F2cfe613 Industrial

CURSOR SERIES
TIER 4B / STAGE IV
Industrial application
TIER 4B
F2CFE613E*B012
F2CFE613A*B012
STAGE IV
F2CFE613E*B013
F2CFE613A*B013
Technical and Repair manual

This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and

specialised personnel.
Before performing any operation check that the part relevant

to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles,
helmet, gloves, shoes, etc. and hoisting and transporting
equipment.
Operations are to be performed by following the indications

included here, using the special equipment indicated and
assuring proper repair, compliance with schedule and
operators safety requirements.
Each repair must aim to restore operating efficiency and safety

in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other

interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the

interventions and all the instructions that are not included on
this publication.
Data included in this publication may not be up-to-date

therefore subject to Manufacturers modifications that can be
added at any time for technical or commercial purposes and
also to meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed

on the unit, please get in touch with the FPT network before
starting any intervention.
It is forbidden to copy this text or any of its parts and all

illustrations included.
Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P2D32C012 E - 2nd Ed. 09.2015
F2CFE613 ENGINES INTRODUCTION 1
Introduction
Page
PREFACE TO USERS GUIDELINE MANUAL . . 3
- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS ON THE ELECTRIC SYSTEM 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL PARTS

INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 9
CONVERSIONS BETWEEN THE MAIN UNITS OF

MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEY OF LECTURE OF THE HEADINGS AND

FOOTNOTES . . . . . . . . . . . . . . . . . . . . . . . . . 10
UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Print P2D32C012 E Base - September 2015

2 INTRODUCTION F2CFE613 ENGINES
Base - September 2015 Print P2D32C012 E

PREFACE TO USERS GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assemblys electronic
systems, wiring diagrams, electric features of components.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the fuel supply type and engine operation.
Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis
of their specific use.
Section 4 describes scheduled maintenance and specific overhauling.
Section 5 deals with removal and refitting of the main engine components.
Section 6 describes general mechanical servicing of the engine on the revolving stand.
Section 7 gives engine technical characteristics such as data, installation clearances and tightening torques.
Section 8 is about the tools necessary for performing these operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS
Warnings
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Service operations
Example
1 1 = Seat of small end bush

Close applying the required torque + angular
value

2 2 = Seat of connecting rod bearings.

Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
! with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and star-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT -

C. CONNECTOR
d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by FPT.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 CV
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1.014 CV
NOTE The unit CV is converted into hp for simplicity according to a 1:1 ratio
1 hp = 1 CV.
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
NOTE Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 273.15 K
0 F = 255.37 K
0 C = 32 F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

vehicle title number
Basic edition referred to When month - year update

Printout Language month - year editorial
number Publication is present (revi) to the basic
phase closing edition

UPDATING
Section Section name Description of change Page Date of revision


F2CFE613 ENGINES 1
CURSOR SERIES TIER 4B / STAGE IV
General Specifications 1
Main engine diagrams 2
Electrical equipment 3
Maintenance planning 4
Removal and refitting of main engine components 5
Engine overhaul 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix

2 F2CFE613 ENGINES

F2CFE613 ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . 3
HOMOLOGATION PLATE . . . . . . . . . . . . . . . . 3
MAPPING BETWEEN TECHNICAL

AND COMMERCIAL CODING . . . . . . . . . . . 4
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 5
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 6
PERSPECTIVE VIEW . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE AND POWER TYPICAL CURVES . . . 8
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 12

2 SECTION 1 - GENERAL SPECIFICATIONS F2CFE613 ENGINES

IDENTIFICATION PLATE
Figure 1
218007
1. Engine serial number - 2. Technical code
HOMOLOGATION PLATE
EPA - TIER 4B (F2CFE613E*B012 - F2CFE613A*B012)
Figure 2
218008
1. Engine type: technical code (F2CFE613E*B012 - F2CFE613A*B012) - 2. Engine serial number (XXXXX) -
3. Construction date (DD/MM/YY) - 4. Engine rating: maximum power expressed in kW (bhp) -
5. Engine model: partial technical code (F2CFE613E*B - F2CFE613A*B)

ECE - STAGE IV (F2CFE613E*B013 - F2CFE613A*B013)
Figure 3
223506
1. Engine type: technical code (F2CFE613E*B013 - F2CFE613A*B013) - 2. Engine serial number (XXXXX) -
3. Construction date (DD/MM/YY) - 4. FPT engine P/N (5801894357 XZ - 5801894336 XZ) - 5. R24 Code
(24R-031580*00 - 24R-031578*00) - 6. R120 Code (120R-011214*00 - 120R-011210*00) - 7. Directive 2000/25/EC -
8. Directive 2010/26/EU
MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING
Technical Code Commercial Code

F2CFE613E*B012
C87 ENT Z W
F2CFE613A*B012
F2CFE613E*B013
C87 ENT L W
F2CFE613A*B013

TECHNICAL CODE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to
characterize its application and power output level. It is stamped on a side of crank-case, close to oil filter.
F2 C F E 6 1 3 E * B 012
Variants to basic engine
Emissions level:
A = TIER 4a
B = TIER 4full/STAGE IV
C = EURO 6
D = Not emissioned
Performances:
1,2,3... A,B,C...= Engine power or torque level
Application:
0 = Other application 5 = Genset
1 = Trucks 6 = Marine
2 = Buses 7 = Cars
3 = Industrial / Agricultural 8 = Railway
4 = Industrial / Agricultural 9 = Military
Engine main characteristics:

0 = Turbocharged CNG
1 = Turbocharged diesel i.d. aftercooled
2 = Naturally Aspirated diesel i.d
3 = Naturally Aspirated diesel i.i
4 = Naturally Aspirated petrol
5 = Naturally Aspirated CNG
6 = Turbocharged diesel i.d.
7 = Turbocharged diesel i.i.
8 = Turbocharged petrol
9 = Turbocharged diesel i.i. aftercooled
No. of cylinders
Cylinder configuration:
A = 4 stroke vertical treat
B = 4 stroke horizontal H = 4 stroke at V
C = 4 stroke vertical with EGR K = 4 stroke at V with post treat
D = 4 stroke horizontal with EGR L = 4 stroke vertical with EGR + post treat
E = 4 stroke vertical with post-treat M= 4 stroke at V with EGR
F = 4 stroke horizontal with post-treat N= 4 stroke at V with EGR+ post treatment
G = 4 stroke horizontal with EGR + post
F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6
Code Type of engine:

C Cursor Tier4 / Euro 6
F2 = New Engine Family

COMMERCIAL CODE
The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical
purpose of recognizing the engines components, which is served by the ENGINE S/N.
C 87 E N T Z W
ENGINE CONTROL UNIT: W = EDC17CV41
EMISSION LEVEL: Z = Tier 4B / L = Stage IV
AIR INTAKE: T = INTERCOOLED SUPERCHARGED
ENGINE BLOCK: N = NOT STRUCTURAL
FUEL SUPPLY: E = ELECTRONIC INJECTION
DISPLACEMENT: 87 = 8700 cc NOMINAL
ENGINE FAMILY IDENTIFIER: C = CURSOR

PERSPECTIVE VIEW
Figure 4
F2CFE613 ENGINES
223489
The engine F2CFE613 is a 6-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the CURSOR
series and operates according to a four-stroke diesel cycle.
The engine supply system is electronically-controlled and its based on the direct injection of the fuel in the combustion chamber
by means of high pressure pump and common rail.

TORQUE AND POWER TYPICAL CURVES

F2CFE613E*B012 - F2CFE613E*B013
Figure 5
Maximum Power
Maximum Torque 218009
F2CFE613A*B012 - F2CFE613A*B013
Figure 6
Maximum Power
Maximum Torque 223490

ENGINE VIEWS
Figure 7
223481
LEFT-HAND SIDE VIEW
Figure 8
223482
RIGHT-HAND SIDE VIEW

Figure 9
223483
FRONT VIEW
Figure 10
223484
REAR VIEW
Figure 11
223491
TOP VIEW

GENERAL CHARACTERISTICS
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
Cycle 4-stroke Diesel
Fuel feed Turbocharged with intercooler
Direct - high pressure pump supply and common
Injection rail system
No. of cylinders 6 in line

Bore mm 117
Stroke mm 135
+ + +.. = Total displacement cm3 8709
Compression ratio 15.9 : 1
Maximum kW 245 305

power hp (333) (415)
rpm 2,100 2,100
Max. torque Nm 1,510 1,800

(kgm) (153.92) (183.49)
rpm 1,500 1,500
Loadless engine idling rpm 600 100
Loadless engine peak rpm 2110 50
Turbocharged with intercooler

SUPERCHARGING Honeywell (HTT)
Turbocharger type Waste-gate turbocharger
(WGT)
LUBRICATION
Oil pressure (warm engine)
Forced by gear pump, relief valve single action oil
(100 C 5 C) filter
bar
- idling bar 0.6
- peak rpm bar 3.5
COOLING Liquid
Water pump control Through belt
Thermostat
- start of opening C 85 1.5
- max. opening C 95
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

F2CFE613
Type E*B012 A*B012
E*B013 A*B013
REFILLING
Cooling circuit (1) L 14
Lubrication circuit (2)
total capacity (3) L (Kg) 26 (23.4)
Periodic replacement:
Sump at minimum level L (Kg) 20 (18)
Sump at maximum level L (Kg) 23 (20.7)
Fuel tank (4) L -
Urea tank (5) L 43 / 80 / 135
(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and Actifull OT
CONCENTRATE (or Actifull OT PREMIX without adding water) even during the summer months. As an alternative to
Actifull OT, use another product that complies with FPT norm FPI9.COOL002 and / or ASTM D-6210 standard.
(2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9. Recommended oil is SAE 10W-40 that
complies with FPT norm FPI9.LUBR001. FPT suggest to use original AkcelA or AmbrA lubricants compliant with SAE 10W40
standard. The oil consumption is considered to be acceptable until a quantity equaling 0.5% of fuel consumption is reached.
(3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.
(4) Use STANDARD fuel compliant to the ASTM D975 or EN 590. Instructions connected to the fuel tank capacity are the
responsibility of the vehicle/equipment manufacturer since these are subject to changes depending on the various
vehicle/equipment configurations.
(5) Only use AdBlue/DEF (32.5% solution in water) in accordance with ISO 22241 specification.
Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection system;
! if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
! by FPT.


F2CFE613 ENGINES SECTION 2 - MAIN ENGINE DIAGRAMS 1
SECTION 2
Main engine diagrams
Page
FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . 3
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 3
- Fuel supply - System layout . . . . . . . . . . . . . . . 4
MECHANICAL SUPPLY PUMP . . . . . . . . . . . . . . 5
- Normal operating conditions . . . . . . . . . . . . . . 5
- Overpressure condition at outlet . . . . . . . . . . . 5
- Drain conditions . . . . . . . . . . . . . . . . . . . . . . . . 5
CP3.3NH HIGH-PRESSURE PUMP . . . . . . . . . . . 6
HIGH-PRESSURE PUMP - INSIDE STRUCTURE 7
- Operating principle . . . . . . . . . . . . . . . . . . . . . . 8
- Pressure regulator description . . . . . . . . . . . . . 10
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RAIL (PRESSURE ACCUMULATOR) . . . . . . . . . 11
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 11
- CRIN 3 Electro-injectors . . . . . . . . . . . . . . . . . 12
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . 15
LUBRICATION CIRCUIT COMPONENTS . . . . 16
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 17
- Oil pressure regulator valve . . . . . . . . . . . . . . . 18
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 19
- Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Replacing oil filter cartridge . . . . . . . . . . . . . . . 21
- Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Oil fume recycle (Blow-by) . . . . . . . . . . . . . . . 23

2 SECTION 2 - MAIN ENGINE DIAGRAMS F2CFE613 ENGINES
Page
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 24
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COOLING CIRCUIT COMPONENTS . . . . . . . . . 25
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . . 26
INTAKE AND EXHAUST SYSTEM COMPONENTS 27
- Honeywell waste-gate Turbocharger . . . . . . . . 27
- Waste gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Motorised throttle valve . . . . . . . . . . . . . . . . . . 29
EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS) 30
- Schematic diagram . . . . . . . . . . . . . . . . . . . . . . 30
- AdBlue specification . . . . . . . . . . . . . . . . . . . . . 34
- System of cooling/heating ATS system . . . . . . . 35
MAIN COMPONENTS OF THE ATS SYSTEM . . 37
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Ad Blue fluid level gauge control . . . . . . . . . . . . 38
- DeNOx 2.2 Supply Module (SM) . . . . . . . . . . . 40
- Filter disassembly . . . . . . . . . . . . . . . . . . . . . . . 41
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 42
- DeNOx 2.2 Dosing module (DM) . . . . . . . . . . 43
- Engine coolant 3 way valve . . . . . . . . . . . . . . . . 43
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Nitrogen oxide detecting sensor . . . . . . . . . . . . 45
- Exhaust gas temperature sensor . . . . . . . . . . . . 46
- Humidity and temperature detecting sensor . . . 47
ATS SYSTEM MAINTENANCE PLANNING . . . . 48
- ATS System filter location . . . . . . . . . . . . . . . . . 48

FUEL SUPPLY SYSTEM

The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
Hydraulic system
Figure 1
Low Pressure 223494
High Pressure
Fuel backflow
1. Common Rail - 2. Electro-injector - 3. Engine Control Unit EDC17CV41 - 4. Fuel high-pressure pump - 5. Fuel filter

Fuel supply - System layout

Figure 2
High Pressure
Low Pressure
223493
Fuel backflow
HYDRAULIC SYSTEM DIAGRAM
1. Common rail - 2. Electro-injector - 3. Common rail excess pressure valve (DBV) - 4. Fuel high pressure pump - 5. Fuel
return from the injectors and rail - 6. High pressure pump backflow - 7. Limiting valve on high pressure pump - 8. Fuel tank -
9. Fuel pre-filter with water separator - 10. Hand priming pump - 11. ECU cooling plate - 12. Mechanical supply pump -
13. By-pass valve - 14. By-pass valve - 15. Fuel filter - 16. Fuel metering unit
The flow rate regulator (16), placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the
low-pressure system.
Afterwards, the high-pressure pump takes care of supplying the rail properly.
This arrangement, by pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.
Function of the pressure relief valve (7), assembled on the high-pressure pump, is keeping the pressure, at the flow rate regulator
inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.
The quick coupler for fuel return housed on the cylinder head, assembled on injector return, permits the fuel return flow from
injectors.
Two by-pass valves (13 and 14) are placed in parallel with the mechanical supply pump (12). The by-pass valve (14) allows fuel
to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.
The by-pass valve (13) allows filling the supply system through the manual priming pump (3).
NOTE Due to the very high pressure that builds within this hydraulic system, the following precautions must be observed
for safety reasons:
- avoid connecting high-pressure pipe fittings with approximate tightening;
- avoid disconnecting the high-pressure pipes when the engine is running
(DO NOT make any attempt at bleeding: this is absolutely useless and dangerous!).
NOTE To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, avoid any
attempt at modification or alteration and intervene immediately if a leak is identified.
NOTE After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level. (IT
MUST NOT INCREASE).

MECHANICAL SUPPLY PUMP Drain conditions

Gear pump, fitted on the rear side of the high pressure pump
and used to supply it. Figure 5
It is controlled by high pressure pump shaft.
Normal operating conditions

Figure 3
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
72592
situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves through B.
in close position
Overpressure condition at outlet
Figure 4
72593
The by-pass valve (1) cuts in when overpressure is generated

at outlet B. The existing pressure, overcoming valve spring (1)
elastic strength, makes inlet and outlet communicating
through duct (2).

CP3.3NH HIGH-PRESSURE PUMP

Pump with 3 radial pistons controlled by the timing gear, without needing any setting. On the rear side of the high pressure pump
is fitted the mechanical supply pump controlled by the high pressure pump shaft.
The high pressure pump cannot be serviced and should not therefore be removed and the fastening bolts should not
be tampered with. The only possible service operation is the replacement of the drive gear.
Figure 6
188494
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter -
6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger -
8. Fuel outlet fitting from supply pump to filter - 9. Mechanical supply pump.

HIGH-PRESSURE PUMP - INSIDE STRUCTURE

Figure 7
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft -
7. Low-pressure fuel inlet - 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a
misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement
along a wider radius, with the resulting alternate actuation of the three pumping elements;
- cap intake valve (3);
- ball delivery valve (4)

Operating principle
Figure 8
Sec. D - D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct -
6. Pressure regulator supply duct - 7. Pressure regulator
Pumping element (3) is oriented to pump shaft (4) cam. During intake, the pumping element is supplied through supply duct (5).
The fuel amount to be sent to the pumping element is set by the pressure regulator (7). The pressure regulator meters fuel flow
to pumping element according to the PWM signal received from ECU. During pumping element compression stage, fuel reaches
the pressure required to open the delivery valve to common rail (2) and to feed it through outlet (1).

Figure 9 Figure 10
72598 72601
Sec. C - C Sec. A - A
1. Pumping element inlet - 2. Pump lubrication ducts - 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
3. Pumping element inlet - 4. Main pumping element from pump with high pressure pipe fitting for common rail.
supply duct - 5. Pressure regulator - 6. Pumping element
inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief
valve - 9. Fuel drain from regulator inlet
Figure shows low pressure fuel paths inside the path and Figure 10 shows high pressure fuel flow through pumping
highlights: main pumping element supply duct (4), pumping element outlet ducts.
element supply ducts (1 - 3 - 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
Pressure regulator (5) establishes the fuel amount to send to
pumping elements; excess fuel is drained out through duct
(9).
5 bar pressure relief valve acts as fuel exhaust manifold and
keeps 5 bar constant pressure at regulator inlet.

Pressure regulator description Operation

The fuel pressure regulator is fitted on the low pressure Figure 11
circuit of pump CP.3. The pressure regulator modulates the
amount of fuel sent to the high-pressure circuit according to
the commands received directly from the engine control unit.
The pressure regulator is mainly composed of the following
components:
- connector,
- casing,
- solenoid,
- pre-load spring
- shutter cylinder.
When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width 185436
Modulation) signal, modulates the change in fuel flow rate in 1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -
the high-pressure circuit by partially closing or opening the 4. Fuel inlet - 5. Fuel outlet.
sections of passage of the fuel in the low-pressure circuit.
When the engine control unit operates the pressure
regulator (via PWM signal), the solenoid (1) is energized,
which in turn generates the movement of the magnetic core
(2). The shift of the core causes the shutter cylinder (3) to
move axially, choking the flow of fuel.
Figure 12
185437
1. Solenoid - 2. Magnetic core - 3. Preload spring -

4. Shutter cylinder.
When the solenoid (1) is not energized, the magnetic core

is pushed into the rest position by the pre-load spring (3). In
this position the shutter cylinder (4) allows the greatest
section of passage for the fuel flow.

Operation RAIL (PRESSURE ACCUMULATOR)

The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 13
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC17CV41 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The pumping element piston goes back towards the bottom 223495
dead center and the remaining fuel is decompressed. 1. Fuel outlet (backflow to tank) - 2. Overpressure valve -
When the pumping element chamber pressure becomes less 3. Common Rail - 4. Fuel inlet coupling from high pressure
than the supply pressure, the intake valve is again opened and pump without throttle valve - 5. Fuel oulet coupling to
the cycle is repeated. electro-injector with throttle valve - 6. Rail pressure sensor
The delivery valves must always be free in their movements, The rail volume is of reduced sizes to allow a quick
free from impurities and oxidation. pressurisation at startup, at idle and in case of high flow-rates.
The rail delivery pressure is modulated by the electronic It anyway has enough volume as to minimise use of plenum
control unit, through the pressure regulator solenoid valve. chambers caused by injectors openings and closings and by
the high-pressure pump operation. This function is further
The pump is lubricated and cooled by the fuel. enabled by a calibrated hole being set downstream of the
The radialjet pump disconnection - reconnection time on the high-pressure pump.
engine is highly reduced in comparison with traditional The throttle valves or control bushes (5) have been fitted to
injection pumps, because it does not require setting. the fuel delivery couplings, which control the fuel pressure
If the pipe between fuel filter and high-pressure pump is to waves generated by the high pressure pump.
be removed-refitted, be sure that hands and components are A fuel pressure sensor (6) is screwed to the rail. The signal
absolutely clean. 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.
Overpressure valve
Overpressure valve is mounted at one rail end. Overpressure
valve task is to protect system components should rail pres-
sure sensor or CP3 pump pressure regulator malfunctioning
cause a pressure excessive increase in high pressure system.
When pressure in rail is reaching 1800 bar, the valve at start
operates in order to make fuel flow and consequently de-
crease pressure to safety values, then mechanically regulates
pressure in rail. The valve enables to operate engine for long
times with limited performance and prevents fuel excessive
overheating, so preserving pipes for fuel return to tank.

CRIN 3 Electro-injectors
The electro-injectors are mounted on the cylinder head and operated by the engine control unit.
Figure 14
204302
INSTALLATION DIAGRAM FOR INJECTORS ON HEAD
1. Bracket - 2. Injector - 3. Cylinder heads- 4. Injector protrusion.
They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot
valve.
Figure 15
114255
1. Fuel return to the LP circuit - 2. HP fuel coupling.

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

- Actuator - nozzle composed of pressure rod (4), needle (5) and nozzle (6);
- Control solenoid valve, consisting of a coil (1) and pilot valve.
Figure 16
188492
INJECTOR SECTION
1. Coil - 2. High-pressure fuel inlet fitting - 3. Filter - 4. Pressure rod - 5. Needle - 6. Nozzle -
7. Pressure chamber - 8. Control volume - 9. Pilot valve shutter - 10. Fuel return.
Electro-injector operation is divided into three phases:

Idle position
The coil (1) is not energised and the shutter (9) of the pilot valve is closed.
Under this condition, opening and closing forces are balanced as fuel pressure in the control volume (9) equals that of the
pressure chamber (7).
Start of injection
The coil (1) is energized and causes the shutter (9) to rise.
The fuel of the control volume (8) flows off towards the return manifold causing a drop in pressure. Simultaneously, the line
pressure exerts an opening pressure in the pressure chamber (7) that lifts the needle (5) thus causing fuel to be injected into
the cylinders.
End of injection
The coil (1) is de-energized and makes the shutter (9) return to its closed position. This creates a balance in the forces acting
upon the needle (5), causing it to return to its closed position and consequently halt the injection of fuel.

Fuel filter
Figure 17
218518
1. Fuel inlet from mechanical pump - 2. Fuel outlet to high-pressure pump - 3. Vent plug - 4. Fuel filter support -
5. Drain screw - 6. Fuel filter - 7. Fuel filter clogging (pressure drop) sensor - 8. Fuel temperature sensor
Characteristics:
- Max flow rate 500 l/h

- Nominal pressure < 13 bar
- Operating temperature -40C/+120C
- Pressure drop with new filter < 0.45 bar @ 500 l/h (ISO 4020/6.3)
- Pressure drop with filter at end of life > 1.5 bar

LUBRICATION CIRCUIT
A gear pump, located at the rear of the crankcase, serves to circulate the lubricant; the oil pump is driven by the crown wheel
keyed to the tang of the crankshaft.
The lubricant is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve actuation.
The lubrication circuit also includes the heat exchanger and the turbocharger.
The pump contains a safety valve, while an oil overpressure valve is fitted on the crankcase.
Figure 18
Routing of oil return by gravity
Routing of oil under pressure
166171
LUBRICATION SYSTEM LAYOUT

LUBRICATION CIRCUIT COMPONENTS

Oil pump
The oil pump (1) is housed in the rear of the crankcase (3). Its a gear pump (6) commanded by helical gear (5).
It receives the motion from the crankshaft (4) by means of helical gear (2) fitted to the stub of the crankshaft (4).
Figure 19
218519
The overpressure valve (1) houses the oil pump body
Figure 20
112327
OIL PUMP SECTION
NOTE The oil pump shall not be overhauled.

If you find any damage, replace the entire oil pump.
Engine speed [rpm] Pump speed [rpm] Outlet pressure [bar] Flow [lpm]
1000 1515 2 62
2400 3636 6 128

Overpressure valve
The valve opening start pressure is 10.1 0.7 bar.
Figure 21
191572
OVERPRESSURE VALVE SECTION

1. Housing valve - 2. Steel ball - 3. Cap - 4. Spring - 5. Circlip - 6. Seal ring.
Figure 22
898 N/mm
219641
OVERPRESSURE VALVE SPRING

1. Unloaded spring - 2. Opening start - 3. Opening end - 4. Spring stuck.

Oil pressure regulator valve

The oil pressure control valve is located on the left-hand side of the crankcase.
Start of opening pressure 5 bar.
Figure 23
73542
OIL PRESSURE REGULATOR VALVE SECTION

Figure 24
188496
OIL PRESSURE REGULATOR VALVE SPRING

1. Unloaded spring - 2. Opening start - 3. Opening end - 4. Spring stuck.

Heat exchanger
The heat exchanger is mounted inside the engine crankcase on the left-hand side.
Figure 25
114246
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4. Oil filter - 5. Oil filter seal

Engine oil filter

Figure 26
114247
1. Closure cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tank O-ring - 6. Washer - 7. Washer - 8. Support -
9. Plug M14x1.5 - 10. Plug M38x1.5 - 11. By-pass valve 3.4 bar.
Characteristics Filter by-pass valve

1. Max working pressure: 13 bar Figure 27
2. Working temperature: - 30 C + 120 C
3. By-pass valve opening value: 3.4 0.3 bar
Lock torques
Cap (part 1): 60 5 Nm
Plug (part 9): 30 5 Nm
Plug (part 10): 90 5 Nm
Installation rule
Use threadlock for plug (part 10).
73545
Valve opens quickly at 3.4 0.3 bar pressure.

Replacing oil filter cartridge Figure 30

Dismantling
Figure 28
115878
Move the upper part of the casing thread close to the first
lower thread of the support (the cartridge cover element
should be in contact with the oil outlet duct on the support).
115876 Proceed with tightening the cartridge-casing assembly (1) on
the support (4).
Remove the plug (2).
During this stage both the seal (3) for the oil outlet
Undo the filter casing (1) by a couple of turns and wait for
duct-cartridge element and the casing-support seal (2) will
a few minutes.
gradually be involved.
In this way the remaining oil in the casing starts firstly to drip
Tighten the filter casing to a torque of 65 Nm.
and then to flow smoothly out.
Completely undo the casing and then replace the cartridge.
Figure 31
Refitting
Figure 29
115877
Insert the cartridge in the casing aligning the centering tabs

(2) on the upper plate (1) with the seats.
The cartridge should be pushed into the container until the
action of the attachment system at the bottom of the casing
is overcome. 115879
At the same time, the tabs on the upper plate should slide Tighten the protective cap (1) on the filter casing.
into the housings.

