in the direction shown by
the arrow and remove the auxiliary component drive belt (2).
Note The flexible belt must be replaced with a new one
every time it is removed from the vehicle.
181789 Figure 7
.760310. Alternator removal

13. Remove the screws (1) and remove the alternator (2).
181790 Figure 8
.543422. Electromagnetic coupling removal

14. Unscrew the screws (1) and remove the electromagnetic coup-
ling (2).
181791 Figure 9
.543210. Water pump removal

15. Remove the automatic tensioner (1), unscrew the screws (2)
and remove the pulley (3), remove the water pump (4), un-
screw the screws (5) and remove the pulley(6).
181792 Figure 10
.543251. Thermostat case removal

16. Remove the air pipe (1), unscrew the screws (3) and remove
the thermostat assembly (2).
219038 Figure 11
.540442. Crankshaft front gasket removal

17. Apply the specified extractor (2) and extract the crankshaft seal
gasket (1); remove the flange (3).
60490 Figure 12
.542410. Turbocharger removal

18. Remove the oil delivery pipe (1) and the oil return pipe (2)
from the turbocharger.
219032 Figure 13
19. Disconnect the coolant pipe (3) from the engine brake device
actuator (2) and remove the exhaust gas outlet pipe (1) to-
gether with the engine brake device.
219033 Figure 14
20. Free the water pipes (3) from the fixing brackets (→) and re-
move them.
21. Loosen the screws securing the exhaust manifold (1) and re-
move it together with the turbocharger (2).
219039 Figure 15
.540720. Exhaust manifold removal

22. Unscrew the screws (1) and the fixing nuts (3). Separate the
exhaust manifold (2) from the turbocharger (4).
191080 Figure 16
.543070. Oil filter removal

23. Unscrew and remove the oil filter (2).
24. Remove the oil filter support (1).
191081 Figure 17
.543110. Heat exchanger removal

25. Unscrew the screws (1) and remove the heat exchanger (2).
191082 Figure 18
.760810. Starter motor disassembly

26. Remove the starter motor (1).
181800 Figure 19
.540710. Intake manifold removal

27. Remove the support for the engine start buttons(3).
28. Loosen the screws (2) and remove the intake manifold (1)
together with the engine preheating resistor.
219034 Figure 20
.766161. Engine control unit removal

29. Detach the fuel piping (1), unscrew the screws (2) and remove
the engine control unit (3).
181802 Figure 21
.540480. Blow-by case removal

30. Unscrew the screws (1) and remove the blow-by case (2).
181803 Figure 22
.540486. Blow-by filter removal

31. Unscrew the screws (1) and remove the blow-by filter (2).
181804 Figure 23
.540452. Timing gear cover disassembly

32. Remove the pipe (1), unscrew the screws (2) and remove the
timing gear cover (3).
181805 Figure 24
.540630. Removal of head cover

33. Unscrew the screws (2) and remove the head cover (1).
181816 Figure 25
.542011. Fuel filter removal

34. Disconnect the pipes (3) from the high-pressure pump.
35. Remove the fuel filter (2) together with the mount (1).
191083 Figure 26
.773010. High pressure pump removal

36. Unscrew the nut (1).
37. Use the specified tool (3) and remove the high pressure pump
control gear (2).
code
Tool for removing the high pressure pump gear 99366198
185514 Figure 27
38. Disconnect pipes (1, 3).

39. Unscrew the screws (4) and remove the high pressure pump
(5).
40. Remove the bracket if necessary (2).
191084 Figure 28
41. Unscrew the retaining screws (1) and remove the flange (2)
supporting the high pressure pump.
160624 Figure 29
42. Unscrew the screws (2) and remove the gear (1) together
with the phonic wheel.
182129 Figure 30
43. Unscrew the screws (2) and remove the thrust plate (1) and
the sheet gasket.
182130 Figure 31
44. Unscrew the screws (2) and remove the idle gear (1).
182131 Figure 32
.540850. Engine flywheel removal

45. Using the specified tool to lock the mounted flywheel (1), un-
screw the retaining screws (2); then remove the tool (1) and
remove the flywheel (3).
code
181810 Figure 33
.540462. Crankshaft rear gasket removal

46. Apply the specified extractor (2) and extract the crankshaft seal
gasket (1).
181811 Figure 34
.540463. Flywheel case removal

47. Remove the cover (3).
48. Unscrew the screws (1) and remove the flywheel case (2).
181813 Figure 35
.543010. Disassembling the oil pump

49. Remove the screws (1) and disassemble the double gear (2).
191085 Figure 36
50. Unscrew the retaining screw (1) and remove the link rod (2).
191086 Figure 37
51. Unscrew the retaining screws (1) and remove the oil pump (2).
191087 Figure 38
.541230. Rocker arm shaft removal

52. Release the check springs (2) of the engine brake lever.
53. Unscrew the screw(1) fixing the rocker arm shaft.
173803 Figure 39
54. Use the specified tool (1) on the rocker arm shaft (2) and
remove the shaft (2) from the cylinder head. Remove the guide
braces (3) from the cylinder head.
code
114025 Figure 40
.774510. Rail removal
183458 Figure 41
55. Unscrew the fittings and remove the high pressure fuel supply pipes (8).
56. Unscrew the fittings from the rail and the injectors and detach the high pressure fuel pipes (1, 2, 3, 4, 5 ) and (6) the fuel
return pipe (7) from the head.
Note The high pressure fuel pipes must be replaced at each disassembly.
57. Disconnect the electrical connection from the pressure sensor (11).
58. Unscrew the retaining screws (9) and remove the rail (10).
.775010. Injector removal
159429 Figure 42
59. Disconnect the electrical connections (1) from the electro-injectors.
60. Disconnect the oil pipe (2) from the engine brake cylinders and the solenoid valve by unscrewing the fittings (3) and (4).
61. Remove the screws (1) from the injector securing (2) brackets.
169827 Figure 43
62. Position the specified tool (1) extract the injectors (2) from the
head.
code
Extraction tool for injectors 99342157
169826 Figure 44
63. Unscrew the screws (3) and remove the engine brake cylinders
(2).
64. Unscrew the screws (1) and remove the engine brake solenoid
valve (4).
183459 Figure 45
.541210. Camshaft removal

65. Install the appropriate plugs in the place of the injectors (1).
66. Extract the camshaft (2).
60514 Figure 46
.540610. Cylinder head removal

67. Unscrew the cylinder head screws (3).
Note The cylinder head fastening screws are to be replaced each time you remove them.
68. Using metal ropes, lift the cylinder head (1).

Tool / Material
Metal ropes
69. Take off the gasket (2).
60515 Figure 47
.540430. Oil sump removal

70. Loosen the screws (2) and remove the engine oil sump (1)
with the spacer (3) and the seal gasket.
60516 Figure 48
.543060. Suction strainer removal

71. Slacken the screws and remove the suction strainer (1).
60517 Figure 49
.540830. Connecting rod removal

72. Turn the crankcase (1) into vertical position.
47574 Figure 50
73. Unscrew the screws (2) fixing the connecting rod cap (3) and
remove it.
Note Keep the connecting rod half-bearings in their respect-
ive housings and/or note down their assembly position
since, if reusing them, they will need to be fitted in the
position found upon removal.
60518 Figure 51
.540830. Axis alignment check

74. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
75. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
76. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 52
.540416. Lower crankcase removal

77. Using an appropriate wrench and the socket threaded wrench
unscrew the screws (1) and (2) and take off the lower crank-
case .
Tool / Material
Socket threaded wrench
Note Note down the assembly position of the top and bot-
tom main half-bearings since, if reusing them, they will
need to be fitted in the position found upon removal.
60519 Figure 53
COMPREHENSIVE CRANKCASE CHECKS
.540810. Crankshaft removal

78. Using the specified tool (1), remove the crankshaft (2).
code
47570 Figure 54
.540816. Main bearings removal

79. Disassemble main half-bearings (1).
47571 Figure 55
.540414. Oil sprayer removal

80. Unscrew the screws and remove the oil sprayers (2).
81. Remove the cylinder sleeves as described in the related paragraph.
Note once the engine disassembly is complete, clean accurately the removed parts and check their integrity.
The following pages give instructions for checks and main measurements to do as to determine whether the parts can
be reused.
.540110. COMPREHENSIVE CRANKCASE CHECKS
Consumables
LOCTITE 270
Work material
Cylinder liner protrusion gauge (to be used with 99360334
99370415-99395603 and special plates)
Spacer (to be used with 99360334) 99360336

Tool for cylinder liner fastening 99360703
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
Dial gauge base to adjust lay shaft bearings (use with 99370415
99395603)
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Dial gauge (0-5 mm) 99395603
Bore gauge
Ring gauge
Micrometer
Centesimal dial gauge
Tightening torques
Protrusion checking tool screw 225 N⋅m
Screws fixing connecting rod cap 1. Step 1 70 N⋅m
2. Step 2 60°
Technical data
Cylinder liner protrusion compared to the cylinder head supporting surface 0.045 mm to0.075 mm
Heating temperature for gear fitting 180 ℃
Main action
.540410. Crankcase checks
1. After disassembling the engine, thoroughly clean the cylinder-
crankcase assembly.
2. Carefully inspect the crankcase for cracks.
3. Check the condition of casting hole plugs. If the caps are rusted,
or if there is any doubt about the efficiency of the seal, replace
them.
4. When assembling plugs, apply the recommended sealant on
them.
Tool / Material
LOCTITE 270
5. In order to check the inner diameter of cylinder liners and

identify the degree of ovalisation, taper and wear, use bore
meter (2) fitted with a centesimal dial gauge (1) previously re-
set (3) on the 135 mm ring gauge. 34994 Figure 56
Tool / Material
Bore gauge
Centesimal dial gauge
Ring gauge
Note If the 135 mm ring gauge is not available, use a micro-

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

liner at three different heights and on two (A-B) perpendicular
plane levels as illustrated in figure.
60596 Figure 57
1 1st measurement 3 3rd measurement
2 2nd measurement
7. When wear is over 0.150 mm or maximum ovalisation is 0.100

mm compared to the values shown in the figure, replace the
cylinder barrel since it is not possible to grind, lap or dress it.
Note Cylinder liners are equipped with spare parts belonging
to selection class «A».
60595 Figure 58
A, Selection classes Y Selection class marking
B area
8. The illustrated diagram refers to the outer diameters of cylinder

liners (C) and (D) and the inner diameters of their seats (A)
and (B).
60597 Figure 59
60598 Figure 60
9. Cylinder liners can be removed and fitted several times into different housings, if needed.
155934 Figure 61
10. During checks, make sure that the main data for the cylinder liners is the same as in the figure.
.540420. Cylinder liners Removal

11. Position the specified parts (2) and the plate (4), as shown in
the figure, checking that the specified plate (4) rests on the
cylinder liner correctly.
code
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
12. Fasten the screw nut (1) and take off the cylinder liner (3)
from the crankcase.
47577 Figure 62
.540420. Cylinder liner refitting and protrusion check

13. Always replace water sealing rings (3, 4, 5).
14. Install the adjustment ring (1) on the cylinder liner (2); lubricate
the lower part of the liner and install it in the cylinder unit using
the proper tool.
Note the adjustment ring (1) is equipped with a spare part
having the following thickness: 0.08 mm - 0.10 mm -
0.12 mm - 0.14 mm.
16798 Figure 63
15. Check the protrusion of the cylinder liners using the specific
tool (2) with spacers and tighten the screw (1) to the torque
specified below.
Tightening torque
Protrusion checking tool screw 225 N⋅m

code
Cylinder liner protrusion gauge (to be used with 99370415- 99360334
99395603 and special plates)
60520A Figure 64
16. Using the dial gauge provided with dial gauge stand (3), meas- 0,045 ÷ 0,075
ure the cylinder liner protrusion compared to the cylinder head
supporting surface, which must be the value indicated in the fig-
ure. Otherwise, replace the adjusting ring (1), supplied as spare
part in different thicknesses.
Technical data
Cylinder liner protrusion compared to the 0.045 mm to0.075 mm
cylinder head supporting surface

code
Dial gauge (0-5 mm) 99395603
99395603)
60520B Figure 65
17. On completing assembly, lock the cylinder liners (1) on the

crankcase (2) with the specified stud bolts (3).
code
Tool for cylinder liner fastening 99360703
60521 Figure 66
.540810. Crankshaft measurements
181690 Figure 67
18. Check the condition of the crankshaft main journals; there must no be signs of scoring, ovalisation or excessive wear. The
values shown refer to rated pin diameter.
.540811. Measuring main journals

19. Before grinding the pins, using a micrometer (1), measure the
shaft pins (2) and decide, on the basis of the undersizing of
the half-bearings, the final diameter to which the pins are to
be ground.
Tool / Material
Micrometer
Note It is advisable to enter readings in a table.
47535 Figure 68
GROUND
181691 Figure 69
X Main journals fillet detail
20. During the grinding operation, pay attention to the values of the main journal couplings shown in the details X.
Note All journals and crankpins must also be ground to the same undersizing class, in order to avoid any alteration to shaft
balance.
36061 Figure 70
21. Write down the measurements of the main journals and crankpins of the crankshaft in the table.
.540812. Measuring crankpins

