Ex215 - 4 - WORKSHOP MANUAL ENGINE PDF

– EXCAVATORS
WORKSHOP MANUAL Ex 215

ENGINE
Ex 135
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.
The right is reserved to make changes at any time without notice.
FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.832

Edition - X
IN-1
INTRODUCTION
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information needed found any errors regarding the contents of this
to maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for correct FIAT-HITACHI S.p.A.

information concerning the service procedures. San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 11 6877357
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition

to this service manual:
- Operator’s Manual
- Spare Parts Catalog
SERVICE MANUAL COMPOSITION
• The complete service manual consists of four

books: performance tests, and troubleshooting
- Technical Manual - Operational Principle procedures.
- Technical Manual - Troubleshooting
- Excavator Workshop Manual - The Excavator and the Engine Workshop Manuals
- Engine Workshop Manual include information needed for maintenance and
repair of the machine, tools and devices needed for
- The Technical Manual-Operational Principle maintenance and repair, maintenance standards,
includes the technical information concerning the removal/installation and assembly/disassembly
operation of main devices and systems. procedures.
- The Technical Manual -Troubleshooting includes • The Service Manual for EX215 Excavator consists
the technical information needed for operational of the following book/print numbers:
BOOK PART NUMBER

- Technical Manual - Operational Principle 604.06.807
- Technical Manual - Troubleshooting 604.06.812
- Workshop Manual - Excavator 604.06.817
- Workshop Manual - Engine 604.06.832
IN-2
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T : Technical Manual
W : Excavator Workshop Manual
EW: Engine Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
! This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 Mpa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposes.
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm2 10.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Weight Kg lb 2.205 Velocity Km/h mph 0.621 4
-1
Force N kgf 0.101 97 min rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m Kgf.m 1.0197 ML/rev Cc/rev 1.0
N.m lbf.ft 0.737 5
WORKSHOP MANUAL EX135–EX215
ENGINES
LIST OF SECTIONS
EW–1–1
Section 1 – Diagnostics
EW–2–1
Section 2 – Removing–refitting engine EX135
EW–3–1
Section 3 – Engine EX135 overhaul
EW–4–1
Section 4 – Removing–refitting engine EX215
EW–5–1
Section 5 – Engine EX215 overhaul
EW–6–1
Section 6 – Recharge and start–up EX135–EX215
SECTION 1 EX135 – EX215
DIAGNOSTICS
CONTENTS
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW–1–3
EW–1–3
DIAGNOSTICS
Main engine troubles:

6 – Exhaust fumes are blue;
1– The engine does not start; 7 – The engine functions irregularly;
2– The engine overheats; 8 – The engine stops;
3– The engine lacks power; 9 – The engine exceeds the maximum rpm;
4– Exhaust fumes are black or dark grey; 10 –Oil pressure is too high or too low;
5– Exhaust fumes are grey (tending towards white); 11 –Fuel consumption is too high.
1 THE ENGINE DOES NOT START
Battery terminals efficient Clean, check and tighten the nuts of the ter-
NO minals or replace them.
YES
Batteries efficient Carry out the checks described in the repair man-
NO ual ” Electrical System ”.
YES
Starter mtor working Carry out the checks described in the repair man-
NO
ual ” Electrical System ”.
YES
Glow plug working Substitute.

NO
YES
Injection pump delivering Check the entire set up as described in the ap-
NO propriate chapter.
(to be continued)
EW–1–4
DIAGNOSTICS
Injection pump efficient Check and calibrate.

NO
YES
No air bubbles in the fuel pipes or injection pump. Check and bleed.
NO
YES
No traces of water in the fuel pipes or the fuel Check and clean the fuel feed circuit, including
pump NO the tank.
YES
Compression ratio correct Check the engine or carry out only the essential
NO
checks (valves, split rings, etc...).
YES
Fuel filters clear Replace.

NO
YES
Automatic spark lead governor and engine Check and replace the necessary parts.
STOP device efficient NO
EW–1–5
DIAGNOSTICS
2 THE ENGINE OVERHEATS
Coolant level correct Check for leakage and top up the level.
NO
YES
Water pump and ventilator working correctly Check and register the tension, if necessary re-
NO place the parts.
YES
Water pump working correctly Check and replace the group.

NO
YES
Thermostat efficient Replace.

NO
YES
Radiator efficient Flush carefully, check for leakage, replace if

NO necessary.
YES
Air filter and piping efficient Clean or replace damaged parts.

NO
(to be continued)
EW–1–6
DIAGNOSTICS
Injection pump adjusted correctly Check the setting as described in the appropriate
NO paragraph.
YES
Cylinder head seal efficient Replace.

NO
YES
Fan working correctly Replace.

NO
3 THE ENGINE LACKS POWER
Fuel filters efficient Replace, following the procedure described in

NO the “Use and Maintenance” manual.
YES
Fuel feed circuit efficient Check and carry out the necessary repairs.
NO
YES
Thermostat efficient Replace.

NO
YES
Fuel pump efficient Replace.

NO
(to be continued)
EW–1–7
DIAGNOSTICS
Injectors efficient Check and register.

NO
YES
Injection pump timing correct Check the registration as described in the corre-
NO sponding paragraph.
YES
Injection pump regulated correctly Check and calibrate the injection pump in the
NO workshop.
YES
Compression ratio correct Check using tool 75301463 Motometer and carry
NO out necessary repairs.
YES
Turbosupercharger working correctly Repair or replace the group.

NO
YES
L.D.A. circuit and device working correctly Check.

NO
EW–1–8
DIAGNOSTICS
4 THE EXHAUST FUMES ARE BLACK OR

DARK GREY
Air filter efficient Replace.

NO
YES
Glow plug efficient Replace.

NO
YES
Automatic spark lead governor working Check and replace if necessary.

NO
YES
Injectors efficient Overhaul and register as described.

NO
YES
Injection pump adjusted correctly Check thesetting as described in the appropriate

NO paragraph.
YES
L.D.A. device efficient Check the setting of the L.D.A. device

NO
YES
Injection pump settings correct Check and calibrate the injection pump in the
NO
workshop.
(to be continued)
EW–1–9
DIAGNOSTICS
Compression ratio correct Check using tool 75301430 Motometer and carry
NO out necessary repairs.
YES
Fuel of good quality Clean the tank and replace the fuel filters.
NO
THE EXAUST FUMES ARE GREY

5
(TENDING TOWARDS WHITE)
Thermostat working properly Replace.

NO
YES
Injectors working properly Check and calibrate as described in S.I. 1094.

NO
YES
Injection pump adjusted correctly Check the settings as described in the relative
NO paragraph.
YES
Coolant level correct Probable leakage of the coolant into the combus-
NO
tion chamber; replace the cylinder head gasket
or overhaul the engine.
YES
Fuel of good quality Clean the tank and replace the diesel filters.
NO
EW–1–10
DIAGNOSTICS
6 THE EXHAUST FUMES ARE BLUE
Excessive oil consumption Check: air–oil bath filter; cylinder compression.

YES Overhaul cylinder head or engine as necessary.
7 ENGINE KNOCKS OR FUNCTIONS

IRREGULARLY
Knocking located in the drive shaft Check for: excessive clearance in one or more
YES big end bearings; loose fixings in the headblock
and flywheel; oil pressure. Replace the damaged
parts or overhaul the engine.
NO
Knocking located in the tie rods Check for: excessive clearance or misshaping in
YES the crankpins; loose fixings in the connecting
rod; misalignment of the connecting rods. Re-
place the damaged parts or overhaul the engine.
NO
Knocking located in the pistons Check clearance of the pistons – piston barrels;
YES split rings; piston pins – piston hubs. Replace
damaged parts or overhaul the engine.
NO
Knocking located in the cylinder head Check the equalisers and the valves; injection
YES pump settings, valve train settings. Calibrate.
NO
Kocking located in the valve train Check and if necessary replace the gears.
YES
(to be continued)
EW–1–11
DIAGNOSTICS
Knocking located in the injectors Check and calibrate them according to S.I. 1094
YES or replace.
8 THE ENGINE STOPS
Fuel in the tank Fill tank and, if necessary, flush.

NO
YES
Fuel filters efficient Replace.

NO
YES
Fuel supply circuit efficient Check the pipes and flush.

NO
YES
Engine timing correct Calibrate.

NO
YES
Injection pumps set correctly Check the flow rate in the workshop.
NO
YES
Injection pump controls working properly Replace damaged parts and calibrate.
NO
EW–1–12
DIAGNOSTICS
9 THE ENGINE EXCEEDS THE MAXIMUM

RPM
Speed regulator working correctly

NO
Check and if necessary replace worn out parts.
10 OIL PRESSURE TOO LOW OR TOO HIGH
Pressure valve working correctly Check and replace if necessary.

NO
YES
Oil pump and supply pipes efficient Check and replace if necessary.
NO
YES
Bearings efficient. Replace the bearings and if necessary grind the

NO driving shaft.
YES
Viscosity of SAE motor oil correct Replace the engine oil with oil of correct viscosity.
NO
EW–1–13
DIAGNOSTICS
11 EXCESSIVE FUEL CONSUMPTION
Tank and fuel pipes efficient Eliminate any leakage and replace the worn out
NO parts.
YES
Air filter efficient Replace.

NO
YES
Injectors calibrated correctly Check and calibrate.

NO
YES
Injection pump calibrated correctly Check and calibrate in the workshop.

NO
YES
L.D.A. device efficient Calibrate the L.D.A. device.

NO
YES
Injection pump adjusted correctly Check static fit of the injection pump.
NO
SECTION 2 EX135
REMOVAL & INSTALLATION

EX135 ENGINE
INDEX
Engine/Pumps Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . EW–2–1
Installation . . . . . . . . . . . . . . . . . . . . . EW–2–6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–7
EW–2– 1
EX135 ENGINE REMOVAL & INSTALLATION
ENGINE/PUMPS ASSEMBLY
REMOVAL
Park the machine on a level surface and lower the

bucket to the ground
! CAUTION
Keep people not involved in the maintenance
work outside the working area. Wear adequate
personal clothes and glasses with side shields as
a protection against flying debris. 1
! WARNING
The hydraulic oil reservoir is under pressure. 2
Press the pressure relieve button (1) on the filler
plug to relieve pressure before maintenance.
Danger of personal injuries.
Remove cover (2) and remove hydraulic oil using

a suction pump. Loosen the drain plug on the res-
ervoir bottom side, allowing oil to flow out into a
suitable container.
NOTE: Hydraulic oil quantity approximately is 120

liters
!
3
CAUTION
The engine reaches high working temperatures. 4
Therefore, it is necessary to let the machine cool
down prior to carrying out this operation.
Remove the lower cover (3) located under the en-

gine, and the lower cover (4) located under the
radiator.
Remove the engine hood, the covers on control

valve and behind the cab; remove the bulkhead
between engine and control valve; remove sup-
port (5) complete of the muttler guard from the hy-
draulic pumps room. 5
EW–2– 2
! CAUTION 6
Always disconnect the negative (–) ground ter-
minal first and reconnect it last.
Remove the batteries cover (6) to allow the dis-

connection of the cables.
Disconnect the ground braid located on frame

near to left rear engine mounting.
! CAUTION
— Pressure fluid. Turn the cap slowly (7) before
removing it completely to relieve pressure. Do
not loosen the radiator cap when the engine is 8 7
hot to avoid burn hazard.
— Do not perform this operation when the ma-
chine is still hot. Contact with engine coolant at
working temperature may cause burns and
personal injuries.
Close the cab heater taps located on the engine,

then disconnect the related hoses from engine
side.
Drain the engine coolant from radiator, by open-

ing the drain tap (9) located on the bottom side of
the radiator.
Disconnect the input and output coolant engine

hoses from the radiator side and the small 9
breather hose (8) from the engine side.
NOTE: Engine coolant quantity approximately is 16

liters.
Disconnect and remove the pipe (10) connecting

the air filter to the turbocharger.
10
EW–2– 3
Disconnect the EC motor tie rod (11) from the

pump inject governor lever and the sheath fixing
(12) from the bracket.
12 11
Set out the radiator tie rod (13) from counter–

weight side.
13
Remove the fan wire net guard (14). 14
Disconnect the fuel supply and return hoses (15).
15
EW–2– 4
AIR CONDITIONER
! CAUTION
The air conditioning system hoses contain re-
frigerant gas under pressure. Wear adeguate pro-
tective clothes, gloves and glanes with side
shields, prior to operate on the system.
If the excavator is equipped with air conditioning sys-

tem, it is required to carry on the gas discharge from
the system, using a proper special tool for the gas re-
covery.
Clean accurately the surrounding area of the hoses
on the compressor.
Disconnect the hoses and protect the compressor
and hoses fitting with caps to avoid the admittance
of foreigh objects or dirt into the system.
IMPORTANT: Absolutely avoid the admittance of

foreign objects into the air conditioning system.
ELECTRICAL CONNECTIONS
Disconnect the following electrical connectors:
— Fuel filter heating temperature sensor (if in-

stalled)
— Fuel filter heater (if installed)
— Engine coolant temperature sensor on engine

cylinder head
— Engine coolant temperature sensor on coolant

pump housing
— Intake air heater temperature sensor on en-

gine cylinder head, pump injection side
— Flame glow plug on air intake piping.
— Intake air heater fuel solenoid valve.
— Engine oil level switch on oil pan (alternator

side)
— Engine oil pressure switch on engine block (al-

ternator side)
— Engine stop solenoid on injection pump.

Disconnect the electrical wires from starter motor
and from alternator
EW–2– 5
HYDRAULIC PUMPS
Disconnect the suction pipe (16) from the hy- 17

draulic main pumps. 17
Disconnect the delivery hoses (17) from the hy- 16
draulic main pumps.
Disconnect the suction and delivery hoses (18)

from pilot pump.
19
Disconnect the electrical connector of the pres-
sure sensors (19) from the hydraulic main pumps. 18
Disconnect the main pump regulators hoses (20).
ENGINE/PUMPS ASSEMBLY LIFTING
Attach a lifting hook and set the hoist to a tension. 20
NOTE: Total weight of engine and hydraulic pump

assembly approximately is 511 kg.
! CAUTION
Check that the hoist ropes are securely anchored
and that the anchor point is sufficiently strong to
sustain the load to be lifted. Keep any person
away from ropes or chains anchor point.
21
Unscrew the bolts on front (21) and rear (22) en-

gine mounts.
22
Hoist up the engine assembly complete with hy-
draulic pumps.
EW–2– 6
INSTALLATION
For the engine/pumps assembly installation
make reference to the procedures previously de-
scribed for the removal, but proceeding step by
step in opposite way.
TIGHTENING TORQUES
Front and rear engine mounts:

Spanner wrench dimension (Exagonal head bolt):
24 mm
Tightening torque: 210 Nm (155 lbf.ft)
Hydraulic pump hoses:

19 mm, 27 mm, 36 mm
Tightening torque: 29 Nm (21 lbf.ft),
93 Nm (68 lbt.ft), 69 Nm (51 lbf.ft)
Socket wrench dimension (Exagonal socket bolt):
8 mm, 10 mm
Tightening torque:
49 Nm (36 lbf.ft), 108 Nm (80 lbf.ft)
Wire net fan guard:

13 mm
Radiator tie rod:

24 mm
Hood and cover:

Spanner wrench (Exagonal head bolt): 17 mm
Hydraulic oil fitting cap:

17 mm
EW–2– 7
FILLING
FILLING CHART Model EX 135

RECOMMENDED FLUIDS AND LUBRICANTS
COMPONENT TO BE QUANTITY
FILLED Litres MANUFACTURER’S INTERNATIONAL
AMBRA NOTES
SPECIFICATIONS SPECIFICATIONS
Protective fluide to
be mixed with
water at 50%.
This mix has ani-
Engine cooling system 16 AGRIFLU NH 900 A – corrosive, antiscal-
ing, and antifoam-
ing properties; does
not freeze down
to –35°C
Diesel fuel ASTM
Fuel tank 250 – – –
N. 2–D type TT
SUPER GOLD
NH 330 G API CF–4/SG
15W–40
Engine 95
9.5 CCMC D4 –
SUPER GOLD MIL–L–2104 E
NH 324 G
10W–30
Hydraulic pump reduc. SUPER GOLD
unit 0.8 NH 330 G
15W–40 API CF–4/SG
Swing reduction unit 32
3.2 CCMC D4 –
Travel reduction unit SUPER GOLD MIL–L–2104 E
NH 324 G
(each) 3.5 10W–30
Attachment hydraulic
120 HI–TECH 46 QFH 583/HD – –
system
EW–2– 8
FUEL SYSTEM AIR BLEEDING
The fuel system air bleeding should be performed

with fuel tank filled up.
Proceed the bleeding air as follows: 3
— Loosen the bleed screw (1) to allow air to bleed;
— Repeatedly press the button (2) located on the

priming pump to circulate fuel inside the fuel sys-
tem; 1
— Continue priming until a minimum amount of fuel

free of bubble comes out of the loosened bleed
screw (1) then close the screw;
— Repeat this operation for bleed screw (3).
Handle and dispose of used fuel filters

according to current regulations. Use
only authorised disposal procedures. If
in doubt, contact authorities concerned.
2
EW–2– 9
FILLING THE COOLING SYSTEM

1
Fill the cooling system as follows:
— Ensure that the tap (1) on the radiator is closed

and tap (2) on the engine is open;
— Slowly pour in coolant (see the FILLING CHART)

through the filler neck (3) until correct level is ob-
tained between the FULL and LOW marks on the
header tank (4);
— Refill the hydraulic oil system (refer to page

EW–2–10);
— Start the engine and let it run for at least 15 min-

utes. Check coolant level again on the header
tank (4). If low, top up to correct level.
4
EW–2–10
HYDRAULIC SYSTEM OIL REFILLING
Pour oil of the type, grade and quantity specified

(see the FILLING CHART) through the hole of
plug (1) until oil level is between the MIN and MAX
marks on the sight glass.
Install cover (1) ensuring that the filter and rod as-
sembly is correctly positioned. Tighten the bolts
to the torque of 50 Nm (37 lbf.ft).
IMPORTANT: Should the hydraulic pump remain

without oil, it would be damaged in a few seconds 1
after engine start–up.
Remove the pump air breather plugs (2).

2
Refill pumps with hydraulic oil through the holes
of plugs.
Reinstall plugs.
Start the engine and let it run to idle.
Ensure that the safety lever is in the LOCK posi-

tion.
Slowly release the air breather plugs (4) to let out

trapped air. Tighten the plugs as soon as air stops
being released and oil starts coming out from the
plug holes.
Bleed air from the hydraulic system by letting the

engine idle and moving all control levers slowly
and gently for 15 minutes. Note that the pilot con-
trol circuit is fitted with an air relief device. There-
fore, air in the pilot control circuit is automatically
bled when this operation is carried out.
Fully retract the arm cylinder and fully extend the

bucket cylinder.
Lower the bucket to the ground.
Switch off the auto–idle.
Stop the engine. Remove the ignition key from the

key–start switch.
Move the safety lever to the LOCK position.
Check the sight glass on the hydraulic oil reser-

voir. Should it be necessary to add more hydraulic
oil, remove cover and top up.
Handle and dispose of hydraulic oil and

filters according to current regulations.
Use only authorised disposal procedure.
If in doubt, contact authorities con-
cerned.
SECTION 3 EX135
ENGINE EX135 OVERHAUL
CONTENTS
Specifications and data . . . . . . . . . . . . . EW–3–3 Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–37

Mounting clearances – Data . . . . . . . . EW–3–6 Mounting of connecting rod –
Tightening torques . . . . . . . . . . . . . . . . . EW–3–14 piston assembly . . . . . . . . . . . . . . . . . . . EW–3–38
Special tools . . . . . . . . . . . . . . . . . . . . . . . EW–3–15 Connecting rod – piston mating . . . . . . . EW–3–38
Stripping down the engine in the Connecting rod – piston rectangularity
workshop . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–17 check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–38
Repairs – Cylinder block – Mounting of piston rings . . . . . . . . . . . . . . EW–3–38
Checks and measurements . . . . . . . . . EW–3–23
Adjustment of the mounting clearance
Replacement of cylinder liners . . . . . . . . EW–3–24 of the connecting rod journals . . . . . . EW–3–39
Camshaft – bushes – Mounting of connecting rod covers . . . . EW–3–40
Valve lifters . . . . . . . . . . . . . . . . . . . . . . . . EW–3–25
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–40
Cam pitch and bearing journal
alignment check . . . . . . . . . . . . . . . . . . . EW–3–26 Check and replacement of
the transmission gear wheel . . . . . . . . EW–3–40
Driven toothed wheel replacement . . EW–3–26
Bush replacement . . . . . . . . . . . . . . . . . . EW–3–26 Replacement of bush for
transmission gear wheel . . . . . . . . . . . . EW–3–40
Valve lifters . . . . . . . . . . . . . . . . . . . . . . . . EW–3–27
Mounting of the transmission gear wheel
Replacement of valve lifters . . . . . . . . . . EW–3–27
and adjustment of the steering . . . . . . . . EW–3–41
Mounting of valve lifters –
camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–28 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW–3–41
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–29 Tightness check . . . . . . . . . . . . . . . . . . . . . EW–3–41
Main and connecting rod bearing Dismounting of valves . . . . . . . . . . . . . . EW–3–42
journals . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–29 Check of cylinder head bearing surface
Check of main bearing journal on cylinder block . . . . . . . . . . . . . . . . . . . . EW–3–42
alignment . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–30 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–42
Replacement of driving toothed wheel Removal of incrustration and
steering and oil pump . . . . . . . . . . . . . . EW–3–31 valve check . . . . . . . . . . . . . . . . . . . . . . . . EW–3–42
Mounting of main bearings . . . . . . . . . EW–3–31
Valve grinding . . . . . . . . . . . . . . . . . . . . . . EW–3–43
Checking of main bearing journal
mounting clearance . . . . . . . . . . . . . . . . EW–3–31 Boring of inner surfaces of valve
stem guides . . . . . . . . . . . . . . . . . . . . . . . . EW–3–43
Crankshaft end play check . . . . . . . . . . . EW–3–32
Check of clearance between valve
Rear flywheel cover . . . . . . . . . . . . . . . . EW–3–33 spindle and valve stem guide . . . . . . . . . EW–3–43
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW–3–33
Refinishing of valve seats . . . . . . . . . . EW–3–44
Replacement of engine flywheel
toothed wheel . . . . . . . . . . . . . . . . . . . . . . EW–3–33 Valve sealing test . . . . . . . . . . . . . . . . . . . EW–3–44
Connecting rod – piston assembly . . EW–3–34 Remounting of valves . . . . . . . . . . . . . . . . EW–3–44
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–34 Mounting of cylinder head . . . . . . . . . . . . EW–3–44
Piston diameter measurement . . . . . . . . EW–3–34 Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–46
Piston pins . . . . . . . . . . . . . . . . . . . . . . . . EW–3–35 Mounting of valve lifter shaft and
Piston rings . . . . . . . . . . . . . . . . . . . . . . . EW–3–36 adjustment of working clearance
between valves and valve liftersi . . . . . . EW–3–47
Connecting rods . . . . . . . . . . . . . . . . . . . EW–3–36
Check of rectangularity of Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW–3–47
connecting rod . . . . . . . . . . . . . . . . . . . . . . EW–3–36 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–47
CONTENTS
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–49 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–63
Oil pump assembly . . . . . . . . . . . . . . . . . . EW–3–49 Automatic injection adjustment . . . . . . . . EW–3–64
Cooling system . . . . . . . . . . . . . . . . . . . . EW–3–49
Starting device disconnected . . . . . . . . . EW–3–65
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW–3–49
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . EW–3–49 Load–dependent feed start
Carrying out engine assembly at (L.F.B.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–66
work bench . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–50 Description . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–66
Injection pump installation and
timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–50 Position of the governor collar in the
LFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–67
Adjustment of the driving belt tension:
water pump – generator and fan . . . . . EW–3–52 Mode of operation . . . . . . . . . . . . . . . . . . . EW–3–67
Turbocharger . . . . . . . . . . . . . . . . . . . . . . EW–3–53 L.D.A. device (load–dependent
Description . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–55 feed adjustment) . . . . . . . . . . . . . . . . . . . . EW–3–68
Necessary checks before dismounting Mode of operation . . . . . . . . . . . . . . . . . . . EW–3–68
the turbocharger from the engine . . . . . . EW–3–56
Dismounting . . . . . . . . . . . . . . . . . . . . . . . EW–3–56 Dismounting of the injection pump . . . . . EW–3–68
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–58 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–74
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–59
Check of pressure increasing
Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–61 control valve . . . . . . . . . . . . . . . . . . . . . . . . EW–3–81
Dismounting . . . . . . . . . . . . . . . . . . . . . . . . EW–3–61
Pre–adjustment of the adjustment screw
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–61 for the L.D.A. device . . . . . . . . . . . . . . . . . EW–3–82
Injection pump . . . . . . . . . . . . . . . . . . . . . EW–3–62
Lift adjustment of the L.D.A. device . . . . EW–3–83
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–62
BOSCH stock number . . . . . . . . . . . . . . EW–3–62 Adjustment of the starting dimension
Mode of operation . . . . . . . . . . . . . . . . . . EW–3–63 “MS” (only engine 8040.45) . . . . . . . . . . . EW–3–85
Feed step . . . . . . . . . . . . . . . . . . . . . . . . . . EW–3–63 Calibration tables . . . . . . . . . . . . . . . . . . . . EW–3–87
EW–3–3