Oil sump
The oil sump has a new type of anchorage to the crankcase: rubber diaphragm.
The edge of the sump (2) is sealed within a thick C rubber gasket (1), and the assembly is contained inside and supported
by an aluminium element (5) bolted to the crankcase with screws (3).
This solution prevents noise and improves seal quality, while using less screws than the traditional system.
Yet another benefit is that the gasket does not require replacement at every removal.
Figure 32
223492
1. Rubber gasket - 2. Oil sump - 3. Fastening screws - 4. Lubricant oil drain plug - 5. Aluminium plate

Oil fume recycle (Blow-by)

Part of gas produced by combustion during engine operation leaks through piston elastic ring openings into sump, mixing with
oil fumes in sump.
This mixture, conveyed upward, is partially separated from oil by a device located in timing cover upper part and introduced in
air intake circuit.
The device mainly consists of a rotary filter (1) secured on camshaft and by a front cover (2) housing the valve (3) controlling
mixture flow.
Figure 33
Gas with oil contents greater than 10 g/h

Gas with oil contents approx. 0,2 g/h
Condensed oil returning to oil sump
193965

COOLING CIRCUIT
Description
The engine cooling system is of the closed-circuit, forced circulation type.
It consists mainly of the following components:
- expansion tank, not supplied (by FPT);
- a heat exchanger to cool down lubrication oil;
- a water pump with centrifugal system incorporated in the cylinder block;
- fan, not supplied;
- thermostat controlling the coolant circulation.
Operation
The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the
cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the
thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan.
Figure 34
Water circulating in the engine

Water to radiator
218520
Water coming into pump

COOLING CIRCUIT COMPONENTS

Water pump
Figure 35
223537
CROSS-SECTION OF THE WATER PUMP

The water pump consists of: rotor, shaft with bearing, T-gasket and drive pulley with dust shield.
NOTE Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.
Thermostat
The thermostat is inserted into the water inlet pipe into the pump; it is an N/C valve.
The valve begins to open with temperatures exceeding 85 C.
When the valve is closed, the water arriving from the heat exchanger on the gearbox, recirculates inside the engine via the
water pump.
When the valve is open, the water arriving from the heat exchanger on the gearbox is sent directly to the radiator where it
is then cooled.
Figure 36
191251
TERMOSTAT SECTION
- The valve starts to open at: 85 C 1.5 C
- The stroke is at least: 9 mm at 95 C

INTAKE AND EXHAUST SYSTEM

Ignition from the panel allows crankshaft rotation, the phase in which the pistons compress the air/fuel mixture inside the
combustion chamber.
After combustion, the exhaust gases cause rotation of the turbine splined to the centrifugal compressor by means of a connecting
shaft. Rotation of the turbine involves the rotation of the compressor which compresses the air coming from the filter. This
compression of the latter causes an increase in temperature and hence its expansion.
In order to introduce a greater quantity of mixture into the combustion chamber, the air is inter-cooled to increase its density
at the same pressure.
A greater quantity of air introduced, corresponds to a greater quantity of fuel injected and, therefore, increased power.
Hence, to obtain an optimal mixture which generates increased power, the correct stoichiometric air-fuel ratio must be observed,
so as to ensure the complete consumption of both during combustion.
The cycle is completed with the introduction of inter-cooled air from the intercooler into the intake manifold and then to the
pistons to be used in combustion.
Figure 37
Exhaust gas
Compressed air 223497
Intake air
DIAGRAM OF TURBOCHARGING
1. Exhaust valves - 2. Exhaust manifold - 3. Motorized throttle valve (Exhaust flap) - 4. Turbocharger with waste-gate valve -
5. Intake valves - 6. Air grid-heater for cold starting (if present) - 7. Intake manifold
A. Cooled compressed air engine intake from intercooler - B. Turbocharger exhaust gas outlet from motorized throttle
valve (Exhaust flap) - C. Turbocharger filtered air inlet from air filter - D. Turbocharger compressed air outlet to intercooler

INTAKE AND EXHAUST SYSTEM COMPONENTS

Honeywell waste-gate Turbocharger
The turbocharger is fitted onto the exhaust manifold.
Figure 38
189008
1. Gasket - 2. Exhaust gas intake - 3. Waste gate valve -

4. Compressed air outlet - 5. Air intake.
The turbocharger mainly consists of:

- a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor
impellers;
- a turbine casing and a compressor casing mounted on the end of the central body;
- an overpressure relief valve (waste-gate) fitted to the turbine body. The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the exhaust pipe, when the boosting pressure downstream the
turbocharger reaches the calibration value.
Figure 39
Closed throttle valve Throttle valve open 75532
DEMONSTRATIVE CROSS-SECTION OF A TURBOCHARGER

WITH WASTE-GATE VALVE
Waste gate
NOTE Verifying an anomalous operation of the engine,
due to the booster system, it is recommended, be- The turbocharger is fitted with a pressure regulation valve,
fore performing controls on the turbocharger, to mounted on the exhaust manifold before the turbine and
check the efficiency of the sealing gaskets and the controlled by a pneumatic actuator, connected via a pipe to
fixing of the connection sleeves, making sure of the intake manifold.
clogging absence inside intake sleeves, air cleaner Its job is to limit the quantity of exhaust gas acting on the tur-
or inside radiators. bine by sending part of it directly into the exhaust pipe when
If the turbocharger damage is due to a lack of lubric- the boost pressure downstream of the compressor reaches
ation, check that the oil circulation pipes are not the maximum value set.
broken or obstructed, in such case replace them or
eliminate the trouble. Check and adjustment
Figure 40
Bearing end play check
Position the tracer point of the magnetic-base dial gauge on
the turbocharger shaft end and set to zero the dial gauge.
Move the turbocharger shaft axially and check that the clear-
ance is not higher than the prescribed value.
Replace the turbocharger if a different value is found.
62873
Cover the air, exhaust gas and lubrication oil inlets and out-
lets.
Carry out an accurate external cleaning of the turbocharger,
using the anticorrosive and antioxidant solution and perform
the check on the actuator (6).
Clamp the turbocharger in a vice.
Disconnect the pipe of the actuator (6) and apply to the actu-
ator union, the pipe of pump 99367121 (1).
Apply the magnetic-base dial gauge (2) on the exhaust gas
inlet flange in the turbine.
Position the tracer point of the gauge (2) on the tie rod (3)
end and set to zero the gauge (2).
Through the pump (1) let in compressed air, in the actuator
(6), at the prescribed pressure and make sure that such value
is kept constant for the whole check time, otherwise replace
the actuator (6).
In the above-mentioned conditions, the tie rod must have
carried out the prescribe stroke.
NOTE During the operation, beat slightly the actuator (6)

in order to eliminate possible sticking of the actu-
ator internal spring.
If a different value is found, loosen the nut (5) and operate

properly the knurled ring nut (4).

Motorised throttle valve

A throttle valve, powered by an electric actuator, is introduced into the exhaust pipe downstream of the turbine.
The valve is controlled by the ECU through an electric actuator which is cooled by the coolant from the engine.
The main novelty is the electric actuator that makes it possible to choke the exhaust gas outlet to increase its output
temperature.
This possibility is used to rapidly bring the catalytic converter to its thermal operating condition (reduction of cold engine
emissions).
Figure 41
188487

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
Figure 42
Exhaust gas
Compressed air
Intake air
Coolant engine
Electric line
AdBlue
223500
Component (v = vehicle mounted)

1. Fuel pre-filter w/ heater (opt) and water-in-fuel switch (v) - 2. Engine Control Unit EDC17CV41 - 3. Fuel filter w/ temp
sensor - 4. Fuel filter delta-p switch or filter clogging (pressure drop) sensor - 5. Fuel high pressure pump - 6. Fuel high
pressure pump metering valve - 7. Boost pressure (P2) and air temperature sensor (intake manifold) - 8. Grid heater relay -
9. Grid heater resistance for engine pre-heating - 10. Overpressure valve - 11. Common Rail - 12. Rail pressure sensor
(RDS4) - 13. Timing segment speed sensor (camshaft) - 14. Electro-injectors (CRIN3) - 15. Flywheel increment speed
sensor (crankshaft) - 16. Intake air humidity & temperature sensor (v) - 17. Motorized throttle valve (Exhaust flap) (CAN
node) - 18. DOC upstream exhaust gas temperature sensor (T4) (v) - 19. SCR downstream NOx sensor w / ECU (v) - 20.
DOC upstream NOx sensor w / ECU (v) - 21. NH3 sensor ECU (v) - 22. NH3 sensor (v) - 23. SCR downstream exhaust
gas temperature sensor (v) - 24. SCR upstream exhaust gas temperature sensor (v) - 25. DeNOx 2.2 Dosing Module (DM)
(v) - 26. DeNOx 2.2 Supply Module (SM) (v) - 27. Urea quality sensor (UQS) w/ ECU (v) - 28. DEF tank level sensor (v) -
29. DEF temperature sensor (v) - 30. Exhaust gas absolute pressure (P3) sensor - 31. Crankcase pressure sensor - 32.
Engine oil pressure and temperature sensor - 33. Engine coolant temperature sensor - 34. Engine coolant 3 way valve (v)

In order to reduce exhaust gas emissions to within the limits required by current standards, it has proved necessary to adopt
the exhaust gas after-treatment system (ATS) which combines two devices:
- two catalytic converters for the treatment of HC (unburned hydrocarbons) and CO (carbon monoxide);
- the device DeNOx 2.2 for the treatment of NOx (nitrogen oxides).
The ATS system is electronically managed by the ECU EDC17CV41 which, based on the number of engine revs, delivered
torque, exhaust gas temperature, amount of nitrogen oxides and air humidity intake, regulates the flow rate of the AdBlue
solution to be introduced into the system.
The pump module draws the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.
Figure 43
185021
The catalytic converters perform two functions:

- the first is composed of a DOC (Diesel Oxidation Catalyst) which removes HC (unburned hydrocarbons) and CO (carbon
monoxide) from the exhaust gases;
- the second is composed of the SCR (Selective Catalyst Reduction) and the CUC (Clean Up Catalyst) upstream of which
are located the AdBlue dosing module and the mixer; this is where the reduction reactions of the NOx (nitrogen oxides)
take place.
In the first phase the exhaust gases exiting the turbine are conveyed into the DOC catalytic converter in which the hydrocarbons
(HC) and carbon monoxide (CO) added to oxygen O2 are converted into carbon dioxide (CO2) and water (H2O) through
oxidation reactions.
In the second phase the dosing module, located in the exhaust pipe upstream of the SCR catalytic converter, introduces a water
and urea solution (AdBlue) into the exhaust gases by means of a dosing injector.
The final phase of the process is realised in the SCR catalytic converter: the reagent solution, due to the temperature of the
exhaust gases, instantly evaporates and, by hydrolysis, is converted into ammonia (NH3) and carbon dioxide (CO2), at the same
time; the evaporation of the solution causes the lowering of the exhaust gas temperature, bringing it close to the optimum
temperature required for the process.
By reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).
The engine control unit, based on the number of engine revs, delivered torque, exhaust gas temperature, air humidity intake,
the amount of nitrogen oxides and urea present in the exhaust gases (detected by the respective sensors), regulates the flow
rate of the AdBlue solution to be introduced into the system.
The amount of AdBlue injected is controlled by the NH3 sensor located downstream of the SCR.
It detects the presence of ammonia in the exhaust gases and transmits a signal to the engine control unit, thus supplying a
feedback signal.

Figure 44
AdBlue
Electric line
Coolant engine
223499
1. Can line - 2. AdBlue tank - 3. AdBlue tank level sensor - 4. Urea quality sensor (UQS) - 5. AdBlue temperature sensor -
6. Engine Control Module (EDC17CV41) - 7. Humidity and temperature sensor (after air filter) - 8. NOx sensor ECU -
9. NH3 sensor ECU - 10. Supply module Denox 2.2 - 11. Urea pressure sensor - 12. NH3 sensor - 13. NOx sensor -
14. SCR downstream exhaust gas temperature sensor - 15. Clean Up Catalyst (CUC) -
16. Selective catalyst reduction (SCR) - 17. SCR upstream exhaust gas temperature sensor - 18. Mixer -
19. Dosing module - 20. Diesel Oxidation Catalyst (DOC) - 21. DOC upstream exhaust gas temperature sensor -
22. NOx sensor - 23. Engine coolant 3 way valve - 24. NOx sensor ECU.
The ATS system is essentially composed of:

- a DOC catalytic converter (Diesel Oxidation Catalyst);
- an SCR catalytic converter (Selective Catalyst Reduction);
- a CUC filter (Clean Up Catalyst)
- a tank of the reagent solution (water + urea: AdBlue) with level indicator, temperature sensor and Urea quality sensor;
- a H2O switch valve;
- a supply module;
- a dosing module;
- three exhaust gas temperature sensors;
- a humidity sensor mounted on the engine air suction pipe downstream of the air filter.
- two sensors to detect the amount of nitrogen oxides (NOx);
- a sensor to detect the presence of NH3 (ammonia) upon exit of exhaust gases.

Figure 45
223498
1. DOC upstream NOx sensor - 2. Engine coolant 3 way valve - 3. Dosing module DeNOx 2.2 -
4. Intake air humidity and temperature sensor - 5. Supply module DeNOx 2.2 - 6. AdBlue tank -
7. AdBlue tank level sensor - 8. Urea quality sensor (UQS) - 9. Selective catalyst reduction (SCR) -
10. SCR upstream exhaust gas temperature sensor - 11. Exhaust flap module - 12. Diesel Oxidation Catalyst (DOC) -
13. DOC upstream exhaust gas temperature sensor - 14. SCR downstream exhaust gas temperature sensor -
15. NH3 sensor - 16. NH3 sensor ECU - 17. SCR downstream NOx sensor

AdBlue specification
ISO 22241 / AUS32 / DIN V 70070
Urea 32.5% - solution in water
Min Max
Urea content 31.8 33.2 % by weight
Density at 20C 1.087 1.093 g/cm3
Refracting index at 20C 1.3814 1.3843
Alkalinity as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chromium 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg

System of cooling/heating ATS system

The system performs two functions:
- continuous cooling of the dosing module;
- heating of the AdBlue tank, the supply module and AdBlue pipes and, at the same time, cooling of the dosing module.
Figure 46
Coolant engine
AdBlue
185019
COOLING CONDITION
1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.
The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures
reached by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously
cooled.

Figure 47
Coolant engine
AdBlue
185023
CONDITION OF SIMULTANEOUS HEATING AND COOLING

1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.
Please note that AdBlue may freeze below temperatures of -11C.

When the temperature of AdBlue in the tank falls below the acceptable limit, the switch valve (3) is activated which enables
the flow of the engine coolant into the heating coil inside the tank (4) and hence into the supply module (5).
In this phase, the engine cooling temperature is such as to carry out the function of heating the components as described above.
Afterwards the engine coolant is conveyed towards the dosing module in order to cool its temperature.

MAIN COMPONENTS OF THE ATS SYSTEM

Tank
Figure 48
215387
The tank has a level indicator command (1) and contains the reducing substance, consisting of a 33% urea and water solution
called AdBlue. The inlet (4) is equipped with a mesh filter (3). A urea quality sensor (2) and a temperature sensor are
incorporated in the tank.
NOTE FPT recommends maintaining AdBlue temperature below 50 C in the tank during operating conditions.
Tank ventilation: the circuit must be protected from dust.

Ad Blue fluid level gauge control

Figure 49
215388
1. AdBlue suction - 2. AdBlue return - 3. Engine coolant outlet - 4. Engine coolant outlet pipe - 5. AdBlue heating coil -
6. Engine coolant inlet pipe - 7. Connector - 8. Engine coolant inlet - 9. Ad Blue suction pipe - 10. Filter -
11. Bottom plate (AdBlue NTC temperature sensor) - 12. Float (AdBlue level sensor) - 13. Reed pipe -
14. AdBlue return pipe
The AdBlue fluid level gauge control consists of

- a float (level sensor);
- an NTC temperature sensor;
- a liquid heating coil in case of low temperatures.
Frozen AdBlue can be melted by means of a coolant heater coil (5).
A solenoid which is actuated by the ECU controls the engine coolant flow through the AdBlue circuit / tank heater.
Urea quality sensor is integrated in the tank unit to fulfil rapid anti-tampering.
NOTE Ensure connectors are properly sealed with a moisture proof plug prior to AdBlue tank leak testing.
Temperature sensor: NTC type;

1kOhm +/-5% @ 25C
Level sensor recommended characteristic: 70 Ohm at low level;
20kOhm at high level

Electrical connections:
Figure 50
215389
Ref. Description
1 Level
2 Common ground
3 NTC signal (temperature)

DeNOx 2.2 Supply Module (SM)

Figure 51
185025
1. Main filter - 2. Electrical connector - 3. Pressure compensation membrane - 4. Supply pipe from tank - 5. Fluid input pipe
of pump module heating - 6. AdBlue return pipe to tank - 7. Fluid output pipe of pump module heating - 8. Delivery pipe
to dosing module
The AdBlue supply module is essentially composed of a diaphragm pump which draws the AdBlue from the tank and conveys
it to the dosing module.
It is equipped with a circuit connected to the engine cooling system which, in the event of low temperatures, prevents the AdBlue
from freezing. A pressure sensor is located inside it.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and
depend on the operating conditions of the engine and the signals sent from the sensors.
Electric power requirements of DeNOx 2.2 Supply Module (SM) for 7.2 kg/h:
24 Volt systems: max 2750 mA @ 28 Volt battery voltage
Figure 52
185029
1. Coolant connector - 2. AdBlue inlet from tank - 3. AdBlue back-flow to tank - 4. AdBlue outlet to DM - 5. Pressure
sensor - 6. Main filter - 7. Membrane pump - 8. 4/2 Way valve.
To prevent damage to the pump and dosing module, the supply module contains a filter which removes any impurities from
the AdBlue.
Please refer to the following procedure for replacement of the filter.

Filter disassembly Figure 56
Figure 53
185430
185435 - Insert the tool (1) in the correct direction in the filter,
based on the colour of the filter supplied
NOTE During installation of the supply module on the
vehicle, take into account the minimum aperture
for filter replacement. Figure 57
The minimum value is approx. 155 mm.
Figure 54
185431
- Insert the appropriate tool (1) until a click is felt which

indicates the complete engagement of the filter (2).
185428
- Unscrew and remove the filter cover (1).

Figure 58
Figure 55
185432
185429
- Remove the equalizing element (1). - Remove the filter (1).

Filter assembly Figure 62

Figure 59
185428
185433 - Carefully clean the filter cover (1).

- Carefully clean the contact surface with water (1). - Tighten the filter cover to a torque of 20 5 Nm.
Figure 60
Figure 63
185434
- Oil gaskets and assembly new filter (1).
185435
Figure 61
NOTE During installation of the supply module on the

vehicle, take into account the minimum aperture
for filter replacement.
The minimum value is approx. 155 mm.
185429
- Assembly a new equalizing element (1).
NOTE Check that the filter cover and the contact surface
of the supply module are not cracked or damaged.
If necessary, replace any damaged components.

DeNOx 2.2 Dosing module (DM)

Figure 64
193974
1. Electrical connector - 2. AdBlue inlet - 3. Coolant engine inlet/outlet
The dosing module is controlled by the engine control unit. Its function is to measure the AdBlue solution to be injected into
the exhaust pipe upstream of the SCR catalytic converter.
It is mounted on the catalytic converter and whilst operating is constantly subjected to high temperatures, hence it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
Hydraulic Capability of DeNOx 2.2 Dosing module (DM):
Normal circulation and no injection: ~ 8 kg/h
Maximum with the small urea injector: ~ 15 kg/h (8 kg/h + 7 kg/h)
Maximum with the large urea injector: ~ 20 kg/h (8 kg/h + 12 kg/h)
Engine coolant 3 way valve

Figure 65
180580
1. Electrical connector - 2. AdBlue tank heating fluid pipe - 3. Dosing module coolant pipe - 4. Engine coolant pipe.
The switch valve is of solenoid valve 2 position/3-way type. Depending on the temperatures detected by the NTC sensor, the
switch valve closes or opens the passage of the engine coolant into the AdBlue tank heating coil. The cooling circuit of the dosing
module instead always stays open.
The first position, in fact, allows the cooling of the dosing module (DM - Dosing Module) whereas the second position allows
the cooling of the AdBlue tank, the supply module (SM - Supply Module) and the relevant pipes, besides heating the DM.

NH3 sensor
Figure 66
185027
The NH3 sensor is connected to the engine control unit and, by detecting the presence of ammonia (NH3) in the exhaust gases
exiting the catalytic converter, enables a more accurate regulation of the amount of AdBlue to be injected.
Figure 67
185028
A. Vehicle connector - B. Sensor connector.

101. Supply - 102. Can H - 103. Can L - 104. Ground.
NH3 SENSOR CHARACTERISTICS NOMINAL
Normal operating voltage 10 to 32 V
Average current 1.2 A
Max current 4.0 A
Temperature / humidity rating -40 to 105 C

Nitrogen oxide detecting sensor
Figure 68
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare

The NOx sensor detects the amount of nitrogen oxides in the exhaust gases entering and exiting the catalytic converters.
Based on this information the engine control unit regulates the amount of AdBlue to be injected and also measures the efficiency
of the catalytic converters.
CHARACTERISTICS OF NOx SENSOR VALUE

Ambient temperature electronics: - 40 to +105 C
(+105 to +115 C allowed for up to 10
min)
Wire temperature: 230 C allowed for up to 100 h

Exhaust gas temperature sensor
Figure 69
102303
Figure 70
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) -
5. Ground cable (white) - 6. Sensor.
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.
CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR VALUE

Power supply 5.00 V 0.1%
Output voltage @ Temperature -40 to 1000 C 0.727 to 2.297 V
Pull up resistance 1000 0.1%
Lead resistance 1

Humidity and temperature detecting sensor

Figure 71
125531
1. Supply - 2. Moisture indicator - 3. Ground connection - 4. Temperature

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to
the control unit. These data are used by the ECU to determine the level of nitrogen oxide emissions.
Figure 72
223113
ELECTRIC BLOCK DIAGRAM

1. Power supply VDC 2. Percentage of humidity 3. Ground 4. NTC Temperature
A. Reference oscillator B. Sensor oscillator C. Sample frequency generator D. Low pass amplifier filter
CHARACTERISTICS OF HUMIDITY SENSOR VALUE

Voltage supply 5.00 0.25 VDC
Current absorption (Max.) 10 mA
Humidity operating range 0% RH 100% RH
Output impedance 70
Isolation resistance 1 M @ 500 V
CHARACTERISTICS OF TEMPERATURE SENSOR VALUE
Temperature operating range -40 125 C
Resistance at 25 C NTC 2.186 k 1%
Max power at 25 C 100 mW

ATS SYSTEM MAINTENANCE PLANNING

The general checking/inspection intervals which must be carried out on the ATS system components are as follows.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested
by common sense and by the specific conditions in which the engine is run.
In case of evident system malfunction immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Component Function Service-Requirement

Tank Neck Filter Protect tank during filling No regular service planned (Cleaning, if
(300 or 100* m) required)
SM Pre-Filter Protect SM from dirt coming from tank Cleaning with water @ every oil change
(100 or 70* m) interval
SM Inlet-Filter (100 m) Protect SM during 1st start-up No regular service planned (Replacement,
if required)
SM Main-Filter Protect DM Change every 3,600 hours or 2 years
(whichever occurs first)
SM Backflow-Filter Protect throttle in backflow connector from dirt No regular service planned (Replacement,
(100 m) coming from pressure line or dirt introduced during if required)
change of SM Main-Filter
Dosing Valve Filter Protect DM during 1st start-up Cannot be serviced
(36 m)
* for application working in dusty environment only.
ATS System filter location

Figure 73
223534
FILTER LOCATION
1. Dosing valve filter (36 m) - 2. Dosing module - 3. Supply module backflow-filter (100 m) -
4. Supply module pre-filter (100 or 70* m) - 5. Tank neck filter (300 or 100* m) - 6. AdBlue tank -
7. Supply module inlet-filter (100 m) - 8. Supply module - 9. Supply module main-filter

F2CFE613 ENGINES SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
MAIN ENGINE ELECTRICAL COMPONENTS . 3
- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Engine Control Unit (EDC17CV41) . . . . . . . . 5
EDC SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . 6
- EDC 17CV41 control unit wiring diagram -

Vehicle side (part 1/2) . . . . . . . . . . . . . . . . . . . 8

Vehicle side (part 2/2) . . . . . . . . . . . . . . . . . . . 9
- Pin out EDC 17CV41 control unit - Vehicle side

connector (connector 1) . . . . . . . . . . . . . . . . 10

Engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Pin out EDC 17CV41 control unit - Engine side

connector (connector 2) . . . . . . . . . . . . . . . . 14
- Electro-injectors (CRIN 3) . . . . . . . . . . . . . . . 17
- Fuel high pressure pump metering unit . . . . . . 18
- Rail pressure sensor (RDS4.4) . . . . . . . . . . . . . 19
- Crankcase pressure sensor . . . . . . . . . . . . . . . 19
- Increment speed sensor (Crankshaft) . . . . . . . 20
- Segment speed sensor (Camshaft) . . . . . . . . . 21
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 22
- Coolant temperature sensor . . . . . . . . . . . . . . 23
- Oil pressure and temperature sensor . . . . . . . 23
- Boost pressure and temperature sensor . . . . . 24
- Main fuel filter clogging switch . . . . . . . . . . . . . 24
- Engine decompression valve . . . . . . . . . . . . . . 25
- Motorized throttle valve actuator connector

(Exhaust flap) . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Grid-heater resistance for engine pre-heating . 27
- Electric starter motor . . . . . . . . . . . . . . . . . . . 28
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2 SECTION 3 - ELECTRICAL EQUIPMENT F2CFE613 ENGINES

MAIN ENGINE ELECTRICAL COMPONENTS
Figure 1
223496
1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor - 4. Fuel temperature and filter
clogging (pressure drop) sensor - 5. Crankcase pressure sensor - 6. Grid-heater resistance for engine pre-heating -
7. Alternator - 8. Boost pressure and air temperature sensor - 9. Engine oil pressure and temperature sensor - 10. Engine
Control Unit EDC17CV41 - 11. Fuel high pressure pump metering unit - 12. Starter electric motor - 13. Flywheel increment
speed sensor (crankshaft) - 14. Motorized throttle valve actuator connector (Exhaust flap) - 15. Timing segment speed sensor
(camshaft) - 16. Exhaust gas absolute pressure sensor

4
Figure 2
Base - September 2015

Engine cable
SECTION 3 - ELECTRICAL EQUIPMENT
223501
1. Electro-injector (cylinder 6) - 2. Electro-injector (cylinder 5) - 3. Electro-injector (cylinder 4) - 4. Electro-injector (cylinder 3) - 5. Electro-injector (cylinder 2) -
6. Rail pressure sensor - 7. Electro-injector (cylinder 1) - 8. Bulkhead connector (wires passage) - 9. Engine decompression electrovalve insertion (Engine brake) - 10. Coolant
temperature sensor - 11. EDC engine side connector 96 pin - 12. In line vehicle side connector 7 pin - 13. Crankcase pressure sensor - 14. Boost pressure and air temperature
sensor - 15. Engine oil pressure and temperature sensor - 16. Fuel filter clogging (pressure drop) sensor - 17. Fuel temperature sensor - 18. Fuel high pressure pump metering unit
- 19. Timing segment speed sensor (camshaft) - 20. Exhaust gas absolute pressure sensor - 21. Motorized throttle valve actuator connector (Exhaust flap) - 22. Flywheel
F2CFE613 ENGINES
increment speed sensor (crankshaft)
Print P2D32C012 E
Engine Control Unit (EDC17CV41)

The connection of the ECU to the components of the EDC system is achieved by two connectors mechanically polarized in the
coupling system in order to prevent mismatching:
- Connector 1 for vehicle side connections;
- Connector 2 for core engine components.
There is an internal ambient pressure sensor used to further improve the injection system control
Figure 3
189003
1. Vehicle connector (Connector 1) - 2. Engine connector (Connector 2)

EDC SYSTEM FUNCTIONS

The EDC 17CV41 electronic center manages the following main functions:
Fuel injection
Accessory functions such as cruise control, speed limiter, PTO and the like
Self-diagnosis
Recovery
It also enables:
Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating
Pressure can be adjusted in case of:

- motorised throttle valve actuation
- serious defects involving load reduction or engine stop.
After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding
mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.
Delivery correction based on water temperature
When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays
are not optimized yet.
Fuel injected also tends to condense on cold metal surfaces.
Fuel dosing with a cold engine is therefore greater than when hot.
Delivery correction to prevent noise, fumes or overloads
Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center
to prevent them.
De-rating
In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

Injection lead electronic control

Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder
to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.
Lead is corrected as required:
- during acceleration
- according to water temperature
and to obtain:
- reduced emissions, noise abatement and no overload
- better vehicle acceleration
High injection lead is set at start, based on water temperature.
Delivery start feedback is given by injection electro valve impedance variation.
Engine start
Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator
pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables
the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn
by the starter motor.
Run Up
When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),
and diagnoses the system.
After Run
At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the
microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom)
memory to make tem available for the next start (Cf. Run Up).
These data essentially consists of:
- miscellaneous settings, such as engine idling and the like
- settings of some components
- breakdown memory
The process lasts for some seconds, typically from 2 to 60 according to the amount of data to be stored, after which the ECU sends
a command to the main relay and makes it disconnect from the battery.
This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before
10 seconds at least after engine cutout.
In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown
memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Repeated procedure interruptions could in fact lead to center damage.
Cut-off
It refers to the supply cut-off function during deceleration.
Cylinder Balancing
Individual cylinder balancing contributes to increasing comfort and operability.
This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each
cylinder, to compensate for injector hydraulic tolerances.
The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information
is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.
Synchronization search
The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.
If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the
sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection
occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence
and start the engine.