22. Before grinding the pins, using a micrometer (1), measure the
shaft pins (2) and decide, on the basis of the undersizing of
the half-bearings, the final diameter to which the pins are to
be ground.
Tool / Material
Micrometer
47536 Figure 71
36061 Figure 72
23. Write down the measurements of the crankpins of the crankshaft in the table.
181692 Figure 73
Y Crankpin fillet detail
24. During the grinding operation, pay attention to the values of the crankpins shown in Y.
Note All journals and crankpins must also be ground to the same undersizing class, in order to avoid any alteration to shaft
balance.
.540816. Defining the diameter class of the seats for half-bearings on the crankcase
190208 Figure 74
25. To identify the diameter class of the seats for the main half-bearings, look at the front part of the crankcase in the position as
indicated in the figure.
190208 Figure 74
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF-BEARINGS ON THE CRANKCASE
CLASS RATED DIAMETER OF MAIN BEARINGS
1 106.300 – 106.309
2 106.310 – 106.319
3 106.320 – 106.330
26. Read the 2 sets of numbers on the front part of the crankcase.
Note The first set of digits (four) is the coupling number of the upper and lower crankcase.
The following seven digits, taken individually, are the diameter class of each of the seats they are referred to.
Each of these digits may be 1, 2 or 3.
.540816. Main half-bearings selection
190220 Figure 75
27. Identify the most suitable half-bearings for each of the shaft pins (the half-bearings, if necessary, can have different classes
from one journal to another).
Thickness of the main bearing shells
Main half-bearings
STD +0.127 +0.254 +0.508
Red 3.110 – 3.120 – – –

Red/Black – – – –
Green 3.121 – 3.130 – – –
Green/Black – – – –
Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign
(red/black - green/black).
The table contains the characteristics of the main bearings available as spare parts in standard measurement (STD).
.540831. Definition of the connecting rod diameter class

28. Select the connecting-rod half bearings by referring to the
markings on the connecting-rod body, in the indicated position.
Note The number indicating the diameter class of the seat
for half-bearings can be: 1, 2 or 3.
155939 Figure 76
1 Standard numbers
2 Letter indicating the weight class
A = 5537 - 5570 g
B = 5571 - 5604 g
C = 5605 - 5637 g
3 Number indicating the selection of the diameter

of the big end bearing seat
1 = 100.000 - 100.010 mm
2 = 100.011 – 100.020 mm
3 = 100.021 – 100.030 mm
4 Engine type
5 Connecting rod identification plate
.540831. Definition of the diameter class of the crankpins (nominal diameter)
190211 Figure 77
29. The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin.
Definition of the diameter class of the crankpins (nominal diameter)
CLASS CRANKPIN NOMINAL DIAMETER
1 95.970 - 95.979
2 95.980 – 95.989
3 95.990 – 96.000
30. In order to identify the diameter class of the crankpins, identify the three sets of figures marked on the front of the crankshaft.
Note The first number, of five digits, is the part number of the shaft.
Below this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the
status of the pins (1 = STD, 2 = - 0.127), the other six digits, taken individually, give the diameter class of each crank-
pin they refer to.
.540831. Selecting the connecting rod half-bearings
190219 Figure 78
31. Identify the most suitable half-bearings for each of the shaft pins (the half-bearings, if necessary, can have different classes
from one journal to another).
Big end half-bearing thickness
Connecting rod
half-bearings
STD +0.127 +0.254 +0.508
Red 1.960 – 1.970 – – –

Red/Black – – – –
Green 1.971 - 1.990 – – –
Green/Black – – – –
Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign
(red/black - green/black).
The table contains the characteristics of the connecting rod bearings available as spare parts in standard measurement
(STD).
.540831. Main half-bearings selection (nominal diameter pins)

32. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.
Main half-bearings selection (nominal diameter pins)
STD CLASS 1 2 3
Green Green Green

1
Green Green Green
Red Green Green

2
Red Green Green
Red Red Green

3
Red Red Green
.540815. Checking the timing and oil pump gear control

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

36. If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
108836 Figure 79
.540817. Checking crankshaft thrust clearance

37. Thrust clearance is checked by placing a specific magnetic dial
gauge (1) on the crankshaft (2), as shown in the figure. If you
find an higher clearance than as required, replace the rear main
half-bearings carrying the thrust bearings and repeat the clear-
ance check.
code
Dial gauge (0-5 mm) 99395603
47588 Figure 80
.540831. Checking assembly clearance of crankpins

38. Connect the connecting rods to the relevant journals of the crankshaft, placing a length of calibrated wire on the journals.
39. Mount the connecting rod caps (1) together with half-bearings;
Tighten the connecting rod caps fixing screws (2) to the pre-
scribed torque. Using the specific tool (3), further tighten the
screws with a specific angle.
Tightening torque
Screws fixing connecting rod 1. Step 1
cap 70 N⋅m
2. Step 2
60°

code
Set of gauges for angle tightening with square connection - 99395216
1/2" and 3/4"
47594 Figure 81
Note Lubricate screw threads (2) with engine oil before
assembly.
40. Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire. When assembly is complete:
check the diameter of the screws threading (2) which must not
be less than 13.4 mm, otherwise replace the screw; lubricate
the crankpins and connecting rod bearings; Tighten the screws
(2) as described above.
OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
.5408. OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
Work material
Pliers for removing/refitting piston rings (105 -160 mm) 99360184
Reamer
Drift
Feeler gauge
Micrometer
Technical data
Bush diameter 59.060 mm to59.076 mm
Main action
155940 Figure 82
1 Connecting rod body 6 Slotted oil scraper ring with spiral spring
2 Half-bearings 7 Claw seal ring
3 Connecting rod cap 8 Trapezoidal seal ring
4 Cap retaining screws 9 Piston pin
5 Circlip 10 Piston
1. Make sure the pistons do not show any sign of seizing, scoring, cracking or excessive wear; otherwise, replace as necessary.
.540842. Piston rings removal

2. Remove the piston rings from the piston (2) using the specific
set of pliers (1).
code
Note Pistons are equipped with three circlips: a sealing ring,

with trapezoidal section; a sealing ring with chamfer cut;
the third oil scraper.
Note Pistons are grouped into classes A and B for diameter.
155941 Figure 83
.540840. Piston removal

3. Remove the retaining piston rings (2) using round tipped pliers
(1).
155942 Figure 84
4. Remove the piston pin (1). If removal is difficult use the appro-
priate drift.
155943 Figure 85
.540840. Measuring the piston diameter

5. Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance; The diameter has to be
detected at the value indicated.
Tool / Material
Micrometer
155944 Figure 86
.540841. Measuring the piston pin diameter

6. Measure pin diameter (2) measuring with a micrometer (1).
Tool / Material
Micrometer
155945 Figure 87
181694 Figure 88
* The distance is measured at the Ø of 130 mm X 0.8 ± 0.1 mm
.540841. Conditions for correct pin-piston coupling

7. During the coupling phase, make sure that the main data for the journal and piston is the same as in the figure.
8. Lubricate the pin (1) and the relevant housings on the internal
piston hubs with engine oil; Pin must be inserted in the piston
with a light finger pressure and it should not come out by grav-
ity.
155946 Figure 89
.540842. Measuring seal rings

9. Check the thickness of the piston ring (2) using a micrometer
(1).
Tool / Material
Micrometer
16552A Figure 90
10. Check the clearance between the sealing rings (2) and the re-
lated housings on the piston (1) using a feeler gauge (3).
Tool / Material
Feeler gauge
181693 Figure 91
11. The sealing ring (2) of the 1st seat is trapezoidal. Clearance "
X" between the sealing ring and its seat is measured by placing
the piston (1) with its ring in the cylinder liner (3), so that the
sealing ring comes half way out of the cylinder liner.
3513 Figure 92
12. Using a feeler gauge (2), check the end gap of the sealing rings
(1) entered in the cylinder liner (3).
Tool / Material
Feeler gauge
13. If the distance between ends is lower or higher than the value
required, replace split rings.
36134 Figure 93
.540830. Connecting rod checks

Caution!
Connecting rods weight class warning during as-
sembly
▶ When installing connecting rods, make sure they all
belong to the same weight class.
14. Data concerning the class section of connecting rod housing and
weight are stamped on the connecting rod.
155939 Figure 94
1 Standard numbers
2 Letter indicating the weight class
A = 5537 -5570 g.
B = 5571 -5604 g.
C = 5605 -5637 g.
3 Number indicating the selection of the diameter

of the big end bearing seat:
1 = 100 - 100.010 mm
2 = 100.011 – 100.020 mm
3 = 100.021 – 100.030 mm
4 Engine type
5 Connecting rod identi-

fication plate
181695 Figure 95
* Dimension to be obtained after driving the bushing
15. During checks make sure that the main data of the bushing, connecting rod, pin and half bearings is that shown in the diagram.
.540830. Axis alignment check

16. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
17. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
18. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 96
.540830. Torsion check

19. Check the bend of the connecting rod (5) by comparing two
points (A) and (B) of the pin (3) on the horizontal plane of the
connecting rod axis.
20. Position the mount (1) of the dial gauge (2) so that this pre-
loads by approx. 0.5 mm on the pin (3) at point A and set the
dial gauge to zero (2). Shift the spindle (4) with the connecting
rod (5) and compare any deviation on the opposite side B of
the pin (3): the difference between A and B must not exceed
0.08 mm.
61694 Figure 97
.540830. Bending check

21. Check the bend of the connecting rod (5) by comparing two
points C and D of the pin (3) on the vertical plane of the con-
necting rod axis. Position the vertical support (1) of the dial
gauge (2) so that this rests on the pin (3) at point C.
22. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condition.
23. Move spindle (4) with connecting rod (5) and repeat the
highest point check on opposite side D of pin (3).
24. The difference between points C and D must not exceed 0.08
mm.
61695 Figure 98
.540834. Small end bushing check

25. Check that the bushing in the small end has not come loose and
shows no sign of seizure or scoring. Otherwise replace it.
26. The bushing (2) is removed and fitted with a suitable drift (1).
Tool / Material
Drift
27. When refitting take care to make the oil holes on the bush
coincide with those on the connecting rod small end.
28. Ream the bush to obtain the diameter specified below.
073535 Figure 99
Technical data
Bush diameter 59.060 mm to59.076 mm
Tool / Material
Reamer
073535 Figure 99
.540840. Piston assembly

29. Fit the piston (1) on the connecting rod (2) so that the graphic
symbol (4), showing the assembly position in the cylinder liner,
and the punch marks (3) on the connecting rod face each other
as shown in the figure.
Note The arrow (5) must face the engine flywheel.
1
2
4 5
181833 Figure 100
CYLINDER HEAD OVERHAUL
30. Fit the pin (2) and fasten it on the piston (1) with the piston
rings (3).
181830 Figure 101
.540842. Fitting piston rings

31. Use pliers (3) to fit the piston rings (1) on the piston (2).
code
32. Position the rings so that «TOP»" (4) is facing upwards, direct
the ring openings so they are staggered 180° apart.
155950 Figure 102
.540610. CYLINDER HEAD OVERHAUL
Work material
Punch for valve guide removal 99360143
Tool to remove and refit engine valves (to be used with 99360259
special plates)
Tool for removing and refitting engine valves (to be used 99360261
with special plates)
Tool for engine valves removal and refitting (use with 99360263
99360259)
Tool for valve guide refitting (use with 99360143) 99360296
Adjuster for gasket assembly on valve guide 99360329
99395603)
Sleeker for valve guide 99390330

Dial gauge (0-5 mm) 99395603
Bore gauge
Drift
Feeler gauge
Dial gauge
Micrometer
Grinder
Ruler
Metal brush
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.65 mm to−1.95 mm
Valve guide standout 30.08 mm to31.2 mm
Cylinder head heating temperature 80 ℃ to100 ℃
Main action
1. Before removing cylinder head, check hydraulic tightness using specific tool; in case of leaks not caused by cup plugs or
threaded plugs, replace cylinder head.
Note When replacing the cylinder head, it is supplied as a spare part with a threaded plug, which must be removed during
assembly.
Note In case of plugs dismounting/replacement, on mounting, apply sealant Loctite 270 or 243 on plugs.
.540662. Valve removal

Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have
to be overhauled or replaced.
Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.
2. Fit the specific tool (2) and fix it with the bracket (4); screw
using the provided device (1) until you can disassemble the
cotters (3); take out the tool (2) and extract the upper plate
(5), spring (6) and bottom plate (7).
code
99360259)
Tool for removing and refitting engine valves (to be used 99360261
with special plates)
Note Repeat this operation for all the valves.