SPECIFICATIONS AND DATA
Type 8045.25.282
Cycle Diesel, 4 stroke, direct injection
Turbocharged
turbocharged with aftercooler
Number of cylinders 4, in line
∅
Diameter mm 104
Stroke mm 115
+ + + ... Total displacement cm3 3907
Compression ratio 17.7
66
Max. output KW (90)
CEE 80/1269 (HP)
2200
rpm
Max. torque Nm
365.9
(Kgm)
(37.3)
rpm
1600
Min. idling speed rpm 950 ± 25
Max. idling speed rpm 2400 ± 25
T.D.C. pressure * bar ≥ 26
Min. permissible
T.D.C. pressure * bar ≥ 19
bar
Engine motoring over
speed rpm ≈ 260
(*) The pressure value is measured by rotating the enging by the starter only, with oil temperature at 40o – 50o C and
injection pump at shut–off.
EW–3–4

8045.25.282
A
TIMING SYSTEM
start, before T.D.C. A 12o
finish, after T.D.C. B 31o
B
C
start, before B.D.C. D 50o
finish, after T.D.C. C 16o

D
Timing check
0.45
mm
X 0.45
X mm
Working clearance (*)

0.25 ÷ 0.35
mm
X 0.25 ÷ 0.35
mm (*) Further adjustment to be performed when reading is
other than 0.15 to 0.45 mm
FUEL SYSTEM By feed pump – injection pump – filters – injectors –
thermostarter
Type BOSCH VE 4/12 F 1100 L 761
α
Pump setting 7o ± 0,5o
X
Beginning of delivery mm 1
Nozzle type DLLA 132 S 1320
Injection order
– injection pump ABCD

– engine 1342
bar
Injection pressure bar 260 + 12

EW–3–5

8045.25.282
TURBOCHARGING
Turbocharger type GARRET TA 03
LUBRICATION SYSTEM Forced feed by gear pump, relief valve, dual action
oil filters
Oil pressure (warm

engine):
bar ≥1.2
– at idle bar
≥3.5
– at peak speed bar
Via centrifugal pump, thermostat, fan radiator,
COOLING SYSTEM
heat exchanger
Water pump control
Thermostat
– opening start 79o ± 2o C
– max. opening
OIL FILLING
Total capacity at 1st filling

litres 11.2
Kg 10
Quantity at periodical
replacements:
– engine sump
litres 9.1
Kg 8.2
– engine sump + filter

litres 10.2
Kg 9.1
EW–3–6

MOUNTING CLEARANCES – DATA
CYLINDER BLOCK AND CRANK MECHANISM 8045.25.282
mm
∅1
Cylinder inner diametre ∅ 1 106.85 ÷ 106.90
L Cylinder sleeve:
106.94 ÷ 106.97
Outer diameter ∅2
∅ Length L
198.00 ÷ 198.50
2
Cylinder sleeve – crankcase
0.04 ÷ 0.12
housing
Outer diameter ∅2 0.2
∅3
Cylinder sleeve
X
Inner diameter ∅3 104.000 ÷ 104.024
Sleeve protrusion X
Pistons:
∅1
X Oversize dimension X 12
Outer diameter ∅1 103.870÷103.852

∅
2 Pin bore ∅2 38.000÷38.006

0.130÷0.170
housing
Cylinder sleeve bore ∅1 0.4 – 0.6 – 0.8
X
Piston protrusion X 0.64÷0.97
∅3 Piston pin ∅3 37.984÷37.990
Piston pin – Pin clearance 0.010÷0.022
X1
X1 3.20÷3.23
X2 Piston ring grooves X2
2.55÷2.57
X3 X3
4.03÷4.05
EW–3–7

8045.25.282
mm
S1 S1 2.932 ÷ 2.963
S2
Piston rings S2 2.478 ÷ 2.490
S3
S3 3.970 ÷ 3.990
1 0.537 ÷ 0.598
Piston ring – grooves 2 0.060 ÷ 0.092
3 0.040 ÷ 0.075
Piston rings *0.4 – 0.6 – 0.8
Piston ring gap in

X1 cylinder sleeve: 0.20 ÷ 0.35
X2 X1
0.60 ÷ 0.85
X3 X2
0.30 ÷ 0.55
X3
∅1 Small end bushing

bore diameter ∅1 41.846 ÷ 41.884
Big end bearing

∅2 67.407 ÷ 67.422
∅2 diameter
∅4
Small end bushing
∅3 Outer dia. ∅4 41.979 ÷ 42.017
Inner dia. ∅3 38.004 ÷ 38.014

S
Big end half – bearings S 1.805 ÷ 1.815
Small end bushing – housing 0.095 ÷ 0.171
Piston pin – bushing 0.014 ÷ 0.031
Big end half – bearings 0.254 – 0.508
X
125
Measuring dimension X
Max. connecting rod axis

misalignment tolerance
0.07
* Oil scraper only.

EW–3–8

805.25.282
mm
∅1 ∅2
79.791 ÷ 79.810
Main journal diameter ∅1
63.725 ÷ 63.744
Crankpin diameter ∅2
2.169 ÷ 2.178
Crankshaft bearings S1
S1 S2
1.805 ÷ 1.815
Big end bearing thickness S 2
∅3 Main bearings ∅3 84.200 ÷ 84.230
Half–bearings – journals 0.034 ÷ 0.101
Crankshaft bearings 0.254 – 0.508
Main journal length X1

32.0 ÷ 32.1
X1
Main bearing width

between thrust washer 25.010 ÷ 25.060
seats X2
X2
X3 Thrust washer
3.378 ÷ 3.429
thickness X3
Crankshaft end float 0.082 ÷ 0.334
Thrust washers 0.127 – 0.254 – 0.508
1 2 1 ≤ 0.10
Alignment
2 0.03
Ovalization 1–2 0.015
Taper 1–2 0.012

EW–3–9

CYLINDER HEAD 8045.25.282
mm
∅1
Diameter of valve guide

13.950 ÷ 13.983
housing ∅1
∅2
∅2 8.023 ÷ 8.043
Valve guide
∅3 13.993 ÷ 14.016
∅3
Valve guide and housing 0.010 ÷ 0.066
Valve guide 0.2
∅4 Valves:
∅4 7.985 ÷ 8.000
α 60o 30’ ± 7’
∅4 7.985 ÷ 8.000
45o 30’ ± 7’
α α
Valve stem and guide 0.023 ÷ 0.058
Valve seat on cylinder head
∅1 –
∅1 39.000 ÷ 39.025
∅1
Valve seat angle on

∅ 2 cylinder head:
∅2 –
60o ± 5’
α
∅2
α 39.136 ÷ 39.161
α 45o ± 5’
Valve fitted depth in 0.7 ÷ 1

X cylinder head X
Between valve seat and

0.111 ÷ 0.161
cylinder head
EW–3–10

8045.25.282
mm
Valve spring heigt:
Free spring H 44.6
H H1 Under a load of N.
H2 270 ± 14 H1 34
528 ± 26 H2 23.8
Injector standout X 0.7 ± 0.4

X
Camshaft bush housing

fitted in engine block
∅1
∅2 54.780 ÷ 54.805
∅ ∅ ∅ ∅3 54.280 ÷ 54.305
1 2 3 53.780 ÷ 53.805
∅ 5
Camshaft journal diameter
∅4
50.970 ÷ 51.000
∅5
50.470 ÷ 50.500
∅6
49.970 ÷ 50.000
∅ 4 ∅ 6
Camshaft bushing
∅1 outer diameter:
∅2
front ∅1 54.875 ÷ 54.930
∅3 ∅2
intermediate 54.375 ÷ 54.430
rear ∅3 53.875 ÷ 53.930
Camshaft bushing
∅1 inner diameter:
∅2 51.080 ÷ 51.130
∅1 50.580 ÷ 50.630
∅3 front
intermediate ∅2 50.080 ÷ 50.130
rear ∅3
Bushing and housing in
0.07 ÷ 0.15
engine block
Bushing and journals 0.08 ÷ 0.16
Cam lift:
H H
5.97
H
6.25
EW–3–11
8045.25.282
mm
∅1
Tappet washer bore ∅1
15.000 ÷ 15.018
Tappet washer outer

∅2 diameter
∅3 ∅2
14.740 ÷ 14.780
∅2 ∅3
14.950 ÷ 14.970
Between tappets and

0.030 ÷ 0.068
housings
Tappets 0.1 – 0.2 – 0.3
∅ 1
Valve lifter diameter ∅1 17.982 ÷ 18.000

∅2
Between valve lifter and

0.016 ÷ 0.052
shaft
EW–3–12
79
72
65
58
51
44
37
30
23

EW–3–13

GRAPHIC REPRESENTATION AND SYMBOLS
Removal
Intake
Disconnect
Re–fit in place
Exhaust
Connect
Removal
Operation
Disassembly
Fitting in place
Assembly r Compression ratio
Tolerance
Driving torque
Weight difference
Driving torque + angular value Rolling torque

a
Replacement
Caulk
Original spare parts
Regulation
Rotation
Adjustment
Caution Angle
! Note Angular value
Visual check
Pre–load
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Face for machining

Pressure
Machine finish bar
Oversizing
Interference
Greater than...
Strained assembly
Maximum
Undersizing
Thickness
Smaller than...
Clearance
Minimum
Lubricate Selection
Damp Classes
Grease Oversizing
Temperature < 0o C
Sealant Cold
Winter
Temperature > 0o C
Air vent Hot
Summer
EW–3–14

TIGHTENING TORQUES
DESCRIPTION TORQUE
Nm (kgm)
Cylinder head attachment bolt 1st stage: preliminary torque 70 (7)
2nd stage: preliminary torque 70 (7)
3rd stage: angle 180°
Main bearing cap attachment bolts preliminary torque 80 (7)
angle 90°
Big end cap attachment bolts preliminary torque 40 (4)
angle 60°
Flywheel attachment bolts reliminary torque 40 (4)
angle 60°
z
Nut for injection fixing stud preliminary torque 9.9 (1)
final torque 22.5 (2.3)
Oil sump drain plug 95 (9.5)
Heater seat plug 125 (12.5)
Capscrew, timing cover and housing 22.5 (2.3)
Nut for timing cover and housing stud 22.5 (2.3)
Pipe union, piston cooling oil nozzle 45 (4.5)
Capscrew, intake manifold 22.5 (2.3)
Capscrew, intake manifold and hook 22.5 (2.3)
Capscrew, exhaust manifold 45 (4.5)
Nut, cylinder upper cover 22.5 (2.3)
Capscrew, valve lifter mounting 50 (5)
Nut, valve lifter adjustment screw 22.5 (2.3)
Capscrew, drive pulley 13.5 (1.4)
Flywheel attachment bolt 295 (29.5)
Capscrew, intermediate pin with flange 50 (5)
Capscrew, camshaft thrust plate 32.5 (5)
Capscrew, gear mounting 22.5 (3.3)
Capscrew, injection pump 22.5 (2.3)
Capscrew, injection pump 50 (2.3)
Capscrew, turbocharger 50 (5)
Capscrew, gas exhaust pipe from turbocharger 16.5 (5)
Capscrew, oil pump to front cover 22.5 (1.7)
Capscrew, retaining plate for oil pressure adjustment valve 22.5 (2.3)
Capscrew, heat exchanger 50 (2.3)
Capscrew, water pump 50 (5)
Capscrew, fan hub 115 (11.5)
Capscrew, belt tightener 50 (5)
– Lubricate with oil
z – Apply “LOCTITE HVX 576”

EW–3–15

SPECIAL TOOLS
75301439 Connecting rod drilling machine with housing
75301440 Spring load check device
75301441 Hot air device
75301124 Telescopic turning support
75301437 Vibration damper pulling–off device
75301436 Shock pulling–off device
75301442 Simple bridge
75301443 Pair of clamps with bore
75301444 Connection for pulling off injection valves (use with 75301436)
75297649 Pulling–off device for injection pump/motor coupling
75301445 Pulling–off device elastic bush, pressure control valve
75297687 Pulling–off device for injection valve bracket
75301446 Pulling–off device for injection valves (use with 75301436 and 75301444)
75301447 Pulling–off device with blocking device
75301448 Universal pulling–off device for inner dimensions of 5 to 70
75297200 Wrench for valve lifter adjusting screw
75301449 Wrench (13 mm) for fastening nut injection pump crankcase side.
75301450 Wrench for nuts injection pump pressure pipe connections (use with pump on test stand)
75301451 Wrench for dismounting and mounting pressure increasing control valve
75301452 Wrench for central hydraulic head connection
75291912 Wrench for dismounting and mounting guide pin control plate
75301434 Pliers for mounting piston rings
75295867 Driving mandrel for dismounting valve stem guide
75293231 Driving mandrel for remounting valve stem guide (use with 75295867)
75298549 Tool for dismounting cartridge filter
75301432 Tool for lock engine flywheel
75301431 Tool for dismounting and mounting engine valves
75301453 Box with complete set of tools for grinding of valve seats
75301430 Connecting piece for cylinder compression check (use with 75301463)
75301454 Ring for lifting cylinder block
75301455 Cables for lifting and transport of kg. 700
75301427 Belt for mounting standard pistons and oversize pistons in the cylinders
75301426 Brackets, engine/turning support 75301124
75297686 Swag housing injection valve brackets
75290239 Adjustable bearing for injection pump overhaul
75301456 Tool for check feed start
75301457 Tool for advanced ignition check
EW–3–16

75296068 Wrench for lock drive clutch injection pump for unscrewing of crankshaft nut
75301458 Tool for check pretension of injection pump countersprings (use with 75290239)
75290752 Retaining plate for injection pump during overhaul (use with 75290239)
75301459 Handle for replaceable driving mandrels
75295890 Valve stem guide reamer
75295896 Set of screws for cutting of injection valve bracket housing that are to be pulled off
75298637 Reamer for refinishing inside injection vavle bracket housing (use with 75298638)
75301423 Milling cutter for refinishing injection valve seat (use with 75298638)
75298638 Guide bush
75301263 Indicating caliper bracket for adjustment of rotating injection pump (use with 75301259)
75301460 Pair of goniometers
75301461 Complete angle for checking rectangularity of connecting rods
75301462 Tool for check of starting dimension ”T.D.C.” and position of LDA membrane
75301463 Device for cylinder compression check
75301464 Reamer (50:175 mm)
75301465 Dynamometer for belt tension check
75290284 Manual pump for injector calibration test
EW–3–17
STRIPPING DOWN THE ENGINE IN THE - Disconnect the check rod sleeve (3);
WORKSHOP - Put the engine on the revolving stand 75301124,
Using a suitable lift (capacity greater than 500 kg) fixing it to the brackets 75301426.
and some ropes, keep the engine suspended, then
apply brackets 75301426 after the operations de-
scribed below: When handling the engine, keep at a safe
! distance in compliance with the accident–
- Remove the supports (1); prevention standards.
- Drain oil from the engine;
- Remove the heat exchanger (2);
Figure 1
1 47277
PREPARING THE ENGINE TO PUT IT ON THE REVOLVING STAND

EW–3–18
Figure 2
1 9
2 10
11
3 12
13
8
14
Figure 3
47279
15
18
19
16
17
47278
1. Air pipeline – 2. Air intake manifold – 3. Fuel filter – 4. Accelerator tie rod – 5. Filter –
6. Starter motor – 7. Fuel pump – 8. Tightener – 9. Fuel pipes – 10. Injection pump – 11. Fuel return piping –
12. Pulley support – 13. Fan – 14. Belts – 15. Turbocharger – 16. Alternator – 17. Oil filter – 18. Exhaust
manifold – 19. Equaliser cover
EW–3–19
Disassemble the components following the se- Figure 4

quence described below, as shown in Figure 2:
- Remove the air pipeline (1).
- Remove the glow plug (5) with the pipes.
- Remove the fuel filter assembly with its support
(3).
- Disconnect and remove the fuel recovery pipes
(11).
- Remove all fuel pipes (9) and the injectors, ex-
tracting them from their seats.
- Disconnect the accelerator tie rods (4), loosen
the screws and remove them from the support,
unscrew the fuel pipe unions and extract the en-
tire injection pump (10). 47284
- Remove the fuel pump (7). Prevent the flywheel from rotating by tool 75301432
- Remove the starter motor (6) from its housing. (2), then loosen the screws (1).
- On the front side, loosen the relevant screws
and remove the fan (13), through the holes of the Figure 5
fan driving pulley loosen the water–pump pulley
screws.
- Loosen the belt tightener (8), loosen the water–
pump alternator driving belt by unscrewing the
screw on the relevant slotted bracket.
- Then extract the two belts (14) from the pulleys.
47285
NOTE – The fan driving belt is self–ventilated. After having definitely removed the pulley on the
water pump, remove the tightener (3), the pipe (2)
NOTE – Where present, loosen the conditioner and the alternator bracket (1).
compressor fixing device to extract the belt, then Figure 6
unscrew the screws completely and remove the
compressor.
- Remove the fan pulley by extracting the entire

support (12) from the thermostat unit.
- Remove the intake manifold (2).
From the opposite side, Figure 3, remove:
- the turbocharger unit (15) by disconnecting the
oil inlet and outlet unions; remove also the pipes
by unscrewing the unions on the crankcase.
- Remove the exhaust manifold (18).
- Finally, disassemble the alternator (16).
- Using a suitable wrench, unscrew the oil filter 47286
(17). Remove the pulley (2) and the flywheel damper (1)
- Remove the equaliser cover. removing the perimeter screws.
EW–3–20
Figure 7 Figure 10
47287 32567
Remove the thermostat unit (1) from the head, and Remove the entire valve lifter shaft (1).
the water pump from the crankcase.
Figure 8 Figure 11
32568
Straighten the locking plate (2) and unscrew the hub Put aside valve lifter control rods (1) and covers (2)
locking nut (1) using a suitable wrench. on valve spindle.
Figure 9 Figure 12
47289
32569
Apply tool 75301437 (2) and pull off the hub (1).
Extract the retaining screws (1) of cylinder head (2)
and remove the cylinder head; keep its gasket.
EW–3–21
Figure 13 Figure 16
47292 47293
Turn engine by 180° and, using a wrench, extract the Remove the timing gear cover (3).
screws and remove the oil sump (1) keeping its Remove the intake pipes (1) and the delivery pipes
gasket. (2); remove the oil sump (4).
Figure 14 Figure 17
47290 47294
Unscrew the flywheel fixing screws (2), which had Loosen the screws (1) and remove the connecting
been already loosen, and extract the flywheel (1). rod covers (2).
Figure 15 Figure 18
47291 32573
Loosen the flywheel cover fixing screws (1) and re- Pull the piston/connecting rod assemblies (1) out of
move the cover. the upper part of crankcase.
EW–3–22
Figure 19 Figure 21
47295 32577
Detach fastening screws and remove the main bear-

ing covers (1). Remove spring ring (1) and pull off the transmission
gear wheel (2).
Remove injection–pump driving toothed wheel (5).
Loosen the locking screws (3) of the collar plate and
extract the camshaft (4).
Figure 22
Figure 20
32578
Remove the transmission gear wheel bracket (1).

Extract the housing of the steering (2). Pull off valve
lifter and dismount oil spraying nozzles. Remove
rear camshaft cover.
NOTE – Clean carefully all disassembled parts and

check their integrity after stripping down the engine.
32576
On the following pages instructions for the main
checks and measuring are given, which have to be
Lift and remove crankshaft (1), put aside main bear- carried out to determine whether the parts can be
ing shells (2) and shoulder semi–rings. used again for mounting.
EW–3–23
REPAIRS Figure 24
CYLINDER BLOCK
CHECKS AND MEASUREMENTS 1. MEASURING
NOTE – Because of its ductility, the cylinder liner must

never be measured inside when dismounted; the inner
diameter must be measured at a completely mounted
2. MEASURING
liner.
3. MEASURING
Figure 23
20581
DIAGRAM FOR CHECK OF CYLINDER LINER

DIAMETER
Each single cylinder must be measured at different

heights of the liner and at two surface planes rec-
tangular to each other; one of these surface planes
is parallel to the longitudinal axis of the engine (A)
and the other is perpendicular to it (B); generally at
the surface plane (B) and at the height of the first
measurement, the cylinder liner is worn most.
Ovalness, conical form or wear can be removed by
regrinding of the liners for a little wear or slide fur-
rows; for deep furrows or marked ovalness the
bored liners must subsequently be surface–ground.
NOTE – For the regrinding, all liners must have the

same overdimension (0.4 – 0.6 – 0.8 mm).
Figure 25
32579
In order to determine the value of the out–of–round,

conical form and wear, the inner diameter of the
liners is checked by means of gauge 99395687 (2)
provided with cent indicating caliper (1), that has
been previously calibrated at a ring gauge (3) with a
diameter of 104 mm.
NOTE – If a ring gauge with a diamter of 104 mm is

not available, use a slide gauge.
32580
DIAGRAM FOR THE CHAMFERING AT THE

CYLINDER LINERS AFTER REGRINDING
EW–3–24
Replacement of cylinder liners Figure 27

Dismounting and mounting of the cylinder block
liners is carried out by means of a hydraulic press
and the corresponding plates.
For mounting the cylinder liners in the crankcase
seats by means of a press, the following steps have
to be carried out:
- Check whether the cylinder liner outer diameter
is 106.970 ÷ 106.940 mm and the cylinder liner
seat inner diameter is 106.850 ÷ 106.900 mm;
- Insert the cylinder liner into the seat at the crank-
case and start pressing it;
- after pressing it by 70 ÷ 90 mm, check that the
load is greater than 5000 N and less than 23,000
N; 32582
- go on pressing in and, at 30 mm before finishing, Check support surfaces (3) of the cylinder head for
check that the load is between 10,000 and unevenness by means of a calibrated ruler (1) and
40,000 N; a feeler gauge (2).
- when pressing is completed, stop for 5” with a Surface–grind the support surface by means of a
press–in load above 50,000 N; grinding machine removing as little material as
possible after determination of the unevenness. Re-
- by restriking, check whether the liner edige is member that, after surface–grinding, the piston
well–set in the crankcase. must project by 0.64 0.97 mm over the cylinder
If the driving load is outside the above limits, the cyl- block.
inder liner must be extracted and replaced.
After driving, the cylinder liners must be bored and NOTE – Pull out centering pin only if the support sur-
ground. face must be surface–ground.
Cylinder liners are delivered as spare parts with an

inner diameter slighlty below the nominal diameter
in order to be able to correct possible deformation
appearing during mounting.
NOTE – The cylinder liners are delivered as spare

parts with the outer diameter oversized by 0.2 mm.
Figure 26
32581
Check condition of the treatment plugs (1) of the cyl-

inder block: if they are worn or their seal is doubtful,
replace them.
EW–3–25
CAMSHAFT – BUSHES – VALVE LIFTERS
Figure 28
5619
MAIN DATA OF THE CAMSHAFT
The surfaces of the bearing journals of the shaft and scoring and furrows, the shaft and their correspon-
the cams must be completely smooth; if they have ding bushes must be replaced.
EW–3–26
CAM PITCH AND BEARING JOURNAL BUSH REPLACEMENT

ALIGNMENT CHECK Figure 32
Figure 29
32583
32586
Clamp camshaft (2) between centers (3) and check In order to check the mounting clearance, measure
the cam pitch (4) by means of a cent indicating caliper the inner diameter of bushes and diameter of cam-
(1). Cam pitches must be: shaft journals (1); the difference represents the
- 5.955 mm for the inlet cam; actual clearance.
For a clearance of more than 0.160 mm, replace the
- 6.027 mm for the outlet cam.
bushes and, if necessary, also the camshaft.
Figure 30
Figure 33
32584
Check alignment of the bearing journals (4) with the 32587

camshaft (2) between centers (3). For the disassembly and reassembly of the bushes
If the offset exceeds 0.020 mm replace the shaft. (1) use a suitable driving mandrel.
NOTE – During mounting of bushes (1), pay attention
DRIVEN TOOTHED WHEEL REPLACEMENT to the alignment of bores (2) which must be aligned
with the crankcase bores for the transition of the lubri-
cating oil.
Figure 31
Figure 34
32585
Check that the toothing of the driven toothed wheel
(1) is not excessively worn or damaged, otherwise 32588
replace it. In order to mount the new toothed wheel,
it must be heated up to 180 °C in the furnace for After mounting, grind the bushes completely by
about 10’ and then drawn upon the shaft together means of the mandrel (1) complete with guide
with the plate (2) and the curved washer. bushes (2–3) and milling cutter (4) in order to obtain
the prescribed values.
EW–3–27
Figure 35
5619
MAIN DATA OF BUSHES FOR CAMSHAFT AND CORRESPONDING SEATS
* Value to be obtain after inserting the bushes.

