CURSOR 13 TDCV General Mechanical Overhaul: .540462. Crankshaft Rear Gasket Assembly

CURSOR 13 TDCV ‒ General mechanical overhaul
GENERAL MECHANICAL OVERHAUL 81

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).
Tool / Material Product
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
Tool for retaining the flywheel 99360351
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
– printed P1D32C016E1114
82 GENERAL MECHANICAL OVERHAUL
ENGINE ASSEMBLY
Tool / Material
Torque wrench
49037 Figure 159
37. Tighten at angle with specific tool (1).

code
Set of gauges for angle tightening with square connection - 99395216
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
Tool for engine T.D.C. positioning 99360612
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°
Note Lubricate the screws (2) with engine oil before as-
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.
Note Lubricate the screws (5) with engine oil before as-
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
Tool for rocker arm shaft assembly and fitting 99360553
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
2. Tightening sequence: 1 - 7
60 N⋅m
80 N⋅m
60°
Tool / Material Product 183461 Figure 173

code
Torque wrench
ENGINE ASSEMBLY

code
Set of gauges for angle tightening with square connection - 99395216
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
Tool for rotating the flywheel 99360321
Spacer (to be used with 99360321) 99360325
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.
Tool / Material Product code
Tool for rotating the flywheel 99360321
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
Cam timing dial gauge value 5.95 ±0.05 mm
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
Tool for retaining the flywheel 99360351
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.
Brackets for fastening engine to 99322230 rotary stand 99361036
.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.

CURSOR 13 TDCV General Mechanical Overhaul: .540462. Crankshaft Rear Gasket Assembly

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CURSOR 13 TDCV General Mechanical Overhaul: .540462. Crankshaft Rear Gasket Assembly

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CURSOR 13 TDCV ‒ General mechanical overhaul

GENERAL MECHANICAL OVERHAUL 81

182145 Figure 157

.540462. Crankshaft rear gasket assembly

60568 Figure 158

.540850. Engine flywheel assembly

36. Tighten using a torque wrench (4).

49037 Figure 159

37. Tighten at angle with specific tool (1).

49036 Figure 160

.541210. Fitting camshaft

160624 Figure 161

Tool / Material Product

160655 Figure 162

182251 Figure 163

160654 Figure 165

182148 Figure 166

.775010. Injector assembly

169828 Figure 168

.774510. Rail installation

183456 Figure 170

183458 Figure 171

.541230. Fitting rocker shaft assembly

116190 Figure 172

70. Screw the screws in four steps as follows:

Tool / Material Product 183461 Figure 173

Tool / Material Product

183461 Figure 173

71. Fit the engine brake lever retainer springs (1).

185511 Figure 174

183457 Figure 175

.541210. Camshaft timing

Note The arrow shows the direction of rotation of the en-

185252 Figure 176

71774 Figure 177

185253 Figure 178

177714 Figure 179

81. reset the dial gauge.

185524 Figure 180

185523 Figure 181

185523 Figure 183

96. Recover the clearance between the timing system gears by

.541215. Pulser ring timing

185254 Figure 185

185254 Figure 185

.771010. High pressure pump assembly

187918 Figure 186

182156 Figure 187

182158 Figure 188

.541230. Intake and exhaust rocker arm clearance adjustment

187916 Figure 189

Tool / Material Product code

.540630. Tappet cover assembly

117545 Figure 191

.542011. Fuel filter assembly

182091 Figure 192

.540452. Timing gear assembly cover mounting

181826 Figure 193

123. Fit the blow-by case (3).

125. Connect the pipe (1).

181805 Figure 194

.540486. Blow-by filter fitting