3. Turn the cylinder head upside down and remove the valves (8).
47583 Figure 103
.540610. Checking the planarity of the head on the cylinder block

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

grinder; the maximum amount of material to be removed is 0.2
mm.
Note After levelling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
36159 Figure 104
.540662. Valve descale and check

6. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
48625 Figure 105
155953 Figure 106

* Measurement obtained after fitting the valve guides
7. Check that the valves show no signs of seizure or cracking and also check with a micrometer that the valve stem diameter
comes within the required values: replace the valves if it does not.
8. Regrind the valve seats, if required, using a grinding machine and removing as less material as possible.
155953 Figure 106
Tool / Material
Micrometer
Grinder
9. Use a bore gauge to check that the diameter inside the valve guide corresponds to the value indicated, after fitting.
Tool / Material
Bore gauge
.540661. Regrinding - replacing the valve seats

Note The valve seats are reground whenever the valves or the valve guides are ground and replaced.
181831 Figure 107

1 Intake valve seat 2 Exhaust valve seat
10. When replacing/checking the valve seats, refer to the main data provided in the figure.
11. Check the valve seats (2). If there are light scorings or burnings,
regrind them with a suitable tool (1) according to angles shown
in the previous figure.
12. Having to replace them, with the same tool and taking care not
to affect the cylinder head, remove as much material from the
valve seats as possible until it is possible to extract them from
the cylinder head with a punch.
13. Heat the cylinder head to 80 –100 ºC and, using a drift, fit in the
new valve seats (2), chilled beforehand in liquid nitrogen. Using
tool (1), regrind the valve seats according to the angles shown
in the previous figure.
Technical data
Cylinder head heating temperature 80 ℃ to100 ℃
Tool / Material
41032 Figure 108
Drift
14. After reaming the valve seats, use the specific tool and the dial
gauge to make sure that the valve position, with respect to the
cylinder head surface, is equal to the values specified below:
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.65 mm to−1.95 mm

code
99395603)
Dial gauge (0-5 mm) 99395603
41032 Figure 108
.540667. Replacing the valve guides

15. Remove the valve guides by means of the specific drift. They
are fitted with the drift equipped with the specific part. The
element determines the exact valve guide fitting position in the
cylinder head; if they are not available, you need to drive the
valve guides into the cylinder head so they protrude by a value
equal to the one given below.
Technical data
Valve guide standout 30.08 mm to31.2 mm

code
Punch for valve guide removal 99360143
Tool for valve guide refitting (use with 99360143) 99360296
16. After installing the valve guides, regrind their bores with a 163815 Figure 109
smoother.
* Measurement to be
Tool / Material Product made after driving in
code the valve guides
Sleeker for valve guide 99390330
.775010. Checking protrusion of injectors

17. Check injector protrusion (2) using a magnetic dial gauge (1).
Tool / Material
Dial gauge
47585 Figure 110
.540665. Valve spring check

18. Before assembly, check the valve spring flexibility using a suitable
tool.
70000 Figure 111
19. Compare the load and elastic deformation data with those of
the new springs indicated in the figure.
108842 Figure 112
.540662. Valve assembly

20. Lubricate the valve stem and insert the valves in the respective
valve guides; fit the lower plates (1).
193982 Figure 113
.540668. Mounting the oil seal ring

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

remount them according to the numbering performed
on dismounting.
Intake valves are different form exhaust valves in that
they have a notch placed at valve head centre.
155958 Figure 114
COMPLETE TIMING SYSTEM OVERHAUL
22. Fit springs (6), upper plate (5).

23. Fit the specific tool (2) and fix it with the bracket (4); screw the
lever (1) until you can assemble the cotters (3); remove the
tool (2).
code
99360259)
Tool to remove and refit engine valves (to be used with 99360259
special plates)
86290 Figure 115
.5412. COMPLETE TIMING SYSTEM OVERHAUL
Work material
Drift to take down and fit back camshaft bushes 99360499
Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
Rated assembling clearance between gear bushings and pins 0.045 mm to0.085 mm
Main action
.541254. Replacement gear bush idle gear
1. Replace the bushings (2) when worn.
182092 Figure 116

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

in the figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown.
3. At the end of the boring operation, check that the gear bush-
ing/journal assembly clearance is equal to the indicated value.
Technical data
Rated assembling clearance between gear 0.045 mm to0.085 mm
bushings and pins
181832 Figure 117
.541254. Replacement of the dual idle gear bushes

4. Replace the bushings (2) when worn.
182092 Figure 118

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

in the figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown.
6. Check that the nominal assembly clearance between gear bush-
ings and pins is equal to the value stated below.
Technical data
Rated assembling clearance between gear 0.045 mm to0.085 mm
bushings and pins
101601 Figure 119
.541211. Checking cam lift and camshaft journals alignment
47506 Figure 120

7. Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2)., comparing the values
with those specified below.
Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
47507 Figure 121

8. Still with the camshaft (4) set on the tailstocks (1), check the alignment of the journals (3) with the dial gauge (2); it must not
exceed 0.030 mm. To check the assembly clearance, measure the inside diameter of the bushings and the diameter of the
journals of the camshaft.
47505 Figure 122

9. In order to check the installation clearance, measure the bushing inner diameter and the camshaft pin (1) diameter; the real
clearance is obtained by their difference. If you find any clearances over 0.135 mm, replace the bushings and, if necessary, the
camshaft as well.
187402 Figure 123

10. The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; whereas, if they show any
signs of seizing or scoring, you should replace the shaft and the relevant bushings.
Tolerance characteristics
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Class of importance product characteristics

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
.541213. Camshaft bushes check
155956 Figure 124

* Bushing inside diameter after driving in
11. The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
12. Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
107217 Figure 125

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

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

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

seat.
Note Removal does not require the drift extension for bush-
ings 5, 6 and 7 and it is not necessary to use the guide
bushing. For bushings 1, 2, 3 and 4 it is necessary how-
ever to use the extension and the guide bushings.
.541213. assembly 71725 Figure 126

15. To insert the bushing (1, 2, 3, 4 , 5 ), proceed as follows.
107217 Figure 127

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

21. Unscrew the grip (I) and the extension (N).
22. Position the extension (N) and the guide bushing (E) as shown
in the figure.
23. Position the bushing to insert on the drift (A) making the grub
screw on it coincide with the seat (B) on the bushing.
24. Position the guide bushing (E) and secure the guide bushing
(G) on the seat of the 7th bushing with the plate (H).
25. While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home, the
lubrication hole on the bushing will coincide with the oil pipe in
its seat. 71723 Figure 128
Note The bushing is driven home when the 1 reference
st
mark (D) is flush with the guide bushing (G).
26. To insert the bushing (7), proceed as follows.

27. Unscrew the grip (I) and the extension (N).
28. Refit the guide (G) from the inside as shown in the figure.
29. Position the bushing on the drift (A) and bring it close up to the
seat, making the bushing hole match the lubrication hole in the
head. Drive it.
30. The 7th bushing is driven in when the reference mark (C) is
flush with the bushing seat.
71724 Figure 129
.541233. Rocker shaft check

Note The camshaft cams directly control the 12 rocker arms for the valves. The intake valve control rocker arms are keyed
on rocker arms shaft directly. Exhaust valves control rocker arms are keyed on rocker arms shaft putting in between the
levers with engine brake control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end acts
on a bar supported by the stem of the two valves. A pad is placed between the rocker adjusting screw and the bar. Two
lubrication holes are obtained inside the rockers.
073557 Figure 130

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

32. The bush surfaces must not show any trace of scoring of ex-
cessive wear; otherwise, replace bushes or the whole rocker.
181688 Figure 131
.541231. Intake valve rocker arms check

155960 Figure 132
.543751. Lever with engine brake control eccentric pin check

92842 Figure 133
ENGINE ASSEMBLY
.540110. ENGINE ASSEMBLY
Consumables
Engine oil
LOCTITE 243
LOCTITE 5970
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Key to fit crankshaft front gasket 99346250
Key to fit crankshaft rear gasket 99346260
Tool for rotating the flywheel 99360321
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Tool for timing of phonic wheel on timing gear 99360613
Tool to check timing (use with 99395606) 99370400
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
Gauge to determine centre distance between camshaft 99395226
and high pressure pump
Dial gauge (0-30 mm) 99395606
Centring ring of crankshaft front gasket cover 99396035
Torque wrench
Box wrench
Hooks
Hoist
Tightening torques
Lower crankcase inner tightening screws 1. Pre-tightening 160 N⋅m
2. Angle tightening 60°
Outer screws fixing lower crankcase 1. 30 N⋅m
2. 60°
Screws fixing connecting rod cap 1. Pre-tightening 70 N⋅m
Cylinder head fixing screws (pre-tightening) 1. Pre-tightening 75 N⋅m
2. Pre-tightening 150 N⋅m
ENGINE ASSEMBLY
Cylinder head screws (angle tightening) 1. Angle tightening 90°

Engine flywheel bolts 1. Pre-tightening 120 N⋅m
High-pressure pump flange support screw 24.5 ±2.5 N⋅m
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
20 ±2 N⋅m
Idle gear pin screws 1. Pre-tightening 30 N⋅m
Injector bracket fixing screws 30 N⋅m to35 N⋅m
Exhaust brake cylinder fixing screws 16 N⋅m to22 N⋅m
Rail fixing screws 23.5 ±2.5 N⋅m
Electro-injector bracket retaining screws 33 N⋅m to37 N⋅m
High-pressure fuel pipe couplings 42 N⋅m
High-pressure fuel pipe fittings 60 ±2.5 N⋅m
Screws fixing the high pressure fuel supply pipe support brackets to the head 23.5 ±2.5 N⋅m
Fuel return coupling from the rail 50 N⋅m
Fastening screws for rocker arm shaft 1. Until in contact Tightening sequence: 1 - 7
25 N⋅m
2. Tightening sequence: 1 - 7
60 N⋅m
80 N⋅m
60°
Cable clamps 1.5 ±0.25 N⋅m
Camshaft gear fixing screws 1. Pre-tightening 60 N⋅m
Screws fixing pulser ring to timing gear 24.5 ±2.5 N⋅m
Tapper cover fixing screws 8.5 ±1.5 N⋅m
Screws fixing the timing gear cover 10 N⋅m
Blow-by case fixing screws 7 N⋅m
Screws securing heat exchanger 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m
Oil filter retainer at the support base 60 ±5 N⋅m
Screws and nuts securing turbocharger 75 N⋅m
Exhaust manifold fixing screws 1. 40 ±5 N⋅m
2. 60 ±5 N⋅m
Oil drain and inlet pipe couplings 22 N⋅m to27 N⋅m
Thermostat case fixing screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11 - 12 - 13 -
14
27 N⋅m to33 N⋅m
Oil pressure regulator valve 23.5 ±2.5 N⋅m
ENGINE ASSEMBLY
Screws fixing the water inlet pipe to the pump 34.5 ±3.5 N⋅m
Technical data
Cam timing dial gauge value 5.95 ±0.05 mm
Main action
1. Fasten the crankcase to the stand using the specific brackets.
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230
.540414. Oil sprayer assembly

2. Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
47586 Figure 134
.540816. Main bearings assembly

3. Install the half-bearings (1) on the main bearings in the crank-
case (2).
Note Refit the main bearings that have not been replaced, in
the same position found at removal.
4. If you have to replace the bearings, choose them according to
selection described in chapters Selecting the main half-bearings
(nominal diameter pins) and Main half-bearings selection (recti-
fied) .
49021 Figure 135
ENGINE ASSEMBLY
.540810. Crankshaft assembly

5. Lubricate the half-bearings.
6. Using the specific hoist and hook (1) assemble the crankshaft
(2).
code
Hoist
47570 Figure 136
.540416. lower crankcase assembly

7. Install the half-bearings (1) on the main bearings in the lower
crankcase (2).
49021 Figure 137
8. Apply the silicone onto the crankcase using an appropriate (1)

tool.
Tool / Material
LOCTITE 5970
47595 Figure 138
ENGINE ASSEMBLY
9. Apply the sealant following the diagram in the figure.

Note fit the lower crankcase within 10' of the application of
the sealant.
60632 Figure 139
10. Fit the lower crankcase (1) by means of a suitable hoist and
hooks.
Tool / Material
Hoist
Hooks
60559 Figure 140
11. Using a torque wrench (3) tighten the internal screws (1) to
the required torque, then using a specific tool (4) tighten them
in two phases to the specific angles, following what is indicated
in the chapter Diagram of tightening sequence for main engine
parts ( ➠ Page 15).
Tightening torque
Lower crankcase inner tight- 1. Pre-tightening
ening screws 160 N⋅m
2. Angle tightening
60°
3. Angle tightening
60°

code 47579 Figure 141
Torque wrench
1/2" and 3/4"
Note Always use new screws each time you assemble the
bedplate.
ENGINE ASSEMBLY
12. Using a torque wrench (2), tighten the outer hex-socket screws
(1) to the prescribed torque, then using the specific tool (3)
tighten to an angle.
Tightening torque
Outer screws fixing lower 1. 30 N⋅m
crankcase 2. 60°

code
1/2" and 3/4"
47581 Figure 142
.540831. Rod half-bearing fitting

13. Lubricate the half-bearings (1 ) and fit them in the connecting
rod and the cap.
Note Not finding it necessary to replace the connecting rod
bearings, you need to fit them back in exactly the same
sequence and position as in removal.
If you have to replace the connecting rod bearings,
choose them according to selection described in
chapter Main half-bearings selection ( ➠ Page 37) and
Selecting the connecting rod half-bearings .
Note Do not make any adjustment on the half-bearings.
155951 Figure 143
ENGINE ASSEMBLY
.540840. Assembling connecting rod - piston assemblies in the cylinder liners
187915 Figure 144

1 Connecting rod-piston assembly 4 Arrow indicating the assembly orientation of the con-
2 Marking area on the piston crown of ideogram specify- necting rod - piston assembly (turned towards the
ing the assembly position and the selection class flywheel)
3 Area of connecting rod punch marking
14. Rotate the crankcase placing it vertically.