VALVE LIFTERS
NOTE – The valve lifters are delivered as normal

spare parts and oversized by 0.10 – 0.20 – 0.30 mm.
Replacement of valve lifters

Figure 36
Figure 37
32589
If the valve lifters are replaced because the clear-

20399
ance in the seats is too large, oversized valve lifters
MAIN DATA OF VALVE LIFTERS AND SEATS IN are required and the seats (2) must be bored by an
CRANKCASE appropriate reamer (1).
EW–3–28
Mounting of valve lifters – Camshaft Figure 41

Figure 38
32593
32590 Mount pin (2) for transmission gear wheel.

Lubricate camshaft bearing and insert shaft (1) into
Mount steering toothed wheel housing together with the crankcase.
a seal; tighten screws to 25 Nm tightening torque.
Mount oil spray nozzles (1) and bend locking plates.
Figure 39
32591 Figure 42
Lubricate the valve lifters (1) and mount them into
their crankcase seats.
Figure 40
32594
Tighten fastening screws (1) of the camshaft locking

plate at the crankcase through the bores (2) in the
toothed wheel (3).
32592
Mount the injection pump driving toothed wheel (4).
Mount cover (1) complete with sealing ring (2) and
fix it with the appropriate plate.
EW–3–29
CRANKSHAFT
Figure 43
21175
MAIN DATA OF THE CRANKSHAFT MAIN AND CONNECTING ROD BEARING JOURNALS
MAIN AND CONNECTING ROD BEARING

JOURNALS
Figure 44 Figure 45
32596
32595
MEASUREMENT OF MAIN BEARING MEASUREMENT OF CONNECTING ROD

JOURNALS BEARING JOURNALS
Masure shaft journals (2) by means of a micrometer NOTE – The measurement carried out at the main or
caliper (1) before grinding of journals, and determine connecting rod bearing journals must be indicated by
by means of the bearing smaller dimension scale a stamp at the side of the crank web No. 1.
which journal diameter must be obtained by grind- For undersized connecting rod bearing journals:
ing. letter M
For undersized main bearing journals: letter B
The smaller dimension classes are 0.254 – For undersized c. rod and main b. j.: letter MB
0.508 mm.
For the grinding of the crankshaft journals the con-
NOTE – All main and connecting rod bearing journals nections values are especially important, because
must always be ground to the same smaller dimension they must correspond to the values in Figure 46,
class in order to avoid out–of–balance of the shaft. Figure 47 and Figure 48.
EW–3–30
Figure 46 Figure 49
ROLLED
*
32597
Check that plugs (2) of the lubricating circuit are not

21177 leaky for an inner pressure of 15 bar, otherwise re-
place plugs by means of driving mandrel, 75295970
DETAIL OF THE MAIN BEARING JOURNAL (1).
CONNECTIONS
CHECK OF MAIN BEARING JOURNAL
ALIGNMENT
Figure 50
Figure 47
ROLLED
32598
21178
This check must be carried out after possible grind-
DETAIL OF THE CONNECTING ROD BEARING ing of the crankshaft journals; for this purpose the
JOURNAL CONNECTIONS shaft (3) must be clamped between centers (2) and
a centi indicating caliper has to be used (1).
Figure 48 - Alignment of main bearing journals: max. toler-
ance > 0.10 mm (total reading at the indicating
caliper).
Figure 51
NORMAL POSITION
LIMIT mm 0,25 LIMIT
POSITION mm POSITION
0,25
ÇÇÇÇ MAIN
ÇÇÇÇ
BEARING
JOURNAL
ÇÇÇÇ CONNECTING
ÇÇÇÇ ROD BEARING

JOURNAL
- Connecting rod bearing journal alignment re-
6236
ROLLED ferred to main bearing journals: the axis of each

21176
connecting rod bearing journal pair and the axis
DETAIL OF THE THRUST BEARING JOURNAL of the main bearing journals must be at one
CONNECTIONS place: max. permissible tolerance perpendicular
to this plane ± 0.25 mm.
EW–3–31
REPLACEMENT OF DRIVING TOOTHED Figure 54

WHEEL STEERING AND OIL PUMP
Figure 52
32575
32599 Lift and mount crankshaft (1).

Check that toothing of toothed wheels (1 – 2) is not CHECKING OF MAIN BEARING JOURNAL
damaged or worn, otherwise pull off toothed wheels MOUNTING CLEARANCE
by means of an appropriate pulling–off tool (3).
In order to mount the new toothed wheels (1 – 2) they Figure 55
must be heated up to 180 °C in the furnace for about
10’ and pulled upon the crankshaft together with the
curved washer.
MOUNTING OF MAIN BEARINGS
The main bearings are delivered as spare parts with

the inner diameter reduced by 0.254 – 0.508 mm.
32602
NOTE – No fitting work at bearings.

The clearance between the shaft journals and the
corresponding bearings is checked by means of a
calibration cable as follows:
Figure 53 - clean the parts carefully and remove oil;
- place a piece of the calibration cable (4) in paral-
lel to the longitudinal axis at the crankshaft jour-
nals (3);
- mount bearing covers (1) with the bearing shells
on their supports;
- mount bearing cover fastening screws and
tighten them by means of a torque wrench to the
prescribed tightening torque. The screws must
be previously lubricated with oil;
- dismount the bearing covers and determine the
clearance between the bearing shells and the
main bearing journals; for that purpose compare
the width of the part of cable (4) that is squeezed
32600 most to the scale printed to the calibration cable
wrapping (2).
Place bearing shells (1) on main bearings.
EW–3–32
Crankshaft end play check Figure 58

The standard mounting clearance is 0.082 ÷ 0.334.
For a larger clearance, the shoulder semi–rings
must be replaced by new ones with standard size or
with oversize.
Overdimension of the shoulder semi-

rings 0.127 - 0.254 - 0.508 mm.
Figure 56
32605
Lubricate the fastening screws (1) and tighten them

by means of a torque wrench (2) to a tightening
torque of 80 Nm.
NOTE – Before re–using the main bearing cover
fastening screws, check whether the thread diameter
measured at a distance of 40 ÷ 60mm from the top of
the screw is not less than 13.5 mm; otherwise replace
the screw.
Figure 59
a
32603
Place shoulder semi–rings (1) at the 4th bearing,

with the surface covered with antifriction metal to-
wards the compensation plate of the crankshaft.
32606
Figure 57 Apply tool 75301460 (1) on the socket wrench (2);

tighten screws by further 90°.
Figure 60
32604
Mount the main bearing covers together with the

bearing shells; before mounting the bearing cover 32607
(1), mount shoulder semi–rings (2) in such a way
that the surface covered with antifriction metal faces Place the indicating caliper (1) with magnetic base
the compensation plate of the camshaft. and check end play.
EW–3–33
REAR FLYWHEEL COVER Figure 63

Figure 61
47290/
47296
Mount flywheel (1). Apply tool 75301432 (3) and
Insert a new seal ring (1) on the flywheel cover (2). tighten the screws that were previously lubricated
with “LOCTITE HVX 576” to a tightening torque of
40 Nm by means of a torque wrench (2).
Some seal rings are supplied as spare parts
! with the built–in ring, to be removed after the
assembly.
Figure 62
47291
Figure 64
Mount the flywheel cover on the crankcase.
ENGINE FLYWHEEL
REPLACEMENT OF ENGINE FLYWHEEL a
TOOTHED WHEEL
Replace the toothed flywheel ring if the teeth of the
toothed flywheel ring mounted on the engine fly-
wheel to start the engine are very damaged. Before
mounting, the thoothed flywheel ring must be heated
up to a temperature of 80 °C.
NOTE – The fastening screws of the engine flywheel

can be used as long as the thread diameter is lot lower
47297
than 11.5 mm.
Place tool 75301460 (2) on the socket wrench (2)
and tighten the screws by further 60°. Dismount the
flywheel fastening tool.
EW–3–34
CONNECTING ROD – PISTON ASSEMBLY PISTON

Figure 65
The pistons are delivered as spare parts with stan-
dard size or oversized by 0.4 – 0.8 mm.
Piston diameter measurement

Figure 68
32612
PARTS OF THE CONNECTING ROD – PISTON

ASSEMBLY
1. Retaining rings. - 2. Pin. - 3. Piston. -
4. Piston rings. - 5. Screws. - 6. Bearing shells. -
7. Connecting rod. - 8. Bush.
Figure 66
32615
Using a micrometer (2), measure the piston diam-

eter (1) to determine the mounting clearance.
NOTE – The diameter must be measured at a dis-

tance of 12 mm from the piston base.
32613
Dismount the piston rings (1) out of piston (2) using

pliers 75301434 (3).
Figure 67 Figure 69
32616
32614
Take off locking rings (2) of piston pin (1) by means The clearance between piston and cylinder liner can
of a center punch (3). also be checked by means of a feeler gauge (1) as
shown in the figure.
EW–3–35
Figure 70
47318
MAIN DATA OF THE PISTON, THE PISTON RINGS AND THE PISTON PIN (ENGINE 8045 25.282)
* Values are measured on 101–mm ∅.
PISTON PINS
The pins are mounted with clearance as well at the
connecting rod eye as at the piston.
Figure 71 Figure 72
32618 32619
Measure the piston pin diameter (1) by a micrometer For mounting the new piston pins (1) check the cor-
(2). rect fit in the piston as follows:
- Lubricate the piston pin and the corresponding
fit at the piston pin hubs with engine oil;
- insert the piston pin vertically in the piston pin
hub;
- it must be possible to insert the piston pin with a
slight pressure;
- the piston pin cannot slip out of the hubs.
EW–3–36
PISTON RINGS Figure 76

The piston rings are supplied as spare parts with
standard diameter size or oversized by 0.4 – 0.6 –
0.8 mm for the seal ring and the 2nd oil scraper and
by only 0.6 mm for the 1st oil scraper.
Figure 73
32621
Measure the clearance between the ends of the pis-

ton rings (2) inserted in the cylinder liner (3) by
16552
means of a feeler gauge (1).
Check the piston ring thickness (2) by means of a
micrometer (1). Figure 77
Figure 74
16556
If the joint clearance is smaller than the prescribed

32620 value, regrind the piston ring joints by means of a
Check clearance between piston rings (3) and corre- suitable tool: if the distance between the ends is
sponding grooves (2) with a feeler gauge (1). larger than the prescribed value, replace the piston
rings.
Figure 75
CONNECTING RODS
Figure 78
3513
The seal ring (2) of the 1st piston groove has a trap-
ezoidal cross section. The clearance between the
sealing ring and the seat is determined as follows: Connecting rod assembly drawing. 32622
arrange piston (1) with the corresponding ring in the

The arrows indicate the area where material can be
cylinder liner (3) in such a way that the sealing ring
removed in order to obtain a counterweight.
projects from the cylinder liner by a half.
EW–3–37
Figure 79 BUSHES
Figure 81
20584
32625
MAIN DATA OF THE CONNECTING ROD, THE
BUSH, THE PISTON AND THE BEARING Dismounting and mounting of the bush (2) are car-
SHELLS ried out with a suitable driving mandrel (1).
* Value to be measured after mounting of bush.
Check of rectangularity of connecting rod

Figure 80
Figure 82
36624
Check that axes of the connecting rods are parallel

by means of tool 75301461 (1) and feeler gauge (2).
The permissible tolerance is 0.07 mm, measured at
a distance of 125 mm from the longitudinal axis of
the connecting rod.
NOTE – Each connecting rod has to be provided – on

the body and cover – with a number corresponding to
the cylinder on which it must be mounted.
32626
Therefore, in case of replacement, the new connect-
ing rod must be marked with the same number.
Finishing treatment of the connecting rod eye bush
by means of drilling machine 75301439.
EW–3–38
MOUNTING OF CONNECTING ROD – Mounting of piston rings

PISTON ASSEMBLY Figure 85
Connecting rod – piston mating
Figure 83
32613
To mount the piston rings (1) onto the piston (2) use
pliers 75301434 (3).
32677
The rings must be mounted with lettering “TOP’’ to-
wards the top; furthermore the joints in the rings
NOTE – The piston (2) must be mounted in such a must be aligned in such a way that they are offset by
way that lettering “VALVE LIFTER SIDE” (1) at the top 120° to each other.
is placed opposite to the number (4)on the connecting
rod.
Insert piston pin (3) and mount the spring rings.
Connecting rod – piston rectangularity check
Figure 84
Figure 86
32630
32628 Mount the bearing shells (1) at the connecting rod as

Check for rectangularity of the connecting rod – pis- well as at the connecting rod bearing cover.
ton assembly by means of tool 75301461 (1) and
feeler gauge (2). The surface of the piston head NOTE – No fitting work at the bearing shells.
must be completely rectangular to the tool surface.
EW–3–39
Figure 87
NOTE – When mounting the connecting rod – piston
assemblies check that:
– the connecting rod number corresponds to the
cylinder number;
– the lettering “VALVE LIFTER SIDE’’ which is
punched into the piston head must point to the
top, i.e. in the direction of the camshaft;
– the connecting rod numbers point to the side op-
posite to the camshaft;
– the piston ring joints must be offset by 120° to
each other.
ADJUSTMENT OF THE MOUNTING

CLEARANCE OF THE CONNECTING ROD
JOURNALS
32631
Figure 89
REPRESENTATION OF THE FIT BETWEEN
CONNECTING ROD AND PISTON FOR
MOUNTING THE ASSEMBLY INTO THE
CYLINDER
1. Piston - 2. Combustion chamber - 3. Stamp
area for the number of the cylinder to which the
connecting rod belongs - 4. Camshaft.
The arrow indicates the direction of rotation of the
engine, as viewed from the steering side.
NOTE – The connecting rod screws can be used as

long as the thread diameter measured between 19 and
35 mm from the screw head is not lower than 10.6 mm.
Figure 88
32633
In order to adjust the clearance, the following oper-
ations must be carried out:
- clean the parts carefully and remove the oil;
- place a piece of calibration cable (2) at the
crankshaft journals (1);
- mount the connecting rod cover (4) and tighten
the screws with the prescribed tightening
torque;
- dismount the cover and determine the existing
clearance; for this purpose compare the width of
the calibration cable (2) with the scale printed at
the calibration cable wrapping.
32632
Mount the connecting rod - piston assembly (1) into

the cylinder line by means of strap retainer NOTE – Lubricate the corresponding parts before the
75301427 (2). final mounting.
Lubricate the corresponding parts before mounting.
EW–3–40
Mounting of connecting rod covers STEERING

NOTE – Before repeated application of the connecting CHECK AND REPLACEMENT OF THE
rod cover fastening screws, check that the thread diam- TRANSMISSION GEAR WHEEL
eter measured from 19 to 35 mm from the screw head
is not below 10.6 mm, otherwise replace the screw. Check that the transmission gear wheel is not dam-
Figure 90 aged or the toothing is too much worn, otherwise it
must be replaced.
32634
Mount connecting rod covers (2) complete with
bearing shells, tighten screws (3) by means of a
torque wrench (1) to a tightening torque of 40 Nm;
the screws must be previously lubricated.
Figure 91
32635
Place tool 75301460 (1) at the socket wrench and
tighten the screws (2) by further 60°.
Check that the connecting rods can be displaced ax- REPLACEMENT OF BUSH FOR TRANS-
ially on the crankshaft journals. MISSION GEAR WHEEL
Figure 92
Figure 93
32636
When mounting is completed, check the piston posi- 32637

tion (4) in the T.D.C. referred to the cylinder block Check the contact surfaces of the bush (1): they
surface (1) by means of an indicating caliper (3) with must not have furrows or score grooves; otherwise
magnetic base. the bush must be replaced by means of a suitable
The upper edge of the piston must project by 0.64 to driving mandrel.
0.97 mm over the cylinder block surface (1).
EW–3–41
Figure 94 Figure 96
32638 32640
After mounting, the bush (1) must be bored in order Shrink on the transmission gear wheel (2) and align
to obtain the diameter given in the drawing. it in such a way that the marks 1 - 2 and 3 punched
into it cover the marks on the driving toothed wheel
(1), the camshaft driven toothed wheel (3) and the
injection pump driving toothed wheel (4).
CYLINDER HEAD
Figure 97
Mounting of the transmission gear wheel and

adjustment of the steering
Figure 95
32641
Tightness check
Before dismounting the cylinder head, check for

47301 tightness by means of a suitable tool.
Fill in water heated up to ≈ 90°C under a pressure of
Rotate the crankshaft and place the piston of the cyl- 4 ÷ 5 bar by means of a pump. Under these condi-
inder No. 1 in the compression stage in the T.D.C. tions no leakage must occur, otherwise the cylinder
This position is reached when the pointer (1) points head must be replaced.
to the “O” (2) that is punched onto the engine fly-
wheel.
EW–3–42
DISMOUNTING OF VALVES Check of cylinder head bearing surface on cyl-

inder block
Figure 98
Figure 100
32642 32644
Place the cylinder head at the work bench and press The bearing surface of the cylinder head on the cyl-
with tool 75301431 (2) on the upper plate (6, inder block is checked by means of a ruler (1) and a
Figure 99) of the springs (3) in order to pull out the feeler gauge (2).
cone halves (4) and detach the valves; pull out the For values above 0.15 mm on the whole surface, the
upper spring plate (6), the springs (3) and the lower head must be reground by means of a surface grind-
spring plate (5). Repeat this for all valves. Turn the ing machine while removing as less material as pos-
cylinder head and pull out the valves. sible.
VALVES
Removal of incrustration and valve check
Figure 99 Figure 101
32643 18625
Components of the valves Remove fuel deposits at the valves by means of a

1. Exhaust valve - 2. Intake valve - suitable steel brush.
3. Springs - 4. Cone halves - 5. Lower spring Check that valves have no grooves or cracks. Check
plates - 6. Upper spring plates. furthermore by means of a micrometer screw that
the valve spindle has the prescribed value (see
Figure 102). Otherwise exchange valves.
EW–3–43
INTAKE EXHAUST 32646
20397 The valve stem guides are dismounted and mounted

by means of driving mandrel 75293231 (1 – 2).
MAIN DATA OF VALVES AND VALVE STEM
GUIDES NOTE – The valve stem guides are also delivered as
spare parts with an oversized outer diameter of 0.2 mm.
*Dimension to be obtained after mounting of valve
stem guides Figure 105
Valve grinding
If necessary, the valve seats must be ground by
means of a grinding machine so that the angle of the
exhaust valves is equal to 45° 30’ ± 7’ and for the in-
take valves is equal to 60° 30’ ± 7’, while removing
as less material as possible.
Check of clearance between valve spindle and

valve stem guide
Figure 103
32647
MOUNTING VALUES OF VALVE STEM GUIDES
Boring of inner surfaces of valve stem guides
Figure 106
32645
Using an indicating caliper with magnetic base (1),

check clearance between valve spindle (2) and 32648
valve stem guide. If case clearance is too large, re- After mounting the valve stem guides (2), regrind the
place the valve and, if necessary, the valve stem bore by reamer 75295890 (1).
guide.
EW–3–44
REFINISHING OF VALVE SEATS Figure 110

Figure 107
16587
32649 The elasticity of the valve springs is checked by

Using the “Hunger’’ tool 75301453 (1), refinish valve means of tool 75301440; compare the load data and
seats (2) at the cylinder head (3) so that maximum the elastic deformation data with those of the new
sealing is obtained. springs that are indicated in the following figure.
Figure 111
NOTE – The valve seats have to be ground if the
valves or valve stem guides are ground or replaced.
Figure 108
EXHAUST INTAKE
0.7 TO 1 VALVE
SINKING
36.4 REFERENCE DIA. 43.2 REFERENCE DIA. 20398
20585 MAIN DATA FOR CHECKING OF VALVE

MAIN DATA OF INTAKE AND EXHAUST VALVE SPRINGS
SEATS
NOTE – After grinding is completed, during mounting
check that the recess of the intake and exhaust valves Remounting of valves
referred to the cylinder head area is equal to 0.7 ÷ 1.0 Figure 112
mm.
Valve sealing test
Figure 109
32642
Mounting is carried out performing the same steps
of the dismounting but in reversed order.
32650
The valve sealing of the cylinder head is checked NOTE – Lubricate the valve spindle with engine oil.
with a suitable tool.
EW–3–45
Mounting of cylinder head Figure 116

Figure 113
18929
Before reusing the cylinder head fastening screws (2), 32653
measure by a micrometer screw (1) that the thread di-
ameter of the screws is not lower than 11.5 mm at any - mount the cylinder head (2), insert the previous-
point; otherwise the screws must be replaced. ly–lubricated screws (3) and tighten them ac-
cording to the following data and in the order
Figure 114 given in Figure 115;
- 1st step, by a torque wrench (1), pretighten to a
tightening torque of 70 Nm;

- 2nd step, tighten again to a tightening torque of
70 Nm.
32652
For mounting and tightening the cylinder head, ob-

serve the following:
Figure 117
- mount seal (1) in the crankcase, with the letter-
ing TOP (2) pointing to the mechanic;
Figure 115
2790
32654
PATTERN OF THE TIGHTENING ORDER OF
THE CYLINDER HEAD FASTENING SCREWS IN - 3rd step, place tool 75301460 (1) on the socket
THE CRANKCASE wrench (2) and tighten with an angle of 180_.
EW–3–46
RODS Figure 121

Figure 118
32655
32656
The control rods of the valve lifters must not be de-
formed. The ball seats which can have contact to the Mount the valve lifter control rods (1) in their seats.
valve lifter adjusting screw and the valve lifter (ar-
rows) must be free from score grooves or wear;
otherwise they must be replaced.
The rods which operate the intake and exhaust
valves are identifical and can be exchanged.
Figure 119
32657
MAIN DATA OF THE BEARINGS OF THE VALVE LIFTER SHAFT AND THE VALVE LIFTER
Figure 120
Check that the sealing surfaces are free from fur-
rows or score grooves; otherwise replace the dam-
aged parts.
Check clearance between valve lifters and valve
lifter shaft, which must be 0.016 ÷ 0.052 and the
clearance between bearing and valve lifter shaft,
which must be 0 ÷ 0.061 mm; replace the parts which
cause larger clearances.
Check the perfect sealing of the plugs mounted at
the shaft end.
32658
PARTS OF THE VALVE LIFTER SHAFT

1. Spring ring - 2. Adjusting rings - 3. Valve lifters -
4. Shaft bearing - 5. Spring - 6. Shaft.
EW–3–47
Mounting of valve lifter shaft and adjustment of The clearance between valve lifters and valves must
working clearance between valves and valve lifters be adjusted carefully in order to avoid changes of the
prescribed control diagram. This would be the case
Figure 122 if the clearance was smaller or larger than pre-
scribed.
The working clearance is 0.25 ÷ 0.35 mm for both
the intake and the exhaust. Place the cylinder for
which the clearance is to be adjusted in the working
stroke; the valves of this cylinder remain closed,
while the valves of the corresponding cylinder are
adjusted.
The cylinder pairs are 1 - 4 and 2 - 3.
NOTE – Re–adjustment is necessary if a value differ-

ent from 0,15 ÷ 0,45 mm is measured.
LUBRICATION
32659
Mount cover (1) to the valve spindle. The engine is lubricated by means of a gear pump
(Figure 125) that is mounted in the lower part of the
Figure 123
crankcase at the front bearing; it is driven by toothed
wheels of the crankshaft.
32567
Mount the complete valve lifter shaft (1). OIL PUMP

Adjust the working clearance between valves and
valve lifters as described below. Figure 125
Figure 124
32662
32661 OIL PUMP.