8
Figure 4

EDC 17CV41 control unit wiring diagram - Vehicle side (part 1/2)
218026
1. Vehicle connector EDC 96 pin - 2. CAN BUS to Customers application computer - 3. Diagnostic connector - 4. Controller Area Network C - 5. SCR downstream NOx
ECU - 6. SCR downstream NOx sensor - 7. DOC upstream NOx ECU - 8. DOC upstream NOx sensor - 9. NH3 ECU - 10. NH3 sensor - 11. Urea Quality sensor -
12. In line connector - 13. Battery Disconnection Switch (BDS) - 14. Alternator - 15. Alternator connector kit (J1) - 16. Starter electric motor - 17. Battery -
18. Battery charge warning lamp - 19. SCR hose suction line heater - 20. Fuel pre-filter heater relay - 21. Fuel pre-filter heater - 22. SCR electrical heater -
23. SCR heater relay - 24. Fuel filter/pre-filter heater relay - 25. Fuel filter heater - 26. Grid-heater relay - 27. Water in fuel switch - 28. ATS intelligent sensors auxiliary relay -
29. Grid-heater - 30. Starter control relay - 31. Starter relay - 32. Body controller starter interlock (Vehicle safety) - 33. Body controller starter interlock relay - 34. Key switch -
35. Alternative connections (A. ECU under time relay - B. ECU under BDS - C. ECU not under BDS)
F2CFE613 ENGINES
Print P2D32C012 E
Print P2D32C012 E
Figure 5
F2CFE613 ENGINES
EDC 17CV41 control unit wiring diagram - Vehicle side (part 2/2)
218027
1. Vehicle connector EDC 96 pin - 2. Controller Area Network B - 3. SCR tank level and temperature sensor - 4. Diagnostic LED - 5. DEF dosing module -
6. SCR downstream exhaust gas temperature sensor - 7. SCR upstream exhaust gas temperature sensor - 8. DOC upstream exhaust gas temperature sensor -
9. Humidity and ambient temperature sensor - 10. SCR tank heating valve - 11. SCR Pump module
(A. SCR pressure sensor - B. SCR reverting valve - C. SCR pump motor)
9

Pin out EDC 17CV41 control unit - Vehicle side connector (connector 1)
Figure 6
189004
Pin Signal Component

01 V_V_BAT +4 Battery plus 4
02 O_T_RL 11 SCR heater
03 G_G_BAT -1 Battery minus 1
04 O_T_RL 14 SCR hose suction line heater
06 - -
07 I_A_AN 23 SCR pressure sensor
08 I_A_AN 25 SCR temperature sensor
09 I_A_AN 22 Catalyst downstream temperature sensor
10 G_R_AN 10 Common ground
11 -
12 -
13 I_S_DIG 01 Water in fuel switch
14 -
15 I_A_AN 04 Humidity sensor
16 I_A_AN 13 Exhaust gas temperature upstream sensor
17 -
18 -
19 O_S_RH 04 Starter relay
20 O_T_RH 03 ATS intelligent sensors Auxiliary Relay (H)
21 -
22 -
23 O_T_RH 01 DEF Dosing Module
24 -
27 O_V_RH 31 Common battery plus


29 G_G_RL 11 Ground for low side power stage 11
30 -
31 I_A_AN 12 SCR level sensor
32 I_A_AN 24 Catalyst upstream temperature sensor
33 -
34 O_F_ENGN Engine speed output
35 .
36 .
37 .
38 .
40 I_A_AN 14 Air temperature sensor
41 -
42 -
44 O_S_RL 24 OBD led
45 O_T_RL 18 ATS intelligent sensors Auxiliary Relay (L)
46 B_D_CANH0 CAN high
47 B_D_CANL0 CAN low
48 -
51 G_G_RL 07 Diagnostic LED ground
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
61 O_S_RL 20 Fuel filter / pre-filter heating relay
62 -
63 I_S_T 50 Start switch term. 50 input signal
64 -
65 -
66 -
67 -
68 V_V_5VSS1D Common supply
69 I_S_T 15 KL15


70 B_D_ISOK ISO-K interface
71 B_D_CANH1 Controller area network 1 (high)
72 O_S_RL 12 SCR Tank Heating Valve
76 G_G_RL 14 Ground for low side power stage 14
77 O_S_RH 07 Diagnostic LED plus
78 -
79 -
80 -
81 -
82 -
83 O_S_RL 22 Grid heater relay
84 O_T_RL 13 SCR pump motor
85 O_T_RL 16 SCR reverting valve
86 -
87 -
88 O_S_RL21 Low side source driver 21
89 G_G_RL 13 SCR pump motor
90 V_V_5VSS3A Common supply
91 -
92 -
93 O_S_RL 27 Auxiliary relay / SCR heater relay
94 -
95 B_D_CANL1 Controller area network 1 (low)
96 0_T_RL 10 DEF Dosing Module

Print P2D32C012 E
Figure 7
F2CFE613 ENGINES
EDC 17CV41 control unit wiring diagram - Engine side
223503
1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Engine oil pressure and temperature sensor -
5. Boost pressure and air temperature sensor - 6. Fuel filter clogging (pressure drop) switch - 7. Motorized throttle valve actuator connector (Exhaust flap) - 8. In line connector -
9.Crankcase pressure sensor - 10. Timing segment speed sensor (camshaft) - 11. Flywheel increment speed sensor (crankshaft) - 12. Fuel high pressure pump metering unit -
13. Exhaust gas absolute pressure sensor - 14. Engine decompression electrovalve insertion (Engine brake) - 15. Bulkhead connector (wires passage) - 16. Rail pressure sensor
(RDS4) - 17. Electro-injector (cylinder 6) - 18. Electro-injector (cylinder 5) - 19. Electro-injector (cylinder 4) - 20. Electro-injector (cylinder 3) - 21. Electro-injector (cylinder 2) -
22. Electro-injector (cylinder 1)
13

Pin out EDC 17CV41 control unit - Engine side connector (connector 2)
Figure 8
Colour legend
C ORANGE
A SKY BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE 189005
Pin Cable colour Signal Component

01 - O_P_SVL21 Injector 1 low, Bank 2, Cylinder 4
04 - - Free
05 - - Free
06 G G_R_DF03 Engine oil pressure and temperature sensor: ground for frequency
input 3
07 V V_V_5VSS21A Boost pressure and air temperature sensor: supply +5V
08 - - Free
09 - - Free
10 - - Free
11 G V_V_5VSS3B Rail pressure sensor: supply +5V
12 H I_A_AN18 Fuel temperature sensor: NTC temperature signal
13 V I_A_AN15 Engine oil pressure and temperature sensor: NTC temperature
signal
14 - - Free
15 - - Free
16 G I_A_AN02 Exhaust gas absolute pressure sensor (P3): pressure signal
17 G B_D_CANH2 Motorised throttle valve actuator connector (Exhaust flap):
Controller Area Network 2 high (CAN H)
18 C B_D_CANL2 Motorised throttle valve actuator connector (Exhaust flap):
Controller Area Network 2 low (CAN L)
19 Z G_R_AN02 Exhaust gas absolute pressure sensor (P3): ground
20 - - Free
21 - - Free
22 - - Free
23 - - Free


24 - - Free
25 - O_P_SVH21 Injector 1 high, Bank 2, Cylinder 4
28 - - Free
29 - - Free
30 - - Free
31 R V_V_5VSS1F Engine oil pressure and temperature sensor: supply +5V
32 L V_V_5VSS1E Crankcase pressure sensor: supply +5V
33 H V_V_5VSS2B Exhaust gas absolute pressure sensor (P3): supply + 5V
34 - - Free
35 Z I_A_AN01 Engine oil pressure and temperature sensor: pressure signal
36 S I_A_RAILPS Rail pressure sensor: pressure signal
37 R I_A_AN16 Boost pressure and air temperature sensor: NTC temperature
signal
38 - - Free
39 H I_A_AN17 Coolant temperature sensor: NTC temperature signal
40 - - Free
41 - - Free
42 Z G_R_AN20 Crankcase pressure sensor: ground
43 - - Free
44 - - Free
45 - Free
46 - - Free
47 - - Free
48 - - Free
52 - - Free
53 - - Free
54 - - Free
55 - - Free
56 - - Free
57 - - Free
58 S O_V_MEU Fuel high pressure pump metering unit: supply
59 L G_R_AN18 Fuel/coolant temperature sensor: common ground analog input 18
60 N G_R_RAILPS Rail pressure sensor: ground
61 G I_A_AN03 Crankcase pressure sensor: pressure signal
62 - - Free


63 - - Free
64 - - Free
65 N G_R_CRS Flywheel increment speed sensor (crankshaft): signal negative
66 B I_F_CRS Flywheel increment speed sensor (crankshaft): signal positive
67 N G_R_CAS Timing segment speed sensor (camshaft): signal negative
68 B I_F_CAS Timing segment speed sensor (camshaft): signal positive
69 - G_R_AN07 Common ground analog input 7
70 - G_G_RL05 Ground for low side power stage 5
71 - - Free
72 - - Free
76 - - Free
77 - - Free
78 H G_R_DF02 Fuel filter clogging sensor: ground
79 Z I_F_DF02 Fuel filter clogging sensor: pressure drop signal
80 - - Free
81 - - Free
82 - - Free
83 V O_T_MEU Fuel high pressure pump metering unit: signal
84 - - Free
85 - - Free
86 Z I_A_AN05 Boost pressure and air temperature sensor: pressure signal
87 - - Free
88 - - Free
89 - - Free
90 G G_R_AN05 Boost pressure and air temperature sensor: ground analog input 5
91 - - Free
92 - - Free
93 - - Free
94 - - Free
95 - O_S_RH05 Engine brake 1 (Engine decompression valve)
96 - - Free

Electro-injectors (CRIN 3)
Figure 9
114255
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.
It is an N.A. type solenoid valve. The solenoid valve controls the lift of the nozzle needle.
The resistance of the coil of each individual injector is 0.56 0.57 .
The injectors are connected to the control unit via the engine cable.
Injector No. Injector PIN Control unit PIN

1 49
1
2 73
1 50
2
2 74
1 51
3
2 75
1 25
4
2 01
1 27
5
2 03
1 26
6
2 02

Fuel high pressure pump metering unit Figure 10

A. Fuel drain outlet fitting to filter support
B. Fuel inlet fitting from ECU heat exchanger
C. Fuel inlet fitting from fuel filter
D. Fuel outlet fitting from supply pump to filter
E. Fuel outlet fitting to rail
1. High-pressure pump
2. Supply pump
3. Pressure regulator (NO solenoid valve modulated by
ECU with PWM signal).
Pressure regulator
Located at high-pressure pump inlet, on low pressure system,
it modulates the amount of fuel for high-pressure pump supply
based on commands received from ECU.
It mainly consists of parts below:
- rapezoidal-section lock pin;
- valve control pin;
- pre-load valve;
- coils.
A
When no control signal is present, the pressure regulator is
normally open, therefore the high pressure pump is in max B
delivery condition.
C
The ECU modulates a PWM control signal to extend or
reduce section of fuel supply line to high-pressure pump. D
The component cannot be replaced as an individual part,
therefore it cannot be removed.
The quantity of high-pressure supply fuel is metered by a 3
proportional valve positioned on low-pressure system and it
is managed by the ECU.
E
The delivery pressure to rail is modulated between 250 and
1400 bars by ECU operating on pressure regulator solenoid
valve.
It is a NO solenoid valve. 191577
Its resistance is 3,2 .
Cable
PIN DESCRIPTION TO
colour
1 Supply EDC17, pin 2/58 S
2 Signal EDC17, pin 2/83 V

Rail pressure sensor (RDS4.4) Crankcase pressure sensor

The injection pressure sensor is used to determine the The crankcase pressure sensor is used to measure engine
duration of the injection electric control. internal pressure.
Figure 11 Figure 12
190509 190512
Cable Cable
PIN DESCRIPTION TO PIN DESCRIPTION TO
colour colour
1 Ground (-) EDC17, pin 2/60 N 1 Supply EDC17, pin 2/32 L
2 Signal (Output) EDC17, pin 2/36 S 2 Ground EDC17, pin 2/42 Z
3 Supply Voltage (+) EDC17, pin 2/11 G 3 Signal EDC17, pin 2/61 G
CHARACTERISTIC VALUE
Pressure range 0 2400 bar
Supply Voltage 5V
Output voltage 0.5 4.5V
Tightening torque 140 Nm

Increment speed sensor (Crankshaft) Figure 14

This inductive sensor is located on the flywheel.
NOTE If this signal fails the rev counter will not function.
WARNING This sensors air gap is not adjustable. S
Figure 13
190511
The flywheel has 60 sections, 58 holes and two missing-hole.

The EDC 17 uses this signal to:
- recognise the position of the pistons during normal
operation;
- determine the engine speed.
Figure 15
190510
Cable
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/66 B
2 Signal (-) EDC17, pin 2/65 N
Resistance 850 870
Tightening torque 6 10 Nm
190599

Segment speed sensor (Camshaft) Figure 17

This inductive sensor is located on the camshaft.
The signal generated by this sensor is used by the EDC17
electronic control unit as the injection timing signal.
WARNING This sensors air gap is not adjustable.

S
Figure 16
190511
The sensor generates signals obtained from the magnetic flux

lines which close through the teeth of the phonic wheel fitted
on the same shaft (number of teeth: 7).
Figure 18
190510
Cable
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/68 B 6+1
2 Signal (-) EDC17, pin 2/67 N
Resistance 850 870
115825

Fuel temperature sensor Figure 20

It is an N.T.C. sensor located on the fuel filter.
It measure the fuel temperature, thus enabling the ECU to
determine the fuel density and volume, therefore adjusting its
delivery.
Figure 19
1 2
190515
Figure 21
113561
Cable 190516
PIN DESCRIPTION TO
colour
1 Signal (+) EDC17, pin 2/12 H
2 Signal (-) EDC17, pin 2/59* L
* Common ground

Coolant temperature sensor Oil pressure and temperature sensor

It is an N.T.C. sensor located on the cylinder head water outlet It is a component that measures the engine oil temperature
manifold; it detects the coolant temperature. and pressure. It is mounted on thecrankcase.
This to enrich the mixture when the engine is cold. Signals measured are transmitted to the EDC17 electronic
control unit which, in turn, sends the information to the
instrument panel (indicator/low pressure warning light).
Figure 22 Figure 24
1
2
3
4
113561 190517
Cable Cable
colour colour
1 Signal (+) EDC17, pin 2/39 H 1 Ground EDC17, pin 2/6 G
2 Signal (-) EDC17, pin 2/59* L Temperature
2 EDC17, pin 2/13 V
Signal
* Common ground
3 Supply (+5V) EDC17, pin 2/31 R
4 Pressure Signal EDC17, pin 2/35 Z
Tightening torque 25 Nm
Figure 23 Figure 25
PRESSURESENSOR
4
1 2
190515 190518

Boost pressure and temperature sensor Main fuel filter clogging switch
It is mounted on the intake manifold. This is an electrically normally-closed sensor which identifies
the clogging of the fuel filter, looking if there is a delta pressure
between its two ports - exceeding a certain threshold.
Figure 26
Figure 28
210296 190523
Cable Cable
colour colour
1 Ground EDC17, pin 2/90 G 1 Ground EDC17, pin 2/78 H
2 Temperature EDC17, pin 2/37 R 2 Signal EDC17, pin 2/79 Z
Signal
3 Supply (+5V) EDC17, pin 2/7 V
4 Pressure Signal EDC17, pin 2/86 Z
Nominal Voltage 12 / 24 Vcc
Maximum switched tension 200 mA
Differential opening pressure 150 10 KPa
Maximum working pressure 500 KPa
Operating temperature - 40C / +120C
Figure 27
1 Figure 29
PRESSURESENSOR
4 P
190518 190524

Engine decompression valve Figure 32

It is mounted on the cylinder head.
Figure 30
221074
Cable 223502
PIN DESCRIPTION TO
colour
1 Ground EDC17, pin 2/70 -
2 Signal EDC17, pin 2/95 -
Voltage range 9 16 V
Power requirement 13.9 W
Operating temperature - 40C / +130C
Tightening torque 32 3.2 Nm
Figure 31
223511

Motorized throttle valve actuator connector (Exhaust flap)

The sensor serves to actuate the throttle valve installed on the exhaust pipe of the turbocharger.
Figure 33
188487
PIN DESCRIPTION TO Cable colour

1 - - L
2 - - R
3 Ground EDC17, pin 2/18 C
4 Power Supply EDC17, pin 2/17 G

Grid-heater resistance for engine pre-heating

This element is located on the intake manifold.
It is utilised to heat the air in the operations of pre / post-heating. It is powered via contactor.
Its resistance is of approx.. 0.5 .
Figure 34
188489
Rated voltage: D.C. 24V

Steady current: 120A 150A @ 24V
Pick-up current: 160A 290A @ 24V
Insulation resistance: >1 M @ 500 V D.C.

Electric starter motor
Figure 35 Figure 36
50
30
223510 223509
ELECTRICAL WIRING
1. Current contactor - 2. Command electromagnet - 3. Starter electric motor - 4. Batteryr
The starter motor runs the engine, gaining its inertia and friction, and bringing it to a certain number of revolutions such as to initiate
the formation of the mixture required for combustion and then the autonomous movement of the engine.
The movement is transmitted by a DC electric motor, powered by the battery, via an engagement pinion which rotates the sprocket
formed on the engine flywheel.
Due to a free wheel engagement, the pinion turns off when the main engine rotates faster than the starter motor.
A relay energized by the current of the starter motor engages the pinion by means of a fork.
The starter motor included is a translation type and starts by means of the pinion, with relay housed directly above the starter motor.
Ignition is usually controlled via the ignition switch on the control panel and provides a positive voltage to the relay located on the
starter motor.
Specifications:
Type: DENSO
Nominal voltage: 24 V
Nominal rated power: 4.5 kW
Number of poles: 4
Direction of rotation: clockwise (seen from flywheel side)

Alternator
Figure 37
223508
Figure 38 Figure 39
223507 106282
B terminal: Positive - S terminal: Battery voltage sensor - IG terminal: Alternator ignition - L terminal: to charging light
It is frontally located on the right-hand side of the engine and is controlled by the auxiliary members belt.
Specifications:
Type: MITSUBISHI
Nominal voltage: 24 V
Nominal rated current: 90 A @ 5,000 rpm
Stand-by current consumption: 1mA
Maximum continuous rotation velocity: 16,000 RPM
Operating temperature range: 100 C Max (continuous)
Weight: 6.9 kg
Direction of rotation: clockwise
Number of poles: 12


F2CFE613 ENGINES SECTION 4 - MAINTENANCE PLANNING 1
SECTION 4
Maintenance planning
Page
MAINTENANCE PLANNING . . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Planning of controls and periodical intervention 3
- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE PROCEDURES . . . . . . . . . . . . 5
- Checks (in periods of use) . . . . . . . . . . . . . . . 5
- Planned maintenance . . . . . . . . . . . . . . . . . . . 8
- Extraordinary maintenance . . . . . . . . . . . . . . . 13

2 SECTION 4 - MAINTENANCE PLANNING F2CFE613 ENGINES

MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by
common sense and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure,
immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Planning of controls and periodical intervention

Checks (during the period of use) Frequency
Engine lubricant oil level check Daily
Engine coolant level check Daily
Engine visual inspection 50 hours (7)
Air filter and housing cleanness check (**) 1 month
Tension and condition check of auxilary members belt 300 hours (8)
Exhaust duct(s) condition check 6 months
Planned maintenance Frequency

Water drainage from the fuel pre-filter (if present) 150 hours (8)
Condensed water drainage from fuel tank 150 hours (8)
Engine lubricant oil replacement (*) 600 hours (2) (3)
Lubricant oil filter replacement (*) 600 hours (2) (3) (4)
Fuel pre-filter replacement (if present) 600 hours (1) (2) (5)
Fuel filter replacement 600 hours (1) (2) (4)
Air filter replacement (**) 1,200 hours (5)
Auxilary members belt replacement 1,200 hours (6)
Heat exchanger (radiator) cleaning (**) 1,200 hours (5)
Blow-by filter replacement 1,800 hours (5)
Extraordinary maintenance Frequency

Turbocharger visual inspection 1,200 hours (5)
Valves/rocker arms clearance adjustment 2,400 hours
Engine coolant replacement 3,000 hours (5)
(*) Frequency for construction equipment application: - 100 hours versus standard application.
(**)Indicated frequencies are valid only if the component (s) supplied by FPT.

(1) Maximum period relative to the use of high quality fuel, (specification ASTM D975 or EN 590); this is reduced based on fuel
contamination and the alarm signals due to filter clogging and/or the presence of water in the pre-filter. The filter clogging
signal indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off after drainage,
the filter must be replaced.
(2) To be performed every year even if the specified operating hours interval has not been reached.
(3) The frequencies are applicable for lubricants which meet the international standards API CJ-4 / ACEA E9 as specified in the
REFILLING table.
(4) Only use filters with the following specifications:
- degree of filtering < 12 m
- filtering efficiency 99.5% ( > 200).
(5) To be performed every two years even if the specified operating hours interval has not been reached.
(6) To be performed every three years even if the specified operating hours interval has not been reached.
(7) To be performed every 15 days even if the specified operating hours interval has not been reached.
(8) To be performed every six months even if the specified operating hours interval has not been reached.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
NOTE Diesel fuel for low temperatures. Standard EN590 defines different classes of Diesel fuels, identifying the
characteristics of those most suitable for use in low ambient temperatures.
Compliance with the regulations regarding the distribution of fuels suitable for the climatic and geographic conditions
of the various countries is entirely up to the oil companies.
The time intervals given in this plan are merely approximate as they refer to using the engines in an industrial environment
with average use in relation to displacement.
Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.

MAINTENANCE PROCEDURES Inspection of drive belt tensioning

Checks (in periods of use) The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
Lubricating system check from checking the wear status of the belt itself.
The check must be executed both when the engine
disconnected and when it is running. Check of belts tear and wear status
Carefully verify the belts surface in order to detect any sign
Verify the presence of any oil leakage or blow-by from the
of incision, crack, excessive wear in correspondence of tooth-
head, from the engine pan of from the heat exchanger.
ing; check end and surface grinding.
The engine oil is highly polluting and harmful.

Danger: if the engine is switched off but is still hot,
In case of contact with the skin, rinse well with water unexpected motion of the belt may occur.
and detergent.
Wait for engine temperature cooling as a
Adequately protect the skin and the eyes, operate precaution in order to avoid serious danger injury.
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force. Cooling system inspection
The check must be executed both when the engine discon-
nected and when it is running.
Combustion system inspection
Check the pipelines from the engine to the radiator, from the
The check must be executed both when the engine discon-
expansion tank and vice-versa.
nected and when it is running.
Find out any blow-by, verify the status of the pipes specially
The check operation consists in examining the fuel pipelines
close to the holding strips.
running from the tank to the pre-filter (if provided in the spe-
cific equipment), to the filter, to the high pressure pump and Verify that the radiator is clean, the correct working of the fan
to the rail diffuser and from this last one to the head. flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Special attention must be paid to the connections on the high
pressure pipelines.
Due to the high temperatures achieved by the
system, do not operate immediately after the
Due to the high pressure within the pipelines
engines disconnection, but wait for the time
running from the high-pressure pump to the rail
deemed necessary for the cooling.
diffuser and from this last one to the
electro-injectors, special attention must be aid also Protect the eyes and the skin from any eventual high
in checking presence of any leakage or blow-by. pressure jet of cooling liquid.
Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the The density of the cooling liquid must be checked any how
skin surface provoking serious poisoning. every year before winter season and be replaced in any case
every two year.
Inspection of water presence within fuel filter or

pre-filter NOTE In case of new filling, proceed bleeding system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious
NOTE The components of the common rail system can inconvenience might be caused to the engine due
be damaged very quickly in presence of water or to the presence of air pockets in the engines
impurity within the fuel. head.
Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the
drainage of the water within the feed circuit.

Engine lubricant oil level check

Make sure that the oil dipstick is fully inserted and
Figure 1 that the oil filler cap is fully tightened in a clockwise
direction.
The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
Engine coolant level check

Only proceed when the engine is not turning, and is at low
temperature, so as not to run the risk of burns.
- Remove the pressurization cap from the expansion tank.
- Check that the coolant in the expansion tank is above the
minimum level.
- If necessary, top up the expansion tank with a mixture of
50% water and Actifull OT CONCENTRATE, as
contained in the REFILLING table.
Do not fill the expansion tank to the brim.
223485 - When the engine is cold, make sure that the coolant level
The check must be executed when the engine is is a few centimetres below the filling hole.
disconnected and possibly cool. In the event of an externally located level indicator as regards
- Make sure the machine is on a flat surface. the heat exchangers, proceed with the top up operation by
making sure that the coolant does not overfill the internal
- Use the oil dipstick (not supplied by FPT) to check that volume of the exchanger in order to allow the expansion of
the lubricant oil level is between the Min and Max coolant volume during increases in temperature.
limits.
- Whether it should be difficult to make the evaluation, Engine visual inspection
proceed cleaning the oil dipstick using a clean cloth with Before engine start proceed with the following checks and
no rag grinding and put it back in its slot. Draw it off again controls:
and check the level.
- Level controls and checks of any eventual leakage from
- If the level is insufficient, it is necessary to top up with the fuel, cooling and lubricating circuits.
lubricant oil which meets the international specifications
API CJ-4 / ACEA E9, as indicated in the REFILLING table: After engine start and while engine is running, proceed with
remove the lubricant oil cap (1) and pour engine the following checks and controls:
lubricant oil through the hole. - Check presence of any eventual leakage from the fuel,
- Use the oil dipstick to check that the lubricant oil level cooling and lubricating circuits.
does not exceed the Max limit. - Verify absence of noise or unusual rattle during engine
working.
Always ensure the oil added has the same - Visual check of fumes (colour of exhaust emissions)
characteristics of the oil contained in the sump. - Visual check of cooling liquid level, in the expansion tank.
Mixing is not allowed as this would not guarantee
correct lubrication of the internal parts of the
engine.