15. Lubricate the pistons, piston rings and inside the cylinder liners.
16. Using the clamp (1), install the connecting rod-piston assemblies
(2) in the cylinder linings, according to the diagram in the previ-
ous figure.
17. Check that the number of each connecting rod corresponds to
the cap coupling number.
Caution!
Connecting rods Precautions for cylinder liners
▶ During assembly, pay utmost attention to prevent the
connecting rod from hitting against the cylinder liner
walls.
18. Check that the ideogram stamped on the piston crown faces 60616 Figure 145
the engine flywheel; or the recess in the piston skirt matches the
position of oil nozzles.
ENGINE ASSEMBLY

code
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Note The pistons are supplied as spare parts in class A and

can also be fitted in class B cylinder liners.
Note Before reusing the screws, measure the diameter of

the thread; this has not to be lower than 13.4 mm;
otherwise replace the screw. Before installing, lubricate
the screw thread with engine oil.
19. Connect the connecting rods to the relevant pins of the crank-
shaft, mount the connecting rod caps (1) together with half-
bearings; tighten the connecting rod caps fixing screws (2)
to the prescribed torque. Using the goniometer (3) further
tighten the screws to the angle specified.
Tightening torque
Screws fixing connecting rod 1. Pre-tightening
cap 70 N⋅m
2. Angle tightening
60°

code
1/2" and 3/4" 47594 Figure 146
.540442. Crankshaft front gasket installation

20. By means of centring ring (2), check the exact cover position
(1), otherwise act as necessary and tighten the screws (3).
code
Centring ring of crankshaft front gasket cover 99396035
60563 Figure 147
ENGINE ASSEMBLY
21. Fit precisely the gasket (1), fit the specific keying device (2),
drive in the gasket (1) by screwing the nut (3).
code
Key to fit crankshaft front gasket 99346250
60564 Figure 148
.540610. Cylinder head assembly

22. Check that the pistons: 1 and 6 are exactly at the T.D.C.
23. Put the gasket (2) on the crankcase.
24. Place the cylinder heads (1) on the crankcase.
60515 Figure 149
61270 Figure 150

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

Tightening torque
Cylinder head fixing screws 1. Pre-tightening
(pre-tightening) 75 N⋅m
2. Pre-tightening
150 N⋅m
Tool / Material
Torque wrench
60565 Figure 151
27. Perform angle tightening with specific tool (1):

Tightening torque
Cylinder head screws (angle 1. Angle tightening
tightening) 90°
2. Angle tightening
90°

code
1/2" and 3/4"
60566 Figure 152
.543010. Installing the oil pump

28. Install the oil pump (1) and tighten the retaining screws.
191087 Figure 153
ENGINE ASSEMBLY
29. Install the connecting rod (1) and tighten the screw (2) to the
prescribed torque.
191086 Figure 154
30. Install the double gear (2) and tighten the screws (1) to the
prescribed torque.
Note Lubricate the screws (1) with engine oil before as-
sembly.
191085 Figure 155
.540463. Fitting flywheel box

31. Apply the prescribed silicon on the flywheel case using the spe-
cific tool (1) as shown in the figure.
Tool / Material
LOCTITE 5970
Note Fit the flywheel housing within 10' after sealant applica-
tion.
47592 Figure 156
ENGINE ASSEMBLY
32. Use a torque wrench to tighten the screws to the specific tight-
ening torque in the sequence shown in the figure.
182145 Figure 157
.540462. Crankshaft rear gasket assembly

33. Fit precisely the gasket (1), fit the device (2), drive in the gasket
by screwing the nut (3).
code
Key to fit crankshaft rear gasket 99346260
60568 Figure 158
.540850. Engine flywheel assembly

34. Position the flywheel (1) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down.
35. Block the engine flywheel rotation using the specific tool (3);
tighten the screws (2) in two steps.
code
36. Tighten using a torque wrench (4).

Tightening torque
Engine flywheel bolts 1. Pre-tightening
Lubricant 120 N⋅m
Engine oil
2. Angle tightening
90°
49037 Figure 159
ENGINE ASSEMBLY
Tool / Material
Torque wrench
49037 Figure 159
37. Tighten at angle with specific tool (1).

code
1/2" and 3/4"
49036 Figure 160
.541210. Fitting camshaft

38. Install the high pressure pump support (2) flange and tighten
the retaining screws (1).
160624 Figure 161
ENGINE ASSEMBLY
39. Fit the specific gauge (1) to position the high pressure pump
support flange (2) properly and tighten the screws to the pre-
scribed torque.
Tightening torque
High-pressure pump flange support 24.5 ±2.5 N⋅m
screw

code
Gauge to determine centre distance between camshaft and 99395226
high pressure pump
160655 Figure 162
40. Position the crankshaft with the pistons 1 - 6 at the T.D.C. This
situation occurs when:
41. The hole with one reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
42. The specific tool (1), through the seat (2) of the engine speed
sensor, enters the hole (3) in the flywheel (4).
code
43. If this condition does not occur, turn the engine flywheel (4)
appropriately.
44. Remove the specific tool (1).
code
182251 Figure 163
45. Fit the camshaft (4), positioning it with the reference marks (→)
as shown in the figure.
46. Lubricate the seal (3) and fit it on the thrust plate (2).
47. Fit the thrust plate (2) with the sheet metal gasket (1) and
tighten the screws (5) to the required torque and according
to the sequence shown in relative chapter DIAGRAM OF
TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS
( ➠ Page 15).
Tightening torque
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 -
5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 -
10
20 ±2 N⋅m
182146 Figure 164
ENGINE ASSEMBLY
48. Position the gauge (1). Check and adjust the position of the link
rod (3) for the idle gear; tighten the screw (2) to the specified
torque.
code
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
160654 Figure 165
49. Fit the idle gear (1) back on and lock the screws (2) to the
required torque.
Tightening torque
Idle gear pin screws 1. Pre-tightening
30 N⋅m
2. Angle tightening
90°
sembly.
182148 Figure 166
50. Position the gear (2), without fully tightening the screws (5),
on the camshaft, positioning it so that the 4 eyelet holes are
centred with regard to the camshaft fastening holes.
sembly.
51. With a magnetic dial gauge (1) check clearance between gears
(2, 3), which must be between 0.074 – 0.195 mm, otherwise
adjust the clearance as indicated hereafter:
52. Loosen the screws (4) fixing the idle gear (3).
53. Loosen the connecting rod fixing screw (2), move the connect-
ing rod (3) in order to obtain the required clearance.
54. Lock the rod fixing screw (2) and the idle gear fixing screws (4)
to the required torque. 182149 Figure 167
ENGINE ASSEMBLY
.775010. Injector assembly

55. Replace the sealing gasket (2) on the injectors(1).
169828 Figure 168
56. Fit the retaining brackets on the injectors (5) and position them
in the relevant seats in the cylinder head.
57. Before tightening the screws (4) to torque, fit the high pressure
fuel pipes referring to the indications provided in chapterRail
installation ( ➠ Page 86) (Operation 774510).
58. After having fitted the fuel pipes, lock the screws (4) securing
the injector brackets to the specified torque.
Tightening torque
Injector bracket fixing screws (4) 30 N⋅m to35 N⋅m
Tool / Material
Torque wrench
59. Fit the engine brake cylinders (1) and (2), using a torque
wrench, fix them to specified torque. 183455 Figure 169
Tightening torque
Exhaust brake cylinder fixing screws 16 N⋅m to22 N⋅m
Tool / Material
Torque wrench
60. Mount the guide braces (3) on the valve stem, all with the
largest hole in the same direction.
ENGINE ASSEMBLY
.774510. Rail installation

Note The high pressure fuel pipes cannot be re-used but must be replaced each time they are removed
61. Connect the oil supply pipe (3) to the engine brake actuators
(2) and engine brake solenoid (1).
183456 Figure 170
183458 Figure 171

62. Fit the rail (10) onto the head and tighten the fixing screws (9) to the specified torque.
Tightening torque
Rail fixing screws (9) 23.5 ±2.5 N⋅m
63. Connect the high pressure fuel pipes and tighten the fittings by hand in the sequence (1, 2, 3, 6, 5, 4) to the rail and the
injectors.
Note Before tightening the couplings to torque make sure that the pipes (1) are not touching each other.
64. Complete injector assembly operations by tightening the fastening screws to the specified torque.
Tightening torque
Electro-injector bracket retaining screws 33 N⋅m to37 N⋅m
65. Complete assembly of HP fuel pipes (1, 2, 3, 6, 5, 4) by first tightening the injector side couplings and then those on the rail
side.
ENGINE ASSEMBLY
Tightening torque
High-pressure fuel pipe couplings 42 N⋅m
66. Connect the HP fuel supply pipes (8) and tighten them to the prescribed torque.
Tightening torque
High-pressure fuel pipe fittings 60 ±2.5 N⋅m
67. Fix the fuel supply pipe support brackets, tightening the screws to the required torque.
Tightening torque
Screws fixing the high pressure fuel supply pipe support brackets to the 23.5 ±2.5 N⋅m
head
68. Connect the fuel return pipe (7) from the rail and tighten to the prescribed torque.
Tightening torque
Fuel return coupling from the rail 50 N⋅m
.541230. Fitting rocker shaft assembly

Note before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.
69. Apply the specific tool (1) to the rocker arm shaft (2) and
mount the shaft on the cylinder head.
code
116190 Figure 172
70. Screw the screws in four steps as follows:

Tightening torque
Fastening screws for rocker 1. Until in contact
arm shaft Tightening sequence: 1 - 7
25 N⋅m
60 N⋅m
80 N⋅m
60°
Tool / Material Product 183461 Figure 173

code
Torque wrench
ENGINE ASSEMBLY

code
1/2" and 3/4"
183461 Figure 173
71. Fit the engine brake lever retainer springs (1).
185511 Figure 174
72. Attach the electrical connections (1) to the injectors and block
the cables using cable clamps.
Tightening torque
Cable clamps 1.5 ±0.25 N⋅m
183457 Figure 175
ENGINE ASSEMBLY
.541210. Camshaft timing

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

gine when running.
74. Using the above-mentioned tool, turn the engine flywheel (1) in
the direction of rotation of the engine so as to take the piston
of cylinder no.1 to 54° before T.D.C. in the phase of compres-
sion (cylinder 6 in discharge phase).
Note This condition is verified when the hole with two
notches (5) on the engine flywheel (1) is visible
through the small inspection window (2).
185252 Figure 176
75. Check that the specific tool (1) is inserted in the hole (3)
present in the engine flywheel (4) through the seat (2) of the
engine speed sensor; in this condition, the flywheel is in the
reference position (piston no. 1 to 54th before T.D.C.).
code
76. If this condition does not occur, turn and adjust the engine fly-
wheel (4) appropriately.
77. Remove the specific tool (1).
code
71774 Figure 177
ENGINE ASSEMBLY
78. Carefully clean the surface of the head on which the rocker arm
cover rests.
79. Using the specific magnetic base support (2) as shown in the
figure, position the specific dialogue (1) with the flat based rod
(3) positioned on the rocker arm roller (4) which controls the
exhaust valves of cylinder no. 3 and preload to at least 7 mm.
code
Tool to check timing (use with 99395606) 99370400
Dial gauge (0-30 mm) 99395606
185253 Figure 178
Caution!
Dial gauge pointer Pointer correct positioning
▶ Position the flat based dial gauge rod (see detailed part) so that its axis passes through the centre of the roller on
which it is resting.
Caution!
Tolerances measure Checking and overhauling values
▶ During the CHECK phase, not during the engine overhaul phase, the allowed tolerance of the measurement is
between -0.05 - +0.12 mm.
▶ During OVERHAUL, the allowed tolerance is ± 0.05 mm.
177714 Figure 179

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

Note The dial gauge is to be zeroed with the rocker arm
roller in contact with the base radius of the cam profile.
To this end, turn the flywheel until passing the protru-
sions (A-B) and (B-C) on the cam profile connected
to exhaust brake operation. This occurs when the fly-
wheel is turned in the opposite direction of the operat-
ing direction approx. 1 and 1/4 rotations.
185524 Figure 180

α Camshaft rotation D Cam lift in corres-
angle pondence of 54° be-
Y Cam lift based on the fore the top dead
rotation angle of the centre, 1st cylinder
camshaft end of compression
82. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
83. Check that the required cam lift values are displayed under the
following conditions:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 181
ENGINE ASSEMBLY
84. Perform the following if the conditions stated have not been
obtained:
85. Turn the engine flywheel until the dial gauge indicates the re-
quired cam lift.
86. Loosen the screws (2) that fasten the gear (1) to the camshaft
and use the slots on the gear (1).
87. Act on the flywheel to obtain the conditions indicated and while
keeping the cam lift value unchanged.
88. Lock the screws (2) and repeat timing check as described
above.
Note While performing this operation recover the clearance
between the camshaft gears.
182129 Figure 182
89. Tighten the screws (2) to the specified torque.
Tightening torque
Camshaft gear fixing 1. Pre-tightening
screws (2) 60 N⋅m
Lubricant
2. Angle tightening
Engine oil
60°
90. When adjustment via the slots is not sufficient for recovering
the offset, proceed as follows:
91. Lock the screws (2) and turn the engine flywheel a 1/2 turn in
the opposite direction of the operating direction.
92. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
93. Remove the screws (2) and remove the gear (1) from the
camshaft.
94. Turn the flywheel (4) again until the following conditions occur:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 183
ENGINE ASSEMBLY
95. Mount the gear (2) with the 4 slots (1) centred with the fixing
holes of the camshaft. Lock the relevant screws to the required
torque.
Tightening torque
Camshaft gear fixing screws 1. Pre-tightening
Lubricant 60 N⋅m
Engine oil
2. Angle tightening
60°
96. Recover the clearance between the timing system gears by

turning the flywheel in the opposite direction of the engine
rotation direction and subsequently turning it in the engine
rotation direction until the dial gauge shows the specific value.
Check the previously described conditions.
Technical data 194037 Figure 184
.541215. Pulser ring timing