Adjust the clearance between valve lifters and 1. Pump housing - 2. Control valve -
valves by means of wrench 75297200 (1), box 3. Driven toothed wheel.
wrench (2) and feeler gauge (3).
EW–3–48
Figure 126

6960
OIL PUMP ASSEMBLY COMPONENTS
1. Screw - 2. Washer - 3. Centering dowel - 4. Bushing - 5. Oil pump gear - 6. Centering dowel - 7. Driving
gear - 8. Seal ring - 9. Valve body - 10. Spring - 11. Valve - 12. Screw - 13. Washer - 14. Locking plate - 15.
Oil pump body - 16. Bushing - 17. Oil pump gear - 18. Bushing - 19. Shaft - 20. Oil pump cover.
Figure 127
Check that gear (5 - 17 Figure 126) and gear (7) are

not worn or damaged; otherwise, replace the com-
plete pump.
Check that valve (11, Figure 126) slides freely in its
seat without any scoring or pick–up. Also check
pressure–relief valve spring (10) against those indi-
cated in Figure 129, valve opening starts at: 6 bar;
valve opening ends at: 11 bar.
32663
OIL PUMP CROSS SECTION

Figure 129
Figure 128
32664 32665
PRESSURE–RELIEF VALVE CROSS SECTION MAIN DATA CONCERNING SPRING

ADJUSTMENT FOR THE CONTROL VALVE
EW–3–49
OIL FILTER COOLING SYSTEM

The engine is fitted with a double–action filter. Filter WATER PUMP
valve opening pressure is 2.5 + 0.2 bar. Water pump is of the centrifugal vane type.
Figure 130 Pump bearing (2, Figure 132) is solid with the blow-
ing spindle.
Water tightness between pump body (4, Figure 132)

and spindle (2) is obtained by means of a seal (5).
Bearing stop screw (3, Figure 132) must be sealed

in its seat with “LOCTITE 242’’.
Figure 132
32666
OIL FILTER CROSS SECTION
NOTE – When installing the filter proceed as follows:

– lubricate the seal with oil
– tighten the filter until the seal is in contact with its
rest base
– further tighten by 3/4 turn.
32668
COOLING WATER PUMP CROSS SECTION

1. Hub - 2. Spindle with bearing - 3. Screw -
4. Pump body - 5. Seal - 6. Cover - 7. Blower.
Oil pump assembly
Figure 131 NOTE – Check that pump body is not cracked or that
thre are no water leaks; otherwise replace the entire
pump.
THERMOSTAT
When the engine is cold, water flows from the top
part of the cylinder head and enters a filler pipe
where the thermostat inhibiting water circulation in
the radiator is located.
In this way, water will circulate between pump and
engine only, thus allowing fast heating of the water.
Thermostat valve starts opening at 80°C, allowing
water circulation through the radiator and simulta-
neously inhibiting direct return to the engine. Check
47298
efficiency of thermostat; if in doubt as to its correct
Fit the oil pump (3) and suction (1) and delivery (2) operation, replace it.
pipes.
EW–3–50
Carrying out engine assembly at work bench Figure 135

Figure 133
47299
- remove the plug (1) on the pump closing screw;
32669
Figure 136
Fit injection pump mounting (1).

Use an installer to fit connection joint (2). Remember
that joint engagement is by means of a double tooth
and a double space.
INJECTION PUMP INSTALLATION AND 32672

- fit tool 75301263 (2), together with dial gauge
TIMING (1), with rod positioned against the distributor
piston crown;
Mount the injection pump proceeding as follows: - preload the dial gauge by 3 mm;
- ensure perfect timing of valve system; - turn engine in the counter–rotation direction until
distributor piston reaches B.D.C. (gauge read-
ing);
- reset the gauge;
Figure 134
Figure 137
47300
- turn engine in the direction of rotation and have

notch 7° ± 0,5° (2), stamped on flywheel and
indicating injection advance, match the refer-
32670 ence index (1);
- in this condition, pump distributor should have
- use an installer to assemble the injection pump performed a 1–mm stroke. If this is not so, turn
(3) matching the double space inside the drive pump body about its axis until correct reading is
joint (1) with the double tooth on the bushing (2); obtained;
- lock pump fixing screws;
- tighten screws without locking them;
- remove tool 75301263 and re–tighten the plug
on the closing screw.
EW–3–51
47302 47286
Mount cover (1) for control toothed wheel. Mount the flywheel damper (1) and the driving pulley
(2).
47287/A 47285
Mount the water pump (2) and the thermostat group Mount the belt tensioning device (3), the water pipe
(1). (2) and the generator bracket (1).
Figure 140
Figure 143
47303
47304
Mount tool 75301432 on the engine flywheel in order
to lock it.
Mount the pulley (3) of the water pump; mount the
Mount hub (1) with the locking plate; tighten nut by
generator (1), the fan pulley support and the driving
means of torque wrench (2) to a tightening torque of
belts.
295 Nm, bend the locking plate (3).
EW–3–52
ADJUSTMENT OF THE DRIVING BELT Figure 145

TENSION: WATER PUMP – GENERATOR
AND FAN
Figure 144
47292
Turn the engine, insert the seals, spread some seal-

ing agents on the joints and the oil sump (1).
47714
Put the engine in its previous position rotating it by
180°.
1. Fan – 2. Belt tightener (3) – 3. Fan driving belt – Mount the injection valves and tighten the fastening
4. Driving shaft pulley – 5. Water pump – 6. nuts in two steps: pretightening at 9.9 Nm – final
Generator – 7. Generator driving belt. tightening at 22.5 Nm.
Mount the valve lifter cover (2) (Figure 146), the ex-
Adjust the tension of the new belts as follows: haust manifold (1), the turbocharger (4) with the re-
- rotate the driving shaft by two turns in order to lated pipes; screw a new oil filter (3), according to the
adjust the driving belts; instructions given at pag. 49.
- in the most convenient point for the operator, On the opposite side, NO TAG, mount the starter
apply tool 75301465 on the belt and check that motor (9), the suction manifold (13), the injector
the belt tension is 70 ÷ 80 daN. pump pipes (5), the flow plug tank (10) with the re-
If it is not, act on the belt tensioning device (2) lated pipes, the feed pump (8), connecting carefully
and/or the generator (6). and placing new seal rings; refit the support with the
fuel filters (12), the suction pipe (14); finally, on the
After 1 h of engine operation, check once again that front side, mount the fan (7), insert the accelerator
the tension still is 60 ÷ 70 daN; otherwise adjust the tie rod (11) on the injection pump (6).
belt tension again.
EW–3–53
Figure 146
47278/
Figure 147
47279/
EW–3–54
Lift the engine from the revolving stand for overhaul engine oil exchanger (2) following the connections
by means of an appropriate hoist and, on the fly- with the pipes, remount the sleeve for the oil level-
wheel side, if necessary, remove the flywheel clamp, gauge (3) and the engine supports (1). Then fill oil
then remove the brackets 75301426; remount the according to the indicated quantities.
Figure 148
47277
EW–3–55
TURBOCHARGER Figure 150

Description
The GARRET TA03 turbocharger consists of the fol-

lowing main parts: turbine wheel, central part, com-
pressor wheel and pressure relief valve (waste-
gate).
The turbine wheel is placed at the side of the central
part, the compressor wheel at the other. A shaft with
bearings connects the turbine wheel with the com-
pressor wheel and forms the rotation unit. The turbo-
charger uses the energy contained in the exhaust
gases of the engine.
During operation, the exhaust gases stream through
the turbine housing and rotate the turbine wheel.
The compressor wheel connected with the turbine
wheel by means of a shaft rotates with it. The com- 14185
pressor wheel takes in air under pressure, compres-
ses this air, and feeds it into the suction manifold of The turbocharger and the bearings are cooled and
the engine. lubricated by engine oil.
Figure 149
8862
TURBOCHARGER LONGITUDINAL SECTION

1. Compressor housing - 2. Locking plate - 3. Thrust bearing - 4. Rear support - 5. Self–locking nut - 6.
Compressor wheel - 7. Seal ring - 8. Seal ring support - 9. Seal ring - 10. Central body - 11. Safety spring
ring - 12. Bearing - 13. Peripheral seal ring - 14. Spring ring - 15. Turbine wheel.
EW–3–56
Necessary checks before dismounting the Figure 152

turbocharger from the engine
Before repairs at the turbocharger are carried out,
the following preventive checks are necessary.
Check that the oil feed pipe in the engine is not
blocked.
Check that the oil circulation is not prevented.
Check that the engine vent at the crankcase is not
blocked.
Check all seals and connection pieces.
Check that the air circulation is not prevented by
clogging of the air filter or of the pipes.
33676
Check the radial play of the rotating aggregate (2)

that should be equal to 0.08 ÷ 0,18 mm by means of
an indicating caliper with magnetic base provided
with a special extension piece.
DISMOUNTING
Figure 151
Figure 153
8865
The turbocharger has to be carefully cleaned out-

side by means of anticorrosion or antirust fluids. Fix
the turbocharger in the vice.
Check the axial play of the rotating aggregate (2) by
means of an indicating caliper (1) with magnetic
base; the axial play will be equal to 0.025 ÷ 0.10 mm.
Mark the position of the compressor housing and the
turbine housing referred to the central part; loosen
the screws and remove the housings.
32677
NOTE – In case of dismounting and remounting of the
turbocharger parts, the work bench must be carefully Fix the shaft end (3) in the vice and detach the self–
cleaned. locking nut (2) by means of a suitable wrench (1).
EW–3–57
33584
33678
Pull off the thrust bearing (1) together with the
Pull off the compressor impeller (1). bracket for the spring ring (2) from the rear central
part (3).
Figure 155
33679
Pull off the central part (1) and the seal ring (2). Figure 158
Figure 156
33585
33680
Remove the spring ring (2) by round pliers (1) and
Mark the mounting position of the rear bearing (1) of extract the bearing (3) from the central part; repeat
the central part; unscrew the screws and remove the the same operation on the opposite side of the cen-
bracket (1) from the central part. tral part with the other bearing.
EW–3–58
Checks Figure 161
Clean carefully all parts of the turbocharger by

means of crude petroleum and a hard hair brush and
dry by means of compressed air.
Check that all parts are free from damages, cor-
rosion or wear.
Check in particular that:
Figure 159
33588
- the sealing rings (1, Figure 160) and (1

Figure 161) are not worn or broken; otherwise
replace them;
- the thrust bearing (1, Figure 157) and the
bracket (2, Figure 157) are free from furrows
and score grooves; otherwise replace them;
Figure 162
33586
- the blades of the compressor wheel are not

cracked, worn or warped; do not try to align
them, but replace the parts;
Figure 160 33589
- the bearings are free from score grooves or fur-

rows in the parts indicated by the arrows;
Figure 163
33587
- the blades of the turbine wheel are not cracked,

worn or warped; do not try to align them, but re-
place the part; 33681
- the turbine wheel shaft is free from score - the compressor housing and the turbine housing
grooves or furrows and that it is centered; other- must be free from furrows or wear in the seats of
wise replace the shaft; the rotating parts indicated by the arrows.
EW–3–59
Mounting Figure 166

Figure 164
33594
33592
Clamp the shaft/turbine wheel assembly (1), after
On the central part (3), mount the inner spring rings mounting the sealing ring (4) in the vice.
(2) in their seats by means of round pliers (1). Mount the sealing ring (2) and the central piece (3),
taking care not to damage the ring (4).
33593
Mount the bearings (1) and the outer spring rings. 33595
NOTE – Mount the seal ring. Mount sealing ring on the bearing (2), and insert the
The bearings must be lubricated with engine oil before thrust bearing (3) on the support; then mount these
mounting. to the impeller shaft: the positioning pins (4) must
cover the bores in the thrust bearing.
Mount the sealing ring (1).
Mount the spring at the rear bearing.
EW–3–60
33596 33597
Mount the rear bearing (1) on the central part (2): the Mount the central part at the locking device (3) of the
reference marks applied during dismounting must impeller.
cover each other; mount the locking plates, fix the Mount the compressor wheel (2), lubricate the self–
screws and bend the locking plates. locking nut slightly and tighten it to a tightening
torque of 0.23 kgm by means of a torque wrench (1);
tighten by a further quarter turn and check the pro-
jection of the shaft over the self–locking nut which
should be 0.140 ÷ 0.165 mm.
Check the axial play of the rotary unit.
Mount the compressor and turbine housings and
take care that the reference marks applied during
dismounting cover each other. Mount the locking
plates, tighten the screws and bend the locking
plates.
Lubricate the inner parts of the turbocharger with en-
gine oil after mounting.
EW–3–61
FUEL SYSTEM Figure 171
The fuel system consists of:

- air filter;
- fuel preliminary filter with manual suction pump;
- fuel filter;
- feed pump;
- Bosch injection pump VE with rotating distribu-
tor and speed control lock, ignition timing de-
vice, addition injection device and LDA device;
- pipes for high–pressure circuit;
- injection valves.
19195
NOTE – For a correct mounting, place spring (1) with

variable pitch in such a way that the windings (2) with
Figure 170 larger pitch are located at the side of the spring plate
(3).
Figure 172
19282
PARTS OF THE INJECTION VALVES 16689
1. Nozzle bracket – 2. Adjusting disk – 3. Spring –

4. Spring plate – 5. Distance piece – 6. Nozzle –
7. Fixing block.
CALIBRATION
Check and calibration of the injection valves (1) are

carried out by means of tool (2); the calibration value
Dismounting
should be equal to that shown in the table, otherwise
the adjusting disks must be replaced. Check further-
Clamp the injection valve into a vice, unscrew fixing
more that the liquid flows uniformly out of all nozzle
block (7) of the nozzle. Remove the nozzle (6), the
bores and check subsequently that at a pressure
distance piece (5) with the centering pin, the spring
slightly below calibration pressure no drop formation
plate (4), the spring (3) and put aside the adjusting
will occur.
disk (2) of the nozzle bracket (1). Check that the
parts are free from wear or breakage and replace
defective parts if necessary. For mounting, perform NOTE – Check and calibrate the injection valves as
the same operations carried out during dismounting described in S.I. 1094.
but in reverse order.
EW–3–62
INJECTION PUMP F = mechanical speed controller;

Marking 1100 = rpm of the pump;
L = clockwise direction of rotation;
V = rotary distributor piston; 761= variant of the pump type
E = size of pump;
4 = for 4–cylinder engines; Figure 174
12 = distributor piston diameter in mm;
BOSCH stock number

0 = product number;
460= product designation of rotary piston inj. pump;
4 = number of VE injection pump;
1 = piston number:
8 = 8 mm
9 = 9 mm
0 = 10 mm
1 = 11 mm
2 = 12 mm
3 = 13 mm
4 = 14 mm
30419
4 = number of feed connections;
054= serial number
Figure 173
30454
INJECTION PUMP LONGITUDINAL SECTION

1. Membrane – 2. Adjusting hub nut – 3. Feeler – 4. Control lever – 5. Speed controller – 6. Booster pump – 7.
Driving shaft – 8. Cam disk – 9. Injection adjuster – 10. Distributor piston – 11. Feed connection plate – 12.
Hydraulic head – 13. Control plate – 14. Control rod – 15. Counterspring.
EW–3–63
MODE OF OPERATION
NOTE – The parts listd in the text refer to Figure 176.
Feed step
Figure 175 The distributor piston (5) is lifted under the infuence
of the cam disk to the T.D.C. and rotates at the same
time around its own axis. By means of these two
movements, the fuel intake pipe (1) is closed and the
fuel in the compression chamber (2) is simulta-
neously compressed. The inner pipe (3) of the dis-
tributor piston is connected to pipe (4) thus making
it possible to feed the injection valves (6) with fuel.
19198
1. Fuel intake pipe - 2. Solenoid valve - 3. Axial

hub - 4. Compression chamber - 5. Fuel pipe
between pump element and injection valves - 6.
Distributor piston - 7. Bore for fuel cut–off - 8.
Slide valve - 9. Injection valve
The distributor piston (6) is placed at the B.D.C. and Figure 177
the slive valve (8) closes the bore for fuel cut–off (7).
The fuel is fed into the compression chamber (4) via
feed pipe (1) that is kept open by the solenoid valve
(2).
Delivery
Figure 176
19200
1. Fuel intake pipe - 2. Compression chamber - 3.

Feed pipe - 4. Pipe for fuel cut–off - 5. Slide valve
- 6. Distributor piston.
The distributor piston (6) opens the high–pressure

chamber by means of pipe (1) during its lift to the
T.D.C., thus compensating pressure between inner
19199
chamber of the distributor piston, feed pipe to the in-
1. Fuel intake pipe - 2. Compression chamber - 3. jection valves and inner chamber of the pump hous-
Inner pipe of distributor piston - 4. Fuel pipe ing.
between pump element and injection valves - 5. As this pressure is lower, to operate the injection
Distributor piston - 6. Injection valve. valve the fuel is cut–off.
EW–3–64
19201
6726
1. Piston - 2. Spring - 3. Connecting pin - 4. Coil

1. Fuel intake pipe - 2. Movable valve pin - 3. supporting ring - 5. Stop pin - 6. Connecting
Spring - 4. Solenoid valve - 5. Compression split–pin.
chamber.
The automatic injectino adjustment device is
The engine is stopped by disconnecting the starter mounted in the injection pump.
contact. It operates by means of the pressure of the fuel of the
The solenoid valve current is interrupted (4). By booster pump and is checked by the control valve.
means of the spring (3) the solenoid valve presses The fuel pressure lifts the piston (1), to which the
the movable valve pin (2) to the stop, and thus the spring (2) counteracts. The piston is connected to
fuel intake pipe (1) is interrupted. the split–pin (6) and the coil supporting ring (4) is
connected to the pin (3), in such a way that the axial
movement of the piston (1) is changed into a rotary
movement of the coil supporting ring (4).
The feed pressure increases with increasing speed,
so that the piston (1) is moved to the direction oppo-
site to the spring force (2); this spring keeps the pis-
Automatic injection adjustment ton in general in an injection retarding position.
Figure 179
18588
PARTS OF THE AUTOMATIC INJECTION

ADJUSTMENT
1. Piston - 2. Connecting pin - 3. Solid shim - 4.
Adjusting washer - 5. Spring
EW–3–65
Figure 181
6723
1. Starter lifter - 2. Leaf spring - 4. Slider - 5. Governor collar - 6. Solenoid valve -

7. Compression chamber
If the solenoid valve (6) is supplied with current, fuel (1) and the slider (4) into the additional feed position.
is fed into the compression chamber (7); in this case Thus the whole lift of the pump element is sued for
the governor weighs of the governor collar (5) are the feed to the injection valve.
closed; therefore the leaf spring (2) presses the lifter
Starting device disconnected
Figure 182
7148
1. Starter lever - 2. Leaf spring - 3. Tension lever - 4. Slider - 5. Governor collar -

6. Solenoid valve - 7. Ground
After starting of the engine, the governor collar (5) tension lever (3) and squeezes the leaf spring (2).
moves axially as a result of the centrifugal force Under these conditions the slider (4) is moved to the
caused by the expansion of the governor weights idling position.
(7), causes the starter lifter (1) to contact with the
EW–3–66
Load–dependent feed start (L.F.B.)
Figure 183
30434
DESIGN OF THE CONTROLLER WITH LOAD–DEPENDENT ADJUSTMENT OF FEED START

1. Control spring - 2. Governor collar - 3. Tension lever - 4. Starter lever - 5. Slider -
6. Distributor piston - 7. Control shaft - 8. Governor weights.
Description
The load–dependent adjustment of the feed start - Pump housing with a hole that is closed from
(LFB) enables a “smoother” engine operation (with outside by means of a ball that is connected to
reduced noise). the feed chamber.
The LFB device is realized by means of the following
changes: NOTE – The LFB device is calibrated only on the test
- Governor collar with an additional bore to the bench.
antipump bore.
- Controller shaft with a longitudinal hole and two
cross holes.
EW–3–67
Position of the governor collar in the LFB de- Mode of operation

vice
Figure 184 Irrespective of the position of the outer accelerator
pedal, the fuel feed is reduced, if the governor collar
(4) is displaced by the governor weights of the con-
troller by means of the centrifugal force in case of an
increase of the speed. For a smoother engine opera-
toin and a reduced fuel feed, pre–injection must be
reduced. As the injection adjustment device in the
rotary piston pump is a hydraulic device, the pres-
sure increase must be reduced in order to obtain a
decreasing pre–injection: this is obtained by means
of the LFB device.
If the governor collar (4) that runs on the controller
shaft (2) connects the bore (3) to the hub (6) and the
bore (7), a part of the diesel fuel under pressure is
fed via the pipe (1 and 5) into the feed chamber. This
fuel causes a reduced perssure increase in the
pump and a reduced pre–injection.
30435
a. Collar in idling position - b. Moving collar - c.

Collar in adjustment condition, inner pressure loss
- 1. Longitudinal hole in controller shaft - 2.
Controller shaft - 3. Governor collar cross hole - 4.
Governor collar - 5. Controller shaft cross hole - 6.
Edge from controller center - 7. Controller shaft
cross hole.
EW–3–68
L.D.A. device (load–dependent feed Figure 187

adjustment)
Figure 185
30455
Unhook return spring out of plate (1).
Figure 188
19202
Mode of operation
The L.D.A. device adjusts the fuel throughput irre-
spective of the air pressure in the suction manifold.
This air pressure acts upon the membrane (1) which
is rigidly connected to the controller pin (4). The
lower part of the controller pin (4) is provided with a
conical mounting (5) with a feeler pin (6).
By means of the axial displacement of the controller 26340
pin (4) the feeler pin (6) is also displaced and acts Detect the position of the reference notches be-
upon the stop lever (7). The stop lever rotates on its tween shaft (2) and lever (4).
own axis (8) and acts upon the controller disk in such Unscrew nut (3) and pull off lever (4) together with
a way the the fuel throughput is adjusted to the air plate (5) and controller lever (1) from the shaft.
quantity fed into the cylinders.
Dismounting of the injection pump Figure 189
Figure 186
26341
19203
Remove: spring plate (2), spring (3) and spring plate
Attach the injection pump (1) to the plate (2) of the (4).
adjustable bracket 75290239. Remove the fastening screws and dismount the
L.D.A. cover (1).
EW–3–69
26342
Mark the mounting position (←) of the membrane (1) 19209
referred to the cover (2).