Air filter and housing cleanness check Tension and conditions check of auxiliary members
belt
Figure 2 Proceed only with engine not running and at low
temperature to avoid any risk of burns.
- Check that there are no tears in the belt and that it shows
no obvious signs of wear and tear or of soiling from oil
or fuel. Replace belt if these signs are present.
- Using the wrench square drive 1/2 inch to check the
efficiency of the automatic belt tensioner.
Figure 3
215046
Only proceed with the engine stopped.

- Remove the filter cover (1) after first unscrewing the
locking handle.
- Remove the external cartridge (2), after unfastening the
second locking handle; during this operation, take care to
ensure that no dust get into the sleeve.
- Check that there is no dirt. If there is, clean the filter
element as indicated below.
- Blow dry compressed air through the filter element, from
the inside outward (maximum pressure 200 kPa).
Do not use detergents; do not use diesel.
- Never use tools to beat the filter element, and check its 223488
condition before replacing it.
- Replace the filter if any breakages or tears are found.
When the engine is off, but still hot, the belt may
- Check that the gasket at its base is in good condition. start to move without warning. Wait for the engine
Some filter systems are fitted with a second filter element temperature to decrease to prevent serious danger
(3) which does not require cleaning; this secondary of an accident.
element (3) must be replaced at least once every 3
changes in the main element (2).
- Position the new filter element (2) in its seat. Exhaust duct(s) condition check
Visually check that the exhaust system is not blocked or
- Reassemble by repeating the above operations in reverse
damaged.
order.
- Make sure that there is no risk of dangerous fumes within
- Set up the mechanical blockage indicator for operation
by pressing the button located on the top part of the the machine. Contact the Manufacturer if necessary.
indicator. This operation is not necessary if there is an
electrical sensor.
Take care to ensure that the parts are reassembled

correctly.
Imperfect assembly might result in unfiltered air
being sucked into the engine, causing serious
damage.

Planned maintenance Condensed water drainage from fuel tank

Water drainage from the fuel pre-filter (if present) The high risk of refueling with fuel polluted with foreign
bodies and water requires inspections to be performed even
if no alarm is triggered on the on board panel.
Figure 4
Proceed with engine not running.
- Place a basin under the fuel tank in order to collect liquids.
- Unscrew the cock plug located in the lower part of the
fuel tank.
- Drain the liquid until it is detected as diesel oil only.
- Manually close the plug by screwing completely.
- Dispose drained liquids observing current regulations in
force.
The components of the common rail system will be

215045 rapidly damaged if the fuel contains water or
The high risk of refueling with fuel polluted with foreign impurities.
bodies and water requires inspections to be performed even Immediately perform the operation on the pre-filter
if no alarm is triggered on the on board panel. to drain the water present in the fuel supply circuit.
Proceed with engine not running.
- Place a basin under the pre-filter in order to collect Engine lubricant oil replacement
liquids.
- Unscrew the cock plug (3) located in the pre-filter lower Figure 5
section; in some fittings the plug includes the diesel oil
water sensor.
- Drain the liquid until it is detected as diesel oil only.
- Manually close the plug (3) by screwing completely.
- Dispose drained liquids observing current regulations in
force.
The components of the common rail system will be

rapidly damaged if the fuel contains water or
impurities.
Immediately perform the operation on the pre-filter
to drain the water present in the fuel supply circuit.
223485
Warning: We recommend to wear proper

protections because of high motor service
temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.

- Place a proper container for the oil collecting under the Lubricant oil filter replacement
pan connected with the drain plug (3).
- Unscrew the plug (3) and then take out the control dip- Figure 6
sick (not supplied by FPT) and the inserting plug (1) to
ease the downflow of the lubrication oil.
The oil motor is very pollutant and harmful.

In case of contact with the skin, wash with much
water and detergent.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
- Wait until the oil sump (2) has completely emptied, then
retighten the lubricant oil drain plug (3) under the sump
(2). 223486
- Proceed with the refilling operation through the hole (1)

situated on the tappet cover: add the specified quantity
of recommended lubricant oil that meets the NOTE Warning: the oil filter contains inside a quantity
international standards API CJ-4 / ACEA E9, as indicated of oil of about 1 kg.
in the REFILLING table. Place properly a container for the liquid.
Warning: avoid the contact of skin with the

NOTE Use only the recommended oil or oil having the motor oil: in case of contact wash the skin with
requested features for the corrrect motor running water.
functioning. The motor oil is very pollutant: it must be
In case of topping up, dont mix oils having disposed of according to the rules.
different features.
If you dont comply with theses rules, the service
warranty is no more valid. NOTE Before refitting the new cartridge, wet seal using
engine oil.
- Check the level through the dipsick (not supplied by FPT)
until when the filling is next to the maximum level notch Unscrew and remove the filter (4) from its relative support
indicated on the dipsick. (1) by suitable tool.
Replace the filter element (3) and the sealing gasket (2)
contained inside the filter (4).
Carefully clean the surfaces of the support (1) in contact with
the sealing gasket (2).
Moisten the sealing gasket (2) of the new filter (4) with a thin
layer of oil.
Manually tighten the new filter (4) on the support (1) until it
comes into contact with the gasket (2).
Additionally tighten it using a specific tool to a torque of
60 5 Nm.
Operate the engine for a few minutes and then check the
level using the dipstick. If necessary, top up to compensate for
the quantity of oil used to fill up the filtering cartridge.

Fuel pre-filter replacement Fuel filter replacement
Figure 7 Figure 8
215045
Only proceed with the engine stopped. 223487
- Should the filter be fitted with a sensor to detect the

presence of water (3), remove the whole sensor from its During this operation dont smoke and dont use
seat. free flames.
- Remove the pre-filter by unscrewing it. Avoid to breathe the vapors coming from filter.
- Check that the new filter has performance levels that
satisfy the needs of the engine (e.g. by comparing them
with the old one).
After filters replacement the supply equipment
- Damp the new filter seal with diesel or engine oil. ! deaeration must be carried out.
- Hand screw the new filter into place until the seal gasket
touches the support, then lock by a further 3/4 of a turn.
Place a container for collecting the diesel under the filter
- Place the water presence sensor in its seat, taking care to support (2).
couple the threads correctly.
Drain the fuel from the fuel filter (5) by loosing the drain
- Loosen the bleeder screw (1) on the pre-filter support screw (6).
and activate the hand pump (2) until the supply circuit is
full. Ensure that any fuel coming out is not dispersed into Remove the filter (5) by unscrewing it from its relative
the environment. support (2).
Replace the filter element (4) and the O-ring seal (3)
- Lock the bleeder screw tightly. contained inside the filter (5).
- Start the engine and run it at idle for a few minutes to Carefully clean the surfaces of the support (2) in contact with
eliminate any residual air. the O-ring seal (3).
Smear the O-ring seal (3) of the new filter with oil.
Manually tighten the new filter (5) onto the support (2) until
If it is necessary to speed up the residual air bleeding it comes into contact with the gasket (3).
phase, use the hand pump also while starting. Additionally tighten it using a specific tool to a torque of
32.5 2.5 Nm.
When replacing the filter cartridge (5) do NOT fill

! it.
This operation is banned to avoid impurities
entering into the circuit, which would damage the
injector/pump system components.

Fuel bleeding Air filter replacement

After the fuel filter (5) has been replaced it is possible that air
bubbles get trapped inside the fuel supply circuit. Figure 10
Bleed residual air from the fuel filter (5) by loosing the vent
plug (1) connecting it to a suitable container by a transparent
flexible hose.
Figure 9
215046
Only proceed with the engine stopped.

- Remove the filter cover (1) after first unscrewing the
locking handle.
- Remove the external cartridge (2), after unfastening the
second locking handle; during this operation, take care to
ensure that no dust get into the sleeve.
145887
- Check that there is no dirt. If there is, clean the filter
With the hand pump (2) of the fuel pre-filter (1) pump until housing.
fuel completely free of air bubbles flows from the bleed screw.
- Replace the filter element (2) and the relative gasket at
After the operation, tighten the bleed screw. its base.
Start the engine and allow it to run at minimum for a few
minutes to expel any remaining air. - Some filter systems are fitted with a second filter element
(3) which does not require cleaning; this secondary
element (3) must be replaced at least once every 3
changes in the main element (2).
- Position the new filter element (2) in its seat.
- Reassemble by repeating the above operations in reverse
order.
- Set up the mechanical blockage indicator for operation
by pressing the button located on the top part of the
indicator. This operation is not necessary if there is an
electrical sensor.
Take care to ensure that the parts are reassembled

correctly.
Imperfect assembly might result in unfiltered air
being sucked into the engine, causing serious
damage.

Auxiliary members belt replacement Heat exchanger (radiator) cleaning
Figure 11 Figure 12
223488
Use appropriate equipment (7) on the belt tensioner (8) in

the direction shown by the arrow and extract the belt (4) 200503
from the pulleys of the alternator (1), of the coolant pump Check that the radiator air inlets are free from dirt (dust, mud,
(3), of the fan drive pulley (2) and from the idler pulley (5). straw, etc.).
- Replace the worn belt with a new one. Clean them if necessary, using compressed air or steam.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in The use of compressed air makes it necessary to use
the functioning position. suitable protective equipment for the hands, face
- Further adjustments are not required. and eyes.

Extraordinary maintenance Figure 14

Turbocharger visual inspection
Only proceed when the engine is not turning over. Visually
check that the turbine and compressor impellers and the
relative inlet and outlet ducts are not obstructed or damaged,
otherwise replace them.
Adjustment of valve/rocker arm clearance
Figure 13
114287
Adjustment of clearance between rocker arms and

intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted;
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced.
Symmetric cylinders are 1-6; 2-5 and 3-4.
In order to perform these operations correctly, refer to
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
193948
Unscrew the screws (2). - Use special spanner to lock/unlock adjustment screw.
Remove cylinder head cover (1) and its gasket. - Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
Ref. No. Description
(2) 20 M6x1x50 Follow the firing order indicated in the table below.
Tightening
Ref. No. Description torques
(1) 12 M10x1x1.25 39 5 Nm
IGNITION ORDER 1-4-2-6-3-5
START AND BALANCE ADJUST

ROTATION VALVES OF CLEARANCE
CLOCKWISE CYLINDER No. OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
NOTE In order to correctly carry out adjustments

above, it is mandatory to perform the sequence
indicated in the table, checking exact positioning
at each phase by means of pin 99360612.

Figure 15 Engine coolant replacement

- Only proceedwhen the engine is not turning, and is at
low temperature, so as not to run the risk of burns.
- Place a container for collecting coolant under the heat
exchanger (radiator).
- Remove the pressurization cap from the expansion tank.
- Loosen the retaining elements and remove the sleeves
connecting the engine cooling circuit to the heat
exchanger.
- Drain the coolant fromthe heat exchanger (radiator) and
wait until it is completely empty.
- Once emptied, refit the cooling circuit making sure the
sleeves are perfectly sealed.
193948
Fit the valve cover (1) with the related gasket and insert all - Refill the engine and the heat exchanger until the cooling
the screws (2). circuit has been completely refilled using amixture of 50%
Tighten the fastening screws (2) to the prescribed torque water and Actifull OT CONCENTRATE, as contained in
following order and mode shown in the figure below. the REFILLING table.
Do not fill the expansion tank to the brim.
Tightening - With the coolant cap open, start the engine and let it idle
Ref. No. Description torques for approx. one minute. This helps to completely bleed
(2) 20 M6x1x50 8.5 1.5 Nm the air contained in the cooling circuit.
- Stop the engine and top up with more coolant, if
Figure 16 necessary.
- When the engine is cold, make sure that the coolant in
the expansion tank is a few centimetres below the filling
hole.
- In the event of an externally located level indicator as
regards the heat exchangers, proceed with the top up
operation bymaking sure that the coolant does not
overfill the internal volume of the exchanger in order to
allow the expansion of coolant volume during increases
in temperature.
218020 The failure to observe the aforesaid procedure does

Tightening order layout for valve cover fastening screws not guarantee the presence of the correct quantity
of coolant in the engine.
Drive the screws to spacer contact in this order:
1-14-11-12-13. When the engine is hot, pressure builds up in the
Tighten all the fastening screws to the prescribed torque ! cooling circuits which may eject hot liquid violently,
following the scheme. resulting in a risk of burns.
Open the filler cap of the coolant tank only if
necessary and only when the engine is cold.

F2CFE613 ENGINES SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS 1
SECTION 5
Removal and refitting of main engine
components
Page
AUXILIARY MEMBERS BELT

REMOVAL / REFITTING . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL / REFITTING . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP
REMOVAL / REFITTING . . . . . . . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT REMOVAL / REFITTING . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CONTROL UNIT REMOVAL / REFITTING 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL FILTER SUPPORT REMOVAL / REFITTING 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HIGH-PRESSURE PUMP REMOVAL / REFITTING 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMMON RAIL REMOVAL / REFITTING . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ROCKER ARM SHAFT REMOVAL / REFITTING 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS F2CFE613 ENGINES
Page Page
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OIL SUMP REMOVAL / REFITTING . . . . . . . . . . 25
- Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INJECTOR REMOVAL / REFITTING . . . . . . . . . 14 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TURBOCHARGER REMOVAL / REFITTING . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EXHAUST MANIFOLD REMOVAL / REFITTING 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OIL FILTER REMOVAL / REFITTING . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OIL COOLER REMOVAL / REFITTING . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BLOW-BY REMOVAL / REFITTING . . . . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INTAKE MANIFOLD REMOVAL / REFITTING . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTER REMOVAL / REFITTING . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AUXILIARY MEMBERS BELT ALTERNATOR REMOVAL / REFITTING

REMOVAL / REFITTING Removal
Removal Disconnect the electrical connections of the alternator.
Figure 1 Remove the auxiliary components drive belt as described in
the relative procedure.
Figure 2
223488 223505
Pull the automatic belt tensioner (8) by using appropriate Unscrew fastening screws (1 and 3) and remove the
tool (7) and remove the auxiliary members belt (4) from alternator (4), recovering spacer (2).
alternator (1), water pump (3), fan control pulley (2),
crankshaft pulley with damper (6) and fixed guide roller (5).
Ref. No. Description

(1) 1 M8x1.25x35
(3) 1 M10x1.5x120
Refitting
Refitting
Install alternator (4) on support and tighten fastening screws
Fit the auxiliary members belt (4) on the pulleys and guide (1 and 3) to the prescribed torque.
roller.
Use the appropriate tool (7) on the automatic belt tensioner Ref No. Description Tightening torques
(8) in order to fit the new belt (4) in the operating position. (1) 1 M8x1.25x35 24 3 Nm
(3) 1 M10x1.5x120 43 3 Nm
Additional adjustments are not required. The belt tension is
adjusted automatically by the calibrated spring in the
automatic belt tensioner (8).
Operate the engine for a few hours and check that the Install the auxiliary components drive belt as described in the
auxiliary members belt (4) is properly fitted. relative procedure.
Connect the alternator electrical connections.

WATER PUMP THERMOSTAT REMOVAL / REFITTING

REMOVAL / REFITTING
Removal
Removal
Drain off the coolant.. Figure 4
Remove the auxiliary components drive belt as described in
the relative procedure.
Position a suitable container to catch any coolant.
Figure 3
223513
Unplug the engine cable (4) from the coolant temperature

sensor (3), as described in the relative section.
Open the strap (1) holding the engine cable (4) to the engine
coolant outlet pipe (2) and remove it.
223512
Unscrew the fastening screws (3) and remove the water

pump (2) complete with gasket (1).
Figure 5
Ref No. Description

(3) 4 M8x1.25x25
Refitting
Apply a new seal ring (1) to the coolant pump (2).
Assemble the water pump (2) complete with its sealing
gasket (1) and tighten the fastening screws (3) to the
prescribed torque.
Ref No. Description Tightening torques

(3) 4 M8x1.25x25 24.5 2.5 Nm 213514
Unscrew the fastening screws (4) and disassemble the

thermostat unit: remove the engine coolant outlet pipe (5)
together with its gasket (3), the sealing ring (2) and the
Install the auxiliary components drive belt as described in the thermostat (1).
relative procedure.
Ref No. Description

NOTE Once installed, fill the engine coolant circuit. (4) 5 M8x1.25x70
Start the engine and check for coolant leaks.

Refitting ENGINE CONTROL UNIT

REMOVAL / REFITTING
Figure 6 Removal
Figure 8
223514 218014
Assemble the thermostat unit: fit the thermostat (1), a new Disconnect the engine cable (1) from the ECU (5), as
sealing ring (2) and the engine coolant outlet pipe (5) described in the relative section.
complete with its gasket (3); tighten the fastening screws (4)
Position a suitable container to catch any fuel.
to the prescribed torque.
Disconnect the retainer (2) and remove the low pressure
Ref No. Description Tightening torques fuel pipe from fuel pre-filter to the engine control unit heat
exchanger.
(4) 5 M8x1.25x70 24.5 2.5 Nm
Disconnect the retainer (4) and remove the low pressure
fuel pipe from the engine control unit heat exchanger to to
mechanical pump, as described in the relative section.
Figure 7
Unscrew the fastening nuts (3), and remove the ECU (5),
including the heat exchanger.
Ref No. Description

(3) 3 M8x1.25
(4) 1 M16x1.5
Refitting
Fit the ECU (5) including the heat exchanger on the
crankcase and tighten the fastening nuts (3) to the prescribed
torque.
Connect the low pressure fuel pipe from the mechanical
pump to the engine control unit heat exchanger by means
of the retainer (4), as described in the relative procedure.
223513
Connect the low pressure fuel pipe from fuel pre-filter to the
Connect the engine cable (4) to the coolant temperature engine control unit heat exchanger by means of the retainer
sensor (3), as described in the relative section. (2).
Close the strap (1) retaining the engine cable (4) to the Connect the engine cable (1) to the ECU (5), as described
engine coolant outlet pipe (2). in the relative section.

(3) 3 M8x1.25 24 3 Nm
(4) 1 M16x1.5 30 5 Nm

FUEL FILTER SUPPORT Refitting

REMOVAL / REFITTING
Figure 11
Removal
Figure 9
223515 218016
During this operation dont smoke and dont use Fit the fuel filter support (2) together with the fuel filter
free flames. clogging (pressure drop) sensor (5) and NTC temperature
Avoid to breathe the vapours coming from filter. sensor (4) on the engine cable supporting bracket (1) and
tighten the fastening screws (3) to the prescribed torque.
Disconnect the sensor connections (4) of the engine cable

(2) from the fuel filter support (3), as described in the relative Ref No. Description Tightening torques
procedure. (3) 4 M8x1.25x30 24 3 Nm
Disconnect the fittings (1) of the low pressure fuel pipes from
fuel filter to high pressure pump and from mechanical pump
to fuel filter.
Ref No. Description Figure 12

(1) 2 M16x1.5
Figure 10
223515
Connect the fittings (1) of the low pressure fuel pipes from
fuel filter to high pressure pump and from mechanical pump
218016 to fuel filter.
Place a container for collecting diesel under the fuel filter Connect the sensor connections (4) of the engine cable (2)
support (2). to the fuel filter support (3), as described in the relative
Unscrew the fastening screws (3) and remove the fuel filter procedure.
support (2) together with the fuel filter clogging (pressure
drop) sensor (5) and NTC temperature sensor (4) from the
engine cable supporting bracket (1).
(1) 2 M16x1.5 40 5 Nm
Ref No. Description
(3) 4 M8x1.25x30

FUEL HIGH-PRESSURE PUMP Figure 14

REMOVAL / REFITTING
Removal
Remove the fuel filter support as described in the relative
procedure.
Figure 13
218018
Disconnect the fittings (4 and 8) and the screw (1) to remove

the low pressure fuel pipe (3) from ECU to mechanical
pump.
Disconnect the fittings (2 and 7) and the screw (5) to remove
218017 the backflow fuel pipe (6) from high-pressure pump to fuel
tank.
Disconnect the engine cable from the fuel high-pressure
pump metering unit (8), as described in the relative
procedure. Ref No. Description
Disconnect the fittings (7 and 9) to remove the low pressure (4,8) 2 M16x1.5
fuel pipe (11) from fuel filter to high-pressure pump and the (2,7) 2 M16x1.5
pipe (12) from mechanical pump to fuel filter. (1) 1 M8x1.25x25
(5) 1 M8x1.25x16
Unscrew the hose couplings (3 and 10) and the screw (6) to
remove the high-pressure fuel pipe (5) from high-pressure
pump to cylinder head.
Unscrew the fastening screws (2 and 4) and remove the fuel
filter bracket (1). Figure 15
Ref No. Description

(7,9) 2 M16x1.5
(3,10) 2 M14x1.5
(6) 1 M6x16
(2) 3 M8x1.25x35
(4) 1 M8x25
(4) 1 M10x25
218019
Ensure that the the fuel high-pressure pump (1) is suitably

supported.
Unscrew the fastening screws (3) and remove the fuel
high-pressure pump (1) complete with the mechanical pump
(2) and the gear (4) from the flywheel housing-gear box
carter (5).
Ref No. Description

(3) 3 M8x1.25x40

Refitting Figure 18
Figure 16
218017
Fit the fuel filter bracket (1) and tighten the fastening screws
218019 (2 and 4) to the prescribed torque.
Fit the fuel high-pressure pump (1) complete with the Connect the the high-pressure fuel pipe (5) from
mechanical pump (2) and the gear (4) into the flywheel high-pressure pump to cylinder head and tighten the hose
housing-gear box carter (5). couplings (3 and 10) and the screw (6) to the prescribed
torque.
Tighten the fastening screws (3) to the prescribed torque.
Connect the low pressure fuel pipe (11) from fuel filter to
high-pressure pump and the pipe (12) from mechanical
pump to fuel filter and tighten the fittings (7 and 9) to the
Ref No. Description Tightening torques prescribed torque.
(3) 3 M8x1.25x40 33 3 Nm
Fasten the engine cable to the retainers and connect the
electrical connection to the fuel high-pressure pump
Figure 17 metering unit (8), as described in the relative procedure.

(7,9) 2 M16x1.5 30 5 Nm
(3,10) 2 M14x1.5 35 2 Nm
(6) 1 M6x16 10 1 Nm
(2) 3 M8x1.25x35 24 3 Nm
(4) 1 M8x25 24 3 Nm
(4) 1 M10x25 37.5 7.5 Nm
Install the fuel filter support as described in the relative

procedure.
218018
Connect the backflow fuel pipe (6) from high-pressure pump

to fuel tank and tighten the fittings (2 and 7) and the screw
(5) to the prescribed torque.
Connect the low pressure fuel pipe (3) from ECU to
mechanical pump and tighten the fittings (4 and 8) and the
screw (1) to the prescribed torque.

(4,8) 2 M16x1.5 30 5 Nm
(2,7) 2 M16x1.5 45 5 Nm
(1) 1 M8x1.25x25 24.5 2.5 Nm
(5) 1 M8x1.25x16 24.5 2.5 Nm

COMMON RAIL REMOVAL / REFITTING Figure 21

Removal
Figure 19
193948 218022
Unscrew the screws (2). Unscrew n 3 screws (1); remove common rail (2) and
spacers (3).
Remove cylinder head cover (1) and gasket.
Remove cable on head.
Ref No. Description Ref No. Description

(2) 20 M6x1x50 (1) 3 M8
Refitting
Figure 20 Figure 22
218023 218022
Disconnect fuel delivery pipes (5) between common rail (4) Install rail (2) and spacers (3) on cylinder head.
and electro-injectors, fuel supply pipe (3) between Lock n 3 retaining screws (1) by hand.
high-pressure pump and common rail (4) and fuel return pipe
(1) between common rail (4) and cylinder head.
Unscrew the fastening screws (2) and remove the bracket Ref No. Description Tightening torques
(6) from the cylinder head. (1) 3 M8 23 2 Nm
Ref No. Description The previously removed pipes ca no longer be refit

(5) 6 M18x1.5 and must be replaced.
(5) 6 M14x1.5
(3) 1 M18x1.5
(3) 1 M14x1.5
(1) 2 M16x1.5

Figure 23
NOTE The high-pressure fuel delivery pipes must be
replaced every time they are removed. The hose
couplings must be tightened to torque using
spanner 99368542 and torque wrench 99389833.
After fitting the high-pressure pipelines, during the

following 20 hours of work, frequently check
! engine oil level (IT MUST NOT INCREASE).
218021
NOTE After the assembly procedure, the fuel lines must
definitely not touch each other so as not to get
Install the common rail (3) and high-pressure fuel delivery damaged because of the high stress due to engine
pipes by proceeding as follows: vibration.
- Fit the common rail (3) on the cylinder head (5) and The MINIMUM distance between the individual
manually tighten the fastening screws (12). pipes must NOT be LESS than 2 mm.
- Check that the injectors are installed in correct position
(equidistant from the springs) and locked to required
torque. End assembly procedure by connecting engine cable on head
to injectors and rail sensor.
- Fit the high-pressure fuel delivery pipes (6 and 8) and
manually tighten the hose couplings (4, 7 and 13) first of
all from common rail side and then from injector
-cylinder head side;
Figure 24
- Fit the low-pressure fuel backflow pipe (1) and manually
tighten the hose couplings (2) first of all from common
rail side and then from cylinder head side;
- Tighten the hose couplings (2, 7 and 13) of injector-
cylinder head side to the prescribed torque.
- Tighten the screws (12) fixing the common rail (3) onto
cylinder head (5) to the prescribed torque.
- Tighten the hose couplings (2 and 4) of common rail side
to the prescribed torque.
- Mount the bracket (10) and manually tighten the
fastening screw (9).
- Tighten the screw (11) locking the high-pressure fuel
193948
delivery pipe (8) to the prescribed torque.
- Tighten the fastening screw (9) fixing the bracket (10) Fit the valve cover (1) with the related gasket and insert all
onto cylinder head (5) to the prescribed torque. the screws (2).
Tighten the fastening screws (2) to the prescribed torque
following order and mode shown in the figure below.
Ref No. Description Tightening torques Ref No. Description Tightening torques
(2) 2 M16x1.5 35 2 Nm (2) 20 M6x1x50 8.5 1.5 Nm
(4) 7 M18x1.5 40 2 Nm
(7) 6 M14x1.5 35 2 Nm
(9) 1 M8x1.25x16 24 3 Nm
(11) 1 M6x16 10 1 Nm
(12) 3 M 8x45 24 3 Nm
(13) 1 M14x1.5 35 2 Nm

Figure 25 ROCKER ARM SHAFT

REMOVAL / REFITTING
Removal
Remove cylinder head cover and its gasket.
Figure 26
218020
Tightening order layout for valve cover fastening screws

Drive the screws to spacer contact in this order:
1-14-11-12-13.
Tighten all the fastening screws to the prescribed torque
following the scheme. 169829
Unlock rocker arm shaft retaining screws (1).
Ref No. Description

(1) 7 M12x1.75
Figure 27
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and remove
shaft, remove crosspieces (3) from cylinder head.