97. Turn the crankshaft bringing cylinder piston no. 1 in compres-
sion stage to TDC; turn the flywheel by about 1/4 turn in op-
posite direction than normal sense of rotation.
98. Turn the flywheel again according to normal direction of ro-
tation (anti-clockwise) until the hole marked with the three
notches can be seen through the inspection hole under the fly-
wheel housing (4).
Note If the engine flywheel does not have 3 notches, to
identify the reference hole simply: turn the flywheel
in the direction opposite of the operating direction un-
til reaching the position marked with 2 notches (54°
before cyl. 1 T.D.C.); continue rotating in the engine
operating direction for 4 holes (remember that each
hole corresponds to a flywheel rotation of 6°).
99. Install the specific tool (5) in the flywheel sensor seat (6).
code
100. Insert the specific tool (2), via the seat of the phase sensor,
onto the tooth (↑) obtained on the phonic wheel.
code
Tool for timing of phonic wheel on timing gear 99360613
101. Should tool (2) fitting be difficult, loosen the screws (3) and
direct the phonic wheel (1) properly to position the tool (2) on
the tooth. Then tighten the screws (3).
185254 Figure 185
ENGINE ASSEMBLY
Tightening torque
Screws fixing pulser ring to timing 24.5 ±2.5 N⋅m
gear (3)
185254 Figure 185
.771010. High pressure pump assembly

102. Bring the flywheel to 36° before TDC of the first cylinder.
Note This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to
the 30° position marked by THREE notches (4) and continuing to turn the flywheel in the same direction until reach-
ing the next hole (by 6°).
If the engine flywheel does not have 3 notches, to identify the reference hole simply: turn the flywheel in the direc-
tion opposite of the operating direction until reaching the position marked with 2 notches (54° before cyl. 1 T.D.C.);
continue rotating in the engine operating direction for 3 holes (remember that each hole corresponds to a flywheel
rotation of 6°).
103. Insert the specific tool through the seat of the flywheel sensor in the corresponding flywheel hole.
ENGINE ASSEMBLY
104. Mount the HP pump and make sure that the seat of the key (1)
on the pump shaft is facing the pump intakes (2).
187918 Figure 186
105. Tighten the locking screws (1) of the HP pump (2), connect
the fuel pipes (3) tightening the fittings to the prescribed
torque.
Note Make sure that the pipe is not damaged after mounting
and that there are no fuel leaks while engine is running.
The HP pipes that are disassembled cannot be used
again and must be replaced.
182156 Figure 187
106. Install the gear (1) and tighten the nuts (2) to the prescribed
torque.
107. Remove the specific tool.
code
182158 Figure 188
ENGINE ASSEMBLY
.541230. Intake and exhaust rocker arm clearance adjustment

Note The adjustment of clearance between the rocker arms and bridges controlling the intake and exhaust valves must be done
very carefully.
187916 Figure 189

A Hole on flywheel with reference mark, corresponding D Flywheel hole with two notches corresponding to
to the TDC of pistons 1-6 position 54° before TDC of pistons 1-6 (camshaft
B Hole on flywheel with reference mark, corresponding timing reference);
to the TDC of pistons 2-5 E Flywheel hole with three notches corresponding to
C Hole on flywheel with reference mark, corresponding position 30° before TDC of pistons 1-6 (reference to
to the TDC of pistons 3-4 HP fuel pump and timing system phonic wheel timing).
108. In order to perform adjustments correctly, during each rotation phase check the positioning accuracy using the specific pin,
inserting it into the hole marked with a notch on the flywheel corresponding to piston position.
ENGINE ASSEMBLY

109. Take the cylinder whose clearance has to be adjusted into the
combustion phase; the valves of this cylinder are closed while
they balance the symmetric cylinder valves.
Note The correspondence of the symmetrical cylinders is 1 -
6, 2 - 5 and 3 - 4.
110. In order to properly operate, follow these instructions and data
specified on the table.
111. Using a box wrench, remove the adjustment screw fastening
nut (1).
Tool / Material
Box wrench
112. Insert the thickness gauge blade (3) corresponding to the op-
erating clearance shown in the "Characteristics and data" 114287 Figure 190
table.
113. Screw or unscrew the adjustment screw of the rocker arm (2)
with the appropriate wrench.
114. Check that the feeler gauge blade (3) can slide with slight fric-
tion.
115. Lock the nut (1) by stopping the adjustment screw.
116. To carry out the adjustments stated above, the sequence shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]
Note Check during each rotation phase, the accuracy of the position by using the specific pin and inserting it into the hole
marked with a notch on the flywheel corresponding to piston position.
ENGINE ASSEMBLY
.540630. Tappet cover assembly

117. Position the cover and insert all the screws.
118. Replace the screws in the sequence 1-10-20-21-9 and then in
the sequence shown in the figure until contact.
119. Tighten the screws 1-24 in the sequence shown to the required
torque.
Tightening torque
Tapper cover fixing screws 8.5 ±1.5 N⋅m
117545 Figure 191
.542011. Fuel filter assembly

120. Fit the fuel filter mount (1) and tighten the screws (2) to the
specified torque.
121. Screw the fuel filter (3) onto the support to the required
torque.
182091 Figure 192
.540452. Timing gear assembly cover mounting

122. Fit the gasket (2) onto the blow-by case(1).
181826 Figure 193
ENGINE ASSEMBLY
123. Fit the blow-by case (3).

124. Tighten the screws (2) to the specified torque.
Tightening torque
Screws fixing the timing gear cover Tightening sequence: 1 - 21
10 N⋅m
125. Connect the pipe (1).
181805 Figure 194
.540486. Blow-by filter fitting

126. Mount the blow-by case (2) and tighten the screws (1) to the
specified torque.
Tool / Material
LOCTITE 243
Note Upon assembly, apply LOCTITE 243 to the screws (1).
181804 Figure 195
.540480. Blow-by case fitting

127. Fit the blow-by case (2).
181803 Figure 196
ENGINE ASSEMBLY
128. Tighten the screws to the specified torque.

Tightening torque
Blow-by case fixing screws Tightening sequence: A - F
7 N⋅m
155920 Figure 197
.543060. Suction strainer installation

129. Turn the engine and fit the oil suction strainer (1).
60517 Figure 198
.540430. Oil sump assembly

130. Arrange the gasket (4) on oil sump (1), position the spacer (3)
and fit the sump on crankcase screwing up the screws (2) at
prescribed torque.
60665 Figure 199
ENGINE ASSEMBLY
.766161. Engine control unit assembly

131. Assemble the engine ECU (3) by tightening the screws (2) to
the prescribed torque.
132. Connect the pipe (1).
181802 Figure 200
.540710. Inlet manifold assembly

133. Refit the intake manifold (1) and tighten the screws (2) to the
specified torque.
134. Mount the support (3) for engine start buttons.
219034 Figure 201
.760810. Starter motor assembly

135. Mount the starter motor (1) and tighten the relative screws to
the specified torque.
181800 Figure 202
ENGINE ASSEMBLY
.543110. Heat exchanger assembly

136. Fit the heat exchanger (2) and tighten the fixing screws (1)
following the order indicated below.
191082 Figure 203
137. Tighten the fixing screws to the prescribed torque.

Tightening torque
Screws securing heat ex- 1. 8 N⋅m to15 N⋅m
changer 2. 22 N⋅m to27 N⋅m
180274 Figure 204
.543070. Oil filter assembly

138. Fit the oil filter mount (1).
139. Oil and fit new seals.
140. Screw the filter (2) until the seals come in contact with the
resting bases.
141. Tighten the filter to the specified torque.
Tightening torque
Oil filter retainer at the support 60 ±5 N⋅m
base
191081 Figure 205
ENGINE ASSEMBLY
.542410. Turbocharger assembly

142. Fit the turbocharger (4) with a new gasket on the exhaust man-
ifold (2).
143. Tighten the screws (1) and (3) as described in the following
point.
191080 Figure 206
144. Tighten the screws fixing the turbocharger to the required

torque following the sequence indicated in the figure.
Tightening torque
Screws and nuts securing turbochar- 75 N⋅m
ger
Lubricant
Graphitised oil
160652 Figure 207
.540720. Exhaust manifold assembly

145. Fit the exhaust manifold (1) with new gaskets together with the
turbocharger (2).
219039 Figure 208
ENGINE ASSEMBLY
180272 Figure 209

146. Tighten the exhaust manifold fixing screws to the specified torque.
Tightening torque
Exhaust manifold fixing screws 1. 40 ±5 N⋅m
Lubricant
2. 60 ±5 N⋅m
Graphitised oil
147. Fit the pipes (3) on the indicated mounts (→).
219039 Figure 210
148. Connect the exhaust gas pipe (1) together with the engine
brake device.
149. Connect the coolant pipes (3) to the engine brake device actu-
ator(2).
219033 Figure 211
ENGINE ASSEMBLY
150. Connect the oil delivery pipe (1) and the sump oil return pipe
(2) to the turbocharger. Tighten the couplings to the recom-
mended torque.
Tightening torque
Oil drain and inlet pipe couplings 22 N⋅m to27 N⋅m
219032 Figure 212
.543251. Fitting the thermostat case (version with intarder)

151. Fit the thermostat assembly (2) with a new gasket and tighten
the fastening screws (3) to the prescribed torque following the
sequence indicated in the figure below.
152. Fit the air pipe (1).
219038 Figure 213
218128 Figure 214

153. Tightening sequence for the screws securing the thermostat assembly.
ENGINE ASSEMBLY
218128 Figure 214
Tightening torque
Thermostat case fixing screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11 - 12 - 13 - 14
27 N⋅m to33 N⋅m
.543411. Water pump assembly

154. Fit the automatic chain tensioner (1), fit the pulley (3) and
tighten the screws (2) to the specified torque.
155. Fit the water pump (4), fit the pulley (5) and tighten the screw
(6).
181792 Figure 215
ENGINE ASSEMBLY
.543422. Electromagnetic coupling assembly

156. Block rotation of the flywheel with the specific tool.
code
157. Fit the electromagnetic coupling (2) and tighten the screws (1)
to the specified torque.
181791 Figure 216
.760310. Alternator assembly

158. Fit the alternator (2) and tighten the screws (1) to the required
torque.
181790 Figure 217
.543411. Coolant pump/alternator drive belt assembly

159. To fit the belt (2) use suitable equipment (1) to adjust the belt
tensioner in the direction indicated by the arrow in the figure.
Note Belt tensioner is automatic; therefore, no further ad-
justments are to be made after mounting.
181789 Figure 218
ENGINE ASSEMBLY
.540860. Damper flywheel installation

160. Fit the damper flywheel (2) by turning the 6 fixing screws (1).
Tool / Material
Engine oil
Note Before installing, lubricate the screw thread (1) with

engine oil.
181788 Figure 219
.540110. Removing the engine from the stand

161. Refill the engine with required oil quantity.
162. Remove engine from rotary stand and take off brackets securing the engine.
.543075. Oil pressure adjustment valve assembly

163. Fit the oil pressure adjustment valve (1) and tighten the fixing
screws to the required torque.
Tightening torque
Oil pressure regulator valve 23.5 ±2.5 N⋅m
60486 Figure 220
ENGINE ASSEMBLY
.543211. Fitting the water inlet pipe

164. Fit the water inlet pipe (1) together with the sleeve (3) and
tighten the screws (2) to the specified torque.
Tightening torque
Screws fixing the water inlet pipe to 34.5 ±3.5 N⋅m
the pump
165. Secure the sleeve (3) to the thermostat assembly (4) and
tighten the relevant clip.
219037 Figure 221
.790510. Air compressor assembly

166. Fit the air compressor (3) and tighten the fastening screws (4)
to the specified torque.
167. Connect the water pipes (2).
168. Connect the air pipes (1) and (5).
219030 Figure 222
110 DIAGNOSTICS
DIAGNOSTICS 111
Contents
Contents
The engine does not start . . . . . . . . . . . . . . . . . 113
The engine lacks power . . . . . . . . . . . . . . . . . . . 113
Abnormal engine knock . . . . . . . . . . . . . . . . . . . 114
The engine stops . . . . . . . . . . . . . . . . . . . . . . . 114
The engine does not stop . . . . . . . . . . . . . . . . . 115
Insufficient or excessive oil pressure . . . . . . . . . . . 115
Engine overheats . . . . . . . . . . . . . . . . . . . . . . . 115
112 DIAGNOSTICS
DIAGNOSTICS 113
The engine does not start
DIAGNOSTICS
Main mechanical malfunctions
The engine does not start