Unscrew the hub nut (1) for spring load adjustment.
Remove the lead seal (3), the stop position pins (5)
and the max. supercharging throughput screw (4).
Remove the plugs (6). Figure 194
Figure 191
19210
Remove the sealing plug (2), and the vent screw (1);
19207
detach the fixing screws (3) of the cover to the pump
Turn and pull off the membrane (1) together with the housing.
adjustment pin (2).
19208
19211
Remove the pressure spring (1) of the membrane Dismount the cover (1) and extract the driving shaft
and the distance bush (2). (2) by means of pressing the bottom (arrow).
Remove the cover seal.
EW–3–70
19215
19212
Measure the distance between the upper bush end
Pull off the guide pin by means of a center punch and (1) and the cover surface. Detach nut (3), remove
pull off the stop lever (1). locking pin (2) and detach the guide bush (1) for the
controller pin.
19213 26345
Pull out the feeler pin (1) by means of suitable pliers. For removing the driving shaft (1) and the governor
lever, unhook the spring (4) out of the pin (3) to which
the spring plate and the idling spring are mounted
Figure 198 (2).
Figure 201
19214
Detach the hub nut (1) from the cover (5); then pull 26346
off the seal ring (2), the guide bush (3) and the seal Dismount the pressure increase control valve by
(4) by means of a suitable pulling–off device. means of wrench 75301451 (1).
EW–3–71
19220
19218
Take off the locking nut and the plane washer; screw Take off solenoid valve (1) and valve (2) with inner
off the governor shaft (1) by means of a hexagon spring.
socket wrench.
Figure 206
Figure 203
19221
Turn pump and screw off the plug of the hydraulic

19219 head by means of wrench 75301449 (1). Unscrew
Take out speed governor (1) and keep collar disk the 4 feed pipe connections (2).
and adjustment plate (2).
Figure 207
Figure 204
30341
26348
The speed governor (1) consists of the governor col- PARTS OF THE FEED PIPE CONNECTIONS
lar (4) with adjustment plug and locking clamp, collar 1. Pipe connection - 2. Spring support - 3.
disk (3) and governor weights (2). Adjustment disks - 4. Spring - 5. Valve seat - 6.
Ball - 7. Spring support with calibrated bore - 8.
Spring - 9. Valve housing.
EW–3–72
19223 19226
By means of wrench (1) screw off the fastening Take out the distributor piston (1) together with the
screws (2) of the hydraulic head. return springs (2), the slider (3), the spring plate (4),
and the condensating washers.
Figure 209
Figure 212
19224
Act upon the distributor piston (3) and pull out the hy-
19227
draulic head (1); the guide pins (4) and the pressure
springs (2) of the governor disk must remain in the By means of wrench 75291912 (1) screw off and pull
hydraulic head. out the fastening screws of the governor disk (2) and
extract it.
30343
19228
On the lower part of the hydraulic head, take out the Pull off the cam disk (2) together with the adjusting
spring plates (2) of the pump element return springs, screw (1) for feed start by means of suitable round
the distance washers, the guide pins (1), the pres- pliers.
sure springs (3) and the seal ring (4).
EW–3–73
18609
19229
Pull out coil supporting ring (1) but do not change the
Take out Oldham coupling (1) by means of round position of the coils in their seats.
pliers.
18623 19230
Take off the locking clamp (1) and locking pin (2) of By means of wrench (2) unscrew fastening screw (1)
the connection pin (3). and take off both covers of the injection adjuster.
18608
Press operating pin (2) of the injection adjuster in 19231
coil supporting ring (3) to inside. Pull out the whole injection adjuster (1).
EW–3–74
19232
Uscrew nut (1) for fastening of coupling (3) at the 19234

pump driving shaft; avoid rotation of coupling by Mount driving shaft, turn injection pumpand pull out
means of wrench 75296068 (2). the booster pump parts (2) together with the driving
shaft (1).
19233 18618
Pull off coupling from pump driving shaft by means Take off the toothed wheel (3) for driving of the speed
of pulling–off device 75297449 (1). controller and buffer (2) from the driving shaft (1).
Figure 222
CHECKS
Clean pump housing and the various dismounted

parts carefully with petroleum benzine.
Check if the parts are worn or cracked; check care-
fully if working surfaces have score grooves. Test if
springs are deformed or broken.
Replace damaged parts.
18611
Pull off driving shaft provisionally, screw off fasten-

ing screw of plate (1) for booster pump.
EW–3–75
Figure 225
NOTE – For correct mounting it is necessary to align
the eccentric ring (1, Figure 227), in such a way that
the transition opening (3, Figure 227) for the pressure
increase points to the cover and the bore (2,
Figure 227), which is recognized because the it is lo-
cated at a larger distance from the inner diameter of
the ring, points to the nameplate of the pump.
18614
Arrange pump housing on plate 75290239 (1).
Figure 226
Figure 228
18615
Mount seals (2) on pump housing by means of a

standard driving mandrel (1).
Figure 227
19235
PARTS OF THE BOOSTER PUMP

1. Driving shaft - 2. Buffer - 3. Controller driving
toothed wheel - 4. Compensation washer - 5.
Fastening washer - 6. Vance–cell booster pump -
7. Eccentric ring.
NOTE – In order to avoid jamming of the eccentric

rings during assembly it is necessary to provisionally
mount the following parts: driving shaft (1), toothed
wheel (3), controller drive, buffer (2), compensation
18616 washer (4), fastening disk (5), vane–cell booster pump
(6) and eccentric ring (7).
Mount eccentric ring (1) and corresponding booster
pump with blades (4) into pump housing.
EW–3–76
18617
19236
Take out the driving shaft and fix the fastening disk Mount connection pin into piston (1) and insert it into
(1) by means of the corresponding screws. its seat.
Mount key to driving shaft and insert this assembly
into the pump housing in such a way that the key
locks into its seat in the impeller. NOTE – The spring part of the piston must correspond
to the antipump bore in the pump housing.
Figure 230
Figure 233
18620
Mount operating pin (2) of the injection adjuster in its 18608
seat in the coil supporting ring (1). Press operating pin (2) into the connection pin of the
governor piston.
18623
18621
Insert locking pin (2) and corresponding locking
clamp (1) into connection pin (3).
Mount coil supporting ring (1) in pump housing.
EW–3–77
18624
18625
Mount seal rings (2) and flat cover (5). Arrange a
1–mm adjustment washer in spring seat and mount Place indicating caliper in tool 75301458 (2), and ad-
spring (3). Place adjustment washer (4) in the cover just it to zero on surface plate (1) with a pretension
hollow (1) and mount cover. of 6 mm.
NOTE – Exact adjustment washer quantity is deter- Figure 239

mined on the test bench.
Figure 236
19858
19237
Mount spring journal (5), adjustment washers (4),
Mount Oldham coupling (1) in its seat. spring plates (2) and springs (3) into the hydraulic
Figure 237 head (1).
Figure 240
18629
Place cam disk (1); the stop for pump element (2) 19859
must point to the notch in the driving shaft.
Mount the washer for adjustment of feed start (3). Mount the distributor piston (1) together with spring
plate (4) and collar disks (2 and 3) in hydraulic head.
EW–3–78
18627
26352
Place tool 75301458 as shown in the figure and

check. The controller washer with negative adjustment in-
creases the fuel feed for increased engine speed.
Figure 244
Figure 242
19238
Mount distributor piston (1) in the piston housing in

such a way that the milling at the piston foot locks at
the driving pin (2) of the cam disk.
Figure 245
23046
Without squeezing the springs, test if dimension KF

is 5.2 to 5.4 mm; otherwise replace adjustment
washers.
NOTE – Only one single adjustment washer must be

mounted to the guide journals.
19239
Place slider in distributor piston. Lubricating hole Mount controller disk (3) and place operating pin (2)
must be turned towards piston foot. into the fit (1) in the slider.
EW–3–79

Dimension ”K”
23047
After mounting of springs (3) in the spring plate and

20853
the pressure springs (2) in their seats, fit the hy-
Check dimension “K”, which must be 3.3 mm.
draulic head (1) in the pump element and insert it
into the pump housing. Fix the hydraulic head by
NOTE – The dimension K is the distance between the
means of four fastening screws which have to be
sealing surface of the head (2) and the surface of the
tightened at a tightening torque of 11 ÷ 13 Nm.
distributor piston (1).
Figure 247
Figure 250
26354
18625
If dimension “K” deviates from the prescription, the
Mount the indicating caliper in tool 75301458 (2), adjustment washer (2) below the foot (1) of the dis-
and adjust it to zero on the surface plate (1) with a tributor piston must be replaced.
pretension of 6 mm.
Figure 251
Figure 248
18633
Mount plug (3) with vent screw and tighten at a

26353
tightening torque of 60 ÷ 80 Nm; mount feed valves
and pressure pipe connections (2) and tighten them
Place the tool with indicating caliper (1) on the hy- at 35 ÷ 45 Nm. Mount solenoid valve (1).
draulic head (2).
EW–3–80
26356
Mount locking clamp (2) on plug (1) and insert them

into the adjusting bushing (3).
Figure 253 26357
Using a feeler gauge (2) check that the shaft end

piece of the controller (1) is placed at a distance of
3 mm from the pump housing flange.
Figure 256
30433
PARTS OF THE CONTROLLER GROUP

1. Fastening hub nut of the governor shaft -
2. Plain washer - 3. Governor shaft - 4. Adjusting
plate - 5. Compensation washer -
6. Housing governor group - 7. Weights - 8.
20893
Compensation washer - 9. Adjusting bushing.
Place in the housing of the controller group (6): the GOVERNOR SHAFT ADJUSTMENT
weights (7), the plain washers (5 and 8) and the ad- A=X3
justing bushing (9). The exact adjustment is carried out subsequently
at the test bench.
19240
19218 Using a feeler gauge (1), test the end play of the con-
Mount the shim (4, Figure 253) and the controller troller group (3). The clearance must be between
group in the pump housing. Screw in the shaft (1) 0.25 ÷ 0.45 mm between journal (2) and controller
about 3 mm. (3), otherwise replace adjusting washer.
EW–3–81
Check of pressure increasing control valve Figure 261
Figure 258
30668 19241
Using tool 75301445 (1) pull out the locking clamp Screw cover (3) provisionally to pump housing,
(1, Figure 259), extract piston (2, Figure 259) and screw down bush (1) in such a way that the distance
spring (3, Figure 259) out of valve housing (5, between the bush end and the cover surface is equal
Figure 259). to the dismounting distance and that the bore (2)
points to the bottom and the feeler pin seat (4).
Figure 259
Figure 262
26359
19242
PRESSURE CONTROL VALVE
1. Elastic locking ring - 2. Piston - 3. Spring - 4. Sealing Mount locking clamp (1).
ring - 5. Valve housing - 6. Sealing ring.
Check that the controller valve parts are not worn,
otherwise they must be replaced. Figure 263
Figure 260
19046
Place adjusting piston at the height of the valve 19243
housing by means of a center punch. Remount pres-
sure increasing controller valve and screw it down Screw down fastening nut and tighten it by means of
into the pump housing. torque wrench at 25 ÷ 30 Nm.
EW–3–82
19244 19246
Screw down adjusting groove nut (1) to bush until Insert indicating caliper (1) in tool 75301458 (2) and
stop. adjust it to zero with a pretension of 10 mm.
19245 19247
Using a feeler gauge (1), measure the distance be- Place indicating caliper (1) at membrane (2);
tween the groove nut (1, Figure 264) and the upper measure and note dimension “C”.
part of the cover; then unscrwe the groove nut (1,
Figure 264) in order to reduce the previously Figure 268
measured distance by 3 mm.
NOTE – The exact adjustment is carried out subse-

quently on the test bench.
Pre–adjustment of the adjustment screw for

the LDA device
This adjustment is carried out in order to avoid con-
tact between the membrane retaining disk and the
cover of the L.D.A. device.
19248
Using the indicating caliper (1) measure dimension

“F” at cover (2); the dimension must be “C-1 mm”.
EW–3–83
19249
19252
If dimension “F” does not correspond to the prescrip-
Dismount segment cover and membrane once
tion, it must be adjusted at screw (1) by means of a
again and mount subsequently the adjustment
hexagon socket wrench (2).
screw (2) and the spring (1).
Lift adjustment of the L.D.A. device
Figure 273
Figure 270
26360
Mount spring and membrane together with the gov-

ernor rod in such a way that the marks (1 and 2) ap-
19250 plied during dismounting coincide with each other.
Mount spring (2) and membrane (1) together with
adjustment rod. NOTE – In case of replacement of the membrane or
Figure 271 the cover look for the membrane postiion as described
below.
Figure 274
19251
Mount segments (2) without adjustment screw;

place feeler (1) at the membrane disk (3), pretension 30670
and adjust to zero. Press governor rod of the mem- Place tool 75301462 (3) at cover (1) with the bent
brane to the bottom and check maximum lift (L.D.A. tool part connecting the lever (2). The exact mount-
lift). Subtract the value that is to be read at the adjusting position of the membrane is determined by
ment table from the determined value (L.D.A. lift). means of turning the membrane and noticing a
The difference must be compensated by means of hardening caused by the contact of the conical part
an adjustment washer. of the shaft with the feeler pin.
EW–3–84
19253 19256
Mount cover (1) and fix with its screws. Using a hexagon socket wrench (2) screw down
plug (1).
19254
19257
Place groove nut (2), guide bush (1) together with
sealing ring and copper seal at a suitable tool and in- Take off cover (1) from the pump, mount stop lever
sert them into the pump housing. (3) and fix it to the cover by the guide pin (2).
19255 19258
Mount feeler pin (1) with the top oriented to inside. Screw down screws (1) at the side together with the
corresponding seals by means of a screwdriver.
EW–3–85
Adjustment of the starting dimension “MS” Figure 283

(only engine 8040.45)
Figure 281
26364
Place tool 75301462 (2) on the pump housing (3)

and fix it with screws (1).
Place feeler gauge (5) as represented in the figure,
30669 while the adjustment disk (4) of the pin (6) must still
Mount tool 75301462 on the cover (3). Put the mov- be in contact; check dimension “MS” .
able part (2) of the tool in contact with the super-
charger adjustment screw (4) and fix it in this posi- Figure 284
tion by the screw (5).
Using a feeler gauge (1) measure the distance be-
tween the milling work of the tool and the inner side
surface of the movable part (2): dimension “A”, e.g.
11.5 mm.
26356
For a different value, dismount controller group once

again out of the pump housing; remove plug (1) from
Figure 282 the adjustment bushing (3) and replace the plug with
a different one having adequate thickness. Remount
the controller group into the pump housing.
Figure 285
26363
Place screw (2) of tool 75301462 (1) in such a way

that the screw (2) projects referred to the inner side 30339
surface of the tool (1): dimension C, resulting from
C = A – B, where A is the previously–measured di- Mount the guide pin (3), the idling spring (5) and the
mension (11.5 mm), B is the distance between the spring plate (4) into the adjustment disk, then hook
screw center line (3) and the tool inner side surface the tension spring (2) and the driving shaft (1) to-
(1) and is equal to 9 mm, it follows that gether with the sealing ring and the compensation
C = 11.5 – 9 = 2.5 mm washer.
EW–3–86
19260 26340
Place seal (1) in its fit at the cover. Mount lever (4) together with plate (5) and operating
lever (1), in such a way that the reference notch
covers the one applied to the shaft (2) and fix the
Figure 287 lever by the nut (3).
26367
Mount cover (4), vent valve (1), the min. and max.
speed adjustment screws (2) and the max. throuhg- Figure 290
put adjustment screw (3).
Figure 288
19263
26341 Mount the key, the driving clutch (2), and the plain
washer; using the torque wrench (3) and tool
Mount the lower spring plate (4), the spring (3) and 75296068 (1), tighten the nut at 59 Nm.
the upper spring plate (2) at the shaft.
EW–3–87
IVECO ENGINEERING N. 99466254 Ed. 1

ROTARY INJECTION PUMP – TEST VALUES
Injection pump: VE4/12F1100L761 IVECO P.N.: 99459163
Speed governor: ANY SPEED BOSCH P.N.: 0460 424 159
Engine: 8045.25.282
Injection pump timing:
– Static setting (Ref. outlet “A”) 7 ± 0.5 degrees before (X) after ( ) T.D.C. with pump plunger positioned on
start of delivery at 1 mm from B.D.C.
– Or: with engine piston at T.D.C. and injection pump plunger positioned on start of delivery at 1 mm from
B.D.C
– Engine idling speed: 950 ± 25 revs/min.
TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS

CONPLYWING WITH ISO STANDARDS 4008/1 – /2
– Direction of rotation: Clockwise – Feed pressure. bar: 0.35

Counterclockwise X – Burette draining time: 30”
– Pipings: 6X2X450 – Test fluid: ISO 4113
– Injectors: 1.688.901.027 – Temperature: Increase
– Pastille with calibr.’ed hole: d=0.5 mm Decrease X
– Injector setting bar bar: 250 – Thermometer: 40
– Backflow nwcks: d= 0.55 mm – Electronic:
“ADJUSTMENT VALUES OF THE INJECTION PUMP”

“THE NUMBERS GIVEN IN BRACKETS SHOULD BE USED ONLY AS TEST VALUES”
1 – START OF DELIVERY 5 – DELIVERY AT FULL LOAD WITHOUT

Pre–lift SUPERCHARGING PRESSURE
(from B.D.C.) mm: 0 Speed rpm :500
2 – ADVANCE VARIATOR STROKE Delivery for 1000 shots cc :70.1±0.5
Speed rpm :1180 Max imbalance cc :
Supercharging press. hPa :1000 6 – IDLING SPEED ADJUSTMENT
Adjustments values mm :1±0.2 Speed rpm :425
3 – TRANSFER PUMP PRESSURE Delivery for 1000 shots cc :21±2.0
Speed rpm :1180 Max imbalance cc :3.5
Supercharging press. hPa :1000 7 – RESIDUAL DELIVERY ADJUSTMENT
Adjustment values bar :7.8±0.3 Speed rpm :
4 – DELIVERY AT FULL LOAD WITH Delivery for 1000 shots cc :
SUPERCHARGING PRESSURE 8 – PEAK SPEED ADJUSTMENT
Speed rpm :800 Speed rpm :1190
Supercharging press. hPa :1000 Supercharging press. hPa :1000
Delivery for 1000 shots cc :87±0.5 Delivery for 1000 shots cc :25.1±5.0
Max. imbalance cc :3.5
EW–3–88

9 – STARTING .2 Speed rpm :1100
Speed rpm :100 Supercharging press. hPa :1000
Delivery for 1000 shots cc :120±20 Backflow cc/10s :52...108
Min. delivery cc :100 delivery cc/10s :(38...122)
10 – “LFB” CALIBRATION 14 – PROGRESS OF DELIVERY RATES
Speed rpm : AND ADJUSTMENT
Supercharging press. hPa : .1 Speed rpm :650 (*)
.1 Delivery difference Supercharging press. hPa :350
for 1000 shots mm : Delivery for 1000 shots cc :80.3±0.5
.2 Transfer pump pressure cc :(±3)
difference bar : .2 Speed rpm :1250
Supercharging press. hPa :1000
Delivery for 1000 shots cc :1.5±1.5
11 – INJECTION ADVANCE PROGRESS
cc :(±3)
.3 Speed rpm :1190
.1 Speed rpm :1180
Advance stroke mm :1±0.2
mm :(±0.5)
cc :(±8)
.2 Speed rpm :1250
.4 Speed rpm :1160
Advance stroke mm :1.6±0.3
mm :(±0.3)
Delivery for 1000 shots cc :57.2±3
.3 Speed rpm :
cc :(±6)
Advance stroke mm :
.5 Speed rpm :1100
mm :
.4 Speed rpm :
Advance stroke mm :
cc :(±3,5)
mm :
.6 Speed rpm :800
Pressione sovral. hPa :1000
12 – TRANSFER PRESSURE PROGRESS Delivery for 1000 shots cc :87±0.5
Supercharging press. hPa :1000 cc :(±3)
.1 Speed rpm :1180 .7 Speed rpm :500
Transfer pump Supercharging press. hPa :0
pressure bar :7,8±0,3 Delivery for 1000 shots cc :70.1±0.5
.2 Speed rpm :500 cc :(±3)
Transfer pump .8 Speed rpm :
pressure bar :3,6±0,3 Supercharging press. hPa :
.3 Speed rpm : Delivery for 1000 shots cc :
Transfer pump cc :
pressure bar : .9 Speed rpm :
.4 Speed rpm : Supercharging press. hPa :
Transfer pump Delivery for 1000 shots cc :
pressure bar : cc :
13 – DELIVERY ON BACKFLOW VALVE .10 Speed rpm :
.1 Speed rpm :500 Supercharging press. hPa :
Supercharging press. hPa :0 Delivery for 1000 shots cc :
Backflow cc/10s :41...75 cc :
delivery cc/10s :(35...80)
EW–3–89

15 – ZERO DELIVERY (STOP) 19 – SETTING AND CHECKING THE
.1 Mechanical: POTENTIOMETER
Speed rpm :425 Supply volt :
Delivery for 100 shots cc :1.5±1.5 Setting :
Voltage volt :0 Speed rpm :
.2 Electrical: Delivery for 1000 shots cc :
Speed rpm : Potentiometer
Delivery for 100 shots cc : output voltage volt :
Voltage volt : Check:
Speed rpm :
16 – DELIVERY AT IDLING SPEED
Delivery for 1000 shots cc :
.1 Speed rpm :425
Potentiometer
Delivery for 100 shots cc :21±2.0
output voltage volt :
cc :(±4)
.2 Speed rpm :500 20 – EGR MICROSWITCH SETTING
Delivery for 100 shots cc :1.5±1.5 Speed rpm :
cc : Supercharging press. hPa :
Delivery for 1000 shots cc :
.3 Speed rpm :400
Delivery for 100 shots cc :50±4.0
cc :(±6) 21 – GLOW PLUG MICROSWITCH
.4 Speed rpm : ADJUSTMENT
Delivery for 100 shots cc : contact closed at:
cc : of the injection pump
Residual delivery check: lever stroke
.5 Speed rpm : 22 – STOP ELECTROMAGNET
Delivery for 100 shots cc : Min. operating
voltage volt :20
17 – “LFB” CHECK
Nominal voltage volt :24
Speed rpm :
Supercharging press. hPa : 23 – FITTING AND SETTING MEASUREMENTS
.1 Delivery difference Description:
for 100 shots cc : K mm :3.3
Delivery stroke KF mm :
difference mm : MS mm :0.4
SVS max. mm :
.2 Delivery for 1000 shots cc :
MS1 mm :
Delivery stroke
Ya mm :38.2...40.2
difference mm :
Yb mm :45.9...51.1
18 – AUTOMATIC STARTER EXTRA TLA–E mm :
DELIVERY Devices:
.1 Speed rpm :100 HBA STROKE mm :
Delivery for 1000 shots cc :120±20 LDA STROKE mm :5.5
cc :100 min. KSB LEVER :
.2 Speed rpm :280 KSB REG. rpm :
Delivery for 1000 shots cc :77±5 KSB TRANSFER bar :
cc :82 max. KSB ADVANCE mm :
.3 Speed rpm :160 KSB H.P. ADVANCE DEGREES:
Delivery for 1000 shots cc :130±20 KSB VALVE VOLT :
cc :110 min.
EW–3–90

NOTES:
1) Entries with no alphanumeric values refer to different injection pump types.
2) Follow instructions given in the Iveco Technical Publications and Training no. XXXXXXXXX to carry out cor-
rect pump adjustment at the electrical test bench.
3) Measurements carried out on injection pumps fitted with “KSB” must be taken with KSB unit off.
4) (*) LDA setting point: tighten/slacken spring pre–loading adjustment nut.
5) After any variation in LDA pressure, actuate the control lever.
6) To adjust the starting point (ARF valve) insert a spacer (12.0 mm) in connectino with the 3rd delivery stop.
SECTION 4 EX215
REMOVAL & INSTALLATION

EX215 ENGINE
INDEX
Removal . . . . . . . . . . . . . . . . . . . . . . . . EW–4–1
Installation . . . . . . . . . . . . . . . . . . . . . EW–4–6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . EW–4–7
EW–4– 1
REMOVAL
Park the machine on a level surface and lower the

bucket to the ground
! CAUTION
Keep people not involved in the maintenance
work outside the working area. Wear adequate
personal clothes and glasses with side shields as
a protection against flying debris. 1
! WARNING
The hydraulic oil reservoir is under pressure. 2
Press the pressure relieve button (1) on the filler
plug to relieve pressure before maintenance.
Danger of personal injuries.
Remove cover (2) and remove hydraulic oil using

a suction pump. Loosen the drain plug on the res-
ervoir bottom side, allowing oil to flow out into a
suitable container.
NOTE: Hydraulic oil quantity approximately is 200

liters
! CAUTION
The engine reaches high working temperatures.
Therefore, it is necessary to let the machine cool 3
down prior to carrying out this operation.
Remove the lower cover (3) located under the en-

gine, and the lower cover (4) located under the
radiator.
Remove the engine hood; remove support (5)

complete of the muttler guard from the hydraulic
pumps room. 5
EW–4– 2
! CAUTION 6
Always disconnect the negative (–) ground ter-
minal first and reconnect it last.
Remove the batteries cover (6) to allow the dis-

connection of the cables.
Disconnect the ground braid located on frame

near to left rear engine mounting.
! CAUTION 7
— Pressure fluid. Turn the cap slowly (7) before
removing it completely to relieve pressure. Do
not loosen the radiator cap when the engine is 8
hot to avoid burn hazard.
— Do not perform this operation when the ma-
chine is still hot. Contact with engine coolant at
working temperature may cause burns and
personal injuries.
10
Close the cab heater taps located on the engine,
then disconnect the related hoses from engine
side.
Drain the engine coolant from radiator, by open-

ing the drain tap (9) located on the bottom side of 9
the radiator.
Disconnect the input and output coolant engine

hoses from the radiator side and the small
breather hose (8) from the engine side.
NOTE: Engine coolant quantity approximately is 19

liters.
Disconnect the pipe (10) connecting the air filter

to the turbocharger loosing the relate hose
clamps.
Disconnect the EC motor tie rod (11) and the

sheath fixing (12) from the bracket.
12 11
EW–4– 3
Remove the fan wire net guard (13).
13
Disconnect the fuel supply hoses (14) from injec-

tion pump.
14
Disconnect the fuel return hoses (15). 15

EW–4– 4
AIR CONDITIONER
! CAUTION
The air conditioning system hoses contain re-
frigerant gas under pressure. Wear adeguate pro-
tective clothes, gloves and glanes with side
shields, prior to operate on the system.
If the excavator is equipped with air conditioning sys-

tem, it is required to carry on the gas discharge from
the system, using a proper special tool for the gas re-
covery.
Clean accurately the surrounding area of the hoses
on the compressor.
Disconnect the hoses and protect the compressor
and hoses fitting with caps to avoid the admittance
of foreigh objects or dirt into the system.
IMPORTANT: Absolutely avoid the admittance of

foreign objects into the air conditioning system.
ELECTRICAL CONNECTIONS
Disconnect the following electrical connectors:
— Fuel filter heating temperature sensor (if in-

stalled)
— Fuel filter heater (if installed)
— Engine coolant temperature sensor on engine

cylinder head
— Engine coolant temperature sensor on coolant

pump housing
— Intake air heater temperature sensor on en-

gine cylinder head, behind fuel filter.
— Flame glow plug on air intake piping.
— Intake air heater fuel solenoid valve.
— Engine oil level switch on oil pan (injection

pump side).
— Engine oil pressure switch on engine block (al-

ternator side).
— Engine stop solenoid on injection pump.