Refitting Figure 30
Figure 28
223535 223536
Install crosspieces (5) on valve rod. Remove lock blocks (1) and tighten the fastening screws (4)
to prescribed torque. Remove tool 99360558 (2) from the
rocker arm shaft (3) by using a hoist.
NOTE Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws (2) have
been fully unscrewed.
(4) 7 M12x1.75 104.5 10.5 Nm
Apply tool 99360558 (1) and related lock blocks (3) to the
rocker arm shaft (4).
Lift and install the rocker arm shaft (4) on the cylinder head Figure 29
(6) by using a hoist.
70567A
Tightening order layout for rocker arm fastening screws.

Intake and exhaust rocker arm clearance Figure 32

adjustment
Figure 31
115880
114287
Fit the head internal electric wire (injectors + pressure
sensor) and securing it using bands as illustrated in the
Adjustment of clearance between rocker arms and diagram ().
cylinder valves are balanced. Figure 33
Symmetric cylinders are 1-6; 2-5 and 3-4.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
Ref No. Description Tightening torques 166177

(1) 12 M10x1.25 39 5 Nm
Install cylinder head cover (1) and lock screws (2) at required
torque.

ROTATION VALVES OF CLEARANCE Ref No. Description Tightening torques
CLOCKWISE CYLINDER No. OF VALVES (2) 20 M6x1x50 8.5 1.5 Nm
CYLINDER No.
1 and 6 at TDC 6 1 Figure 34
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
NOTE In order to correctly carry out adjustments above,

it is mandatory to perform the sequence indicated
in the table, checking exact positioning at each 218020
phase by means of pin 99360612.
Lock screws following the tightening order shown in the
figure.

INJECTOR REMOVAL / REFITTING Figure 38

Removal
Remove cylinder head cover and its gasket.
Figure 35
169827
Remove screws (1) from brackets (2) fixing injectors.
114024
Disconnect fuel pipelines (1) from injector rail, fuel supply Ref No. Description
line (2) of high pressure pump to rail and return line (3).
Unlock rocker arm shaft retaining screws (4). (1) 6 M10x1.5x40
Ref No. Description

(1) 6 M18x1.5
(1) 6 M14x1.5
(2) 1 M18x1.5 Figure 37
(2) 1 M14x1.5
(4) 7 M12x1.75
Figure 36
114025
shaft, remove crosspieces (3) from cylinder head.
169826
Position the tool 99342157 (1) and hook on the injector (2).

Figure 39 Ref No. Description Tightening torques

(1) 6 M10x1.5x40 41 2 Nm
The previously removed pipes ca no longer be refit

and must be replaced.
NOTE Be very careful when fitting high pressure fuel pipes.
Figure 41
169828
Drive out the injector (1) complete with bracket and seal (2).
Refitting
169816
Lubricate the injector fastening O-Rings using the
following lubricants: PDE SILIKONFETT 22, NLG Install new pipes on rail and lock fittings by hand.
12, PDE LUBRICOMET GR 220 NLG12. - supply line (2) of high pressure pump to rail;
- return line (3);
Install the injector comprehensive of bracket and seal in the - n 6 fuel pipelines (1) between injectors and rail.
seat on the cylinder head.
Figure 40
169827
Tighten screws on injector fixing brackets to prescribed

torque.

Figure 42
193973
Check that the injectors (2) are equidistant from After fitting the high-pressure pipelines, during the
! the springs (1). Distance X which separates ! following 20 hours of work, frequently check
them should always be the same. engine oil level (IT MUST NOT INCREASE).
Lock fittings on rail (A, C) at required torque. NOTE After the assembly procedure, the fuel lines must
Lock fittings on injectors and head (B, C) at required torque. definitely not touch each other so as not to get
damaged because of the high stress due to engine
vibration.
The MINIMUM distance between the individual
pipes must NOT be LESS than 2 mm.
TYPE DESCRIPTION LOCK TORQUE

A M18 x 1.5 40 2 Nm NOTE Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws have been
B M14 x 1.5 35 2 Nm fully unscrewed.
C M16 x 1.5 40 2 Nm

Figure 43 Figure 44
223535 223536
Install crosspieces (5) on valve rod. Remove lock blocks (1) and tighten the fastening screws (4)
NOTE Before refitting rocker arm shaft assembly, check
that all adjustment screws (2) have been fully
unlocked. Ref No. Description Tightening torques
(4) 7 M12x1.75 104.5 10.5 Nm
Figure 45
Lift and install the rocker arm shaft (4) on the cylinder head
70567A


adjustment
Figure 46
114287
115880
Adjustment of clearance between rocker arms and Fit the head internal electric wire (injectors + pressure
intake/exhaust valve control crosspieces must be performed sensor) and securing it using bands as illustrated in the
with utmost care. Bring to blast phase cylinder to be adjusted; diagram ().
cylinder valves are balanced.
Symmetric cylinders are 1-6; 2-5 and 3-4. Figure 48

166177
(1) 12 M10x1.25 39 5 Nm
IGNITION ORDER 1-4-2-6-3-5 Install cylinder head cover (1) and lock screws (2) at required
torque.
ROTATION VALVES OF CLEARANCE OF
CLOCKWISE CYLINDER No. VALVES Ref No. Description Tightening torques
CYLINDER No. (2) 20 M6x1x50 8.5 1.5 Nm
1 and 6 at TDC 6 1
120 3 4 Figure 49
120 5 2
120 1 6
120 4 3
120 2 5

in the table, checking exact positioning at each
phase by means of pin 99360612.
218020

figure.

TURBOCHARGER Refitting
REMOVAL / REFITTING Mount a new gasket on exhaust manifold; fit the
Removal turbocharger and screw n 4 nuts.
Figure 50 Ref No. Description Tightening torques

(1) 4 M10x1.5 46 2 Nm
Figure 52
169819
Disconnect oil return pipe (1) and oil delivery pipe (2).
Ref No. Description

(1) 2 M8x1.25
169819
(1) 1 M30x2
(2) 2 M16x1.5 End the assembly procedure by connecting oil pipes.

Figure 51 (1) 2 M8x1.25 25 5 Nm
(1) 1 M30x2 25 5 Nm
(2) 2 M16x1.5 42 2 Nm
169820
Unscrew n 4 nuts (1).

Remove turbocharger (3) and gasket (2).
Ref No. Description

(1) 4 M10x1.5

EXHAUST MANIFOLD Figure 54

REMOVAL / REFITTING
Removal
Figure 53
169822
Unscrew n 24 M10 screws (2).

Remove exhaust manifold (3) and n 6 gasket (1).
Ref No. Description

(2) 24 M10x1.5x38
169821
To dismount the exhaust manifold (1), proceed as follows. Refitting

Proceed with the disassembly of the turbocharger: Mount 6 new gaskets and fit exhaust manifold.
- disconnect oil return pipe; Tighten the fastening screws (2) to the prescribed torque
- disconnect oil delivery pipe; following order and mode shown in the figure below.
- unscrew n 4 nuts;
- remove turbocharger and gasket. Ref No. Description Tightening torques
M10x1.5x38
(2) 24 1st phase 30 5 Nm
2nd phase 60 5 Nm
Figure 55
171168
Tightening order layout for exhaust manifold fastening screws.

The central section of the exhaust manifold (1) must be tightened first.

OIL FILTER REMOVAL / REFITTING Ref No. Description

Removal (1) 2 M8x1.25x90
(-) 2 M8x1.25x60
(-) 1 M8x1.25x20
WARNING: the oil filter contains inside a
quantity of oil of about 1 kg.
Place properly a container for the liquid. Refitting
Avoid the contact of skin with the motor Fit oil body filter with new gasket; screw n 2 M8 screws to
oil: in case of contact wash the skin with prescribed torque.
running water.
The motor oil is very pollutant: it must be Install bracket fixing oil delivery pipe.
disposed of according to the rules.
(1) 2 M8x1.25x90 24.5 2.5 Nm
(-) 2 M8x1.25x60 24.5 2.5 Nm
Figure 56 (-) 1 M8x1.25x20 24 3 Nm
NOTE Before refitting the new cartridge, wet seal using

engine oil.
Screw the oil filter by hand until it touches the support, then
tighten 3/4 of a turn to the required torque.
Add the required amount of recommended engine oil
through the filler.
119976
Use tool 99360252 to slacken the oil filters (1).
Figure 57
169823
Remove bracket fixing oil delivery pipe to turbocharger

unscrewing n 3 M8 screws.
Unscrew n 2 M8 screws (1); remove oil filter body (2) and
gasket (3).

OIL COOLER BLOW-BY REMOVAL / REFITTING

REMOVAL / REFITTING
Removal
Removal
Figure 59
NOTE Under oil cooler place a container for engine
coolant drain.
Figure 58
169825
Remove n 3 M6 screws (1) and blow-by box (2).
169824
Ref No. Description
Unscrew n 16 M8 screws (1).
Remove oil cooler body (4) and its gasket (2). (1) 3 M6x1
Unscrew n 2 screws (5).
Separate oil cooler (3) from oil body cooler.
Figure 60
Ref No. Description
(1) 16 M8x1.25x50
(5) 2 M12x1.75x30
Refitting
Assemble the oil cooler body with oil cooler, screwing in 2
screws.
Mount the oil cooler complete with new gasket to the
crankcase housing.

M8x1.25x50
(1) 16 1st phase 11.5 3.5 Nm
2nd phase 24.5 2.5 Nm 219644
(5) 2 M12x1.75x30 63 7 Nm
Unscrew the fastening screws (4) and remove the timing
cover (3).
Unscrew the fastening screws (2) and remove the blow-by
filter (1).
Ref No. Description

(2) 3 M6x1x16
(4) 6

Refitting INTAKE MANIFOLD

Install centrifugal filter on tune wheel and lock n 3 M6 screws REMOVAL / REFITTING
at required torque. Removal
Install timing cover and lock n 6 M8 retaining screws at
required torque. Figure 63
Figure 61
169825 223516
Install blow-by body (2) with related seal and lock screws Disconnect the engine cable (2) from the boost pressure and
n 3 M6 (1) at required torque. air temperature sensor (1) fitted on the intake manifold (3).

(1) 3 M6x1 9 1 Nm
Figure 64
Figure 62
223517
219644 Unscrew the fastening screws (5) and remove the intake
manifold (6), recovering relevant gaskets (1, 4) and air
grid-heater (if present) or spacer (3) from the cylinder head
Install the centrifugal filter element (1) on the timing gear (5) (2).
and tighten the fastening screws (2).
Fit the timing cover (3) and tighten the fastening screws (4).
Ref No. Description Tightening torques Ref No. Description

(2) 3 M6x1x16 9 1 Nm (5) 2 M10x1.5x110
(4) 6 (5) 3 M10x1.5x100
(5) 1 M10x1.5x150

Refitting STARTER REMOVAL / REFITTING

Removal
Figure 65 Figure 67
223517
Fit the intake manifold (6) together with new gaskets (1, 4) 193050
and air grid-heater (if present) or spacer (3) on the cylinder
head (2). Unscrew the fastening nuts (2) and remove the starter
Tighten the fastening screws (5) to the prescribed torque. electric motor (1).
Remove the studs.

(5) 2 M10x1.5x110 43 3 Nm Ref No. Description
(5) 3 M10x1.5x100 43 3 Nm (2) 3 M10x1.5
(5) 1 M10x1.5x150 43 3 Nm (2) 3 M10x1.5x30
Figure 66 Refitting
Screw the studs into flywheel housing and fit starter electric
motor (1).
Tighten fastening nuts (2) to prescribed torque.

(2) 3 M10x1.5 43 3 Nm
(2) 3 M10x1.5x30 25 5 Nm
223516
Connect the engine cable (2) to the boost pressure and air
temperature sensor (1) fitted on the intake manifold (3).

OIL SUMP REMOVAL / REFITTING Figure 69

Removal
NOTE Place a proper container for the oil collecting

under the sump connected with the drain plug.
Figure 68
223504
Unscrew fastening screws (1) and remove oil sump (3)

together with spacer (2) and gasket (5) from crankcase (4).
Ref No. Description

(1) 26 M10x1.5x45
Figure 70
223485
Unscrew the drain plug (3) from the oil sump (2) and then
take out oil level dipstick (not supplied by FPT) and oil filler
cap (1) to ease the down flow of lubricant oil.
Remove the oil filter as described in the relative procedure.
218523
Unscrew fastening screws (4) and remove brackets (1 and

3).
Unscrew fastening screws (5) and remove oil suction strainer
(2) and pipe (6).
Ref No. Description

(1) 1 M10x1.5x12
(4) 2 M10x1.5x25
(5) 2 M10x1.5x20
The oil motor is very pollutant and harmful. In case

of contact with the skin, wash with much water and
detergent.
Protect properly skin and eyes: operate according

to safety rules. Dispose of the residual properly
following the rules.

Refitting Figure 73
Figure 71
170127
Turn engine.
223504
Install gasket (5) onto the oil sump (3) and fit the oil sump
(3) together with spacer (2) on the crankcase (4).
NOTE Before assembling the suction rose, it is necessary Tighten fastening screws (1) to prescribed torque following
to seal the contact area between basement, order and mode shown in the figure below.
flywheel casing and front cover with LOCTITE,
following the herein instructions. Clean the surfaces
of the parts to be joined removing impurities and oil
residuals. Ref No. Description Tightening torques
(1) 26 M10x1.5x45 41.5 3.5 Nm
Apply silicon LOCTITE 5970 (1) as shown in the picture. Figure 74

The diameter of the sealing string must be 1.5 0.5/0.2 mm.
Figure 72
223518

figure.
218523
Fit oil suction strainer (2) and pipe (6) and tighten fastening
screws (5) to prescribed torque.
Install brackets (1 and 3) and tighten fastening screws (4) to
prescribed torque.

(1) 1 M10x1.5x12 41.5 3.5 Nm
(4) 2 M10x1.5x25 41.5 3.5 Nm
(5) 2 M10x1.5x20 41.5 3.5 Nm

Figure 75 Figure 76
193945
223485
Lock drain plug (3) under oil sump (2) at prescribed torque.
Install the oil filter as described in the relative procedure.
Add the required amount of recommended lubricant oil
through the oil filler cap (1) and refit oil level dipstick (not
supplied by FPT).
NOTE Use only the recommended oil or oil having the

requested features for the correct motor
functioning.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service
warranty is no more valid.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.


F2CFE613 ENGINES SECTION 6 - ENGINE OVERHAUL 1
SECTION 6
Engine overhaul
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 5
FITTING THE ENGINE TO THE ROTATING STAND 6
- Engine lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Engine cleaning . . . . . . . . . . . . . . . . . . . . . . . . 6
- Engine cable removal . . . . . . . . . . . . . . . . . . . 7
- Engine coolant and lubricant oil drain . . . . . . . 8
- Removal of components hindering bracket

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Engine brackets and rotating stand installation 10
ENGINE DISASSEMBLY AT BENCH

(FRONT SIDE COMPONENTS) . . . . . . . . . . 11

(RIGHT HAND SIDE COMPONENTS) . . . . 13

(LEFT HAND SIDE COMPONENTS) . . . . . . 14

(REAR SIDE COMPONENTS) . . . . . . . . . . . . 16

(BOTTOM SIDE COMPONENTS) . . . . . . . . 17

(REAR SIDE COMPONENTS) . . . . . . . . . . . . 18

(FRONT SIDE COMPONENTS) . . . . . . . . . . 18

(TOP SIDE COMPONENTS) . . . . . . . . . . . . 19
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 20
ENGINE REMOVAL AT THE BENCH . . . . . . . . 20
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 21
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 21
- Checks and measurements . . . . . . . . . . . . . . . 21
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 23
- Replacing cylinder liners . . . . . . . . . . . . . . . . . 25

2 SECTION 6 - ENGINE OVERHAUL F2CFE613 ENGINES
Page Page
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - Piston protrusion check . . . . . . . . . . . . . . . . . 52
- Measuring main journals and crank pins . . . . . 27 - Checking assembly clearance of big end pins . 52
PRELIMINARY MEASUREMENT OF MAIN AND CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 53

BIGEND BEARING SHELL SELECTION DATA 28
- Dismounting the valves . . . . . . . . . . . . . . . . . . 53
DEFINING THE CLASS OF DIAMETER OF THE MAIN
JOURNALS AND CRANKPINS - Checking the planarity of the head on the cylinder
(journals with nominal diameter) . . . . . . . . . . 29 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- Defining the class of diameter of the main journals VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
(nominal diameter) . . . . . . . . . . . . . . . . . . . . . 30
- Removing deposits and checking the valves . . 54
- Defining the class of diameter of the crankpins
(nominal diameter) . . . . . . . . . . . . . . . . . . . . . 31
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . 54
- SELECTING THE MAIN AND BIG END
BEARING SHELLS . . . . . . . . . . . . . . . . . . . . . 32 - Replacing of valve guides . . . . . . . . . . . . . . . . 55
- Thickness of the big end half-bearing . . . . . . . 33 - Replacing - Reaming the valve seats . . . . . . . . 55
SELECTION OF MAIN HALF-BEARINGS (NOMINAL TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 56

DIAMETER PINS) . . . . . . . . . . . . . . . . . . . . . . 34
- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . 56
- Selection of main half-bearings (rectified pins) 35
- Intermediate gear pin . . . . . . . . . . . . . . . . . . . 56
SELECTING THE BIG END BEARING SHELLS
(JOURNALS WITH NOMINAL DIAMETER) 38 - Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
- Selection of connecting rod half-bearings (nominal - Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . 56

diameter pins) . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Replacing the bushings . . . . . . . . . . . . . . . . . . 56
- Selection of connecting rod half-bearings
(rectified pins) . . . . . . . . . . . . . . . . . . . . . . . . . 40 - Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Replacing the timing control gear and the oil pump 43 - Checking cam lift and pin alignment . . . . . . . . 57
- Checking main journal installation clearance . . 43 - Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
- Checking crankshaft end float . . . . . . . . . . . . . 45 - Use beater 99360505 to change bushings . . . 59
PISTON-CONNECTING ROD ASSEMBLY . . . . 46 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 - Fitting the valves and oil seal ring . . . . . . . . . . 59
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 60
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . 49 - Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
- Conditions for correct gudgeon pin-piston coupling51 - Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
- Mounting the connecting rod - piston assembly 51 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
- Mounting the piston rings . . . . . . . . . . . . . . . . 51 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . 65
- Fitting the connecting rod-piston assembly into the - Engine flywheel installation . . . . . . . . . . . . . . . 66
piston liners . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Page
- Camshaft installation . . . . . . . . . . . . . . . . . . . . 69
- High pressure pump installation . . . . . . . . . . . 70
TIMING CAMSHAFT AND FLYWHEEL USING

TOOL 99395223 . . . . . . . . . . . . . . . . . . . . . . 71
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 71
- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 73
TIMING CAMSHAFT AND FLYWHEEL WITHOUT

TOOL 99395223 . . . . . . . . . . . . . . . . . . . . . . 73
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 73
- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 77

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ENGINE ASSEMBLY AT BENCH

(LEFT HAND SIDE COMPONENTS) . . . . . . 81

(RIGHT HAND SIDE COMPONENTS) . . . . 83

(FRONT HAND SIDE COMPONENTS) . . . . 85
REMOVING THE ENGINE FROM THE ROTATING

STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
COMPLETING ENGINE ASSEMBLY . . . . . . . . . 87
- Engine cable refitting . . . . . . . . . . . . . . . . . . . . 89
CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 90


INTRODUCTION
The following description covers general mechanical overhaul starting from the engine which has been removed from the vehicle.
NOTE Refer to the specific publication for removing the engine from the vehicle.
Engine removal operations, as with overhauling, must be carried out by specialised personnel with specific equipment.
This section contains:
- the operations to perform for mounting the engine on the rotating stand
- the sequence of removal operations for the main components
- overhaul of the engine block and the cylinder head
- the sequence of refitting operations for the main components
- operations required for completing engine assembly after removal from the rotating stand
- final checks and tests.
Part of the operations covered in this section can be performed directly on the engine still fitted in the vehicle, in relation to their
accessibility in the engine compartment and on the vehicle version; these are listed in Section 5 - Removal/refitting of main the
engine components.

FITTING THE ENGINE TO THE ROTATING STAND

Engine lifting
Figure 1
223519
Install the lifting eyelets (3) and tighten the screws to the Engine cleaning
prescribed torque.
Plug all openings (air intake, exhaust duct, fuel pipes, coolant
Apply the engine lifting sling 99360585 (2) to lifting eyelets (3) pipes).
and to hoist (1). Remove the main electrical components (engine control unit,
Adjust the lifting points on the tool so that the engine remains starter electric motor, alternator).
in equilibrium when it is raised. Cover all electrical components not removed (sensors, cables,
connectors, ECU) with plastic and tape before washing with
high-pressure water jets in order to prevent damage.

(3) 6 M12x1.75x25 74 8 Nm
NOTE Use extreme caution when lifting and never stay

with any part of the body under the engine while
it is being lifted or suspended.

Engine cable removal

Figure 2
223520
1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor - 4. Crankcase pressure sensor -
5. Fuel temperature and filter clogging (pressure drop) sensor - 6. Boost pressure and air temperature sensor -
7. In line connector - 8. Engine Control Unit EDC17CV41 - 9. Engine oil pressure and temperature sensor -
10. Fuel high pressure pump metering unit - 11. Flywheel increment speed sensor (crankshaft) -
12. Timing segment speed sensor (camshaft) - 13. Motorized throttle valve actuator connector (Exhaust flap) -
14. Exhaust gas absolute pressure sensor
Before fitting the engine onto the rotating stand 99322230, remove the engine cable by unplugging it from the engine control unit
(9), from the motorized throttle valve actuator connector (13) and from all the sensors and transmitters to which it is
connected.Open the straps holding the engine cable to the engine block and remove it completely.

Engine coolant and lubricant oil drain Figure 3

Drain the engine coolant if not already done.
Place a suitable container for collecting the spent oil under the
oil sump next to the lubricant oil drain plug. Unscrew the
lubricant oil drain plug; afterwards extract the oil level dipstick
and remove the lubricant oil cap to assist the flow of the engine
lubricant oil.
Wait until the oil sump has completely emptied, then retighten
the lubricant oil drain plug.
Removal of components hindering bracket

assembly
Remove all those parts that can interfere with the assembly of
the brackets 99361046 to the engine block for fastening the
engine to the rotating stand 99322230.
223521
Position a suitable container to catch any oil.

Remove the turbocharger lubrication oil discharge pipe (2) by
proceeding as follows:
- unscrew the fastening screws (1) in the lower part of the
turbocharger, recovering the relevant gasket;
- unscrew the coupling (3) from the crankcase.
Remove the oil level dipstick pipe and lubrication oil filling pipe
(if fitted) from the crankcase.
Ref No. Description

(1) 2 M8x1.25x25
(3) 1 M30x2

Figure 4 Figure 6
223522 218036
Position a suitable container to catch any coolant. Position a suitable container under lubricant oil heat
exchanger to catch any coolant.
Remove engine coolant delivery (4) and return (7) pipes of the
motorized throttle valve actuator by proceeding as follows: Unscrew fastening screws (2) together with spacers (3) and
remove lubricant oil heat exchanger (4) complete with
- unscrew the fittings (1 and 3) and remove the engine
relevant gasket (1) from crankcase (5).
coolant delivery pipe (4);
- unscrew the retaining screws (5 and 6) and the fittings (2
and 8) and remove the engine coolant return pipe (7). Ref No. Description
(2) 16 M8x1.25x50
Ref No. Description
(1) 1 M14x1.5
(3) 1 M16x1.5
(2,8) 2 M14x1.5
(5,6) 2 M8x1.25x18 Figure 7
Figure 5
223523
Unscrew the fastening screws (1) and remove the cover (6),
retrieving relative sealing O-ring (7).
If the power take-off (PTO) is present, remove the power
steering pump and the service air/conditioning compressor
218035 with relative coolant pipes.
Unscrew fastening screw (3) and loosen V-clamping collar (1) Ensure that the starter electric motor (3) is suitably supported.
to remove motorized throttle valve (2) together with actuator Unscrew the fastening nuts (2) and remove the starter electric
(4) from turbocharger (5). motor (3).
Unscrew the studs (4) from the flywheel housing (5).

(3) 1 M8x1.25x70 (1) 3 M12x1.75x25
(2) 3 M10x1.5
(4) 3 M10x1.5x30

Engine brackets and rotating stand installation

Figure 8
223524
Fit brackets 99361046 to the engine block and mount the engine on the rotating stand 99322230.