No. Possible cause Check Remedy
1 Inefficient connections to battery terminals Cause confirmed ▶ Clean, check and tighten or replace
the cable terminal nuts.
Cause not confirmed Check: 2
2 Batteries inefficient Cause confirmed ▶ Carry out the checks described in the
section Impianto elettrico.
3 Inefficient starter motor Cause confirmed ▶ Carry out the checks described in the
section Impianto elettrico.
4 Rev. sensor on flywheel Cause confirmed ▶ Check the electric connection, sensor
cleaning, sensor efficiency, distance
from the flywheel.
5 Injectors Cause confirmed ▶ Check injectors opening/closing
through active diagnosis.
6 Electronic control unit inefficient Cause confirmed ▶ replace.
7 Not required compression ratio Cause confirmed ▶ Overhaul the engine or limit repairs to
parts concerned (valves, rings, elastics,
etc.).
Cause not confirmed ▶ Contact the service network.
The engine lacks power

1 Wrong ignition advance Cause confirmed ▶ Check, adjust as necessary.
2 Turbocharger not working Cause confirmed ▶ Check wastegate valve.
3 Overpressure regulation unit inefficient Cause confirmed ▶ Check or adjust.
4 Not required compression ratio Cause confirmed ▶ Check using a suitable tool and carry
out the necessary repair operations.
5 Pressure compensation tube inefficient Cause confirmed ▶ Check for leaks.
114 DIAGNOSTICS
Abnormal engine knock
Abnormal engine knock

1 Knock detected in crankshaft Cause confirmed ▶ Check: clearance and ovalization of
main journals; connecting rod cap
fastening screws and engine flywheel;
oil pressure.
▶ Replace the parts or overhaul the
engine.
2 Knock identified in piston rods Cause confirmed ▶ Check: clearance and ovalization of
crankpin; tightness of connecting rod
cap screws and connecting rod square-
ness.
engine.
3 Knock identified in pistons Cause confirmed ▶ Check: clearance between pistons and
cylinder liners; integrity of the circlips;
pin clearance - piston hubs.
engine.
4 Knock identified in cylinder head Cause confirmed ▶ Check: operating clearance between
rocker-arms and valves; methane gas
quality, excessive supply pressure, igni-
tion advance.
5 Knock identified in timing system Cause confirmed ▶ Check and replace gears if necessary.
6 Knock found in the air compressor Cause confirmed ▶ overhaul or replace the air
compressor.
The engine stops

1 Inefficient ignition system Cause confirmed ▶ Check, adjust or replace parts if neces-
sary.
2 Idle speed irregular. Cause confirmed ▶ Check: idle valves, LAMBDA probe or
control unit.
DIAGNOSTICS 115
The engine does not stop
The engine does not stop

1 Supply on ignition Cause confirmed ▶ Checking ignition block.
Insufficient or excessive oil pressure

1 Pressure regulation valve does not work Cause confirmed ▶ Check and replace if necessary.
properly Cause not confirmed Check: 2
2 Oil pump and delivery pipes inefficient Cause confirmed ▶ Check and replace if necessary.
3 Main and connecting rod bearings inefficient Cause confirmed ▶ Replace the bearings and grind the
crankshaft if necessary.
4 Engine oil SAE viscosity not correct Cause confirmed ▶ Replace the engine oil with oil of ap-
propriate viscosity.
Engine overheats
1 Coolant level not exact Cause confirmed ▶ Check for leaks and top up.
2 Hydraulic fan control system inefficient Cause confirmed ▶ Check oil level and pressure adjust-
ment valve operation.
3 Water pump inefficient Cause confirmed ▶ Overhaul or replace the assembly.
4 Thermostat inefficient Cause confirmed ▶ replace.
5 Radiator inefficient Cause confirmed ▶ Wash well, check for leaks, replace the
part if necessary.
6 Clean or replace defective parts. Cause confirmed ▶ Inefficient air filter and circuit piping.
116 DIAGNOSTICS
CURSOR 13 TDCV ‒ technical specifications
Contents 1
Contents
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
2 Contents
TECHNICAL SPECIFICATIONS 3
Contents
Contents
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . . 5
DATA - INSTALLATION CLEARANCES . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 12
LAYOUT OF TIGHTENING SEQUENCE FOR MAIN

ENGINE PARTS . . . . . . . . . . . . . . . . . . . . . . . . 15
Tightening sequence diagram for lower crankcase
fixing screws . . . . . . . . . . . . . . . . . . . . . . . . 16
Outer screws . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head fastening screw tightening
diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Layout of tightening sequence for exhaust manifold
fastening screws . . . . . . . . . . . . . . . . . . . . . . 18
Diagram of tightening sequence for turbocharger
fastening screws and nuts . . . . . . . . . . . . . . . . 18
Diagram of tightening sequence for intake manifold
Diagram of tightening sequence for screws
fastening flywheel housing to crankcase . . . . . . . . 20
Diagram of tightening sequence for screws
fastening thrust plate to cylinder head . . . . . . . . 21
Layout of tightening sequence for screws fastening
blow-by case to gear casing . . . . . . . . . . . . . . . 21
Diagram of tightening sequence for heat exchanger
fixing screws . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagram of tightening sequence for thermostat
Layout tightening sequence for rocker arm cover
Diagram of tightening sequence for alternator
Diagram of the tightening sequence for oil sump
Diagram of the tightening sequence of Blow-by
filter retainer screws . . . . . . . . . . . . . . . . . . . 24
Diagram of the tightening order for pulser ring
fixing screws and nuts . . . . . . . . . . . . . . . . . . 25
Scheme of the tightening order of rocker arms
shafts fastening screws and nuts . . . . . . . . . . . . 25
Diagram of tightening sequence for engine ECU
fastening screws and nuts . . . . . . . . . . . . . . . . 26
4 TECHNICAL SPECIFICATIONS
GENERAL CHARACTERISTICS
TECHNICAL SPECIFICATIONS
F3H
type
F3HFE611B F3HFE611A
Diesel 4-stroke
Cycle
Power supply Turbocharged with aftercooler
Injection
Direct
Number of cylinders 6 in line
Bore mm 135
Stroke mm 150
Total displacement cm3 12880
Compression ratio 16.5 : 1
kW 368 412
(HP) (500) (560)
Max. power
rpm 1900 1900
Nm 2300 2500
(kgm) (234) (255)
maximum torque
rpm 900-1550 1000-1550
Idle speed with no load rpm 550 ± 50
Maximum engine idle speed rpm 2320 ± 50 2320 ± 50
DISTRIBUTION
start before T.D.C. A = 19°
end after B.D.C. B = 31°
start before B.D.C. D = 50°
End after T.D.C. C= 9°
F3H
type
F3HFE611B F3HFE611A
For timing check
mm −
X
mm −
Of operation
mm 0.40 ± 0.05
X
mm 0.60 ± 0.05
The high pressure fuel supply system is managed
by the BOSCH EDC 17. It consists of the CPN
POWER SUPPLY 5.2 high-pressure pump, electro-injectors, hydraulic
accumulator (rail), EDC 17 ECU and pressure and
temperature sensors.
Injection
–
Bosch
Electro-injectors type CRIN 3.3
Firing order 1–4–2–6–3–5
Varying injection pressure bar bar 2000
TURBOCHARGING
GT 4502V EVGT variable geometry with

Turbocharger type:
electronic control system.
Forced by gear pump, pressure relief valve, oil

LUBRICATION
filter
Oil pressure with hot engine (100 °C ± 5 °C):

at idle speed bar 1.5
at max speed bar 4.5 - 5
COOLING By means of centrifugal pump, thermostat for reg-
ulation, fan with electromagnetic coupling, radiator,
heat exchanger.
Water pump drive: Belt driven
Thermostat: No. 1
opening start: 84°C ± 2°C
maximum opening: 94°C ± 2°C
FILLINGS:
Total capacity of 1st filling litres 30.5 - 31
engine sump min level. litres 20
DATA - INSTALLATION CLEARANCES
F3H
type
F3HFE611B F3HFE611A
engine sump max level litres 28

oil change with filter change litres 30.5 - 31
F3H
type
mm
CYLINDER ASSEMBLY AND CRANK GEARS
Cylinder liner housing:
upper –
Ø1
lower –
Cylinder liners:
outer diameter:
upper 153.461 - 153.486
Ø2
lower 151.890 - 151.915
length L 252.2
Cylinder liners - crankcase seat
upper –
lower –
Outer diameter Ø2 −
Cylinder liners:
inner diameter Ø3 135.000 - 135.020
Protrusion X** 0.045 – 0.075
** With a load of 8,000 kg

Pistons:
measuring point X 50
outer diameter Ø 1 Ø1A 134.903 - 134.933
pin housing Ø2 59.063 - 59.093
A* 0.067 - 0.117
Piston - cylinder liners
B* ‒
Piston diameter Ø1 −
Piston protrusion X –
F3H
type
mm
Piston pin Ø3 58.994 - 59.000
Piston pin - pin seat 0.063 - 0.099
X1 2.480 - 2.510
Piston ring slots X2 2.580 - 2.610
X3 4.050 - 4.080
* measured on Ø of 121 mm
** measured on Ø of 120 + 0.15 mm
Piston rings:
trapezoidal sealing S1* 2.296 – 2.340
bevelled S2 2.470 - 2.500
milled scraper ring with slots and internal spring S3 3.970 - 3.990
* measured at 2 mm from Ø at the outside
1 0.140 - 0.214
Piston rings - slots 2 0.065 - 0.140
3 0.060 - 0.110
Piston rings −
Piston ring end gap in cylinder liner:

X1 0.35 - 0.45
X2 0.65 – 0.80
X3 0.40 – 0.75
Connecting rod small end bush seat Ø1 63.000 - 63.030
Connecting rod bearing seat Ø2 100.000 - 100.030
1 100.000 - 100.010
Classes 2 100.011 - 100.020
3 100.021 - 100.030
Bushing diameter at connecting rod small end
external Ø4 63.120 - 63.160
internal Ø3 59.060 - 59.076
Connecting rod half-bearings (S) thickness
Red colour 1.960 – 1.970
Green colour 1.971 - 1.980
Yellow colour* 1.981 - 1.990
* Fitted in production only and not supplied as spares.
Bush at connecting rod small end - housing 0.090 - 0.160
Piston pin - bushing 0.060 – 0.082
Connecting rod half-bearings –
F3H
type
mm
Connecting rod weight

A 5537÷ 5570 g
Class B 5571 ÷ 5604 g
C 5605÷ 5637 g
Measuring point X –
Maximum error in parallelism of connecting rod

⁄⁄ –
axes
Main journals Ø1 nominal value 99.970 – 100.000

1 99.970 – 99.979
Selection class 2 99.980 – 99.989
3 99.990 – 100.000
Crankpins Ø2 nominal value 95.970 - 96.000
1 95.970 - 95.979
Selection class 2 95.980 – 95.989
3 95.990 – 96.000
Main half-bearings S1
Red colour 3.110 – 3.120
Green colour 3.121 – 3.130
Yellow colour* 3.131 – 3.140
Connecting rod half-bearings S2
Red colour 1.960 – 1.970
Green colour 1.971 - 1.980
Yellow colour* 1.981 - 1.990
* The yellow half bearing is mounted only during production
Main bearings Ø3 106.300 - 106.330
1 –
Selection class 2 –
3 –
Main journals half-bearings 0.060 - 0.108
Half-bearings crankpins 0.060 - 0.100
Main half-bearings –
Connecting rod half-bearings –
Thrust main journal X1 47.95 - 48.00
Thrust main bearing X2 40.94 - 40.99
F3H
type
mm
Half thrust washers (thickness) X3 3.38 – 3.43
Crankshaft thrust 0.10 - 0.30
Alignment 1-2 –
Centring 1-2 –
CYLINDER HEAD - TIMING SYSTEM
Valve guide housing on cylinder head Ø1 15.980 - 15.997
Ø2 10.015 - 10.030
Valve guides
Ø3 16.012 - 16.025
Valve guides and seats on the head 0.015 – 0.045
Valve guides –
Valves:
Ø4 9.960 - 9.975
α 60° 30' ± 7' 30''
Ø4 9.960 - 9.975
α 60° +30' ± 7' 30''
Valve stem and related guide 0.040 – 0.070
Housing on head for valve seat:
Ø1 49.185 - 49.220
Ø1 46.985 - 47.020
F3H
type
mm
Outside diameter of valve seats: valve housing inclination on cylinder head:
Ø2 49.260 - 49.275
Ø2 47.060 - 47.075
Valve seat 0.2
X 0.54- 0.86
Recessing
X 1.65- 1.95
Between valve seat and cylinder head 0.040 - 0.090
Valve spring height:

free spring H 76
under a load of:
660 ± 33 N H1 59
1140 ± 57 N H2 46
Camshaft bush housing fitted in the cylinder head:

Ø 88.000- 88.030
1⇒7
Camshaft journals: 1 ⇒ 7 Ø 82.950 – 82.968
Camshaft bushing outer diameter: Ø 88.153 – 88.183
Bushing inner diameter Ø 83.018 – 83.085
Bushings and seats in cylinder head 0.123 - 0.183
Bushings and supporting pins 0.050 – 0.135
Useful cam height:

9.231
9.5607
Rocker-arm shaft Ø1 41.984 – 42.000
mm
TIGHTENING TORQUES
F3H
type
mm
Internal rocker arm diameter:
42.045 – 42.061
59.000 – 59.019
Rocker arm bush outer diameter:
–
59.070 – 59.110
Rocker arm bush inner diameter:
–
56.045 – 56.064
Bushes and housings:
–
0.051 – 0.110
Rocker arm bushes and shaft:

0.045 - 0.077
Engine brake control lever

Eccentric pin outer diameter Ø2 55.981 – 56.000
Rocker shaft seat Ø1 42.025 – 42.041
Rocker arms and engine brake control lever pin 0.045 – 0.083
Rocker arm shaft and seat on engine brake con-

0.025 – 0.057
trol lever
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Screws securing the crankcase to the lower crankcase ★
Inner screws First step: pre-tightening 160 16
Inner screws Second step: Angle tightening M18x2 60°
Inner screws Third step: Angle tightening 60°
Outer screws Fourth step: pre-tightening 30 3
M12x1.75
Outer screws Fifth step: Angle tightening 60°
Union for piston cooling nozzle 50 ± 5 5 ± 0.5
pre-tightening 11.5 ± 3.5 1.15 ± 0.35
Screws securing heat exchanger to crankcase ★ M8x1.25
tightening 24.5 ± 2.5 2.4 ± 0.25
Screws fixing suction strainer to bedplate 24.5 ± 2.5 2.4 ± 0.25
First step 45 ± 4.5 4.5 ± 0.45
Screws securing spacer and oil sump ★ M10x1.5
Second step 45 ± 4.5 4.5 ± 0.45
Oil sump drain plug 95 ± 10 9.5 ± 1
Oil level dipstick retainer 39 ± 6 3.9 ± 0.6
Pre-tightening 20 2
Screws securing flywheel case to crankcase ★ M12x1.75
Tightening 63 ± 7 6.3 ± 0.7
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Screws securing flywheel case to head ★ M10x1.5 44 ± 4 4.4 ± 0.4
First step: pre-tightening 75 7.5
Second step: pre-tightening 150 15
M18x2 screw fixing cylinder head: ♦ (*)
Third step: Angle tightening 90 °
Fourth step: Angle tightening 90 °
First step: pre-tightening 25 2.5
Second step: pre-tightening 60 6
M16x1.5 Screw securing rocker arm shaft ★
Third step: pre-tightening 80 8
Fourth step: Angle tightening 60
Screws fastening oil pressure regulating valve 23.5 ±2.5 2.3 ± 0.2
Rocker arm cover M6x1 fastening screws 8.5 ± 1.5 0.8 ± 0.1
Lock nut for rocker arm adjustment screw M10x1.25 39 ± 5 3.9 ± 0.5
M8x1.25 screws for injector brackets 35 3.5
M8x1.25 Screws securing camshaft shoulder plate First step 20 ± 2 2 ± 0.2
to head ★ Second step 20 ± 2 2 ± 0.2
Screws securing bracket on cylinder head to lift engine M12x1.75 100 ± 10 10 ± 1
First step: pre-tightening 60 6
M14X2 screws fastening the camshaft gear (*)
Second step: Angle tightening 60°
Screw fixing pulser ring to timing gear M8x1.25 24.5 ± 2.5 2.5 ± 0.2
M10x1.5 screws securing exhaust manifold (**) pre-tightening 40 ± 5 4 ± 0.5
★ tightening 60 ± 5 6 ± 0,5
Screws fastening collars on exhaust manifold M6x1 12 ± 0.5 1.2
Screws fastening collars on exhaust pipe 8±2 0.8 ± 0.2
Screws fixing the exhaust brake hydraulic actuator cylinder 19 ± 3 1.9 ± 0.3
M14x2 screws fixing the connecting rod cap
Second step: Angle tightening 60°
M18x1.5 screws fixing the engine flywheel (*)
Second step: Angle tightening 90 °
M14x2 screws fixing the damper flywheel to the First step: pre-tightening 70 7
drive pulley (*) Second step: Angle tightening 50 °
M14x2 screws fixing the drive pulley to the First step: pre-tightening 70 7
crankshaft (*) Second step: Angle tightening 50 °
M12x1.75 screw fixing the intermediate gear pins First step: pre-tightening 30 3
(*) Second step: Angle tightening 90 °
Screw fixing rod to adjust transmission gear M8x1.25 24.5 ± 2.5 2.4 ± 0.2
M8x1.25 screws fixing the oil pump 24.5 ± 2.5 2.4 ± 0.2
M8x1.25 screw fixing crankshaft gasket front cover 24.5 ± 2.5 2.4 ± 0.2
Diesel filter breather 18 ± 2 (1.8 ± 0.2)
M8x1.25 screw fastening fuel filter support 24.5 ± 2.5 2.4 ± 0.2
Fuel filter cap 32.5 ± 2.5 3.2 ± 0.2
Fuel filter drain 1.5 ± 0.5 0.2 ± 0.1
Screw fastening oil filter support M8x1.25 23.5 ±2.5 2.4 ± 0.2
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Oil filter cap 60 ± 5 6 ± 0,5
Oil filter drain plug 6.5 ± 1.5 0.7 ± 0.1
Screw fastening control unit mount 19 ± 3 1.9 ± 0.3
Screws and nuts securing turbocharger M12x1.75 75 7.5
Electrical actuator to turbocharger retainer nut 31.8 ± 1.75 3.2 ± 0.2
Screws fastening actuator bracket mount to turbocharger 22.6 ± 1.7 2.3 ± 0.2
Screws fastening oil return pipe to turbocharger M8x1 24.5 ± 2.5 2.4 ± 0.2
Screws securing thermostat assembly ★ M8x1.25 30 ± 3 3 ± 0.3
Screws securing water pump M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Screws fixing water inlet pipe to crankcase M8x1.25 34.5 ± 3.5 3.4 ± 0.3
Screws fastening fan to electromagnetic coupling M8x1.25 34.5 ± 3.5 3.4 ± 0.4
M12x1.75 screws fixing the electromagnetic coupling to the crankcase 100 ± 5 10 ±0.5
Screw fixing the automatic belt tensioner M10x1.5 50 ± 5 5 ± 0.5
Screws securing steady tensioner M12x1.75 105 ± 5 10.5 ± 0.5
Starter motor fastening screws M12x1.75 74 ± 8 7.4 ± 0.8
Screws securing the air heater and the intake manifold to the cylinder head ★ M10x1.5 50 ± 5 5 ± 0.5
Screws fixing air compressor M12x1.75 74 ± 8 7.4 ± 0.8
Nut fixing air compressor drive gear 170 ± 10 17 ± 1
M12x1.5 screws fastening HP pump to the support plate 37.5 ± 2.5 3.7 ± 0.2
M8x1.25 screws fastening HP pump mounting plate to the timing system casing 24.5 ± 2.5 2.4 ± 0.2
M24x1.5 nut for fixing the high pressure pump gear 250 ± 15 25 ± 1.5
M16x1.5 fuel filler on head 55 ± 5 5.5 ± 0.5
M12x1.75 screws securing the oil pump to the bracket 32.5 ± 2.5 3.3 ± 0.2
M16x1.5 couplings fixing the high pressure fuel pipe to the HP pump 42 4.2
M18x1.5 couplings securing the LP fuel pipe to the HP pump 37 ± 3 3.7 ± 0.3
screws marked with numbers 10 ± 1 1 ± 0.1
M6x1 screws securing Blow-by to timing case ★
screws marked with letters 7±1 0.7 ± 0.1
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the fuel pipe to rail
Chesini supplier 60 ± 2.5 6 ± 0,25
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the fuel pipe to injectors
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the HP pipes to the head
M14x1.5 coupling securing the fuel return pipe to rail 50 5
M8x1.25 screws securing the rail to the head 24.5 ± 2.5 2.5 ± 0.3
M20x1.5 rail pressure relief valve 110 ± 5 11 ± 0,5
M8x1.25 nut fixing the heater electrical connections 16 ± 1 1.6 ± 0.1
pre-tightening 5 0.5
Screws securing Blow-by filter★
tightening 15 1.5
M10x1.5x35
44 ± 4 4.4 ± 0.4
(lower retainer)
Screws fastening alternator support
M10x1.5x60
44 ± 4 4.4 ± 0.4
(lower retainer)
LAYOUT OF TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS
TORQUE
DETAIL
Nm ° kgm
M8x1.25x30 (up-
Screws fastening alternator support 24.5 ± 2.5 2.45 ± 0.25
per retainer)
M10x1.5 44 ± 4 4.4 ± 0.4
Alternator fixing screws
M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Alternator pulley securing 75 7.5
Power steering retainer collar 6 ± 2.5 0.6 ± 0.25
Screws fixing power steering pump to the compressor M10x1.5 46.5 ± 4.5 4.6 ± 0.4
Screws fixing air-conditioner compressor to mount M8x1.25 24.5 ± 2.5 2.4 ± 0.25
Screws fixing the air-conditioner compressor mount M8x1.25 24.5 ± 2.5 2.4 ± 0.25
Fixing screw for guard 24.5 ± 2.5 2.5 ± 0.25
Flywheel rev sensor support fastening 23.5 ±2.5 2.3 ± 0.2
M18x1.5 Rail pressure sensor retainer 70 ± 5 7 ± 0.5
Filter clogging sensor fastening 55 ± 5 5.5 ± 0.5
Water/fuel temperature sensor fastener 35 3.5
Thermometric switch/transmitter fastener 25 2.5
Air temperature transmitter fastener 35 3.5
Pulse transmitter fastener 8±2 0.8 ± 0.2
Pressure sensor retainer on the rocker cover 27.25 ± 2.75 2.7 ± 0.28
Exhaust brake solenoid valve fastener M24x1.5 32 ± 3 3.2 ± 0.3
PWM solenoid valve fastener 8±2 0.8 ± 0.2
Nuts for injector electrical connection 1.5 ± 0.25 0.15
Head wiring connector fixing screw 8±2 0.8 ± 0.2
* Lubricate with engine oil before assembly
** Lubricate with graphitised oil before assembly
☆ Apply LOCTITE 243 before assembly
★ See tightening sequence
540110 LAYOUT OF TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS

F3HFE611
Tightening sequence diagram for lower crankcase fixing screws
60593 Figure 1
First step
Tightening torque
Lower crankcase inner screws Pre-tightening
160 N⋅m
Second step
Technical data
Lower crankcase internal screws (angle closing) 60°
Third step
Technical data
Lower crankcase internal screws (angle closing) 60°
Outer screws
60592 Figure 2
Fourth step
Tightening torque
Lower crankcase external screws Pre-tightening
30 N⋅m
60594 Figure 3
Fifth step
Technical data
Lower crankcase external screws (angle closing) 60°
Cylinder head fastening screw tightening diagram
61270 Figure 4
Tightening torque
Cylinder head fixing screws 1. 75 N⋅m
2. 150 N⋅m
3. 90°
4. 90°
Layout of tightening sequence for exhaust manifold fastening screws
180272 Figure 5
Tightening torque
Exhaust manifold fixing screws 1. Tightening sequence: 1-2-3-4
20 N⋅m
2. Tightening sequence: 5-6-7-8
45 N⋅m
Diagram of tightening sequence for turbocharger fastening screws and nuts
213469 Figure 6
Diagram of tightening sequence for intake manifold fastening screws
218129 Figure 7
Tightening torque
Intake manifold fixing screws 1. Tightening sequence: 1-2-3-4-5-6
45 N⋅m to55 N⋅m
2. Tightening sequence: 1-5-3-4-6-2
45 N⋅m to55 N⋅m
Diagram of tightening sequence for screws fastening flywheel housing to crankcase
180269 Figure 8
Tightening torque
Flywheel housing fastening screws 1. Tightening sequence: 1 – 19
63 ±7 N⋅m
2. Tightening sequence: 20 – 21
44 ±4 N⋅m
Diagram of tightening sequence for screws fastening thrust plate to cylinder head
151833 Figure 9
Tightening torque
Thrust plate fastening screws 1. Tightening sequence: 1-2-3-4-5
18 N⋅m to22 N⋅m
2. Tightening sequence: 6-7-8-9-10
18 N⋅m to22 N⋅m
Layout of tightening sequence for screws fastening blow-by case to gear casing
155920 Figure 10
Tightening torque
Screws fixing blow-by box 1. Tightening sequence: from 1 to 21
9 N⋅m to11 N⋅m
2. Tightening sequence: from A to F
6 N⋅m to8 N⋅m
Diagram of tightening sequence for heat exchanger fixing screws
180274 Figure 11
Tightening torque
Heat exchanger fastening screws 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m
Diagram of tightening sequence for thermostat fastening screws
218128 Figure 12
Tightening torque
Thermostat fixing screws 1. Tightening sequence: 1-2-3-4-5-6-7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8-9-10-11-12-13-14
27 N⋅m to33 N⋅m
Layout tightening sequence for rocker arm cover fastening screws
Tightening torque
Tightening
Rocker arm cover fastening screws
(Tighten the screws to contact in the
8.5 ±1.5 N⋅m
following order: 1 - 10 - 20 - 21 - 9
and then according to the diagram)
180275 Figure 13
Diagram of tightening sequence for alternator fastening screws
180276 Figure 14
Alternator support
tightening torque
Detail
Nm kgm
1 Screws fixing the alternator mount to the crankcase 24.5 ± 2.5 2.45 ± 0.25
2 Alternator fixing pin 44 ± 4 4.4 ± 0.4
3 Alternator fixing screw 24.5 ± 2.5 2.45 ± 0.25
4 Screws fixing the alternator mount to the head 24.5 ± 2.5 2.45 ± 0.25
Diagram of the tightening sequence for oil sump fastening screws
155922 Figure 15
Tightening torque
Oil sump fastening screws 1. Tightening sequence: from 1 to 16
40.5 N⋅m to49.5 N⋅m
2. Tightening sequence: from 1 to 4
40.5 N⋅m to49.5 N⋅m
Diagram of the tightening sequence of Blow-by filter retainer screws
160656 Figure 16
Tightening torque
Blow-by filter fixing screws 1. 5 N⋅m
2. 15 N⋅m
Diagram of the tightening order for pulser ring fixing screws and nuts
162194 Figure 17
Tightening torque
Pulser ring locking screw 1. 10 N⋅m
2. 25 N⋅m to32 N⋅m
Scheme of the tightening order of rocker arms shafts fastening screws and nuts
180277 Figure 18
Tightening torque
Rocker arm shaft fixing screws 1. 25 N⋅m
2. 60 N⋅m
3. 80 N⋅m
4. 60°
Diagram of tightening sequence for engine ECU fastening screws and nuts
180271 Figure 19
Fuel pipe couplings