Disconnect the electrical wires from starter motor
and from alternator
EW–4– 5
HYDRAULIC PUMPS
Disconnect the suction pipe (16) from the hy-
draulic main pumps.
Disconnect the delivery hoses (17) from the hy-

draulic main pumps. 17
Disconnect the suction and delivery hoses (18)
from pilot pump.
16
Disconnect the electrical connector of the pres- 18 19

sure sensors (19) from the hydraulic main pumps.
Remove the screws (20) to free the two hydraulic

clampers from the frame. 20
Disconnect the main pump regulators hoses (21)
and (22).
Disconnect the N sensor connector (23), on

pumps transmission housing. 22 21 23
ENGINE/PUMPS ASSEMBLY LIFTING

Attach a lifting hook and set the hoist to a tension.
NOTE: Total weight of engine and hydraulic pump

assembly approximately is 716 kg.
! CAUTION
Check that the hoist ropes are securely anchored
and that the anchor point is sufficiently strong to
sustain the load to be lifted. Keep any person
away from ropes or chains anchor point.
Unscrew the bolts on front (24) and rear (25) en-

gine mounts.
Hoist up the engine assembly complete with hy-

draulic pumps.
24
25
EW–4– 6
INSTALLATION
For the engine/pumps assembly installation
make reference to the procedures previously de-
scribed for the removal, but proceeding step by
step in opposite way.
TIGHTENING TORQUES
Front engine mounts:

29 mm
Rear engine mounts:

30 mm
Hydraulic pump hoses:

19 mm, 22 mm, 27 mm, 36 mm
Tightening torque:
29 Nm (21 lbf.ft), 49 Nm (36 lbf.ft),
93 Nm (68 lbf.ft), 69 Nm (51 lbf.ft)
Socket wrench dimension (Exagonal socket bolt):
8 mm, 10 mm
Tightening torque:
49 Nm (36 lbf.ft), 108 Nm (80 lbf.ft)
Hydraulic damper fixing screws:

19 mm
Wire net fan guard:

13 mm
Hood and cover:

Spanner wrench (Exagonal head bolt): 17 mm
Hydraulic oil fitting cap:

17 mm
EW–4– 7
FILLING
FILLING CHART Model EX 215

RECOMMENDED FLUIDS AND LUBRICANTS
COMPONENT TO BE QUANTITY
FILLED Litres MANUFACTURER’S INTERNATIONAL
AMBRA NOTES
SPECIFICATIONS SPECIFICATIONS
Protective fluide to
be mixed with
water at 50%.
This mix has ani-
Engine cooling system 19 AGRIFLU NH 900 A – corrosive, antiscal-
ing, and antifoam-
ing properties; does
not freeze down
to –35°C
Diesel fuel ASTM
Fuel tank 285 – – –
N. 2–D type TT
SUPER GOLD
NH 330 G API CF–4/SG
15W–40
Engine 13 7
13.7 CCMC D4 –
SUPER GOLD MIL–L–2104 E
NH 324 G
10W–30
Hydraulic pump reduc.
unit 1 SUPER GOLD
NH 330 G
15W–40
Swing reduction unit 8.2 API CF–4/SG
Travell reduction
T d ti unitit CCMC D4 –
Type A (each) 4.5 MIL–L–2104 E
SUPER GOLD
NH 324 G
Travel reduction unit 10W–30
Type B (each) 5.5
Attachment hydraulic
200 HI–TECH 46 QFH 583/HD – –
system
EW–4– 8
FUEL SYSTEM AIR BLEEDING

3 1
The fuel system air bleeding should be performed
with fuel tank filled up.
Proceed the bleeding air as follows:
— Loosen the bleed screw (1) to allow air to bleed;
— Repeatedly press the button (2) located on the

priming pump to circulate fuel inside the fuel sys-
tem;
— Continue priming until a minimum amount of fuel

free of bubble comes out of the loosened bleed
screw (1) then close the screw;
— Repeat this operation for bleed screw (3). 2
Handle and dispose of used fuel filters

according to current regulations. Use
only authorised disposal procedures. If
in doubt, contact authorities concerned.
EW–4– 9
FILLING THE COOLING SYSTEM

1
Fill the cooling system as follows:
— Ensure that the tap (1) on the radiator is closed

and tap (2) on the engine is open;
— Slowly pour in coolant (see the FILLING CHART)

through the filler neck (3) until correct level is ob-
tained between the FULL and LOW marks on the
header tank (4);
— Refill the hydraulic oil system (refer to page

EW–4–10);
— Start the engine and let it run for at least 15 min-

utes. Check coolant level again on the header
tank (4). If low, top up to correct level.
3
4
EW–4–10
HYDRAULIC SYSTEM OIL REFILLING
Pour oil of the type, grade and quantity specified

(see the FILLING CHART) through the hole of
plug (1) until oil level is between the MIN and MAX
marks on the sight glass.
Install cover (1) ensuring that the filter and rod as-
sembly is correctly positioned. Tighten the bolts
to the torque of 50 Nm (37 lbf.ft). 1
IMPORTANT: Should the hydraulic pump remain
without oil, it would be damaged in a few seconds
after engine start–up.
Remove the pump air breather plugs (2).
Refill pumps with hydraulic oil through the holes

of plugs.
2
Reinstall plugs.
Start the engine and let it run to idle.
Ensure that the safety lever is in the LOCK posi-

tion.
Slowly release the air breather plugs (4) to let out

trapped air. Tighten the plugs as soon as air stops
being released and oil starts coming out from the
plug holes.
Bleed air from the hydraulic system by letting the

engine idle and moving all control levers slowly
and gently for 15 minutes. Note that the pilot con-
trol circuit is fitted with an air relief device. There-
fore, air in the pilot control circuit is automatically
bled when this operation is carried out.
Fully retract the arm cylinder and fully extend the

bucket cylinder.
Lower the bucket to the ground.
Switch off the auto–idle.
Stop the engine. Remove the ignition key from the

key–start switch.
Move the safety lever to the LOCK position.
Check the sight glass on the hydraulic oil reser-

voir. Should it be necessary to add more hydraulic
oil, remove cover and top up.
Handle and dispose of hydraulic oil and

filters according to current regulations.
Use only authorised disposal procedure.
If in doubt, contact authorities con-
cerned.
SECTION 5 EX215
CONTENTS
Specifications and data . . . . . . . . . . . . . EW–5–3 Replacement of engine flywheel
Fitting data . . . . . . . . . . . . . . . . . . . . . . . . EW–5–6 toothed wheel . . . . . . . . . . . . . . . . . . . . . . EW–5–32
Tightening torques . . . . . . . . . . . . . . . . . EW–5–12 Mounting of engine flywheel . . . . . . . . . . EW–5–32
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–15 Connecting rod–piston assembly . . . EW–5–32
Stripping down the engine in the Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–33
workshop . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–17 Piston diameter measurement . . . . . . . . EW–5–33
Repairs Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–33
Cylinder block Check of correct fit between
Checks and measurements . . . . . . . . . EW–5–22 piston pin and piston . . . . . . . . . . . . . . . . . EW–5–33
Replacement of cylinder liners . . . . . . EW–5–23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . EW–5–34
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–24 Connecting rods . . . . . . . . . . . . . . . . . . . EW–5–35
Bushes – valve lifters . . . . . . . . . . . . . . . EW–5–24 Check of rectangularity of
Cam pitch and bearing journal connecting rod . . . . . . . . . . . . . . . . . . . . . . EW–5–36
alignment check . . . . . . . . . . . . . . . . . . . EW–5–24 Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–36
Driven toothed wheel Mounting of connecting rod – piston
replacement . . . . . . . . . . . . . . . . . . . . . . . EW–5–24 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–36
Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–25 Connecting rod–piston mating . . . . . . . . EW–5–36
Bush replacement . . . . . . . . . . . . . . . . . . EW–5–25 Mounting of piston rings . . . . . . . . . . . . . . EW–5–37
Valve lifters . . . . . . . . . . . . . . . . . . . . . . . . EW–5–26 Adjustment of the mounting clearance
Replacement of valve lifters . . . . . . . . EW–5–26 of the connecting rod journals . . . . . . EW–5–38
Mounting of valve lifters – Mounting of connecting rod covers . . . . EW–5–38
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–26 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–38
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–27 Check and replacement of the
Main and connecting rod transmission gear wheel . . . . . . . . . . . . EW–5–38
bearing journals . . . . . . . . . . . . . . . . . . . EW–5–28 Replacement of bush for
Check of main bearing journal transmission gear wheel . . . . . . . . . . . . EW–5–39
alignment . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–29 Mounting of the transmission gear wheel
Replacement of driving toothed wheel and adjustment of the steering . . . . . . . . EW–5–39
steering and oil pump . . . . . . . . . . . . . . EW–5–29 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW–5–40
Mounting of main bearings . . . . . . . . . EW–5–30 Tightness check . . . . . . . . . . . . . . . . . . . . . EW–5–40
Crankshaft end play check . . . . . . . . . . . EW–5–30 Dismounting of valves . . . . . . . . . . . . . . EW–5–40
Rear flywheel cover . . . . . . . . . . . . . . . . EW–5–32 Check of cylinder head bearing surface
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW–5–32 on cylinder block . . . . . . . . . . . . . . . . . . . . EW–5–40
CONTENTS
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–41 Injection pump installation and
timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49
Removal of incrustration and valve
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–41 Adjustment of the tension of control
belts: water pump – generator and
Valve grinding . . . . . . . . . . . . . . . . . . . . . . EW–5–41 fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–50
Check of clearance between valve Turbocharger . . . . . . . . . . . . . . . . . . . . . . EW–5–53
spindle and valve stem guide . . . . . . . . . EW–5–41 Description . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–53
Necessary checks before dismounting
Valve stem guide . . . . . . . . . . . . . . . . . . . EW–5–41
the turbocharger from the engine . . . . . . EW–5–53
Boring of inner surfaces Dismounting . . . . . . . . . . . . . . . . . . . . . . . EW–5–54
of valve stem guides . . . . . . . . . . . . . . . . . EW–5–42 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–55
Remounting of valves . . . . . . . . . . . . . . . . EW–5–43 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–57
Fuel system . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Mounting of cylinder head . . . . . . . . . . . . EW–5–43
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Mounting of valve lifter shaft and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
adjustment of working clearance
between valves and valve lifters . . . . . . . EW–5–45 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Injection pump with RSV
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW–5–46 speed governor . . . . . . . . . . . . . . . . . . . . EW–5–60
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–46 L.D.A. device (delivery adjustment
as a function of load) . . . . . . . . . . . . . . . . EW–5–60
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–48
Pump marking . . . . . . . . . . . . . . . . . . . . . . EW–5–60
Oil pump assembly . . . . . . . . . . . . . . . . . . EW–5–48 Speed governor marking . . . . . . . . . . . . . EW–5–60
Cooling system . . . . . . . . . . . . . . . . . . . . EW–5–48 Speed governor . . . . . . . . . . . . . . . . . . . . . EW–5–60
High–pressure pumping elements . . . . . EW–5–60
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW–5–48
Delivery valves . . . . . . . . . . . . . . . . . . . . . . EW–5–61
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49 Pressure control valve assembly . . . . . . EW–5–61
Carrying out engine assembly at Fuel injector units . . . . . . . . . . . . . . . . . . . EW–5–61
work bench . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49 Calibration tables . . . . . . . . . . . . . . . . . . . . EW–5–63
EW–5–3

SPECIFICATIONS AND DATA
Type 8065.25.085
Cycle Diesel, 4 stroke, direct injection
Turbocharged
turbocharged with aftercooler
Number of cylinders 6, in line
∅
Diameter mm 104
Stroke mm 115
+ + + ... Total displacement cm3 5861
Compression ratio 17.7
Max. output KW
107
CEE 80/1269 (HP)
(145)
rpm
2150
Max. torque Nm
558.6
(Kgm)
(60)
rpm
1600
Min. idling speed rpm 850 ± 25
Max. idling speed rpm 2400 ± 25
T.D.C. pressure * bar

≥ 26
Min. permissible T.D.C.
pressure * bar
bar ≥ 19
Engine motoring over
speed rpm ≈ 260
(*) The pressure value is measured by rotating the enging by the starter only, with oil temperature at 40o – 50o C and
injection pump at shut–off.
EW–5–4

8065.25.085
A TIMING SYSTEM
start, before T.D.C. A

12o
finish, after T.D.C. B
31o
B
C
50o
start, before B.D.C. D
16o
finish, after T.D.C. C
D
Timing check
mm 0.45
X
mm 0.45
X
Working clearance (*)
mm 0.25 ÷ 0.35
X
mm 0.25 ÷ 0.35
(*) Further adjustment to be performed when reading is
other than 0.15 to 0.45 mm
FUEL SYSTEM By feed pump – injection pump – filters – injectors –
thermostarter
Type PES6A90D410RS2757
α
Pump setting 18o ± 0.5o
X
Beginning of delivery mm 2.25 ÷ 2.35
DLLA 132S1320
Nozzle type
Injection order
– injection pump A–B–C–D–E–F

– engine 1–5–3–6–2–4
bar
Injection pressure bar 260+12

EW–5–5

8065.25.085
TURBOCHARGING
Turbocharger type GARRETT TO 4E 36
LUBRICATION SYSTEM Forced feed by gear pump, relief valve, dual action
oil filters
Oil pressure (warm engine):

bar
– at idle bar >1.2
– at peak speed bar >3.5

Via centrifugal pump, thermostat, fan radiator,
COOLING SYSTEM
heat exchanger
Water pump control By V–belts
Thermostat
– opening start 79o ± 2o C
– max. opening
OIL FILLING
Total capacity at 1st filling

litres 12.6
Kg 14.2
Quantity at periodical
replacements:
– engine sump
litres 9.3
Kg 10.5
– engine sump + filter

litres 11.1
Kg 12.5
EW–5–6

FITTING DATA
CYLINDER BLOCK AND CRANK MECHANISM 8065.25.085

mm
∅1
Cylinder sleeve bore ∅1 106.85 ÷ 106.90
Cylinder sleeve:
L 106.94 ÷ 106.97
Outer diameter ∅2
198.00 ÷ 198.50
Length L
∅
2
0.04 ÷ 0.12
housing
Outer diameter ∅2 0,2
∅3
Cylinder sleeve
X
Inner diameter ∅3 104.000 ÷ 104.060
Sleeve protrusion X
∅1 Pistons:
X Oversize dimension X 12
∅ Outer diameter ∅1 103.870÷103.852

2 Pin bore ∅2 38.000÷38.006
Piston – cylinder sleeve 0.130÷0.170
Piston diameter ∅1 0.4 – 0.6 – 0.8
X
Piston protrusion X 0.64 ÷ 0.97
∅3 Piston pin ∅3 37.984 ÷ 37.990
Piston pin – Pin clearance 0.010 ÷ 0.022
X1 X1 3.20 ÷ 3.23
X2
Piston ring grooves X2 2.55 ÷ 2.57
X3
X3 4.03 ÷ 4.05
EW–5–7

8065.25.085
mm
S1 S1 2.932 ÷ 2.963
S2
Piston rings S2 2.490 ÷ 2.478
S3
S3 3.990 ÷ 3.975
1 0.537 ÷ 0.598
Piston ring – grooves 2 0.060 ÷ 0.092
3 0.040 ÷ 0.075
Piston rings 0.4 – 0.6* – 0.8
Piston ring gap in

X1 cylinder sleeve: 0.20 ÷ 0.35
X2 X1
0.60 ÷ 0.85
X3 X2
0.30 ÷ 0.55
X3
∅1 Small end bushing

bore diameter ∅1 41.846 ÷ 41.884
Big end bearing 67.407 ÷ 67.422

∅2 diameter ∅2
∅4
Small end bushing
∅3 Outer dia. ∅4 41.979 ÷ 42.017
Inner dia. ∅3 38.004 ÷ 38.14

S
Big end half – bearings S 1.805 ÷ 1.815
Small end bushing – housing 0.095 ÷ 0.171
Piston pin – bushing 0.014 ÷ 0.031
Big end half – bearings 0.254 – 0.508
Measuring dimension X
125
Max. connecting rod
axis misalignment
tolerance
0.07
* Oil scraper only

EW–5–8
8065.25.085
mm
∅1 ∅2
79.791 ÷ 79.810
Main journal diameter ∅1
63.744 ÷ 63.725
Crankpin diameter ∅2
2.169 ÷ 2.178
Crankshaft bearings S1
S1 S2
1.805 ÷ 1.815
Big end bearing thickness S 2
Main bearings ∅3
∅3 84.200 ÷ 84.230
Half–bearings – journals 0.082 ÷ 0.153
Crankshaft bearings 0.254 – 0.508
Main journal length X1

32.0 ÷ 32.1
X1
Main bearing width

between thrust washer 25.010 ÷ 25.060
seats X2
X2
X3 Thrust washer
3.378 ÷ 3.429
thickness X3
Crankshaft end float 0.082 ÷ 0.334
Thrust washers 0.127 – 0.254 – 0.508
1 2 1 ≤ 0.10
Alignment
2 0.03
Ovalization 1–2 0.015
Taper 1–2 0.012

EW–5–9
CYLINDER HEAD 8065.25.085

mm
∅1
Diameter of valve guide

housing ∅1 13.950 ÷ 13.983
∅2
∅2 8.023 ÷ 8.043
Valve guide
∅3 13.993 ÷ 14.016
∅3
Valve guide and housing 0.010 ÷ 0.066
Valve guide 0,2
∅4 Valves:
∅4 7.985 ÷ 8.000
60o 30’ ± 7’
α
∅4 7.985 ÷ 8.00
45o 30’ ± 7’
α α
Valve stem and guide 0.023 ÷ 0.058
Valve seat on cylinder head
∅1
–
∅1
∅1 39.000 ÷ 39.025
Valve seat outer diameter;

Valve seat angle on
∅ 2 cylinder head:
∅2
–
α 60o ± 5’
∅2
α 39.136 ÷ 39.161
α 45o ± 5’
Valve fitted depth in 0.7 ÷ 1

X cylinder head X
Between valve seat and

0.111 ÷ 0.161
cylinder head
EW–5–10

8065.25.085
mm
Valve spring height:
Free spring H 44.6
H H1 Under a load of
H2 270 ± 14 N H1 34
528 ± 26 N H2 23.8
Injector standout X 0.7 ÷ 0.4

X
Camshaft bush housing

fitted in engine block
55.280 ÷ 55.305
∅1
54.780 ÷ 54.805
∅2
∅ ∅ ∅ ∅3
54.280÷ 54.305
1 53.780 ÷ 53.805
2 3 ∅4
∅ 6
Cam shaft journal diameter
51.470 ÷ 51.500
∅5
50.970 ÷ 51.000
∅6
50.470 ÷ 50.500
∅7
49.970 ÷ 50.000
∅ 5 ∅ 7 ∅8
Camshaft bushing
∅1 outer diameter:
∅2 front ∅1 55.375 ÷ 55.430
∅3 front intermediate ∅2 54.875 ÷ 54.930
rear intermediate ∅3 54.375 ÷ 54.430
rear ∅4 53.875 ÷ 53.930
Camshaft bushing
∅1 inner diameter:
∅2 51.580 ÷ 51.630
front ∅1
∅3 front intermediate ∅2 51.080 ÷ 51.130
rear intermediate ∅3 50.580 ÷ 50.630
rear ∅4 50.080 ÷ 50.130
Bushing and housing in
0.07 ÷ 0.15
engine block
Bushing and journals 0.08 ÷ 0.16
Cam lift:
H H
5.97
H
6.25
EW–5–11
8065.25.085
mm
∅1
Tappet washer bore ∅1
15.000 ÷ 15.018
Tappet washer outer

∅2 diameter
∅3 ∅2
14.740 ÷ 14.780
∅2 ∅3
14.950 ÷ 14.970
Between tappets and

0.030 ÷ 0.068
housings
Tappets 0.1 – 0.2 – 0.3
∅ 1
Valve lifter diameter ∅1 17,982 ÷ 18,000

∅2
Between valve lifter and

0.016 ÷ 0.052
shaft
EW–5–12
112
105
98
91
84
77
70
63
56
49
42

EW–5–13

GRAPHIC REPRESENTATIONS AND SYMBOLS
Removal
Intake
Disconnect
Re–fit in place
Exhaust
Connect
Removal
Operation
Disassembly
Fitting in place
Assembly r Compression ratio
Tolerance
Driving torque
Weight difference
Driving torque + angular value Rolling torque

a
Replacement
Caulk
Original spare parts
Regulation
Rotation
Adjustment
Caution Angle
! Note Angular value
Visual check
Pre–load
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Face for machining

Pressure
Machine finish bar
Oversizing
Interference
Greater than...
Strained assembly
Maximum
Undersizing
Thickness
Smaller than...
Clearance
Minimum
Lubricate Selection
Damp Classes
Grease Oversizing
Temperature < 0o C
Sealant Cold
Winter
Temperature > 0o C
Air vent Hot
Summer
EW–5–14

TIGHTENING TORQUES
DESCRIPTION TORQUE
Nm (kgm)
Cylinder head attachment bolt 1st stage: preliminary torque 70 (7)
2nd stage: preliminary torque 70 (7)
3rd stage: angle 180°
Main bearing cap attachment bolts preliminary torque 80 (7)
angle 90°
Big end cap attachment bolts preliminary torque 40 (4)
angle 60°
Flywheel attachment bolts reliminary torque 40 (4)
angle 60°
z
Nut for injection fixing stud preliminary torque 9.9 (1)
final torque 22.5 (2.3)
Oil sump drain plug 95 (9.5)
Heater seat plug 125 (12.5)
Capscrew, timing cover and housing 22.5 (2.3)
Nut for timing cover and housing stud 22.5 (2.3)
Pipe union, piston cooling oil nozzle 45 (4.5)
Capscrew, intake manifold 22.5 (2.3)
Capscrew, intake manifold and hook 22.5 (2.3)
Capscrew, exhaust manifold 45 (4.5)
Nut, cylinder upper cover 22.5 (2.3)
Capscrew, valve lifter mounting 50 (5)
Nut, valve lifter adjustment screw 22.5 (2.3)
Capscrew, drive pulley 13.5 (1.4)
Flywheel attachment bolt 295 (29.5)
Capscrew, intermediate pin with flange 50 (5)
Capscrew, camshaft thrust plate 32.5 (5)
Capscrew, gear mounting 22.5 (3.3)
Capscrew, injection pump 22.5 (2.3)
Capscrew, injection pump 50 (2.3)
Capscrew, turbocharger 50 (5)
Capscrew, gas exhaust pipe from turbocharger 16.5 (5)
Capscrew, oil pump to front cover 22.5 (1.7)
Capscrew, retaining plate for oil pressure adjustment valve 22.5 (2.3)
Capscrew, heat exchanger 50 (2.3)
Capscrew, water pump 50 (5)
Capscrew, fan hub 115 (11.5)
Capscrew, belt tightener 50 (5)
– Lubricate with oil
z – Apply “LOCTITE HVX 576”