ENGINE DISASSEMBLY AT BENCH Figure 11

(FRONT SIDE COMPONENTS)
Figure 9
223527
Unscrew the fastening screws (4) and disassemble the

223525
thermostat unit: remove the engine coolant outlet pipe (5)
Pull the automatic belt tensioner (8) by using appropriate tool together with its gasket (3), the sealing ring (2) and the
(7) and remove the auxiliary members belt (4) from thermostat (1).
alternator (1), water pump (3), fan control pulley (2),
crankshaft pulley with damper (6) and fixed guide roller (5). Ref No. Description
(4) 5 M8x1.25x70
Figure 10
Figure 12
223526
Unscrew the fastening screw (5) and remove the automatic

belt tensioner (6).
Unscrew the fastening screws (3 and10), recovering spacer
(11), and remove the alternator (4).
Unscrew the fastening screws (8 and 9) and remove the
alternator lower support (7).
Unscrew the fastening screws (1) and remove the alternator
upper support (2).
Ref No. Description
(1) 2 M8x1.25x30
(3) 1 M8x1.25x35 223528
(5) 1 M10x1.5x70
Unscrew the fastening screws (1, 4 and 5) and remove the
(8) 2 M10x1.5x70
engine coolant inlet pipe (3) from the crankcase recovering
(9) 1 M10x1.5x30 the sealing ring (2).
(10) 1 M10x1.5x120
Ref No. Description
(1,5) 2 M8x1.25x50
(4) 1 M8x1.25x70

Figure 13
NOTE The flywheel blocking device can aid the removal of
the damper pulley (2) fitted onto the crankshaft
pulley (6).
223529
Unscrew the fastening screws (5) and remove the fan-fixing

spacer (4) from the fan drive pulley (8).
Unscrew the fastening screw (6) and remove the shoulder
washer (7) and the fan drive pulley (8) from the fan support
(1) together with the bearing (2) retained by the ring split Figure 15
circlip (3).
Unscrew the fastening screws (9) and remove the support (1)
from the cylinder head.
Ref No. Description

(5) 6 M8x1.25x50
(6) 1 M10x1.5x80
(9) 4 M8x1.25x50
Figure 14
218041
Unscrew the fastening screws (3) and remove the water

pump (2) together with its sealing gasket (1).
Ref No. Description

(3) 4 M8x1.25x25
223530
Unscrew the fastening screws (4) together with washers (3)

and remove the damper pulley (2) from the crankshaft pulley
(6).
Unscrew the fastening screw (8) and remove the idler guide
pulley (1).
Unscrew the fastening screws (5) and remove the crankshaft
pulley (6) from the crankshaft (7).
Apply extractor and remove crankshaft rear seal.
Ref No. Description

(4) 6 M12x1.75x30
(5) 6 M14x2x60
(8) 1 M12x1.75x70


(RIGHT HAND SIDE COMPONENTS)
Figure 16
218017
Disconnect the engine cable from the fuel high-pressure pump

218042
metering unit (8), as described in the relative procedure.
Position a suitable container to catch any fuel. Disconnect the fittings (7 and 9) to remove the low pressure
fuel pipe (11) from fuel filter to high-pressure pump and the
Disconnect the fitting (5) and remove the low pressure fuel pipe (12) from mechanical pump to fuel filter.
pipe from the engine control unit heat exchanger to
mechanical pump. Unscrew the hose couplings (3 and 10) and the screw (6) to
remove the high-pressure fuel pipe (5) from high-pressure
Unscrew the fastening nuts (3) and remove the ECU (2) pump to cylinder head.
including the heat exchanger.
Unscrew the fastening screws (2 and 4) and remove the fuel
Unscrew the fastening screws (6) and remove the engine oil filter bracket (1).
pressure and temperature sensor (1) from the crankcase.
Unscrew the spacers (4). Ref No. Description
(7,9) 2 M16x1.5
Ref No. Description (3,10) 2 M14x1.5
(3) 3 M8x1.25 (6) 1 M6x16
(4) 3 M8x1.25x47 (2) 3 M8x1.25x35
(5) 1 M16x1.5 (4) 1 M8x25
(4) 1 M10x25
Figure 17
Figure 19
218016 218043
Place a container for collecting diesel under the fuel filter Disconnect the fittings (4 and 8) and the screw (1) to remove
support (2). the low pressure fuel pipe (3) from ECU to mechanical pump.
Unscrew the fastening screws (3) and remove the fuel filter Disconnect the fittings (2 and 7) and the screw (5) to remove
support (2) together with the fuel filter clogging (pressure the backflow fuel pipe (6) from high-pressure pump to fuel
drop) sensor (5) and NTC temperature sensor (4) from the tank.
engine cable supporting bracket (1). Ref No. Description
Ref No. Description (4,8) 2 M16x1.5
(3) 4 M8x1.25x30 (2,7) 2 M16x1.5
(1) 1 M8x1.25x25
(5) 1 M8x1.25x16

Figure 20 ENGINE DISASSEMBLY AT BENCH

(LEFT HAND SIDE COMPONENTS)
Figure 21
223531
Unscrew the fastening screws (7) and remove the oil pressure
and temperature sensor (6). 218046
Unscrew the fastening screws (10, 12) and remove the Unscrew the screw (3) fixing the lubrication oil delivery pipe
bracket (11). (2) to oil filter bracket (4)
Unscrew the fastening screw (2) and remove the crankcase Position a suitable container to catch any oil.
pressure sensor (1).
Unscrew the hose couplings (1 and 5) and remove the
Unscrew the fastening screws (8) and remove the intake lubrication oil delivery pipe (2) from crankcase to
manifold (9) together with boost pressure and air turbocharger.
temperature sensor from the cylinder head, recovering
grid-heater resistance (4) and relative gasket (3, 5). Ref No. Description
(1,5) 2 M18x1.5
Ref No. Description (3) 1 M8x1.25x20
(2) 1 M12x1.5
(10) 1 M10x1.5x16
(12) 1 M8x1.25x16 Figure 22
(8) 2 M10x1.5x110
(8) 3 M10x1.5x100
(8) 1 M10x1.5x150
223532
Unscrew the hose couplings (1 and 6) and remove the

exhaust gas pipe (2) from exhaust manifold.
Unscrew the fastening screws (3 and 7) and remove the
bracket (4) together with the exhaust gas absolute pressure
sensor (5).
Ref No. Description
(1,6) 2 M14x1.5
(3,7) 2 M6x1x14

Figure 23 Figure 25
218048
218050
Position a suitable container to catch any oil.
Unscrew the fastening screws (6 and 7) and remove the oil Unscrew fastening screws (4) and remove exhaust manifold
filter (5) with its support recovering relative gasket (2) and the (1) recovering relevant gaskets (3) from cylinder head (2).
bracket (1).
Unscrew the fastening screws (4) and remove the oil pressure
relief valve (3) from the crankcase.

(4) 2 M8x1.25x20 (4) 24 M10x1.5x38
(6) 2 M8x1.25x90
(7) 2 M8x1.25x60
Figure 24
218049
Unscrew the fastening nuts (4 and 7) and remove the

turbocharger (6), recovering relevant gasket (2).
Unscrew the studs (3 and 5) from the exhaust manifold (1).
Ref No. Description

(3,5) 4 M10x1.5x30
(4,7) 4 M10x1.25


(REAR SIDE COMPONENTS)
Figure 26
192060
Unscrew the screws (1) and remove the high pressure pump
(2).
Ref No. Description

114018
(1) 3 M8x1.25x40
Unlock screws (2) and remove cover (1). Remove centrifugal
filter (3) below. Figure 29
Ref No. Description

(3) 3 M6x1x16
(2) 6
Figure 27
114020
Unlock screws (1) and remove thrust plate (2).

Use specific spanner to unlock screws (4) and remove relay
gear (5).
Remove high pressure pump mount flange (3).
192059
Use specific spanner to unlock screws (2) and remove gear (3)
complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure Ref No. Description
pump. (1) 5 M8x1.25x20
Remove rpm sensor (1). (4) 3 M12x1.5
Ref No. Description

(2) 4 M10x1.5x45
(4) 1 M18x1.5
(1) 1 M6x1
NOTE In case removal of gear (5) is difficult, release high

pressure pump screws with light beater strokes on
control shaft and remove gear (5).

Figure 30 ENGINE DISASSEMBLY AT BENCH

(BOTTOM SIDE COMPONENTS)
Figure 31
192061
Remove the crankshaft rpm sensor (3).

Use specific tool 99360351 lock engine flywheel (2) rotation,
unlock retaining screws (1) and remove engine flywheel. 223533
Unscrew fastening screws (1) and remove oil sump (3)

together with spacer (2) and gasket (5) from crankcase (4).

(3) 1 M6x1 (1) 26 M10x1.5x45
(1) 8 M18x1.5x72
Figure 32
192063
Unlock screws and remove suction rose (1).

Ref No. Description
(1) 1 M10x1.5x12
(1) 2 M10x1.5x25
(1) 2 M10x1.5x20

ENGINE DISASSEMBLY AT BENCH ENGINE DISASSEMBLY AT BENCH

(REAR SIDE COMPONENTS) (FRONT SIDE COMPONENTS)
Figure 33 Figure 35
114022
166329
Apply extractor and remove crankshaft rear seal.
Unlock screws (1) and remove flywheel box (2). Use extractor (2) and remove the crankshaft front seal (1)
from the front cover (3).
Ref No. Description
(1) 1 M10x1.5x110
(1) 3 M10x1.5x35
(1) 1 M12x1.75x120
(1) 1 M10x1.5x180
(1) 7 M12x1.75x80
(1) 2 M12x1.75x193
Figure 34
Figure 36
114023 218501
Remove screws (2) and double gear (3). Unscrew the fastening screws (3) and remove the front cover
(1) from the crankcase (5), recovering the washers (2).
Remove retaining screw (5) and connecting rod (4).
Remove oil pump (1).
NOTE Crankcase (5) has two reference studs (4) that must
match with related housings on the front cover (1).
Ref No. Description
(1) 3 M8x1.25x45 Ref No. Description
(1) 5 M8x1.25x60 (3) 9 M8x1.25x20
(2) 3 M12x1.75x90
(5) 1 M8x1.25x16


(TOP SIDE COMPONENTS)
Figure 37
192067
114027
Unlock rocker arm shaft retaining screws (4). Remove retaining brackets (3) and remove injectors (4).
Disconnect fuel pipelines (1) from injector rail, fuel supply line Remove retaining screws (1) and remove rail (2).
(2) of high pressure pump to rail and return line (3).
Ref No. Description
Ref No. Description (1) 3 M8
(1) 6 M18x1.5 (3) 1 M10x1.5x40
(1) 6 M14x1.5
(2) 1 M18x1.5
(2) 1 M14x1.5
(4) 7 M12x1.75 Figure 40
Figure 38
192068
Remove camshaft and remove cylinder head retaining screws.
192075
Use metallic ropes to lift cylinder head (1) and remove seal (2).
shaft, remove crosspieces from cylinder head.
Ref No. Description
(-) 26 M16x2x170

ENGINE OVERHAUL Figure 41

ENGINE REMOVAL AT THE BENCH
The following instructions are prescribed on the
understanding that the engine has previously been placed on
the rotating bench and that removal of all specific components
of the equipment have been already removed as well.
The section illustrates therefore all the most important engine
overhaul procedures.
Figure 42
191584
115882 Use adequate hexagonal spanner, unlock screws (1 and 3) and

remove stiffening plate (2) as well as main journals (4).
Rotate the block to the vertical position.
Untighten screws (2) fixing the connecting rod cap (3) and
remove it. Remove the connecting rod-piston (1) assembly
from the upper side. Ref No. Description
Repeat these operations for the other pistons. (1) 8 M10x1.5x20
(3) 14 M16x2x168
Ref No. Description
(2) 12 M10x1.5x20
NOTE Note down the assembly position of the top and

Keep the big end bearing shells in their respective bottom main bearing shells since, if reusing them, they
housings and/or note down their assembly position will need to be fitted in the position found upon
since, if reusing them, they will need to be fitted in the removal.
position found upon removal.

Figure 45 REPAIR OPERATIONS

CYLINDER BLOCK
Checks and measurements
Figure 43 (Demonstration)
114035
Using tool 99360500 (1), remove the crankshaft (2).
Figure 46
34994
Internal diameter of the cylinder liners is checked for

ovalization, taper and wear, using a bore dial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 117 mm.
NOTE If dia.117 mm ring gage is not available, use a

micrometer.
47571
Remove the main bearing shells (1), unscrew the screws and Figure 44
take out the oil nozzles (2).
Remove the cylinder liners as described under the relevant
subheading on Replacing cylinder liners paragraph.
Ref No. Description

(2) 6 M8
After disassembling the engine, thoroughly clean

disassembled parts and check their integrity.
Instructions for main checks and measures are given
in the following pages, in order to determine whether
the parts can be re-used.
114035
1 = 1st measuring
2 = 2nd measuring
3 = 3rd measuring
Carry out measurings on each cylinder liner at three different

levels and on two (A-B) surfaces, to one another
perpendicular, as shown in Figure.

Figure 47
225036
A = Selection class 117 117.012 mm
B = Selection class 117.010 117.022 mm
In case of maximum wear >0.150 mm or maximum
ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
NOTE Cylinder liners are equipped with spare parts with

A selection class.
Figure 48
114037
A = 130.500 to 130.525 mm
B = 129.510 to 129.535 mm
C = 130.461 to 130.486
D = 129.475 to 129.500 mm
The figure shows the outer diameters of the cylinder liners and
the relative seat inner diameters.
The cylinder liners can be extracted and installed several times
in different seats, if necessary.

CYLINDER LINERS
Figure 49
114038
CYLINDER BLOCK ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS
Figure 50
193967
CYLINDER LINERS MAIN DATA
Selection class A mm 117.000 to 117.012

B mm 117.010 to 117.022
X = Selection class marking area

Figure 51
DETAIL A
145837
Figure 52
DETAIL B
145838

Replacing cylinder liners Figure 55

Removal
Figure 53
77812
Check cylinder barrel protrusion with tool 99360334

(1-2-3-4) and tighten screw (1) to 225 Nm.
47577
With dial gauge 99395603 (5) placed on base 99370415 (6)
measure the cylinder barrel protrusion compared to the
Place details 99360706 (1 and 2) and plate 99360724 (4) as cylinder head supporting plane, it must be 0,035 to 0,065 mm
shown in the figure, by making sure that the plate (4) is (figure below); otherwise replace the adjusting ring
properly placed on the cylinder liners. (1, previous figure) fitted with spare parts having different
thickness.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the block.
Figure 56
Fitting and checking protrusion
Figure 54
114041
CYLINDER LINER PROTRUSION
Figure 57
16798
Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2); lubricate
lower part of liner and install it in the cylinder unit using the
proper tool.
NOTE The adjustment ring (1) is supplied as spare parts in

the following thicknesses: 0.08 mm - 0.10 mm - 0.12 35012
mm. When the installation is completed, block the cylinder liners

(1) to the block (2) with studs 99360703 (3).

CRANKSHAFT
Figure 58
Upper main journal half bearing
Lower main journal half bearings

144835
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
Figure 59 Figure 60
114043 114044
X. Detail of main journals connections Y. Detail of crank pins connections

Measuring main journals and crank pins Figure 62

Before grinding the crank pins using a micrometer (1),
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.
For a more accurate reading, take different measurements on
more than one point of the shaft and calculate the average
value.
Figure 61
47536
MEASURING CRANK PINS

During grinding, pay attention to journal and crank pins values
specified previous figures.
47535
MEASURING THE MAIN JOURNALS

NOTE All journals and crank pins must also be ground to
the same undersizing class, in order to avoid any
NOTE It is advisable to enter the values found in a table alteration to shaft balance.
(Figure below).
Figure 63
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
MIN.
MAX.
MIN.
MAX.
CRANK PINS 114045

PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:

- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
- On the rear of the crankcase a set of seven numbers (A) are marked.
- The value of each number may be 1, 2 or 3 depending on the nominal diameter class of each seats.
- The main bearing caps (B) are marked by one sets of progressive numbers for locate them on the crankcase.
Figure 64
210298

DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS

(journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown in figure:
Figure 65
210301
- A: The set of seven digits, refers to the crankpins and is preceded by a single digit:
G 1st digit shows the status of the journals (1 = STD, 2 = -0.127),
G Six digits, taken singly, give the class of diameter of each of the crankpins
- B: The set of eight digits, refers to the main journals and is preceded by a single digit:
G 1st digit shows the status of the journals (1 = STD, 2 = -0.127),
G Seven digits, taken singly, give the class of diameter of each of the main journals.
- C: The numbers of five digits, refers to the part number of the crankshaft.

Defining the class of diameter of the main journals (nominal diameter)

Before selecting the journal bearings, define the diameter class of each main journal; in order to identify the diameter class of the
main journals, identify the set (Rif. A - Figure 65) marked on the front of the crankshaft.
Figure 66
210302
Example:
Figure 67
210315

Defining the class of diameter of the crankpins (nominal diameter)

The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin, in order to
identify the diameter class of the crankpins, identify the three set (Rif. C - Figure 65) marked on the front of the crankshaft.
Figure 68
210303
Example:
Figure 69
210316

SELECTING THE MAIN AND BIG END BEARING SHELLS

NOTE To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described
hereunder
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected in classes of tolerance marked by a colored sign (red-green - red/black
- green/black)
Thickness of the main bearing shells
Figure 70
210304
1. Color marking
STD +0.127 +0.254 +0.508
210308
Red 2.968 to 2.978 - 3.092 to 3.102 3.219 to 3.229

Red/Black - 3.031 to 3.041 - -
Green 2.978 to 2.988 - - -
Green/Black - 3.041 to 3.051 - -
Yellow* 2.988 to 2.998 - - -
Yellow/Black** - 3.051 to 3.061 - -
* Production only. Substitute Green bearings if needed.

** Production only. Substitute Green\Black bearings if needed.
NOTE In case of the use of main bearings of different thicknesses on the same pin always assemble the thicker bearing on the
bottom (bed plate side).

Thickness of the big end half-bearing
Figure 71
210305
1. Color marking
STD +0.127 +0.254 +0.508
210311
Red 1.994 to 2.002 - 2.120 to 2.129 2.247 to 2.256

Red/Black - 2.057 to 2.065 - -
Green 2.002 to 2.010 - 2.129 to 2.130 2.256 to 2.265
Green/Black - 2.065 to 2.073 - -
Yellow* 2.010 to 2.018 - - -
Yellow/Black** - 2.073 to 2.081 - -

** Production only. Substitute Green\Black bearings if needed.
NOTE In case of the use of conrod bearings of different thicknesses always assemble the thicker bearing towards the small end
of the conrod.

SELECTION OF MAIN HALF-BEARINGS (NOMINAL DIAMETER PINS)

After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
210306 210299
1 2 3
STD CLASS 99.000 99.010 99.020
99.010 99.020 99.030
1 green green yellow*

92.270
92.979 green yellow* yellow*
2 red green green

92.980
92.989 green green yellow*
3 red red green

92,990
93.000 red green green
210307

Selection of main half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each under sizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
210306 210299
1 2 3
-0.127 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
1 green/black green/black yellow/black*

92.843
92.852 green/black yellow/black* yellow/black*
2 red/black green/black green/black

92.853
92.862 green/black green/black yellow/black*
3 red/black red/black green/black

92.863
92.872 red/black green/black green/black
210307
* Production only. Substitute Green\Black bearings if needed.

210306 210299
1 2 3
-0.254 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
1 red red red

92.726
92.746 red red red
210307

210306 210299
1 2 3
-0.508 CLASS 99.000 99.010 99.020
99.010 99.020 99.030
1 red red red

92.472
92.492 red red red
210307

SELECTING THE BIG END BEARING SHELLS (JOURNALS WITH NOMINAL DIAMETER)
On the body of the connecting rod, in the position shown in the view from A there are three markings:
1) Letter indicating the weight class:
A (yellow) = 3308 3338 g.
B (green) = 3339 3368 g.
C (blue) = 3369 3398 g.
2) Number identifying the diameter grade:
1 = 85.987 85.996 mm
2 = 85.997 86.005 mm
3 = 86.006 86.013 mm
3) Progressive number for identifying the connecting rod.
NOTE The identification colors of the marks are given in the table on CONNECTING ROD paragraph.
The number, indicating the class of diameter of the bearing shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal by following the indications in the table (Figure 201455).
Figure 72
201455

Selection of connecting rod half-bearings (nominal diameter pins)
210309 210312
1 2 3
STD CLASS 85.987 85.997 86.006
85.996 86.005 86.013
1 green green yellow*

81.915
81.925 green yellow* yellow*
2 red green green

81.925
81.935 green green yellow*
3 red red green

81.935
210310
of the conrod.

Selection of connecting rod half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each under sizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
210309 210312
1 2 3
-0.127 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
1 green/black green/black yellow/black*

81.789
81.799 green/black yellow/black* yellow/black*
2 red/black green/black green/black

81.799
81.809 green/black green/black yellow/black*
3 red/black red/black green/black

81.809
81.819 red/black green/black green/black
210310
of the conrod.

210309 210312
1 2 3
-0.254 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
1 red green green

81.661
2 red red green

81.671
81.681 red red green
210310
of the conrod.

210309 210312
1 2 3
-0.508 CLASS 85.987 85.997 86.006
85.996 86.005 86.013
1 red green green

81.407
2 red red green

81.417
81.427 red red green
210310
of the conrod.

Replacing the timing control gear and the oil Figure 75

pump
Check that the teeth of the gears are not damaged or worn,
otherwise remove them using the appropriate extractor.
Figure 73
210314
Position the lower shoulder rings (1) on the crankcase.
NOTE Grease the shoulder rings at the bottom (1) so they

lock in their position on the crankcase during
assembly.
144834
NOTE Before fitting the gear, spread Loctite type 603 on

approx. 5 mm wide band on crankshaft, at 30 mm
from contact surface.
Figure 76
After fitting the gear (1) on the crankshaft (2), heat it for ~15
minutes in an oven at temperature not higher than 180C.
Let them cool down after the installation.
Checking main journal installation clearance
Figure 74
114034
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
114049
Fit the oil jets (2) aligning the dowel with the opening (3) in
the crankcase.
Position the half-bearings (1) and the thrust bearing half rings
on bearing journals as shown in the figure.

(2) 6 M8 50 5 Nm

Figure 77 Figure 79
145839
114050
Clean accurately the parts and remove any trace of oil;
Fit caps (1), including the half bearings (2) on the relevant
Place bearing halves (1) on main journals (2). supports.
Check the installation clearance between the main journals
and the relative bearings as follows. Figure 80
Figure 78
210313
Position the upper shoulder rings (2).

Position the cap (1), together with the half-bearing. 191584
Position the main journal caps (4) and fit the strengthening
plate (2) following the procedure described:
NOTE Grease the shoulder rings at the top (2) so they lock
in their position on the crankcase during assembly. Tighten the inner bolts and then the outer bolts by hand
starting from main journal 7 and continuing until main journal
1.
Tightening the bolts using torque wrench always starting from
main journal 7 and continuing until main journal 1

M16x2x168
1st phase 140 7 Nm
(3) 14
2nd phase 60
3rd phase 60
(1) 8 M10x1.5x20 49 3 Nm

Checking crankshaft end float

Figure 81
208346
End float is checked by placing a magnetic dial gauge (1) on the

crankshaft (2), as shown in the figure.
If the value obtained is higher than specified, replace the rear
thrust half-bearings and repeat this check.

PISTON-CONNECTING ROD ASSEMBLY
Figure 82
193957
PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring with
spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston
Make sure the piston does show any trace of seizing, scoring, cracking; replace as necessary.

Removal Figure 85
Figure 83
126311 49026
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin (1).
(1).
If removal is difficult use the appropriate beater.
Pistons are equipped with three elastic rings: a sealing ring, a

trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Figure 84 Figure 86
126312 32618
Remove the piston pin split rings (2) using the round tipped Measuring the gudgeon pin diameter (1) with a micrometer
pliers (1). (2).

Figure 87
191256
MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0,6 0,1 Figure 90
Piston rings
Figure 88
3513
The sealing ring (2) of the 1 cavity is trapezoidal. Clearance

X between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3), so
that the sealing ring is half-projected out of the cylinder barrel.
16552
Check the thickness of the piston ring (2) using a micrometer

(1). Figure 91
Figure 89
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
16552
Check the clearance between the sealing rings (2) and the If the distance between ends is lower or higher than the value
relative piston housings (1) using a thickness gauge (3). required, replace split rings.

CONNECTING ROD
Figure 92
209171
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
NOTE The connecting rod/cap is of torn type; before assembly verify that the connecting rod is not damaged.
Each connecting rod can assembled with the relative cap only. If the cap is assembled on the reverse side, the connecting
rod must be rejected.
NOTE In spare parts catalogue there are connecting rod grade B only, use it for any replacement
NOTE All dimensions indicated in figure, must be controlled with bush assembled and finished.
On the external breaking line, gap area allowed must be < 5 mm2.
No cracks are allowed in the threaded area.
NOTE Make sure that the values of small end bush are between values listed in the Section 8:Technical Specification Cylinder unit
and crankshaft components; otherwise, replace the connecting rod.

Figure 93
193969
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from the
front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
3308 g - 3338 g 85.997-86.005 Green
Yellow
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
3339 g - 3368 g 85.997-86.005 Green
Green (*)
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
3369 g - 3398 g 85.997-86.005 Green
Blue
86.006-86.013 Blue
(*) As spares, only Grade B connecting rod are provided and can replace Grade A and C.

Conditions for correct gudgeon pin-piston Fitting the connecting rod-piston assembly
coupling into the piston liners
Figure 94
Figure 97
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight finger
pressure and it should not come out by gravity.
115885
Mounting the connecting rod - piston assembly Mount the selected half-bearings (1) both on the connecting
rod and the cap.
Figure 96
If the cap (1) is fitted upsidedown, the connecting
rod should be discarded.
NOTE As spares, class A pistons are provided and can be

fitted also to cylinder barrels belonging to class B.
117694
NOTE The connecting rod screws can be reused as long Fit the connecting rod-piston assemblies (1) into the piston
as the diameter of the thread is not less than 11.4 liners (2) using band 99360605 (1, following Figure). Check
mm. the following:
- the openings of the split rings are offset by 120;
Mounting the piston rings

Figure 95
Figure 98
47593
49029
- all pistons belong to the same class, A or B;

To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3). - ideogram stamped on the piston crown is placed toward
The rings need to be mounted with the word TOP (4) facing the engine flywheel, or the cavity, on the piston cover,
upwards. Direct the ring openings so they are staggered 120 corresponds to the position of the oil spray nozzles.
apart.

Piston protrusion check

Once assembly is complete, check piston protrusion from cylinder barrels: it must be 0.873 to 1.177 mm.
Figure 99
1 Connecting rod-piston assembly
2 Marking area on the piston crown of ideogram specifying

the assembly position and the selection class
3 Connecting rod marking area.
188462
Checking assembly clearance of big end pins Ref No. Description Tightening torques
M12x1.25x69
To check the clearance proceed as follows: (2) 12 1st phase 50 2.5 Nm
connect the connecting rods to the relative main journals, 2nd phase 60
place a length of calibrated wire on the latter.
Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
Figure 100 envelope containing the wire.
115886
Fit the connecting rod caps (1) together with half-bearings and
tighten the screws (2) to the torque indicated in the table using
tool 99395216 (3).

CYLINDER HEAD Checking the planarity of the head on the

Before dismounting cylinder head, check cylinder head for cylinder block
hydraulic seal by proper tooling; in case of leaks not caused by
cup plugs or threaded plugs, replace cylinder head.
Figure 102
NOTE In case of plugs dismounting/replacement, on

mounting, apply sealant Loctite 121078 on plugs.
Dismounting the valves
NOTE Before dismounting cylinder head valves, number

them in view of their remounting in the position
observed on dismounting should they not have to
be overhauled or replaced.
Intake valves are different form exhaust valves in 198334
that they have a notch placed at valve head centre. The planarity (1) is checked using a ruler (2) and a thikness
gauge (3). If deformations exist, surface the head using proper
surface grinder; the maximum amount of material to be
removed is 0.2 mm.
Figure 101
NOTE After leveling, make sure that valve sinking and

injector protrusion are as described in the relative
paragraph.
47583
Install and fix tool 99360257 equipped with part 99360256 (2)
with bracket (4); tighten by lever (1) until cotters are removed
(3); remove the tool (2) and the upper plate (5), the spring (6)
and the lower plate (7).
Repeat the operation on all the valves.
Turn the cylinder head upside down and remove the valves
(8).

VALVE Figure 104

Removing deposits and checking the valves
Figure 103
92841
MAIN DATA - VALVES AND VALVE GUIDES

48625
* Values to be obtained after installing the valve guides
Remove carbon deposits using the metal brush supplied.
Check that the valves show no signs of seizure or cracking. Check, by means of a micrometer, that valve stem diameters
Check the diameter of the valve stem using a micrometer (see are as specified; if necessary, grind the valves seat with a
following Figure) and replace if necessary. grinder, removing the minimum quantity of material.
VALVE GUIDES
Figure 105
191585
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves

Replacing of valve guides Checking protrusion of injectors

Remove valve guides by means of tool 99360288.
Install by means of tool 99360288 equipped with part Figure 107
99360294, which determines the exact installation position
of valve guides into the cylinder heads; if they are not available,
install the valve guides in the cylinder head so that they project
out by mm 16.3 to 16.7 (Previous Figure).
After installing the valve guides, smooth their holes with
sleeker 99390310.
Replacing - Reaming the valve seats

To replace the valve seats, remove them using the appropriate
tool.
47585
Figure 106
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.53 mm.
41032
Ream the valve seats (2) on cylinder head using tool (1).
NOTE Valve seats must be reamed whenever valves or

valve guides are replaced or ground.
After reaming the valve seats, use tool 99370415, to make

sure that the valve position, with respect to the cylinder head
surface, is the following:
- -0.5 to -0.8 mm (recessing) of exhaust valves;
- -1.65 to 1.95 mm (recessing) of discharge valves.