Pipe tightening torque
Detail
mm Nm kgm
M12 x 1.5 6x1 16 ± 2 1.6 ± 0.2
M14 x 1.5 8x1 19 ± 3 1.9 ± 0.3
M18 x 1.5 12 x 1.5 35 ± 5 3.5 ± 0.5
M22 x 1.5 15 x 1.5 37 ± 5 3.7 ± 0.5
M22 x 1.5 16 x 2 39 ± 6 3.9 ± 0.6
Couplings with pressure ring
M26 x 1.5 18 x 2 44 ± 6 4.4 ± 0.6
Pipe tightening torque

Detail
mm Nm kgm
M10 x 1 – 15 ± 1.5 1.5 ± 0.15
M12 x 1.5 – 20 ± 2 2 ± 0.2
M14 x 1.5 – 24 ± 2.4 24 ± 0.24
M16 x 1.5 – 30 ± 3 3 ± 0.3
M22 x 1.5 – 34 ± 3.4 3.4 ± 0.34

Connection couplings
M10 x 1 – 18 ±1.8 1.8 ± 0.18
M12 x 1.5 – 35 ± 3.5 3.5 ± 0.35
M14 x 1.5 – 50 ± 5 5 ± 0.5
M16 x 1.5 – 60 ± 6 6 ± 0.6
M18 x 1.5 – 70 ± 7 7 ± 0.7
M22 x 1.5 – 120 ± 12 12 ± 1.2

Eyelet couplings
Couplings between the fuel supply system and the engine – 32 ± 3.2 3.2 ± 0.32
CURSOR 13 TDCV ‒ Equipment
Contents 1
Contents
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Contents
TOOLS 3
Contents
Contents
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 TOOLS
TOOLS 5
TOOLS
TOOLS
TOOLS
Rotary telescopic stand(range 2000 daN, torque 375 daNm) (99322230)
Extraction tool for injectors (99342157)
Key to fit crankshaft front gasket (99346250)
Key to fit crankshaft rear gasket (99346260)
6 TOOLS
TOOLS
Socket wrench for idle gear support fastening screws (99350072)
Punch for valve guide removal (99360143)
Pliers for removing/refitting piston rings (105 -160 mm) (99360184)
Guide for fitting rubber belt (99360192)
Tool to remove and refit engine valves (to be used with special plates) (99360259)
TOOLS 7
TOOLS
Tool for engine valves removal and refitting (use with 99360259) (99360263)
Tool for valve guide refitting (use with 99360143) (99360296)
Tool for rotating the flywheel (99360321)
Spacer (to be used with 99360321) (99360325)
Adjuster for gasket assembly on valve guide (99360329)
8 TOOLS
TOOLS
Cylinder liner protrusion gauge (to be used with 99370415-99395603 and special plates)
(99360334)
Spacer (to be used with 99360334) (99360336)
Tool for cylinder liners compression (use with 99360334 -99360336) (99360338)
Tool for retaining the flywheel (99360351)
Drift to take down and fit back camshaft bushes (99360499)
TOOLS 9
TOOLS
Crankshaft lifting tool (99360500)
Bracket for removing and refitting engine flywheel (99360551)
Tool for rocker arm shaft assembly and fitting (99360553)
Arm for engine removal and refitting (99360585)
Clamp for fitting piston into cylinder liner (90 - 175 mm) (99360603)
10 TOOLS
TOOLS
Tool for engine T.D.C. positioning (99360612)
Tool for timing of phonic wheel on timing gear (99360613)
Tool for cylinder liner fastening (99360703)
Tool to extract cylinder liners (use with special rings) (99360706)
Ring (135 mm) (to be used with 99360706) (99360728)
TOOLS 11
TOOLS
Brackets for fastening engine to 99322230 rotary stand (99361036)
Tool for removing the high pressure pump gear (99366198)
Tool to check timing (use with 99395606) (99370400)
Dial gauge base to adjust lay shaft bearings (use with 99395603) (99370415)
Torque wrench (20-120 Nm) with 1/2" square head (99389813)
12 TOOLS
TOOLS
Coupling torque wrench 9X12 (5-60 Nm) (99389829)
14X18 coupling torque wrench (20-120 Nm) (99389833)
Torque screwdriver (1-6 Nm) for adjusting the locking nut of the injector solenoid valve
connectors (99389834)
Sleeker for valve guide (99390330)
Set of gauges for angle tightening with square connection - 1/2" and 3/4" (99395216)
TOOLS 13
TOOLS
Gauge for defining the distance between the centres of camshaft and timing gear
(99395225)
Gauge to determine centre distance between camshaft and high pressure pump
(99395226)
Dial gauge (0-5 mm) (99395603)
Dial gauge (0-30 mm) (99395606)
14 TOOLS
TOOLS
Centring ring of crankshaft front gasket cover (99396035)
CURSOR 13 TDCV ‒ safety regulations
Contents 1
Contents
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . 3
2 Contents
SAFETY REGULATIONS 3
Contents
Contents
Standard safety precautions . . . . . . . . . . . . . . . . . . 5
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . 5
During maintenance . . . . . . . . . . . . . . . . . . . . . . . 5
Protection of the environment . . . . . . . . . . . . . . . . 6
4 SAFETY REGULATIONS
SAFETY REGULATIONS 5
Standard safety precautions
SAFETY REGULATIONS
Standard safety precautions
We direct your attention on some precautions that must be necessarily followed in a regular work environment and, in case of
non-compliance, any other precaution will not be sufficient to protect the safety of the staff in charge of maintenance.
● Please obtain information and inform the staff on applicable laws on safety, making the informative material available for con-
sultation.
● Please keep the rooms as clean as possible and properly ventilated.
● Equip the rooms with specific, well-visible first-aid boxes, always stocked up with suitable medical aids.
● Be equipped with suitable fire extinguishing devices, properly signalled and never obstructed. Check their operation on a regu-
lar basis and train the staff on the intervention priorities and methods.
● Arrange gathering points for the evacuation of the rooms, properly signalling the exit routes.
● Absolutely prohibit smoking in the areas where the works subject to fire hazard are carried out.
● Draw the attention on prohibitions and indications with suitable signs, which are immediately comprehensible always in case of
emergency.
Accident prevention
● Do not wear cloths with loose edges, rings and chains, while working near engines and moving organs.
● Use protective gloves and glasses when: - filling up inhibitors or antifreeze; - replacing or filling up lubricant; - using air or li-
quids under pressure (permitted pressure ≤ 2 bar).
● Wear a protective helmet if working in an area with suspended loads or overhead systems.
● Always wear safety shoes and cloths fitted to the body, better if equipped with rubber bands at the edges.
● Use protective creams for hands.
● Change wet clothes as soon as possible.
● In the presence of voltage higher than 48-60V, check the efficacy of the ground electric connections. Make sure your hands
and feet are dry and perform the work standing on insulating platforms. Do not proceed if not qualified!
● Do not smoke or spark free flames near batteries and any combustible material.
● Return oily rags or solvents to fire-proof containers.
● Do not perform operations without the necessary instructions.
● Do not use equipment to perform works other than those for which they have been designed, you may sustain accidents,
even of serious type.
● In case of checks or calibrations that require the engine to be on, make sure that the room is properly ventilated and use
proper fans to remove exhaust gases: intoxication and death hazard.
During maintenance
● Never open the filling cap of the cooling circuit when the engine is hot. The operating pressure will spill the high temperature
liquid with serious risk of burns. Wait until the temperature drops below 50 °C.
● Never add coolant to an overheated engine and only use appropriate fluids.
● Always operate with engine off: in case particular circumstances require maintenance with the engine on, consider all the risks
involved in these operations.
● Use adequate and safe containers for draining the engine fluids and exhaust oil.
● Preserve the engine clean from oil, gas oil stains and/or chemical solvents.
● The use of solvents or detergents during maintenance may develop toxic vapours. Always ventilate the work rooms. Use
safety masks when required.
● Do not leave cloths soaked with flammable substances near the engine.
● When starting up the engine after a repair operation, foresee suitable measures to stop air suction in case of over-revving.
● Do not use quick screwers.
● Do not disconnect the batteries whilst the engine is running.
6 SAFETY REGULATIONS
Protection of the environment
● Before any interventions involving the electrical circuits, disconnect the batteries.
● Disconnect the batteries from the on-board network while charging.
● After each intervention, make sure the polarity of the battery's terminals is respected and the latter are well tightened and
protected against accidental short circuits and oxidation phenomena.
● Do not disconnect and connect the electric connections when power is on.
● Before carrying out removal operations on pipes (pneumatic, hydraulic or fuel pipes), check the possible presence of fluid or
air under pressure. Adopt the necessary precautions, exhausting the residual pressures or closing the shut-off valves. Always
wear suitable masks or protective glasses. Serious accidents and intoxications may occur if not respecting these rules.
● Avoid improper tightening operations or out of torque. The engine's components may be damaged also seriously, thus preju-
dicing their life cycle.
● Avoid draughts from fuel tanks in copper alloy and/or pipes without filters.
● Do not apply changes to the cabling, their length must not be modified.
● Do not connect any utility to the engine's electric equipment, unless specifically approved.
● Do not modify the fuel or hydraulic systems without authorization. Any unforeseen change will void the warranty and may
prejudice the engine's duration and life cycle.
For engines equipped with electronic units:
● Do not carry out any arch welding without previously removing the electronic units.
● Remove the electronic control units in case of interventions in which the temperatures will exceed 80 °C.
● Do not paint the electronic components and connections.
● Do not modify or alter the data contained in the engine management electronic control unit. Any manipulation or alteration of
the electronic components will invalidate the service warranty of the engine and may also affect its operation and duration.
Protection of the environment

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

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CURSOR 13 TDCV

Technical repair manual

FPT Industrial S.p.A.

Figures and words: FPT Industrial S.p.A. 2014

Technical repair manual 1

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

GENERAL WARNINGS REGARDING THE

Grounding and screening . . . . . . . . . . . . . . . . . . . 10

Optional electrical and mechanical parts

Conversions between the main units of measurement

Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

SYMBOLS - SERVICE OPERATIONS

Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

543010 Oil pump

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Grounding and screening

Optional electrical and mechanical parts installations

Revolutions per time unit

CORRESPONDENCE BETWEEN TECHNICAL

POWER AND TORQUE CHARACTERISTICS

POWER AND TORQUE CHARACTERISTICS

● F3HFE611B*C001 ‒ Engine family indication

● F3HFE6 11B*C001 ‒ Number of cylinders

● F3HFE611B*C 001 ‒ Gas emission level given same curves

● F3HFE611B*C 001 ‒ Variant number in B.O.M.

5401 ENGINE VIEWS

LEFT SIDE VIEW

RIGHT SIDE VIEW

5401 POWER AND TORQUE CHARACTERISTICS F3HFE611A

5401 POWER AND TORQUE CHARACTERISTICS F3HFE611B

International lubricants and fuels designation Original products

SCRT (Selective Catalytic Reduction Technology)

Rail (pressure accumulator) . . . . . . . . . . . . . . . . . . 8

Oil pressure regulator valve . . . . . . . . . . . . . . . . . 15

Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . . 18

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 19

Valve integrated in piston cooling nozzle . . . . . . . . . 20

Oil vapour recirculation (Blow-by) . . . . . . . . . . . . . 20

Engine fuel supply diagram

1 High-pressure pump 6 Electric injectors

771010 CPN 5.2 high pressure pump

High pressure pump section

774510 Rail (pressure accumulator)

The electro-injector may be considered as mainly made up of two parts:

542010 Fuel filter

Oil filter tightening torques

543010 Oil pump

Oil pump cross-section

543076 Overpressure valve

543075 Oil pressure regulator valve

Main data to check the oil pressure adjustment valve spring

543110 Heat exchanger

543077 Filter by-pass valve

543070 Engine oil filter

540414 Valve integrated in piston cooling nozzle

540480 Oil vapour recirculation (Blow-by)

Oil vapour recirculation (Blow-by) diagram

1 Vapour breather valve 3 Blow-by filter