EW–5–15

TOOLS
75301438 Crankcase for disassembled engine

75301437 Puller, damper flywheel
75295944 Puller, pulley hub and water pump blower
75301436 Slide hammer
75297687 Puller, injector sleeve
75297200 Spanner, valve lifter adjustment screw
75301435 Spanner, engine block oil circuit plugs
75301434 Pliers, engine piston ring assembly
75301433 Pliers, compression piston ring assembly
75295867 Drift, valve guide disassembly
75293231 Drift, valve guide disassembly (use with 75295867)
75298549 Tool for dismantling cartridge filters
75301432 Tool for retaining engine flywheel
75301431 Tool for engine valve removal–refitting
75294026 Drift, water pump blower seal
75301430 Connection, engine cylinder compression test (use with 99395682)
75301429 Lifter, crankshaft
75301428 Set of eyes, engine block lift and transport (order 2 sets)
75295960 Rocking sling, engine removal – installation
75301427 Compressor, standard piston installation in cylinders
75301426 Brackets for securing engine to revolving stand
75297686 Burnisher, injector sleeve
75295883 Handle, drift, interchangeable
75301425 Handle, drift, interchangeable
75295970 Drift, crankshaft core plugs
75295890 Reamer, valve guide
75295896 Set of taps for threading injector sleeves before removing them
75298637 Dresser, lower injector sleeve portion (use with 99394019)
75301423 Cutter, injector housing (use with 99394019)
75298638 Bushing, pilot
75301424 Graduated sector, engine timing test at bench
75290284 Manual pump for injector calibration
75301124 Telescopic turning support
75301465 Reamer (50 ÷ 175 mm)
EW–5–16

75301461 Complete angle for checking rectangularity of connecting rods
75301453 Box with tools for valve seat refinishing
75301440 Load pretension check tool
75301460 Pair of goniometers
75301465 Dynamometer for belt tension check
EW–5–17
STRIPPING DOWN THE ENGINE IN THE - Disconnect the check rod sleeve (3);
WORKSHOP - Put the engine on the revolving stand 75301124,
Using a suitable lift and some ropes, keep the en- fixing it to the brackets 75301426.
gine suspended, then apply brackets 75301426
after the operations described below:
When handling the engine, keep at a safe
- Remove the supports (2); ! distance in compliance with the accident–
- Drain oil from the engine; prevention standards.
- Remove the heat exchanger (1) and its pipes;
Figure 1
47280
PREPARING THE ENGINE TO PUT IT ON THE REVOLVING STAND

1. Heat exchanger – 2. Supports – 3. Oil level rod
EW–5–18
Figure 2
Figure 3 47282

47281
1. Air pipeline – 2. Fuel pipes – 3. Intake manifold – 4. Fuel filter – 5. Accelerator tie rod – 6. Starter motor – 7.
Elettric stop device – 8. Fuel pump – 9. Water pump – 10. Belt tightener – 11. Air intake pipe – 12. Pipe fixing
bracket – 13. Fuel return piping – 14. Pulley support – 15. Belts – 16. Fan – 17. Alternator – 18. Turboblower –
19. Oil filters – 20. Exhaust manifold.
EW–5–19
Disassemble the components following the se- Figure 4

quence described below, as shown in Figure 2:
- Remove the bracket (12) with the relevant pipe-
line by disconnecting it from the pipeline (1);
- Remove the turbofan pipeline (1);
- Remove all fuel pipes from pump injectors and

glow plug on the manifold (2);
- Remove the intake pipe (1);
- Remove the fuel pipe (13);
- Remove the fuel filters (4) with their pipes;

47306
Using tool 75301432, prevent the flywheel from ro-
- Remove the intake manifold (3); tating by inserting the two screws (1) on piece (2)
and the retainer screw on one hole in the flywheel
- Remove the solenoid valve (7); (3); loosen without removing the screws (4).
- Disconnect the accelerator valve lifters from the Figure 5
injection pump and support (5);
- Remove the starter motor (6);
- Loosen the screws on the flange and extract the

injection pump (8) with its oil lubrication pipe,
after having unscrewed the relevant connection.
- On the front side, loosen the screws and remove

the fan (16);
- Through the holes of the fan driving pulley

loosen the water–pump pulley screws (9); 47321
- Loosen the belt tightener (10); On the front side remove the thermostat unit (1) ex-
tracting it from the water pump, then remove the
- Loosen the alternator fixing screws (17, pump (2) after having previously removed: the pipe
Figure 3). from the heat exchanger and the drive pulley (previ-
ously loosened), remove the perimeter screws on
the pulley, then extract the pulley (4) and the fly-
wheel damper (3).
NOTE – The fan driving belt is self–ventilated.
Figure 6
NOTE – Where present, slacken the conditioner com-

pressor to extract the belt, then completely loosen the
screws and remove the compressor.
- Remove the alternator (17);

- Loosen the two oil filters (19) by tool 75298549;
- Remove the turbofan (18) from the exhaust
manifold by disconnecting the lubrication pipes
from the crankcase.
47308
- Remove the exhaust manifold (20).
Straighten the locking plate (1) on the hub and
unscrw the nut (2).
EW–5–20
Figure 7 Figure 10
47309 32702
Remove the hub (1) of the flywheel damper using Put aside the valve lifter control rods (1) and covers
tool 75301437 (2). (2) on valve spindle.
Extract the retaining screws (3) of cylinder head (4)
and remove the head keeping its gasket.
Figure 8 Figure 11
32700 47324
Remove the valve lifter cover (1). Turn the engine by 180° and remove the oil sump
(1), keeping its gasket.
Figure 9 Figure 12
32701 47310
Remove the injector (1) and the entire shaft (2). After removing tool 75301432 (Figure 4), loosen the
screws and remove the flywheel, then remove the
cover (1).
EW–5–21
Figure 13 Figure 16
32704 32709
Dismount oil suction pipe (1), the oil feed pipe (2) Detach the fastening screws (1) of the main bearing
and the control toothed wheel cover (3). covers (2) and remove them.
Figure 17
Figure 14
32710
32705
Using tool 75301429 (1) lift and remove the cran-
shaft (2); put aside main bearing shells and shoulder
Using round pliers (2) remove spring ring (3) and pull semi–rings.
off the transmission gear wheel (4). Remove the oil
pump (1). Remove the injection pump driving wheel
(5).
Figure 18
Figure 15
32711
Loosen the collar plate locking screws (1) and ex-

32706 tract the camshaft. Pull off valve lifters and dismount
oil spraying nozzles.
Remove the connecting rod caps, put aside the Remove the transmission gear wheel support (3)
bearings shells and and pull off the piston–connect- and the entire housing of the steering (2).
ing rod assemblies (1) from the crankcase top.
EW–5–22
Figure 20
NOTE – Clean carefully all disassembled parts and
check their integrity after stripping down the engine.
On the following pages instructions for the main
1. MEASURING
checks and measuring are given, which have to be
carried out to determine whether the parts can be
used again for mounting.
2. MEASURING
REPAIRS
CYLINDER BLOCK 3. MEASURING
CHECKS AND MEASUREMENTS
20581
NOTE – Because of its ductility, the cylinder liner must
never be measured inside when dismounted; the inner DIAGRAM FOR CHECK OF CYLINDER LINER
diameter must be measured at a completely mounted DIAMETER
liner.
Figure 19
Each single cylinder must be measured at different
heights of the liner and at two surface planes rec-
tangular to each other; one of these surface planes
is parallel to the longitudinal axis of the engine (A)
and the other is perpendicular to it (B); generally at
the surface plane (B) and at the height of the first
measurement, the cylinder liner is worn most.
Ovalness, conical form or wear can be removed by
regrinding of the liners for a little wear or slide fur-
rows; for deep furrows or marked ovalness the
bored liners must subsequently be surface–ground.
NOTE – For the regrinding, all liners must have the

same overdimension (0.4 – 0.8 mm).
Figure 21
32579
In order to determine the value of the out–of–round,

conical form and wear, the inner diameter of the
liners is checked by means of gauge 75301465 (2)
provided with cent indicating caliper (1), that has
been previously calibrated at a ring gauge (3) with a
diameter of 104 mm.
NOTE – If a ring gauge with a diamter of 104 mm is

not available, use a slide gauge. CHAMFERING PATTERN TO BE APPLIED TO
CYLINDER LINERS AFTER REGRINDING
EW–5–23
REPLACEMENT OF CYLINDER LINERS Figure 23

Figure 22
32713
Check condition of the treatment plugs (1) of the cyl-

32712 inder block: if they are worn or their seal is doubtful,
Dismounting and mounting of the cylinder block replace them.
liners is carried out by means of a hydraulic press Figure 24
and the corresponding plates.
For mounting the cylinder liners in the crankcase
seats by means of a press, the following steps have
to be carried out:
- Check whether the cylinder liner outer diameter
is 106.94 ÷ 106.97 mm and the cylinder liner
seat inner diameter is 106.850 ÷ 106.900 mm;
- Insert the cylinder liner into the seat at the crank-
case and start pressing it;
- after pressing it by 70 ÷ 90 mm, check that the
load is greater than 5000 N and less than 23,000
N;
- go on pressing in and, at 30 mm before finishing, 32714
check that the load is between 10,000 and Check support surfaces (3) of the cylinder head for
40,000 N; unevenness by means of a calibrated ruler (2) and
- when pressing is completed, stop for 5 seconds a feeler gauge (1).
with a press–in load above 50,000 N; Surface–grind the support surface by means of a
grinding machine removing as little material as
- by restriking, check whether the liner edige is
possible after determination of the unevenness.
well–set in the crankcase.
If the driving load is outside the above limits, the cyl-
inder liner must be extracted and replaced. Figure 25
After driving, the cylinder liners must be bored and
ground. Cylinder liners are delivered as spare parts
with an inner diameter slighlty below the nominal di-
ameter in order to be able to correct possible de-
formation appearing during mounting.
32715
NOTE – The cylinder liners are delivered as spare

parts with the outer diameter oversized by 0.2 mm. NOTE – Pull out centering pin only if the support sur-
face must be surface–ground.
Remove the centering pin (2) from the cylinder head

support surface (3) using tool (1).
EW–5–24
CAMSHAFT
BUSHES – VALVE LIFTERS
Figure 26
1403
MAIN DATA OF THE CAMSHAFT
The surfaces of the bearing journals of the shaft and scoring and furrows, the shaft and their correspon-
the cams must be completely smooth; if they have ding bushes must be replaced.
CAM PITCH AND BEARING JOURNAL Figure 29

ALIGNMENT CHECK
Figure 27
32718
In order to check the mounting clearance, measure

32716 the inner diameter of bushes (Figure 32) and diam-
Clamp camshaft (4) between centers (1) and check eter of camshaft journals (1 Figure 29); the differ-
the cam pitch (2) by means of a cent indicating caliper ence represents the actual clearance.
(3). Cam pitches must be: For clearances of more than 0.160 mm, replace the
bushes and, if necessary, also the camshaft.
- 5.955 mm for the inlet cam;
- 6.027 mm for the outlet cam.
DRIVEN TOOTHED WHEEL
Figure 28 REPLACEMENT
Figure 30
32719
32717
Check that the toothing of the driven toothed wheel
Always with the camshaft (4) between centers (1), (1) is not excessively worn or damaged, otherwise
check alignment of the bearing journals (3) with a replace it. In order to mount the new toothed wheel,
1/100 gauge (2); this alignment cannot exceed it must be heated up to 180 °C in the furnace for
0.020 mm. If the measured value exceeds 0.020 about 10 minutes and then drawn upon the shaft (4)
mm, replace the shaft. together with the plate (3) and the curved washer
(2).
EW–5–25
BUSHES
The surfaces of the bushes must have no signs of
seizing or scores, otherwise they must be replaced.
Figure 31
1403
MAIN DATA OF THE BUSHES FOR CAMSHAFT AND RELEVANT CRANKSHAFT SEATS
BUSH REPLACEMENT
Figure 32 Figure 33
32720 32587
Before replacing the bushes (1) measure their diam-

eter with a reamer (2). NOTE – During mounting of bushes (1), pay attention
For the disassembly and reassembly of the cam- to the alignment of bores (2) which must be aligned
shaft bushes use a suitable driving mandrel. with the crankcase bores for the transition of the lubri-
cating oil.
EW–5–26
Figure 34 Figure 36
32721
After mounting, grind the bushes completely by

means of the mandrel (1) complete with guide
bushes (2) and milling cutter (3) in order to obtain the
prescribed values. 20399
MAIN DATA OF VALVE LIFTERS AND
CORRESPONDING SEATS ON THE CRANKCASE
Mounting valve lifters – Camshaft
Figure 37
VALVE LIFTERS
The valve lifters are delivered as normal spare parts
and oversized by 0.10 – 0.20 – 0.30 mm.
REPLACEMENT OF VALVE LIFTERS 32722
Figure 35 Mount steering toothed wheel housing (2) on the

crankcase together with a seal; tighten screws to 25
Nm tightening torque. Mount oil spray nozzles (1)
and bend locking plates.
Figure 38
32795
If the valve lifters are replaced because the clear-

ance in the seats is too large, oversized valve lifters 32723
are required and the seats (2) must be bored by an Lubricate the camshaft bearings and insert the shaft
appropriate reamer (1). (1) into the crankcase.
EW–5–27
Figure 39
32724
Tighten fastening screws (2) of the camshaft locking

plate at the crankcase through the bores (1) in the
toothed wheel.
Mount the transmission gear wheel pin (3) and the
driving toothed wheel for injection pump (4).
CRANKSHAFT
Figure 40
20400
MAIN DATA OF THE CRANKSHAFT MAIN AND CONNECTING ROD BEARING JOURNALS
EW–5–28
MAIN AND CONNECTING ROD BEARING NOTE – The measurement carried out at the main or
JOURNALS connecting rod bearing journals must be indicated by
Masure shaft journals (2) by means of a micrometer a stamp at the side of the crank web No. 1.
caliper (1) before grinding of journals, and determine For undersized conn. rod b. journals: letter M
by means of the bearing smaller dimension scale (7) For undersized main bearing journals: letter B
which journal diameter must be obtained by grind- For undersized c. rod and main b. j.: letter MB.
ing.
The smaller dimension classes are 0.254 – 0.508
mm. Figure 43
Figure 41 ROLLED
21177
DETAIL OF THE MAIN BEARING JOURNAL

CONNECTIONS
Figure 44
ROLLED
32725
MEASUREMENT OF MAIN BEARING

JOURNALS
21178
NOTE – All main and connecting rod bearing journals DETAIL OF THE CONNECTING ROD BEARING
must always be ground to the same smaller dimension JOURNAL CONNECTIONS
class in order to avoid out–of–balance of the shaft. Figure 45
Figure 42
ROLLED
21176
32726
DETAIL OF THE THRUST BEARING JOURNAL

MEASUREMENT OF CONNECTING ROD CONNECTIONS
BEARING JOURNALS
EW–5–29
Figure 46 Figure 48
bar NORMAL POSITION

LIMIT POSITION mm 0,25 mm 0,25 LIMIT POSITION
ÇÇÇÇ
ÇÇÇÇ
MAIN BEARING JOURNA
ÇÇÇÇ CONNECTING ROD

BEARING JOURNAL
32597 2219
Check that plugs (2) of the lubricating circuit are not - Connecting rod bearing journal alignment re-
leaky for an inner pressure of 15 bar, otherwise referred to main bearing journals: the axis of each
place plugs by means of an appropriate driving man- connecting rod bearing journal pair and the axis
drel. of the main bearing journals must be at one
place: max. permissible tolerance perpendicular
to this plane ± 0.25 mm.
- The maximum admitted tolerance for the dis-
tance between the rotation axis of the shaft and
the outer surface of the connecting rod bearing
journals is + 0.10 mm.
REPLACEMENT OF DRIVING TOOTHED

CHECK OF MAIN BEARING JOURNAL
WHEEL STEERING AND OIL PUMP
ALIGNMENT
Figure 49
Figure 47
32599
32727
Check that toothing of toothed wheels (1 – 2) is not

This check must be carried out after possible grind- damaged or worn, otherwise pull off toothed wheels
ing of the crankshaft journals; for this purpose the by means of an appropriate pulling–off tool (3).
shaft (3) must be clamped between centers (2) and In order to mount the new toothed wheels (1 – 2) they
a centi indicating caliper has to be used (1). must be heated up to 180 °C in the furnace for about
- Alignment of main bearing journals: max. toler- 10’ and pulled upon the crankshaft together with the
ance > 0.10 mm (total reading at the indicating curved washer.
caliper).
EW–5–30
MOUNTING OF MAIN BEARINGS Figure 52

The main bearings are delivered as spare parts with
the inner diameter reduced by 0.254 – 0.508 mm.
NOTE – No fitting work at bearings.
32730
The clearance between the shaft journals and the

corresponding bearings is checked by means of a
calibration cable as follows:
- clean the parts carefully and remove oil;
Figure 50
- place a piece of the calibration cable (6) in paral-
lel to the longitudinal axis at the crankshaft jour-
nals (4);
- mount bearing covers (1) with the bearing shells
on their supports;
- mount bearing cover fastening screws and
tighten them by means of a torque wrench to the
prescribed tightening torque. The screws must
be previously lubricated with oil;
- dismount the bearing covers and determine the
clearance between the bearing shells and the
main bearing journals; for that purpose compare
the width of the part of cable that is squeezed
most to the scale printed to the calibration cable
32728 wrapping (3).
Place bearing shells (1) on crankcase main bear-

ings.
Figure 51
Crankshaft end play check
The standard mounting clearance is 0.082 ÷ 0.334.

32710
For a larger clearance, the shoulder semi–rings
must be replaced by new ones with standard size or
Lift the crankshaft (2) by tool 75301429 (1) and place with oversize oroversized by 0.127 – 0.254 or 0.508
it on the bearing shells.
mm.
EW–5–31
Figure 53
NOTE – The screws must be lubricated.
Figure 56
32603

Figure 54 32779
Using tool 75301460 (1) tighten screws by further

90°.
32731

Figure 57
Figure 55
32732 32733
Tighten the fastening screws (2) by means of a Place the indicating caliper (1) with magnetic base
torque wrench (1) to a tightening torque of 80 Nm. and check end play.
EW–5–32
REAR FLYWHEEL COVER Mounting of engine flywheel
NOTE – The fastening screws of the engine flywheel

Figure 58 can be used as long as the thread diameter is lot lower
than 11.5 mm.
Figure 60
47312
Insert a new seal ring (1) on the flywheel cover (2). 47313
Mount flywheel (1). Apply tool 75301432 (3) and

tighten the screws that were previously lubricated
NOTE – Some seal rings are supplied as spare parts with “LOCTITE HVX 576” to a tightening torque of
with the built–in ring, to be removed after the assem- 40 Nm by means of a torque wrench.
bly. Figure 61
Figure 59
47314
Place tool 75301460 (1) and tighten the screws (2)

by further 60°.
CONNECTING ROD – PISTON ASSEMBLY
Figure 62
47310
Mount the flywheel cover (1) on the crankcase.
ENGINE FLYWHEEL
REPLACEMENT OF ENGINE FLYWHEEL

TOOTHED WHEEL
32612
Replace the toothed flywheel ring if the teeth of the PARTS OF THE CONNECTING ROD – PISTON
toothed flywheel ring mounted on the engine fly- ASSEMBLY
wheel to start the engine are very damaged. Before 1. Reatining rings – 2. Pin – 3. Piston –
mounting, the thoothed flywheel ring must be heated 4. Piston rings – 5. Screw – 6. Bearing shells –
up to a temperature of 80 °C. 7. Connecting rod – 8. Bush.
EW–5–33
Figure 63 Figure 66
32616
The clearance between piston and cylinder liner can

32613
also be checked by means of a feeler gauge (1).
Dismount the piston rings (1) out of piston (2) using PISTON PIN
pliers 75301434 (3). The pins are mounted with clearance as well at the
connecting rod eye as at the piston.
Figure 64
Figure 67
32618
32614
Take off locking rings (2) of piston pin (1) by means Measure the piston pin diameter (1) by a micrometer
of a center punch (3) as shown in the figure. (2).
Check of correct fit between piston pin and
PISTON piston
The pistons are delivered as spare parts with stan-
Figure 68
dard size or oversized by 0.4 – 0.6 – 0.8 mm.
Piston diameter measurement
Figure 65
32619
For mounting the new piston pins check the correct

fit in the piston as follows:
- lubricate the piston pin and the corresponding fit
at the piston pin hubs with engine oil;
Using a micrometer (2), measure the piston diam-
32615
- insert the piston pin vertically in the piston pin
eter (1) to determine the mounting clearance. hub;
- it must be possible to insert the piston pin with a
NOTE – The diameter must be measured at a dis- slight pressure;
tance of 12 mm from the piston base.
- the piston pin cannot slip out of the hubs.
EW–5–34
Figure 69
47318
MAIN DATA OF THE PISTON, THE PISTON RINGS AND THE PISTON PIN (ENGINE 8065.25.085)
* Values are measured on 101–mm ∅.
PISTON RINGS
The piston rings are supplied as spare parts with
standard diameter size or oversized by 0.4 – 0.6 –
0.8 mm for the seal ring and the 2nd oil scraper and
by only 0.6 mm for the 1st oil scraper.
Figure 70 Figure 71
16552 32620
Check the piston ring thickness (2) by means of a Check clearance between piston rings (3) and corre-
micrometer (1). sponding grooves (2) on the piston with a feeler
gauge (1).
EW–5–35
Figure 72 CONNECTING RODS
Figure 75
3513
20584
The seal ring (2) of the 1st piston groove has a trap-
ezoidal cross section. The clearance between the
sealing ring and the seat is determined as follows:
arrange piston (1) with the corresponding ring in the
cylinder liner (3) in such a way that the sealing ring
projects from the cylinder liner by a half.
Figure 73
MAIN DATA OF THE CONNECTING ROD, THE

BUSH, THE PISTON AND THE BEARING
SHELLS
* Value to be measured after mounting of bush.
32737
Measure the clearance between the ends of the pis-

ton rings (1) inserted in the cylinder liner (3) by
means of a feeler gauge (2).
Figure 74 Figure 76
16556
If the joint clearance is smaller than the prescribed 32622

value, regrind the piston ring joints by means of a
suitable tool: if the distance between the ends is The arrows indicate the area where material can be
larger than the prescribed value, replace the piston removed in order to obtain a counterweight.
rings.
EW–5–36
Check of rectangularity of connecting rod MOUNTING OF CONNECTING ROD – PIS-

Figure 77 TON ASSEMBLY
Connecting rod – piston mating
Figure 80
32738
Check that axes of the connecting rods are parallel.
The permissible tolerance is 0.07 mm, measured at
a distance of 125 mm from the longitudinal axis of
the connecting rod.
NOTE – Each connecting rod has to be provided – on
the body and cover – with a number corresponding to 32627
the cylinder on which it must be mounted. Therefore,
in case of replacement, the new connecting rod must
be marked with the same number. NOTE – The piston (2) must be mounted in such a
way that the lettering “VALVE LIFTER SIDE” (1) at
BUSHES the top is placed opposite to the number (4) punched
Figure 78 into the connecting rod.
Insert the piston pin (3) and mount the spring rings.
32625
Dismounting and mounting of the bush (2) are car- Figure 81

ried out with a suitable driving mandrel (1).
NOTE – After the insertion of the bush into the con-

necting rod eye, remove the part that is projecting at
the side, then regrind the bush in order to obtain the
prescribed diameter.
Figure 79
32628
Check for rectangularity of the connecting rod – pis-

ton assembly by means of tool 75301461 (1) and
feeler gauge (2). The surface of the piston head
32626 must be completely rectangular to the tool surface
Finishing treatment of the connecting rod eye bush
by means of a drilling machine.
EW–5–37
Mounting of piston rings Figure 84