TIMING GEAR Idler gear

Camshaft drive
Figure 108 Figure 110
193958
TIMING CONTROL COMPONENT PARTS 193970
1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -

5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear -
8. Drive shaft driving gear.
Intermediate gear pin Twin idler gear
204132 193971
Rated assembling play between idler gear bushings and pins: Replacing the bushings
0.040 0.080 mm.
Bushings (1) can be replaced when they are worn. Put up the
bushing, then grind it so as to bring it to a dimension of
65.010 0.10 mm.
NOTE Bushing fitting in gears (2, previous Figures) must be

performed in arrow direction, placing them as
shown in figures.

Camshaft
Checking cam lift and pin alignment
Figure 112
47506
Place the camshaft (4) on the live centre (1) and using a centesimal dial gauge (2) check the lift value of the cams (3) indicated in
the DATA -ASSEMBLY CLEARANCE table.
Figure 113
47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed
0.030 mm.
If misalignment exceeds this value, replace the shaft.
Figure 114
1
47505
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.

Figure 115
204131
MAIN DATA - CAMSHAFT AND TOLERANCES

The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the
shaft and the relative bushes.
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Bushes
Figure 116
114214
MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS

* Bush inner diameter after installation
The bush surfaces must not show any sign of seizing or scoring; Measure the bush inner diameters with a baremeter and replace
if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360505.
Use beater 99360505 to change bushings Fitting the valves and oil seal ring
Removal
Figure 119
Figure 117
114280
Use tool 99360505 (3) fitted as shown in fig. to remove

bushings (2).
Accurately position beater during removal phase.
Fitting
For fitting, reverse operations performed for removal, with
care to make lube hole (1), drilled on bushing, coincide with
corresponding hole in housing.
87051
Lubricate the valve stem and insert the valves in the respective
valve guides; fit the lower caps (1). Use tool 99360292 to fit
VALVE SPRINGS the oil seal (2) on the valve guides (3) of the exhaust valves;
then, to fit the valves, proceed as follows.
Figure 118
Valve closed
NOTE Should valves not have been overhauled or
replaced, remount them according to numbering
performed on dismounting.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre.
Valve open
Figure 120
114215
MAIN DATA TO CONTROL EXHAUST AND

DISCHARGE VALVE SPRING
86290
- fit springs (6) and the upper plate (5);

- apply tool 99360257 equipped with part 99360256 (2)
and block it with bracket (4); tighten the lever (1) until
cotters are installed (3), remove tool (2).

ROCKER SHAFT
Figure 121
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker a
rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
Shaft
Figure 122
114217
MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
Rocker
Figure 123
114219
DISCHARGE VALVE ROCKER

Figure 124
114218
EXHAUST VALVES ROCKER

The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.

ASSEMBLY Figure 127
Figure 125
117690
218502
Clean the surface of the parts to be joined removing impurities
and oil residuals. Apply silicon LOCTITE 5970 (1) to the cover - Fit part (4) of the tool 99346265 on the front tang (3) of
(2) as shown in the picture. the crankshaft; fasten it with the screws (5) and spline the
new tight ring (6) on it.
The diameter of the sealing string must be 1.5 0.5/0.2.
- Fit part (1) on part (4), screw-tighten the nut until the
assembly of the tight ring (6) into the front cover (2) is
completed.
Fit the front cover within 10 minutes after applying
the sealer.
218501 218503
Install front cover (1) on crankcase (5) and tighten fastening Fit the oil pump (4) on crankcase (2) and tighten fastening
screws (3) to the prescribed torque after having interposed screws (1 and 3) to the prescribed torque.
washers (2).
NOTE Crankcase (5) has two reference studs (4) that must
match with related housings on the front cover (1).

Ref No. Description Tightening torques (1) 3 M8x1.25x45 24 3 Nm
(3) 9 M8x1.25x20 19 3 Nm (3) 5 M8x1.25x60 24 3 Nm

218028
Clean surfaces to be coupled to remove dirt and oil residuals.

218504 Apply LOCTITE 5970 (2) silicone on gear casing (1) as shown
Install the clearance adjusting rod (2) on crankcase (3) and in the figure.
tighten fastening screw (1) to the prescribed torque. The sealant seam diameter must be 1.5 0.5/0.2 mm.

Install gear casing within 10 min. from sealant
(1) 1 M8x1.25x16 24.5 2.5 Nm application.
!
218505
Fit gear pin (2) in position into clearance adjusting rod (1) and
install double gear (5) complete with shoulder plate (4).
Tighten fastening screws (3) in two phases to prescribed
torque.
218506
Use two suitable lifting hooks (2) in order to lift and fit flywheel
box (1) to engine block (3) by using a hoist.
M12x1.75x90
(3) 3 1st phase 30 Nm
2nd phase 90

218508
Check that pistons 1-6 are exactly at T.D.C.

Use suitable lifting hooks (1 and 3) in order to lift and fit the
218507
cylinder head (2) on the engine block (4) after having
interposed a new gasket (5) by using a hoist with engine lifting
Use torque wrench to lock fastening screws (1, 2, 3, 4, 6 and sling 99360585.
7) at prescribed torque on flywheel box (5) following the
scheme shown in the figure below.
NOTE If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.
(1) 1 M10x1.5x110 41.5 3.5 Nm
(2) 3 M10x1.5x35 41.5 3.5 Nm
(3) 1 M12X1.75X120 63 7 Nm
(4) 1 M10x1.5x180 41.5 3.5 Nm
Removed screws must not be used again. Employ
(6) 7 M12x1.75x80 63 7 Nm new screws only.
(7) 2 M12x1.75x193 63 7 Nm
Figure 134
Figure 136
218509
The fastening screws (1) must be lubricated with MOLYKOTE

treatment before being mounted on the cylinder head (2).
Tighten the screws (1) fixing cylinder head (2) to engine block
in four phases to prescribed torque following order and mode
shown in the figures below.
M16x2x170
1st phase 50 Nm
218029
(1) 26 2nd phase 100 Nm
Tightening order layout for flywheel box fastening screws 3rd phase 90
4th phase 75

Figure 139
NOTE The screws (1) must be tightened following a
spiral pattern starting in the middle and going
outwards.
NOTE The angle tightening is carried out through tool

99395216.
NOTE Before any assembly operation always verify that the

hole and screw threads have no evidence of wear
or dirt.
45268
- Angle locking by means of tool 99395216 (1):

Figure 137 3rd phase: 90 angle
4th phase: 75 angle.
198348
Cylinder head retaining screw locking sequence diagram.
Figure 138
45267
- Pre-lock by torque wrench (1):

1st phase: 50 Nm (5 kgm);
2nd phase: 100 Nm (10 kgm).

ENGINE FLYWHEEL
NOTE If toothing on engine flywheel for engine start-up is

very damaged, change crown wheel.
Refit crown wheel after heating up at approx.
200C.
Figure 140
218514
- Fit part (6) of the tool 99346260 on the rear tang (3) of
the crankshaft; fasten it with the screws (1) and spline the
new tight ring (2) on it.
- Fit part (5) on part (6), screw-tighten the nut (4) until the
assembly of the tight ring (2) into the flywheel box is
completed.

Engine flywheel installation
NOTE Crankshaft has a reference pin that must match with related housing on engine flywheel.
Figure 141
114265
A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to
piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2 notches,
position corresponding to 54.

145832 192078
Position flywheel (1) on crankshaft, lubricate screws (2) Install rail on cylinder head and lock retaining screws by hand.
threading with engine oil and lock them.
Install injectors in correct position and lock to required torque.
M18x1.5x72 (-) 6 M10x1.5x45 46 3 Nm
2nd phase 90
Stop rotation using specific tool (99360351).

1st phase: pre-lock with torque wrench (3) at 120 Nm torque.
Figure 143
49036
2nd phase: 90 angle locking using tool 99395216 (1).

Figure 145
193973
Fit pipes on injectors and head locking fittings by hand.

The previously removed pipes ca no longer be refit
and must be replaced. Lock fittings on injectors and head (B) at required torque.
Lock rail to cylinder head retaining screws at required torque.
Lock fittings on rail (A, C) at required torque.
Lubricate the injector fastening O-Rings using the
following lubricants: PDE SILIKONFETT 22, NLG
12, PDE LUBRICOMET GR 220 NLG12.
TYPE DESCRIPTION LOCK TORQUE
A M18 x 1.5 40 2 Nm
Check that the injectors (2) are equidistant from the
springs (1). Distance X which separates them B M14 x 1.5 35 2 Nm
!
should always be the same. C M16 x 1.5 35 2 Nm
Install pipes on rail and lock fittings by hand.
After fitting the high-pressure pipelines, during the

! following 20 hours of work, frequently check engine
oil level (IT MUST NOT INCREASE).

Camshaft installation Figure 147

Figure 146
114267
Install camshaft (3) and orient it with references ()

193964
positioned as in the figure.
Clean the matching surfaces of the plate (1) to remove
Position crankshaft with pistons 1 and 6 at TDC. impurities and oil residues.
This condition is obtained when: Apply silicon LOCTITE 5970 (6) on the plate (1) as shown in
1. the opening with one reference (5) for the engine the picture.
flywheel (4) is visible from the inspection window;
2. tool 99360612 (1), through housing (2) of engine rpm NOTE Take care NOT to get sealant on the inner groove
sensor, inserts in hole (3) drilled on engine flywheel (4). (5).
Otherwise, adjust engine flywheel orientation (4).
Remove too 99360612 (1).
+ 0,5
The diameter of the sealant bead should be 1.5 - 0,2 mm.
Fit the plate (1) within 10 mins of applying the sealant with the
gasket (2) and tighten the screws (4) to the prescribed torque.

(4) 5 M8x1.25x20 20 2 Nm

Figure 148 High pressure pump installation

Figure 150
198353
Apply gage 99395222 (1), check and adjust position of

connecting rod (3) for relay gear, lock screw (2) at required
torque.
227375
Clean surfaces to be coupled to remove dirt and oil residuals.

Apply LOCTITE 5970 silicone on gear casing (1) as shown in
the figure.
+ 0,5
Figure 149 The sealant seam diameter must be 1.5 - 0,2 mm.
Install gear casing within 10 min. from sealant

! application.
Figure 151
114270
Refit relay gear (2) and lock screws (1) using six-splined
spanner at required torque.

(1) 3 M12x1.5 25 5 Nm
NOTE The relay gear (2) bushing can be replaced when

227374
worn out. After securing bushing, grind it to reach
dia. 58.010 0.10 mm. Apply gauge 99395230 (1) on flywheel box (4) to check and
adjust centre-to-centre distance between camshaft and fuel
high-pressure pump.
Fit connection flange (2) in position on the tool (1) and tighten
fastening screws (3) to prescribed torque by allen wrench.
Remove tool 99395230 (1) from flywheel box (4).

Figure 152 TIMING CAMSHAFT AND FLYWHEEL

USING TOOL 99395223
Timing camshaft
Figure 153
192060
Install high-pressure pump (1) on flange (2).

Tighten the screws (1) to the prescribed torque.

(1) 3 M8x1.25x40 33 3 Nm
193960
Rotate the crankshaft with the tool 99360341 so that the

opening marked with two references (5) is visible from the
lower inspection window in the flywheel cover casing.
In this condition, insert the tool 99360612 (1) via the housing
(2) for the engine rpm sensor in the opening (3) in the engine
flywheel (4).
Figure 154
192072
Fit the tool 99395223 (1) at the front of the camshaft.

2
3
192073
Rotate the tool (1) 99395223 in order to insert the pin (3) in
the opening (2, previous Figure) in the head. Fasten the tool
223535
(1) 99395223 using two M8x1.25 bolts (2).
Install crosspieces (5) on valve rod.

unlocked.
Lift and install the rocker arm shaft (4) on the cylinder head
117691
Fit the camshaft drive gear (1) so that the fastening openings
in the shaft are aligned with the slots (2) in the drive gear.
223536
Position the gear (1) taking care to position the spokes (4) as Remove lock blocks (1) and tighten the fastening screws (4)
illustrated. to prescribed torque. Remove tool 99360558 (2) from the
Tighten the fixing bolts (3). rocker arm shaft (3) by using a hoist.
M10x1.5x45 (4) 7 M12x1.75 104.5 10.5 Nm
(3) 4 1st phase 25 5 Nm
2nd phase 45

Figure 159 TIMING CAMSHAFT AND FLYWHEEL

WITHOUT TOOL 99395223
Timing camshaft
Figure 161
70567A
Timing flywheel
Figure 160 192079
Secure special tool 99360341 to gear casing.
NOTE The arrow indicated engine rotation direction.
With the aforementioned tool, turn the flywheel (1) in the

direction of the engine rotation so as to bring cylinder piston
1 to 54 before the T.D.S. during compression (cylinder 6 in
discharge phase).
145834 This condition occurs when the hole with two notches (3) on
the engine flywheel (1), can be seen through the small
Fit the high pressure pump gear (5) tightening the nut (4) to inspection window (2).
torque.
Use the flat washer in conjunction with the nut (4) replacing
the one supplied with the Bosch CP3 pump.
Fit the flywheel (6) so that the tooth marked with the arrow
() is in line with the sensor housing (2).
To check that the position is correct, insert tool (1) 99360613
in the timing sensor (2) housing.
Proceed with tightening the bolts (3).
Remove the tools 99395223, 99360612 and 99360613.

(4) 1 M18x1.5 105 5 Nm
(6) 3 M8x1.25 23 2 Nm

71774
117691
The exact position of piston 1 at 54 before T.D.C. is obtained
when, under the conditions described above, the specific tool Install gear (1) controlling camshaft so that fastening holes on
(1) is inserted into the hole (3) on the engine flywheel (4) shaft coincide with slots (2) on control gear.
through the engine rpm sensor seat (2).
Otherwise, rotate engine flywheel (4) to adjust its orientation. Position the gear (1) taking care to position the
NOTE
Remove the specific tool (1). spokes (4) as illustrated.
This operation is necessary in order to be able to fit
the flywheel correctly which can only be fitted in one
position in relation to the gear.
Figure 163
Lock retaining screws (3).

M10x1.5x45
(3) 4 1st phase 25 5 Nm
2nd phase 45
115063
Rotate the camshaft so that the openings at the rear of the

engine are arranged in the configuration illustrated in the
diagram.

70567A
Figure 168
223535
Install crosspieces (5) on valve rod.

unlocked.
Lift and install the rocker arm shaft (4) on the cylinder head 185253
As shown in the figure, position the dial gauge (1) with the flat
Figure 166 based rod (3) on the roller (4) of the rocker arm controlling
the discharge valve of cylinder 3 and preload it to at least 7
mm.
NOTE 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.
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.
223536
Remove lock blocks (1) and tighten the fastening screws (4)
(4) 7 M12x1.75 104.5 10.5 Nm
Remove tool 99360612.
177714
114281
Using the appropriate tool, turn the flywheel in a clockwise
direction until the needle of the dial gauge reaches the
minimum value possible. In case conditions shown in previous Figure and shown at
paras 1 and 2 are not found, operate as follows:
- turn the engine flywheel until the required cam lift value
NOTE The measurement is to be taken keeping the rocker appears on the dial gauge;
arm roller in contact with the profile of the exhaust
cam on the camshaft. - release screws (2) securing gear (1) of camshaft to as to
The dial gauge is to be zeroed with the rocker arm make control gear and camshaft independent;
roller in contact with the base radius of the cam - conveniently operate on engine flywheel so as to obtain
profile. conditions indicated at paras 1 and 2, previous Figure,
considering that cam lift value must remain unchanged;
- use the slots on the gear (1); lock screws (2) and repeat
Reset the dial gauge. control as already described;
Turn the flywheel in an anticlockwise direction, until the dial
- lock screws (2) at required torque.
gauge shows the timing system cam lift value of 4.70 0.05
mm. Ref No. Description Tightening torques
M10x1.5x45
Figure 170 (2) 4 1st phase 25 5 Nm
2nd phase 45
NOTE While performing this operation recover the

clearance between the camshaft gears.
When adjustment via the slots is not sufficient for recovering

the offset, proceed as follows:
Lock the screws (2) and turn the flywheel 1/2 turn in a
clockwise direction.
Turn the flywheel in an anticlockwise direction, until the dial
gauge shows the timing system cam lift value of 4.70 0.05
mm.
115064 Remove the screws (2) and disassemble the camshaft gear (1).
Camshaft is timed if conditions below are found at cam lift
values 4.70 0.05:
1) hole identified with two notches (5) is visible through
manhole;
2) fixture 99360612 (1) through housing (2) of engine rpm
sensor inserts in hole (3) on engine flywheel (4).

Figure 172 Timing flywheel

Figure 174
185523
Turn the flywheel (4) again until it reaches the following

conditions:
- the hole marked with two notches (5) can be seen from
the small inspection window;
- the specific tool (1) is inserted into the hole (3) on the
engine flywheel (4) through the engine rpm sensor seat
(2). 114284
Install gear (7) of high pressure pump and lock nut (8) at
Figure 173 required torque.

(8) 1 M18x1.5 105 5 Nm
NOTE When refitting, use the flat washer in conjunction

with the nut replacing the one supplied with
BOSCH pump CP3.
Turn the flywheel in an anticlockwise direction until the

inspection window (3) corresponds with the hole marked
with 2 notches (2) (cylinder 1 compressing).
114281
Insert the specific tool through the flywheel sensor seat.
Mount the gear (1) with the four slots centred in relation to
the camshaft fastening holes locking the relevant screws (2) to Mount the phonic wheel (4) so that the tooth marked with the
the prescribed tightening torque. arrow () corresponds with the sensor seat (6).
In order to check the correct positioning, insert the specific
tool into the timing sensor seat (6).
M10x1.5x45 Tighten the screws (5).
(2) 4 1st phase 25 5 Nm Remove the specific tools.
2nd phase 45
Recover the clearance between the timing gears by turning the
flywheel in a clockwise direction and then in an anticlockwise
direction until the dial gauge shows the value of 4.70 0.05
mm. Check the conditions described above.
(5) 3 M8x1.25 23 2 Nm


adjustment
Figure 175
204128
Fit the blow-by valve body (2) together with a new gasket and
114287 tighten the fastening screws (1) to the prescribed torque.
Adjustment of clearance between rocker arms and

the valves of this cylinder are closed while the symmetric Ref No. Description Tightening torques
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5 (1) 3 M6x1 9 1 Nm
and 3-4.
- Use a polygonal spanner to release lock nut (1) of rocker Figure 177

(1) 12 M10x1.25 39 5 Nm

115880
ROTATION VALVES OF CLEARANCE OF
CLOCKWISE CYLINDER No. VALVES Fit the head internal electric wire (injectors+pressure sensor)
CYLINDER No. passing it through the opening and securing it using bands as
1 and 6 at TDC 6 1 illustrated in the diagram ().
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5

in the table, checking exact positioning at each phase
by means of pin 99360612.

166177
219644
Install cylinder head cover (1) and lock screws (2) at required
torque following order shown in Figure below diagram. Install the centrifugal filter element (1) on the timing gear (5)
and tighten the fastening screws (2).
Fit the timing cover (3) and tighten the fastening screws (4)
(2) 20 M6x1x50 8.5 1.5 Nm (2) 3 M6x1x16 9 1 Nm
(4) 6
Figure 179
218020

Figure 181
117695
Rotate the engine

Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel casing and front cover
with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing impurities and oil residuals.
Apply silicon LOCTITE 5970 (1) as shown in the picture. The diameter of the sealing string must be 1.5 0.5/0.2 mm.

Figure 182 ENGINE ASSEMBLY AT BENCH

(LEFT HAND SIDE COMPONENTS)
Figure 185
192063
Install suction rose (1). 218050
Fit the exhaust manifold (1) in position with new gaskets (3)
Figure 183 to the cylinder head (2) and tighten the fastening screws (4)
to the prescribed torque following order and mode shown in
the figure below.

M10x1.5x38
(4) 24 1st phase 30 5 Nm
2nd phase 60 5 Nm
NOTE Always replace the gaskets (3) using new ones.

Check the threads of the fixing screws: there shall be
no evidence of wear or dirt deposit.
223533 Figure 186

Install gasket (5) onto the oil sump (3) and fit the oil sump (3)
together with spacer (2) on the crankcase (4).
Tighten fastening screws (1) to prescribed torque following
order and mode shown in the figure below.

(1) 26 M10x1.5x45 41.5 3.5 Nm
171168
Figure 184
Tightening order layout for exhaust manifold fastening screws
The central section of the exhaust manifold (1) must be
tightened first.
223518

218049 223532
Screw the studs (3 and 5) on the exhaust manifold (1); Fit the bracket (4) together with the exhaust gas absolute
pressure sensor (5) and tighten fastening screws (3 and 7) to
Hold the turbocharger (6) together with the waste-gate valve
prescribed torque.
and place it on the exhaust manifold (1) after having
interposed a new gasket (2); Install exhaust gas pipe (2) onto exhaust manifold and tighten
hose couplings (1 and 6) to prescribed torque.
Tighten the fastening nuts (4 and 7) to the prescribed torque.
(3,5) 4 M10x1.5x30 (1,6) 2 M14x1.5 30 2 Nm
M10x1.25 (3,7) 2 M6x1x14 10 2 Nm
(4,7) 4 1st phase 35 5 Nm (9) 1 M6x1x50 7 1 Nm
2nd phase 46 2 Nm
Figure 188
Figure 190
218048 218046
Install the oil pressure relief valve (3) into the crankcase and Install lubrication oil delivery pipe (2) from crankcase to
tighten the fastening screws (4) to prescribed torque. turbocharger and tighten hose couplings (1 and 5) to
prescribed torque.
Fit new gasket (2) on the crankcase and install the oil filter (5)
with its support and bracket (1). Tighten the screw (3) fixing lubrication oil delivery pipe (2) to
oil filter bracket (4).
Tighten the fastening screws (6 and 7) to prescribed torque.

(4) 2 M8x1.25x20 23.5 2.5 Nm Ref No. Description Tightening torques
(6) 2 M8x1.25x90 24.5 2.5 Nm (1,5) 2 M18x1.5 50 5 Nm
(7) 2 M8x1.25x60 24.5 2.5 Nm (3) 1 M8x1.25x20 24 3 Nm

ENGINE ASSEMBLY AT BENCH Figure 192

(RIGHT HAND SIDE COMPONENTS)
Figure 191
218043
Install backflow fuel pipe (6) from high-pressure pump to fuel

223531
tank. Connect fittings (2 and 7) and tighten fastening screw (5)
to prescribed torque.
Install the intake manifold (9) together with boost pressure
and air temperature sensor on the cylinder head, after having Install low pressure fuel pipe (3) from ECU to mechanical
interposed new gaskets (3, 5) and the grid-heater resistance pump. Connect fittings (4 and 8) and tighten fastening screw
(4). (1) to prescribed torque.
Tighten fastening screws (8) to prescribed torque.
Fit the oil pressure and temperature sensor (6) and tighten the
fastening screws (7) to prescribed torque. Ref No. Description Tightening torques
(4,8) 2 M16x1.5 30 5 Nm
Fit crankcase pressure sensor (1) and tighten fastening screw
(2,7) 2 M16x1.5 45 5 Nm
(2) to prescribed torque.
(1) 1 M8x1.25x25 24.5 2.5 Nm
Install the bracket (11) and tighten fastening screws (10, 12) (5) 1 M8x1.25x16 24.5 2.5 Nm
to prescribed torque.

(8) 2 M10x1.5x110 43 3 Nm
(8) 3 M10x1.5x100 43 3 Nm
(8) 1 M10x1.5x150 43 3 Nm
(2) 1 M12x1.5 44 4 Nm
(10) 1 M10x1.5x16 43 3 Nm
(12) 1 M8x1.25x16 24 3 Nm

218017 218016
Fit the fuel filter bracket (1) and tighten the fastening screws Fit the fuel filter support (2) together with the fuel filter
(2 and 4) to the prescribed torque. clogging (pressure drop) sensor (5) and NTC temperature
sensor (4) on the engine cable supporting bracket (1) and
Connect the high-pressure fuel pipe (5) from high-pressure tighten the fastening screws (3) to the prescribed torque.
pump to cylinder head and tighten the hose couplings (3 and
10) and the screw (6) to the prescribed torque.
Connect the low pressure fuel pipe (11) from fuel filter to Ref No. Description Tightening torques
high-pressure pump and the pipe (12) from mechanical pump (3) 4 M8x1.25x30 24 3 Nm
to fuel filter and tighten the fittings (7 and 9) to the prescribed
torque.
Fasten the engine cable to the retainers and connect the
electrical connection to the fuel high-pressure pump metering
unit (8), as described in the relative procedure.
Figure 195
(7,9) 2 M16x1.5 30 5 Nm
(3,10) 2 M14x1.5 35 2 Nm
(6) 1 M6x16 10 1 Nm
(2) 3 M8x1.25x35 24 3 Nm
(4) 1 M8x25 24 3 Nm
(4) 1 M10x25 37.5 7.5 Nm
218042
Screw the spacers (4). Install the ECU (2) including the heat
exchanger and tighten fastening nuts (3) to prescribed torque.
Connect the fitting (5) of low pressure fuel pipe from engine
control unit heat exchanger to mechanical pump.
Fit engine oil pressure and temperature sensor (1) on the
crankcase and tighten fastening screws (6) to prescribed
torque.

(3) 3 M8x1.25 24 3 Nm
(4) 3 M8x1.25x47 -
(5) 1 M16x1.5 30 5 Nm

ENGINE ASSEMBLY AT BENCH Figure 198

(FRONT HAND SIDE COMPONENTS)
Figure 196
223529
Fit the support (1) on the cylinder head and tighten the
218041
fastening screws (9) to prescribed torque.
Apply a new seal ring (1) to the coolant pump (2). Install the fan drive pulley (8) together with the bearing (2)
retained by the ring split circlip (3) and the shoulder washer
Assemble the water pump (2) complete with its sealing gasket (7) on the fan support (1) and tighten the fastening screw (6)
(1) and tighten the fastening screws (3) to the prescribed to prescribed torque.
torque.
Fit the fan-fixing spacer (4) on the fan drive pulley (8) and
tighten the fastening screws (5) to prescribed torque.
(3) 4 M8x1.25x25 24.5 2.5 Nm
(5) 6 M8x1.25x50 23.5 2.5 Nm
Figure 197 (6) 1 M10x1.5x80 55 5 Nm
(9) 4 M8x1.25x50 34.5 3.5 Nm
Figure 199
223530
Install the crankshaft pulley (6) on crankshaft (7) and tighten

the fastening screws (5) to prescribed torque.
Install the idler guide pulley (1) and tighten the fastening screw
(8) to prescribed torque.
Fit the damper pulley (2) on crankshaft pulley (6) and tighten
223528
the fastening screws (4) together with washers (3).
Apply a new sealing ring (2) on the engine coolant inlet pipe
Ref No. Description Tightening torques (3).
(4) 6 M12x1.75x30 115 5 Nm
M14x2x60 Fit the engine coolant inlet pipe (3) to the crankcase and
tighten the fastening screws (1, 4 and 5) to prescribed torque.
2nd phase 50 Ref No. Description Tightening torques
(8) 1 M12x1.75x70 60 8 Nm (1,5) 2 M8x1.25x50 23.5 2.5 Nm
(4) 1 M8x1.25x70 23.5 2.5 Nm
NOTE The flywheel blocking device can aid the installation
of the damper pulley (2) fitted onto the crankshaft
pulley (6).

223527 223525
Assemble the thermostat unit: install the thermostat (1) into Fit the auxiliary members belt (4) on the alternator (1), water
cylinder head together with the gasket (3); apply a new sealing pump (3), fan control pulley (2), crankshaft pulley with damper
ring (2) and fit the coolant outlet pipe (5) together with (6) and fixed guide roller (5).
coolant temperature sensor and tighten the fastening screws
Use the appropriate tool (7) on the automatic belt tensioner
(4) to the prescribed torque.
(8) in order to fit the new belt (4) in the operating position.
Ref No. Description Tightening torques Additional adjustments are not required. The belt tension is
(4) 5 M8x1.25x70 24.5 2.5 Nm adjusted automatically by the calibrated spring in the
automatic belt tensioner (8).
Operate the engine for a few hours and check that the
Figure 201 auxiliary members belt (4) is properly fitted.
223526
Fit the alternator upper support (2) and tighten the fastening
screws (1) to prescribed torque.
Fit the alternator lower support (7) and tighten the fastening
screws (8 and 9) to prescribed torque.
Install the alternator (4) and tighten the fastening screws (3
and10), after having interposed the spacer (11).
Install the automatic belt tensioner (6) and tighten the
fastening screw (5) to prescribed torque.
(1) 2 M8x1.25x30 24 3 Nm
(3) 1 M8x1.25x35 24 3 Nm
(5) 1 M10x1.5x70 45 5 Nm
(8) 2 M10x1.5x70 43 3 Nm
(9) 1 M10x1.5x30 43 3 Nm
(10) 1 M10x1.5x120 43 3 Nm

REMOVING THE ENGINE FROM THE RO- Figure 204

TATING STAND
Support the engine appropriately with a hoist, disconnect it
from the rotating stand, remove brackets 99361046 and place
it on a suitable support to complete engine assembly.
COMPLETING ENGINE ASSEMBLY
Figure 203
218036
Install lubricant oil heat exchanger (4) complete with relevant

gasket (1) into crankcase (5). Tighten fastening screws (2)
together with spacers (3) to prescribed torque.

M8x1.25x50
(2) 16 1st phase 11.5 3.5 Nm
223523 2nd phase 24.5 2.5 Nm
Screw the studs (4) into flywheel housing (5) and fit starter
electric motor (3).
Tighten fastening nuts (2) to prescribed torque. Figure 205
If the power take-off (PTO) is present, install the power
steering pump and service air/conditioning compressor with
relative coolant pipes.
Apply a new sealing O-ring (7) , fit the cover (6) and tighten
fastening screws (1) to prescribed torque.

(1) 3 M12x1.75x25 63 5 Nm
(2) 3 M10x1.5 43 3 Nm
(4) 3 M10x1.5x30 25 5 Nm
218035
Install motorized throttle valve (2) together with actuator (4)

onto turbocharger (5).
Screw fastening screw (3) to tighten V-clamping collar (1) to
prescribed torque.

(3) 1 M8x1.25x70 14 1 Nm

223522
Install engine coolant delivery (4) and return (7) pipes of the 223521
motorized throttle valve actuator by proceeding as follows:
Fit the oil level dipstick pipe and lubrication oil filling pipe (if
- fit engine coolant return pipe (7) and tighten fittings (2 and present) to the crankcase.
8) and retaining screws (5 and 6) to prescribed torque;
Install the turbocharger lubrication oil discharge pipe (2) by
- fit engine coolant delivery pipe (4) and tighten fittings proceeding as follows:
(1 and 3) to prescribed torque.
- Tighten the coupling (3) on the crankcase to prescribed
torque;
(1) 1 M14x1.5 43 3 Nm - Tighten fastening screws (1) in the lower part of the
turbocharger, after having interposed a new gasket.
(3) 1 M16x1.5 43 3 Nm
(2,8) 2 M14x1.5 35 Nm
(5,6) 2 M8x1.25x18 24 3 Nm
(1) 2 M8x1.25x25 24 3 Nm
(3) 1 M30x2 110 5 Nm

Engine cable refitting

Figure 208
223520
1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor -

4. Crankcase pressure sensor - 5. Fuel temperature and filter clogging (pressure drop) sensor -
6. Boost pressure and air temperature sensor - 7. In line connector - 8. Engine Control Unit EDC17CV41 -
9. Engine oil pressure and temperature sensor - 10. Fuel high pressure pump metering unit -
11. Flywheel increment speed sensor (crankshaft) - 12. Timing segment speed sensor (camshaft) -
13. Motorized throttle valve actuator connector (Exhaust flap) - 14. Exhaust gas absolute pressure sensor
After removing the engine from the rotating stand 99322230, Close the straps holding the engine cable to the engine block.
place the engine cable in position and connect it to engine
control unit (9), to motorized throttle valve actuator
connector (13) and to all the sensors and transmitters
indicated in the electrical equipment section.

CHECKS AND INSPECTIONS
NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle .
Preventively check that the liquid levels have been
correctly restored.
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- that there are no water leaks from the connecting sleeves

of engine cooling circuit pipes and cab internal heating
pipes, tighten the clamping collars if required;
- check carefully the connection between the low pressure
fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes;
- check also proper operation of the warning lights set on
the instrument panel and of the equipment disconnected
when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.

F2CFE613 ENGINES SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3
ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 11

2 SECTION 7 - TECHNICAL SPECIFICATIONS F2CFE613 ENGINES

GENERAL CHARACTERISTICS
F2CFE613
Type
E*B012 A*B012
E*B013 A*B013
A
VALVE TIMING
opens before T.D.C. A 15
closes after B.D.C. B 30

B
opens before B.D.C. D 50
closes after T.D.C. C 5

D
For timing check
mm 0.4 0,05
X
X mm 0.4 0,05
Bosch Common Rail with CRIN3 injectors and

FEED high pressure pump CP3.3 NH
Nozzle type DLLA 145
Injection order 1-4-2-6-3-5
bar
Injection pressure bar
1800
Injector calibration bar
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.

ASSEMBLY CLEARANCE DATA
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
CYLINDER BLOCK AND
CRANKMECHANISM COMPONENTS mm mm
1
Bores for cylinder liners:
upper 130.500 130.525
1
lower 129.510 129.535
Cylinder liners:
external diameter:
L upper 130.461 130.486
2
lower 129.475 129.500
2 length L 226.15
Cylinder liners -
crankcase bores
upper 0.014 0.064
lower 0.010 0.060
External diameter 2 -
Cylinder sleeve
3
inside diameter 3A* 117.000 117.012
X inside diameter 3B* 117.010 117.022
Protrusion X 0.035 0.065
* Selection class
Pistons: Federal Mogul Mahle
1
measuring dimension X 15 18
X
external diameter 1A* 116.894 116.906 116.871 116.883
2 external diameter 1B* 116.904 116.916 116.881 116.893
* Selection class pin bore 2 52.016 52.022 52.010 52.018
Piston - cylinder sleeve Federal Mogul Mahle
A* 0.094 0.118 0.117 0.141
B* 0.094 0.118 0.117 0.141
* Selection class
Piston diameter 1 -
X
Pistons protrusion X 0.094 0.118
3 Gudgeon pin 3 51.994 52.000
Federal Mogul Mahle

Gudgeon pin - pin housing
0.016 0.028 0.010 0.024

F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
X1 Federal Mogul Mahle

X2 X1* 2.582 2.716 2.585 2.615
X3
Piston ring grooves X2 2.550 2.570 2.550 2.570
* measured on 113.850
114.000 X3 4.020 4.040 4.020 4.040
Piston rings: Federal Mogul Mahle
S1 trapezoidal seal S1* 2.429 2.473 -
S2 lune seal S2 2.470 2.500 -
S3 milled scraper ring
with slits and internal
* measured on 113 spring S3 3.970 3.990 -
Federal Mogul Mahle

1 0.109 0.287 0.112 0.186
Piston rings - grooves 2 0.050 0.100 0.050 0.100
3 0.030 0.070 0.030 0.070
Piston rings - -
X1 Piston ring end gap
X2 in cylinder liners Federal Mogul Mahle
X1 0.30 0.40 -
X3 X2 0.60 0.75 -
X3 0.35 0.65 -
Small end bush housing

1 1 55.690 55.710
Big end bearing

2 housing 2 85.987 86.013
1 85.987 85.996
Selection classes
{2
3
85.996 86.005
86.005 86.013
Small end bush diameter

3
inside 3 52.015 52.030
Piston pin - bush 0.015 0.036

Connecting rod weight g
A 3308 3338
Class B 3339 3368
C 3369 3398

F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Main journals 1
- nominal 92.970 93.000
- class 1 92.970 92.980
- class 2 92.980 92.990
- class 3 92.990 93.000
1 2 Crankpins 2
- nominal 81.915 81.945
- class 1 81.915 81.924
- class 2 81.925 81.934
- class 3 81.935 81.945
S1 S 2 Main bearing shells S1
Red 2.968 2.978
Green 2.978 2.988
Yellow * 2.988 2.998
Big end bearing shells S2
Red 1.994 2.002
Green 2.002 2.010
Yellow * 2.010 2.018
Main bearing housings 3
- nominal 99.000 99.030
3 - class 1 99.000 99.009
- class 2 99.010 99.019
- class 3 99.020 99.030
Bearing shells -
main journals 0.050 0.090
Bearing shells -
0.040 0.080
big ends
Main bearing shells 0.127 - 0.254 - 0.508
Big end bearing shells 0.127 - 0.254 - 0.508
Main journal,
thrust bearing X1
1-2-3-4-5-6 39.900 40.100
X1 7 39.960 40.040
Main bearing housing,

thrust bearing X2 32.94 32.99
X2
X3 Thrust washer
halves X3 3.38 3.43
Crankshaft end float 0.11 0.34
1 2 Concentricity 0.040
Ovalization 0.010
Taper -
* Fitted in production only and not supplied as spares

F2CFE613
Type E*B012 A*B012
E*B013 A*B013
CYLINDER HEAD - VALVE TRAIN mm
1
Valve guide housings

in cylinder head
1 12.980 12.997
2 8.023 8.038
Valve guide
3 13.012 13.025
3
Valve guides - housings

in the cylinder heads 0.015 0.045
Valve guide 0.2 - 0.4
4
Valves:
4 7.970 7.985
60 30 7 30
4 7.970 7.985
60 30 7 30

Valve stem and its guide 0,038 0,068

Valve seat in
head
1 41.985 42.020
1 1 40.985 41.020
Outside diameter of valve
seat; angle of valve seat
2 in cylinder head:
2
42.060 42.075
60 30
2
41.060 41.075
60 30
X 0.5 0.8
Recessing of valve
X X 1.65 1.95
Between valve 0.040 0.090

seat and head

Table 1
F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Valve spring height: A* B*
free height H 70.77 71.34
under a load of:
H H1 N 460 23 H1A {
N 460 22 H1B 51
H2
N 740 33 H2A {
N 731,4 42 H2B 39
Injector protrusion X 1.53

X
Camshaft bushing housing

in the cylinder head:
17 69.000 69.030

Camshaft bearing
journals:
17 64.924 64.940
1 3
Outer diameter of
camshaft bushings:
69.090 69.130
Inner diameter of
camshaft bushings: 65.080 65.116
Bushings and housings

in the cylinder head 0.060 0.130
Bushings and bearing

journals 0.140 0.192
Cam lift:
H 7.404
8.211
1
Rocker shaft 1 31.964 31.980
* Refereed to different supplies

F2CFE613
Type E*B012 A*B012
E*B013 A*B013
mm
Seats for bushes in rocker arms
32.025 32.041
35.000 35.016
Rocker arm bush outer diameter:
35.070 35.110
Rocker arm bush inner diameter:

-

32.025 32.041
Rocker arm bushings and housings:

-
0.054 0.110
Rocker arm bushings and shaft:

0.045 0.077
0.045 0.077

TIGHTENING TORQUES
PART TORQUE
Nm kgm
Piston cooling spray nozzles (6 screws M8) 50 5 5.0 0.5
Camshaft shoulder plate (5 screws) 20 2 2.0 0.2
Crankcase stiffening plate (8 screws M10x1.5x20) 49 3 4.9 0.3
Main bearing caps (14 screws M16x2x168)
1st phase 140 7 14.0 0.7
2nd phase 60
3rd phase 60
Camshaft gear (4 screws M10x1.5x45)
1st phase 25 5 2.5 0.5
2nd phase 45
Transmission gear (3 screws M12x1,5) 25 5 2.5 0.5
Connecting rod caps (12 screws M12x1.25x69)
1st phase 50 2.5 5.0 0.25
2nd phase 90
High pressure pump (3 screws M8x1.25x40) 33 3 3.3 0.3
High pressure pump gear (1 nut M18x1.5) 105 5 10.5 0.5
Phonic wheel timing sensor (3 screws M8x1.25) 23 2 2.3 0.2
Blow-by rotating filter (3 screws M6x1x16) 91 0.9 0.1
Blow-by rotating filter cover (3 screws M6x1x16) 91 0.9 0.1
Blow-by valve cover (3 screws M6x1) 91 0.9 0.1
Fuel pipe from rail to electro-injectors
(6 fittings M18x1.5) 40 2 4.0 0.2
(6 fittings M14x1.5) 35 2 3.5 0.2
Fuel pipe from high pressure pump to rail
(1 fitting M18x1.5) 40 2 4.0 0.2
(1 fitting M14x1.5) 35 2 3.5 0.2
Fuel return pipe
(1 fitting M16x1.5) 35 2 3.5 0.2
(1 fitting M14x1.5) 35 2 3.5 0.2
Fuel pipe from pressure pump to intermediate fitting
(2 fittings M16x1.5) 35 5 3.5 0.5
Fuel delivery and return pipe from pressure pump to fuel filter
(4 fittings M16x1.5) 35 5 3.5 0.5
Fuel pipe from injection control unit heater to pressure pump
(2 fittings M18x1.5) 40 5 4.0 0.5
Cylinder head (26 screws M16x2x170)
1st phase 50 2.5 5.0 0.25
2nd phase 100 2.5 10.0 0.25
3rd phase 90
4thphase 75

PART TORQUE
Nm kgm
Rocker arm shaft (7 screws M12x1.75) 105 10 10.5 1.0
Tappet cover (20 screws M6x1x50) 8.5 1.5 0.85 0.15
Engine oil pump
(5 screws M8x1.25x60) 24 3 2.4 0.3
(3 screws M8x1.25x45) 24 3 2.4 0.3
Double gear (3 screws M8)
1st phase 30 3.0
2nd phase 90
Crankcase front cover (9 screws M10x1.25x20) 19 3 1.9 0.3
Engine flywheel housing
(3 screws M10x1.5x35) 41.5 3.5 4.15 0.35
(1 screws M10x1.5x110) 41.5 3.5 4.15 0.35
(1 screws M10x1.5x180) 41.5 3.5 4.15 0.35
(2 screws M12x1.75x193) 63 7 6.3 0.7
(1 screws M12x1.75x120) 63 7 6.3 0.7
(7 screws M12x1.75x80) 63 7 6.3 0.7
Engine oil sump (26 screws M10x1.5x45) 42 3 4.2 0.3
Engine oil intake suction strainer (3 screws M8x1.25) 20 2 2.0 0.2
Engine oil drain plug (1 M22x1.5) 40 10 4.0 1.0
Engine oil filter housing (5 screws M8x1.25) 34 4 3.4 0.4
Engine oil filter body 60 5 6.0 0.5
Heat exchanger (4 screws M8x45) 23 2 2.3 0.2
Heat exchanger body (16 screws M8x1.25x50)
1st phase 11.5 3.5 1.15 0.35
2nd phase 24.5 2.5 2.45 0.25
Damper pulley (6 screws M12x1.75x30) 115 5 11.5 0.5
Crankshaft pulley (6 screws M14x2x60)
1st phase 70 7.0
2nd phase 50
Electro-injector brackets (6 screws M10x1.5x40) 46 3 4.6 0.3
Rail (3 screws M8) 23 2 2.3 0.2
Intake manifold
(3 screws M10x1.5x100) 43 3 4.3 0.3
(2 screws M10x1.5x110) 43 3 4.3 0.3
(1 screw M10x1.5x150) 43 3 4.3 0.3
Air conditioning compressor / PTO cover
(3 screws M12x1.75x25) 63 5 6.3 0.5
Starter motor (3 nuts M10x1.5) 43 3 4.3 0.3
(3 studs M10x1.5x30) 25 5 2.5 0.5
Engine brake collar (1 nut M6x1) 61 0.6 0.1
Engine coolant return and delivery pipes to engine brake control actuator
(4 fittings M12x1.5) 25 5 2.5 0.5
Turbocharger (4 nuts M10x1.5) 46 2 4.6 0.2
Shoulder plate (5 screws M8x1.25x20) 20 2 2.0 0.2

PART TORQUE
Nm kgm
Oil outlet pipe from turbocharger
(2 screws M8x1.25x25) 24 3 2.4 0.3
(1 fitting M27x1.5) 25 5 2.5 0.5
(1 fitting M30x2) 110 5 11.0 0.5
Oil delivery pipe to turbocharger (2 fittings M16x1.5) 42 2 4.2 0.2
Bracket retaining oil delivery pipe to turbocharger (1 screw M8x1.25x16) 23 2 2.3 0.2
Exhaust manifold (24 screws M10x1.5x38) 45 5 4.5 0.5
Engine management control unit (3 nuts M8x1.25) 24 3 2.4 0.3
Timing sensor (1 screw M6x1) 91 0.9 0.1
Engine rpm sensor (1 screw M6x1) 91 0.9 0.1
Air temperature and pressure sensor (1 screw) 91 0.9 0.1
Engine oil temperature and pressure sensor (2 screws) 91 0.9 0.1
Water pump drive belt mobile tensioner (1 screw M10x1.5x80) 45 5 4.5 0.5
Engine flywheel (8 screws M18x1.5x72)
1st phase 120 5 12.0 0.5
2nd phase 90
Thermostat housing/Engine coolant outlet pipe (5 screws M8x1.25x70) 24.5 2.5 2.45 0.25
Coolant temperature sensor 20 5 2.0 0.5
Water pump (4 screws M8x1.25x25) 24.5 2.5 2.45 0.25
Engine coolant pipes (1 fitting M12x1.5) 20 2 2.0 0.2
Degassing pipe (1 fitting M12x1.5) 20 2 2.0 0.2
Fuel filter support (4 screws M8x1.25x30) 24 3 2.4 0.3
Fuel filter bracket
(3 screws M8x1.25x35) 24 3 2.4 0.3
(1 screw M8x25) 24 3 2.4 0.3
(1 screw M10x25) 37.5 7.5 3.75 0.75
Alternator upper support
(2 screws M8x1.25x30) 24 3 2.4 0.3
Automatic belt tensioner
(1 screw M10x1.5x70) 45 5 4.5 0.5
Alternator lower support
(2 screws M10x1.5x70) 43 3 4.3 0.3
(1 screw M10x1.5x30) 43 3 4.3 0.3
Alternator
(1 screw M8x1.25x35) 24 3 2.4 0.3
( 1 screw M10x1.5x120) 43 3 4.3 0.3
Engine coolant inlet pipe (to water pump)
(2 screws M8x1.25x50) 23.5 2.5 2.35 0.25
(1 screw M8x1.25x70) 23.5 2.5 2.35 0.25
Fan-fixing spacer
(6 screws M8x1.25x50) 23.5 2.5 2.35 0.25
Fan drive pulley bearing
(1 screw M10x1.5x80) 55 5 5.5 0.5
Fan support (on cylinder head)
(4 screws M8x1.25x50) 34.5 3.5 3.45 0.35
Idler guide roller
(1 screw M12x1.75x70) 60 8 6.0 0.8

F2CFE613 ENGINES SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 8 - TOOLS F2CFE613 ENGINES

TOOLS
TOOL NO. DESCRIPTION
99322230 Telescopic revolving stand

(bearing capacity 2000 daN, torque 375 daNm)
99342157 Tool to extract injectors
99346260 Crankshaft rear seal installer
99346265 Crankshaft front seal installer
Piston ring removal and refitting pliers (105 - 160 mm)

99360184
99360256 Cap to take down and fit back engine valves (use with 99360257)

TOOLS
99360257 Engine valves remover/installer (use with 99360256)
99360288 Drift for removing valve guide
99360292 Installer for valve guide seal
99360294 Drift for fitting valve guide (to be used with 99360288)
Compression tool for checking the protrusion of cylinder liners

99360334 (to be used with 99370415-99395603 and special plates)
99360335 Cylinder liner compression plate (to be used with 99360334)

TOOLS
99360341 Flywheel crank handle
Flywheel restrainer
99360351
99360500 Crankshaft lifting tackle
99360505 Camshaft bush assembly and disassembly punch
99360558 Tool for lifting and carrying shaft rockers
99360585 Rocking sling for removing/installing engine

TOOLS
Belt to insert piston in cylinder liner (60 - 125 mm)

99360605
99360612 Engine TDC positioning tool
99360613 Tool for timing adjustment of phonic disc on camshaft
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners (use with special rings)
99360724 Ring (115 mm) (to be used with 99360706)

TOOLS
99361046 Brackets fixing engine to revolving stand 99322230
99367121 Hand pump to measure pressures and vacuums
Set of 9 insert box wrenches 14X18

99368542 (13 - 17 - 18 - 19 - 21 - 22 - 24 - 27 - 30 mm)
Timing control tool (use with 99395606)

99370400
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99389833 Snap coupling torque wrench 14X18 (20-120 Nm)

TOOLS
Dynamometric screwdriver (1-6 Nm) to set injector solenoid valve

99389834 connector check-nut
99390310 Valve guide sleeker
Measuring pair for angular tightening with 1/2

99395216 and 3/4 square couplings
Gauge to determine centre-to-centre distance between camshaft

99395222 and transmission gear
99395223 Gauge for camshaft phasing
Gauge to determine centre-to centre distance between camshaft

99395230 and fuel high-pressure pump

TOOLS
99395603 Dial gauge (0 - 5 mm)
99395606 Dial gauge (0-30 mm)


F2CFE613 ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F2CFE613 ENGINES

F2CFE613 ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones theyve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge - In case of test or calibration operations requiring engine
of maintenance. running, ensure that the area is sufficiently aerated or
Be informed and inform personnel as well of the laws in force utilize specific vacuum equipment to eliminate exhaust
regulating safety, providing information documentation gas. Danger: poisoning and death.
available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Ensure that working areas are provided with emergency - Never open filler cap of cooling circuit when the engine
boxes, that must be clearly visible and always provided is hot. Operating pressure would provoke high
with adequate sanitary equipment. temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50C.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency - Never top up an overheated engine with cooler and
must be checked on regular basis and the personnel utilize only appropriate liquids.
must be trained on intervention methods and priorities. - Always operate when the engine is turned off: whether
- Organize and displace specific exit points to evacuate particular circumstances require maintenance
the areas in case of emergency, providing for adequate intervention on running engine, be aware of all risks
indications of the emergency exit lines. involved with such operation.
- Smoking in working areas subject to fire danger must be - Be equipped with adequate and safe containers for
strictly prohibited. drainage operation of engine liquids and exhaust oil.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy - Keep the engine clean from oil tangles, diesel fuel and or
comprehension of the instructions even in case of chemical solvents.
emergency. - Use of solvents or detergents during maintenance may
Prevention of injury originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering - Do not leave rags impregnated with flammable
ends, nor jewels such as rings and chains when working substances close to the engine.
close to engines and equipment in motion.
- Upon engine start after maintenance, undertake proper
- Wear safety gloves and goggles when performing the preventing actions to stop air suction in case of runaway
following operations: speed rate.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Do not utilize fast screw-tightening tools.
- utilization of compressed air or liquids under pressure - Never disconnect batteries when the engine is running.
(pressure allowed: 2 bar)
- Disconnect batteries before any intervention on the
- Wear safety helmet when working close to hanging electrical system.
loads or equipment working at head height level.
- Disconnect batteries from system aboard to load them
- Always wear safety shoes when and cloths adhering to with the battery loader.
the body, better if provided with elastics at the ends.
- After every intervention, verify that battery clamp
- Use protection cream for hands. polarity is correct and that the clamps are tight and safe
- Change wet cloths as soon as possible from accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working - Before proceeding with pipelines disassembly
operations utilizing isolating foot-boards. Do not carry (pneumatic, hydraulic, fuel pipes) verify presence of liquid
out working operations if not trained for. or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
- Put the dirty rags with oil, diesel fuel or solvents in injury and poisoning.
anti-fire specially provided containers.

4 APPENDIX F2CFE613 ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engines
components, affecting engines duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnels safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved by FPT. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
FPT specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80C temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

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CURSOR SERIES

Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

Data included in this publication may not be up-to-date

If issues on this publication differ from what is actually noticed

It is forbidden to copy this text or any of its parts and all

Publication edited by:

PREFACE TO USERS GUIDELINE MANUAL . . 3

GENERAL WARNINGS ON THE ELECTRIC SYSTEM 7

- Bonding and screening . . . . . . . . . . . . . . . . . . . 8

OPTIONAL ELECTRICAL AND MECHANICAL PARTS

CONVERSIONS BETWEEN THE MAIN UNITS OF

KEY OF LECTURE OF THE HEADINGS AND

Print P2D32C012 E Base - September 2015

Base - September 2015 Print P2D32C012 E

PREFACE TO USERS GUIDELINE MANUAL

Danger for persons

Danger for persons

NOTE It indicates an additional explanation for a piece of information.

1 1 = Seat of small end bush

Print P2D32C012 E Base - September 2015

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

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Print P2D32C012 E Base - September 2015

Base - September 2015 Print P2D32C012 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32C012 E Base - September 2015

Bonding and screening

Further, following warnings are to be compulsorily observed for electronic components:

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT -

Base - September 2015 Print P2D32C012 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

NOTE Where accuracy is not particularly needed:

Print P2D32C012 E Base - September 2015

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Basic edition referred to When month - year update

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Section Section name Description of change Page Date of revision

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CURSOR SERIES TIER 4B / STAGE IV

Main engine diagrams 2

Removal and refitting of main engine components 5

Safety prescriptions Appendix

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MAPPING BETWEEN TECHNICAL

TORQUE AND POWER TYPICAL CURVES . . . 8

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1. Engine serial number - 2. Technical code

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ECE - STAGE IV (F2CFE613EB013 - F2CFE613AB013)