Figure 82
32631
32613
REPRESENTATION OF THE FIT BETWEEN
Use pliers 75301434 (3) to mount the piston rings (1) CONNECTING ROD AND PISTON FOR
in pistons (2). The rings must be mounted with the MOUNTING THE ASSEMBLY INTO THE CYLINDER
lettering “TOP” to the top; furthermore the joints in 1. Piston - 2. Combustion chamber - 3. Stamp area
the rings must be aligned in such a way that they ae for the number of the cylinder to whcih the
offset by 120° to each other. connecting rod belongs - 4. Camshaft.
The arrow indicates the direction of rotation of the
engine, as viewed from the steering side.
NOTE – The connecting rod screws can be used as
long as the thread diameter measured between 19
and 35 mm from the screw head is not lower than 10.5
mm.
Figure 85
Figure 83
47315
Mount the connecting rod - piston assembly (1) into

the cylinder line by means of strap retainer
75301427 (2).
Lubricate the corresponding parts before mounting.
NOTE – In order to adjust the clearance, the follow-
ing operations must be carried out:
- the connecting rod number corresponds to the
cylinder number;
32630 - the lettering “VALVE LIFTER SIDE’’ which is
punched into the piston head must point to the
Mount bearing shells (1) at the connecting rod as top, i.e. in the direction of the camshaft;
well as at the connecting rod bearing cover.
- the connecting rod numbers point to the side op-
posite to the camshaft;
NOTE – No fitting work at the bearing shells. - the piston ring joints must be offset by 120° to
each other.
EW–5–38
ADJUSTMENT OF THE MOUNTING Figure 88

CLEARANCE OF THE CONNECTING ROD
JOURNALS
Figure 86
32740
Place tool 75301460 (1) at the socket wrench and

tighten the screws (2) by further 60°.
32633
Check that the connecting rods can be displaced ax-
In order to adjust the clearance, the following oper- ially on the crankshaft journals.
ations must be carried out:
- clean the parts carefully and remove the oil; Figure 89
- place a piece of calibration cable (2) at the
crankshaft journals (1);
- mount the connecting rod cover (3) and tighten
the screws with the prescribed tightening
torque; the screws must be lubricated;
- dismount the cover (3) and determine the exist-
ing clearance; for this purpose compare the
width of the calibration cable (2) with the scale
printed at the calibration cable wrapping.
NOTE – Lubricate the corresponding parts before the

final mounting.
Before repeated application of the connecting rod
cover fastening screws, check that the thread diam- 32741
eter measured from 19 to 35 mm from the screw head
is not below 10.6 mm, otherwise replace the screw. When mounting is completed, check the piston posi-
tion (4) in the T.D.C. referred to the cylinder block
Mounting of connecting rod covers surface by means of an indicating caliper (2) with
magnetic base.
Figure 87 The upper edge of the piston must project by 0.64 to
0.97 mm over the cylinder block surface (1).
STEERING
CHECK AND REPLACEMENT OF THE

32739 TRANSMISSION GEAR WHEEL
Mount connecting rod covers (2) and tighten screws
(3) by means of a torque wrench (1) to a tightening Check that the transmission gear wheel is not dam-
torque of 40 Nm; the screws must be previously lu- aged or the toothing is too much worn, otherwise it
bricated. must be replaced.
EW–5–39
REPLACEMENT OF BUSH FOR TRANS- Mounting of the transmission gear wheel and
MISSION GEAR WHEEL adjustment of the steering
Figure 90 Figure 92
47316
32637
Rotate the crankshaft and place the piston of the cyl-
Check the contact surfaces of the bush (1): they inder No. 1 in the compression stage in the T.D.C.
must not have furrows or score grooves; otherwise This position is reached when the pointer (2) points
the bush (1) must be replaced by means of a suitable to the “O” (1) that is punched onto the engine fly-
driving mandrel. wheel.
Figure 93
32742
Figure 91 Shrink on the transmission gear wheel (2) and align
it in such a way that the marks 1 - 2 and 3 punched
into it cover the marks on the driving toothed wheel
(1), the camshaft driven toothed wheel (3) and the
injection pump driving toothed wheel (4).
Figure 94
47320
32638 Mount the cover (3) for steering gear.
Apply tool 75301432 on the engine flywheel to pre-
After mounting, the bush (1) must be bored in order
vent it from rotating.
to obtain the diameter given in the drawing (*).
Mount the hub (1) with the locking plate: tighten the
nut by a torque wrench (2) at 300 Nm, bend the lock-
ing plate (4).
(*) Value to be obtained after mounting of bush.
EW–5–40
CYLINDER HEAD Figure 98) of the springs in order to pull out the cone
halves (4) and detach the valves; pull out the upper
Figure 95 spring plate (6), the springs (3) and the lower spring
plate (5). Repeat this for all valves. Turn the cylinder
head and pull out the valves.
Figure 98
32743
Tightness check
Figure 96
32643
COMPONENTS OF THE VALVE ASSEMBLY

1. Exhaust valve - 2. Intake valve -
3. Springs - 4. Cone halves - 5. Lower spring
plates - 6. Upper spring plates.
32744
Before dismounting the cylinder head, check for

tightness by means of a suitable tool (1 – 3).
Fill the union (3) with water heated up to ≈ 90°C un-
der a pressure of 4 ÷ 5 bar by means of a pump. Un-
der these conditions no leakage must occur, other- Check of cylinder head bearing surface on cyl-
wise the cylinder head must be replaced. inder block
Figure 99
DISMOUNTING OF VALVES
Figure 97
32746
The bearing surface of the cylinder head on the cyl-

inder block is checked by means of a ruler and a feel-
er gauge. For values above 0.15 mm on the whole
32745
surface, the head must be reground by means of a
surface grinding machine while removing as less
Place the cylinder head at the work bench and press material as possible.
with tool 75301431 (2) on the upper plate (6,
EW–5–41
VALVES Valve grinding

Removal of incrustration and valve check
If necessary, the valve seats must be ground by
Figure 100 means of a grinding machine so that the angle of the
exhaust valves is equal to 45° 30’ ± 7’ and for the in-
take valves is equal to 60° 30’ ± 7’, while removing
as less material as possible.
Check of clearance between valve spindle and

valve stem guide
Figure 102
18625
Remove fuel deposits at the valves by means of a

suitable steel brush.
Check that valves have no grooves or cracks. Check
furthermore by means of a micrometer screw that
the valve spindle has the prescribed value (see
Figure 101). Otherwise exchange valves.
32747
Using an indicating caliper (2) with magnetic base

(1), check clearance between valve spindle (3) and
valve stem guide. If case clearance is too large, re-
place the valve and, if necessary, the valve stem
guide.
Figure 101
VALVE STEM GUIDE
Figure 103
INTAKE EXHAUST
20397
32748
The valve stem guides are dismounted and

MAIN DATA OF VALVES AND VALVE STEM mounted by means of driving mandrel 75293231.
GUIDES
* Dimension to be obtained after mounting of valve NOTE – The valve stem guides are also delivered as
stem guides. spare parts with an oversized outer diameter of 0.2 mm.
EW–5–42
32647 32749
MOUNTING VALUES OF VALVE STEM GUIDES Using the “Hunger’’ tool 75301453 (1), refinish valve
seats at the cylinder head so that maximum sealing
is obtained.
NOTE – The valve seats on the cylinder head have to
be ground if the valves or valve stem guides are
ground or replaced.
Figure 107
Boring of inner surfaces of valve stem guides
EXHAUST INTAKE
Figure 105
VALVE.
SINKING

20585
MAIN DATA OF INTAKE AND EXHAUST VALVE

SEATS
NOTE – After grinding is completed, during mounting

After mounting the valve stem guides (2), regrind the check that the recess of the intake and exhaust valves
bore by reamer 75295890 (1). referred to the cylinder head area is equal to 0.7 ÷ 1.0
mm.
EW–5–43
Figure 108 Remounting of valves

Figure 111
32750 32745
The valve sealing of the cylinder head (1) is checked Mounting is carried out performing the same steps
with a suitable tool (2 and 3). of the dismounting but in reversed order.
NOTE – Lubricate the valve spindle with engine oil.

Figure 109
16587
Before mounting, the elasticity of the valve springs Mounting of cylinder head
is checked by means of tool 75301440; compare the
load data and the elastic deformation data with
those of the new springs that are indicated in the fol- Figure 112
lowing figure.
Figure 110
18929
20398
Before reusing the cylinder head fastening screws
(2), measure by a micrometer screw (1) that the
MAIN DATA FOR CHECKING OF VALVE thread diameter of the screws is not lower than 11.5
SPRINGS mm at any point; otherwise the screws must be re-
placed.
EW–5–44

32754
32752
- 1st step, by means of a torque wrench (1), per-
tighten to a tightening torque of 70 Nm;
For mounting and tightening the cylinder head, ob-
serve the following: - 2nd step, tighten again to a tightening torque of
70 Nm;
- mount seal (1) in the crankcase, with the letter-
ing TOP (2) pointing to the mechanic; - 3rd step, place tool 75301460 (1) on the socket
Figure 114 wrench and tighten with an angle of 180_.
Figure 117
6935
32655
PATTERN OF THE TIGHTENING ORDER OF
THE CYLINDER HEAD FASTENING SCREWS IN The control rods of the valve lifters must not be de-
THE CRANKCASE formed. The ball seats which can have contact to the
valve lifter adjusting screw and the valve lifter (ar-
rows) must be free from score grooves or wear;
otherwise they must be replaced.
Figure 115 The rods which operate the intake and exhaust
valves are identifical and can be exchanged.
Figure 118
47317
- mount the cylinder head (2), insert the previous-

ly–lubricated screws (3) and tighten them ac- 32755
cording to the following data and in the order
Mount the valve lifter control rods (1) in their seats.
given in Figure 114;
EW–5–45
Figure 119
32658
PARTS OF THE VALVE LIFTER SHAFT

1. Spring ring - 2. Adjusting rings - 3. Valve lifters -
4. Shaft bearing - 5. Spring - 6. Shaft.
Figure 120
32657
MAIN DATA OF THE BEARINGS OF THE VALVE LIFTER SHAFT AND THE VALVE LIFTER
Mounting of valve lifter shaft and adjustment of

working clearance between valves and valve
lifters
Check that the sealing surfaces are free from fur- Figure 121
rows or score grooves; otherwise replace the dam-
aged parts.
Check clearance between valve lifters and valve
lifter shaft, which must be 0.016 ÷ 0.052 and the
clearance between bearing and valve lifter shaft,
which must be 0 ÷ 0.061 mm; replace the parts which
cause larger clearances.
32756
Check the perfect sealing of the plugs mounted at Mount cover (1) to the valve spindle.
the shaft end.
EW–5–46
Figure 122 LUBRICATION

The engine is lubricated by means of a gear pump
(Figure 124) that is mounted in the lower part of the
crankcase at the front bearing; it is driven by toothed
wheels of the crankshaft.
OIL PUMP
Figure 124
32757
Mount the complete valve lifter shaft (1).

Adjust the working clearance between valves and
valve lifters as described below.
Figure 123
32662
OIL PUMP ASSEMBLY

1. Pump housing - 2. Control valve -
3. Driven toothed wheel.
32758
Adjust the clearance between valve lifters and
valves by means of wrench 75297200 (2), box
wrench (1) and feeler gauge (3). The working clear-
ance is 0.25 ÷ 0.35 mm for both the intake and the
exhaust; further adjustments are carried out when a
value different from 0.15 ÷ 0.45 mm is measured.
Place the cylinder for which the clearance is to be
adjusted in the working stroke; the valves of this cyl-
inder remain closed, while the valves of the corre-
sponding cylinder are adjusted. The cylinder pairs
are 1 – 6, 2 – 5 and 3 – 4.
NOTE – In order to facilitate the adjustment of the
valve lifter–valve working clearance, proceed as fol-
lows:
rotate the crankshaft, level the valves of cylinder no.
1 and adjust the valves marked with ’*’ as shown in
the following table:
Cylinder No. 1 2 3 4 5 6
Intake – – * – * *
Exhaust – * – * – *
rotate the crankshaft, level the valves of cylinder No.
6 and adjust the valves indicated by an ’*’ as shown
in the table:
Cylinder No. 1 2 3 4 5 6
Intake * * – * – –
Exhaust * – * – * –
EW–5–47
Figure 125
6960
OIL PUMP ASSEMBLY COMPONENTS

1. Screw - 2. Washer - 3. Centering dowel - 4. Bushing - 5. Oil pump gear - 6. Centering dowel - 7. Driving
gear - 8. Seal ring - 9. Valve body - 10. Spring - 11. Valve - 12. Screw - 13. Washer - 14. Locking plate - 15.
Oil pump body - 16. Bushing - 17. Oil pump gear - 18. Bushing - 19. Shaft - 20. Oil pump cover.
Figure 126 Check that gear (5 - 17 Figure 125) and gear (7) are
not worn or damaged; otherwise, replace the com-
plete pump.
Check that valve (11, Figure 125) slides freely in its
seat without any scoring or pick–up. Also check
pressure–relief valve spring (10) against those indi-
cated in Figure 128.
Valve opening starts at: 6 bar; valve opening ends at:
11 bar.
32663
OIL PUMP CROSS SECTION Figure 128
Figure 127
32664 32665
PRESSURE–RELIEF VALVE CROSS SECTION MAIN DATA CONCERNING SPRING

ADJUSTMENT FOR THE CONTROL VALVE
EW–5–48
OIL FILTER Figure 131

The engine is fitted with two double–action filters.
Filter valve opening pressure is 2.5 + 0.2 bar.
Figure 129
47324
Refit the oil sump (1) with a new gasket using an ap-
propriate sealing compound.
COOLING SYSTEM
WATER PUMP
32666
Water pump is of the centrifugal vane type. Pump
OIL FILTER CROSS SECTION bearing is solid with the blowing spindle.
Water tightness between pump body (4, Figure 132)

NOTE – When installing the filters proceed as follows: and spindle (2) is obtained by means of a seal (5).
– lubricate the seal with oil;
– tighten the filters until the seals are in contact with bearing stop screw (3, Figure 132) must be sealed
their rest base; in its seat with “LOCTITE 242’’.
– further tighten by 3/4 turn.
Figure 132
Oil pump assembly
Figure 130
32668
COOLING WATER PUMP CROSS SECTION

1. Hub - 2. Spindle with bearing - 3. Screw -
4. Pump housing - 5. Seal - 6. Blower - 7. Cover.
32759
NOTE – Check that pump body is not cracked or that
Fit the oil pump (2) and suction (1) and delivery (3) thre are no water leaks; otherwise replace the entire
pipes. pump.
EW–5–49
THERMOSTAT Figure 134
When the engine is cold, water flows from the top

part of the cylinder head and enters a filler pipe
where the thermostat inhibiting water circulation in
the radiator is located.
In this way, water will circulate between pump and
engine only, thus allowing fast heating of the water.
Thermostat valve starts opening at 80°C, allowing
water circulation through the radiator and simulta-
neously inhibiting direct return to the engine. Check
efficiency of thermostat; if in doubt as to its correct
operation, replace it.
47319
Figure 133
Figure 135
47321
Mount the water pump (2), the thermostat unit (1),

the flywheel damper (3) with the pulley located abo-
ve (4).
Carrying out engine assembly at work bench
INJECTION PUMP INSTALLATION AND

TIMING
Turn engine in the direction of rotation and have
notch 18° (1), stamped on flywheel and indicating in-
47325
jection advance, match the reference index on the
flywheel cover (2) (see Figure 134).
- Rotate the injection pump shaft taking element
If, when the flywheel is rotated, the reference point no. 1 to the start–of–delivery condition; this can
is exceeded, it is possible to move back by at least be seen by removing the cover (1, Figure 135).
1/4 turn; in this way, for subsequent exact position-
ing, any clearance of the pump driving gear can be - Key the pump making the double tooth corre-
removed. spond with the notch (arrow) inside the pump
control sleeve.
Screw the fastening screws without tightening
them completely.
EW–5–50
Carry out the “overflow” test as follows: Figure 138

- unscrwe the pressure union (Figure 136) of
pumping element no. 1;
- remove the spring and the delivery valve;
Figure 136
PRESSURE UNION
DELIVERY VALVE
SPRING
DELIVERY VALVE
47323
Mount the generator (2), the driving belt (1), mount

the pulley support with the relevant pulley (4), then
insert the self–ventilated belt (3).
26020 ADJUSTMENT OF THE TENSION OF

CONTROL BELTS: WATER PUMP –
GENERATOR AND FAN
- re–insert the pressure union;
- plug the fuel return union to the tank; Figure 139
- position the rack rod at half stroke;
- feed the injection pump, using a tank that fills the
feeding chamber by drop;
- turn the injection pump on the slots and check
when the fuel does not go out of the pressure
union any more. This isthe exact delivery start
point corresponding to a pre–lift of 2.3 ± 0.05
mm;
- tighten the lock screws without moving the
pump;
- re–insert the pressure valve, the spring and
close the pressure union.
47714
Figure 137
1. Fan – 2. Belt tightener (3) – 3. Fan driving belt –
4. Driving shaft pulley – 5. Water pump – 6.
Generator – 7. Generator driving belt.
Adjust the tension of the new belts as follows:

- rotate the driving shaft by two turns in order to
adjust the driving belts;
- in the most convenient point for the operator,
apply tool 75301465 on the belt and check that
the belt tension is 70 ÷ 80 daN.
If it is not, act on the belt tensioning device (2)
and/or the generator (6).
47322
After 1 h of engine operation, check once again that
the tension still is 60 ÷ 70 daN; otherwise adjust the
Mount the belt tensioning device (1), the water pump belt tension again.
pulley (2), the generator bracket (3) and the water
pump–heat exchanger pipe (4).
EW–5–51
Mount the injection valves (2) Figure 140 and the starter motor, (6), the suction manifold (3) the in-
tighten the fastening nuts in two steps: jection pump – injector pipes (2) pipeline (9); re–con-
pretightening at 9.9 Nm – final tightening at 22.5 Nm. nect all the other recovery pipes, always replacing
Mount the valve lifter cover (3), the exhaust manifold the seal washers, re–connect the fuel filter assembly
(1), the turbocharger (4), the oil filters, according to (4), the accelerator tie rod (5); mount the suction
the instructions given at pag. 48. pipe (11) fixing the bracket (10) to the valve lifter
cover; finally, remount the fan (8).
On the opposite side, Figure 141, mount:
Figure 140
47281/A
Figure 141
47282/A
EW–5–52
Lift the engine from the revolving stand for overhaul Remount the exchanger with the related pipeline (1)
by means of an appropriate hoist and some ropes conneting the pipeline to the water pump, then re-
and, on the flywheel side, if necessary, remove the mount the supports (2) and the oil level rod sleeve
flywheel clamp, then remove the brackets (3).
75301426. Then fill with oil according to the indicated quantities.
Figure 142
47280
EW–5–53
TURBOCHARGER Figure 144

Description
The GARRET T04E turbocharger consists of the fol-
lowing main parts: turbine wheel, central part and
compressor wheel.
The turbine wheel is placed at the side of the central
part, the compressor wheel at the other. A shaft with
bearings connects the turbine wheel with the com-
pressor wheel and forms the rotation unit. The turbo-
charger uses the energy contained in the exhaust
gases of the engine.
During operation, the exhaust gases stream through
the turbine housing and rotate the turbine wheel.
The compressor wheel connected with the turbine
wheel by means of a shaft rotates with it. The com-
pressor wheel takes in air at atmospheric pressure, 33577
compresses this air, and feeds it into the suction
manifold of the engine.
The turbocharger and the bearings are cooled and
lubricated by engine oil.
Necessary checks before dismounting the

turbocharger from the engine Check that the engine vent at the crankcase is not
Before repairs at the turbocharger are carried out, blocked.
the following preventive checks are necessary. Check all seals and connection pieces.
Check that the oil feed pipe in the engine is not Check that the air circulation is not prevented by
blocked. clogging of the air filter or of the pipes.
Check that the oil circulation is not prevented.
Figure 143
8862
TURBOCHARGER LONGITUDINAL SECTION

1. Screw - 2. Locling plate - 3. Thrust bearing - 4. Rear bearing - 5. Self–locking nut - 6. Compressor wheel -
7. Spring ring - 8. Bracket for spring ring - 9. Seal ring - 10. Central part - 11. Locking ring - 12. Bearing - 13.
Seal ring - 14. Spring ring - 15. Turbine wheel.
EW–5–54
DISMOUNTING Figure 147
Figure 145
33578 33580
The turbocharger has to be carefully cleaned out- Fix the appropriate wheel locking tool (3) in the vice;
side by means of anticorrosion or antirust fluids. Fix place the shaft–wheel assembly end and detach the
the turbocharger in the vice. self–locking nut (1) by a suitable wrench (2).
Using a suitable tool (1) provided with an indicated
caliper, check the axial play of the rotating aggregate
(2) which must be equal to 0.025 ÷ 0.10 mm. Figure 148
Align the locking plates; mark the position of the
compressor housing and the turbine housing re-
ferred to the central part; loosen the screws and re-
move the housings.
NOTE – In case of dismounting and remounting of the

turbocharger parts, the work bench must be carefully
cleaned.
Figure 146
33581
Pull off the compressor impeller (1).
Figure 149
33579
33582
Always using a suitable tool (1) with a special exten-
sion, check the radial play of the rotating aggregate Extract the turbine shaft–wheel unit (1) together with
(2) which must be equal to 0.075 ÷ 0.18 mm. the seal ring (2) from the central part (3).
EW–5–55
Figure 150 Checks
Clean carefully all parts of the turbocharger by

means of crude petroleum and a hard hair brush and
dry by means of compressed air.
Check that all parts are free from damages, cor-
rosion or weari.
Check in particular that:
Figure 153
33583
Mark the mounting position of the rear bearing (2) of

the central part; align the locking plates (1), unscrew
the screws and remove the bracket (2) from the cen-
tral part.
33586
Figure 151
- the blades of the compressor wheel are not
cracked, worn or warped; do not try to align
them, but replace the parts;
Figure 154
33584
Pull off the thrust bearing (1) together with the

bracket for the spring ring (2) from the rear central
33587
part (3).
Figure 152 - the blades of the turbine wheel are not cracked,
worn or warped; do not try to align them, but re-
place the part
- the turbine wheel shaft is free from score
grooves or furrows and that it is centered; other-
wise replace the shaft;
33585
Remove the spring ring (2) by round pliers (1) and

extract the bearing (3) from the central part; repeat
the same operation on the opposite side of the cen-
tral part with the other bearing.
EW–5–56
Figure 155
8863
PARTS OF THE TURBOCHARGER

1. Compressor housing - 2. Self–locking nut - 3. Compressor wheel - 4. Plate - 5. Locking plate - 6. Screw -
7. Rear bracket - 8. Spring - 9. Spring ring - 10. Bracket for spring ring - 11. Thrust bearing - 12. Seal ring -
13. Pin - 14. Central part - 15. Locking plate - 16. Screw - 17. Seal ring - 18. Locking rings - 19. Turbine
shaft/wheel - 20. Turbine housing - 21. Plate - 22. Locking plate - 23. Screw - 24. Spring ring - 25. Bearings.
EW–5–57
33588
- the sealing rings (24, Figure 155) and (1,

Figure 156) are not worn or broken; otherwise 33591
replace them;
must be free from furrows or wear in the seats of
- the thrust bearing (11, Figure 155) and the the rotating parts indicated by the arrows.
bracket (10, Figure 155) are free from furrows
and score grooves; otherwise replace them;
Mounting
Figure 160
Figure 157
33592
33589
On the central part (3), mount the inner spring rings
- the bearings are free from score grooves or fur-
(2) in their seats by means of round pliers (1).
rows in the parts indicated by the arrows;
Figure 161
Figure 158
33593
Mount the bearings (1) and the outer spring rings.
33590 NOTE – Replace the seal ring.

- the compressor housing and the turbine housing The bearings must be lubricated with engine oil before
(Figure 159). mounting.
EW–5–58
33594
Clamp the shaft/turbine wheel assembly (1), after

mounting the sealing ring (4) in the vice. 33597
Mount the sealing ring (2)and the central piece (3),
taking care not to damage the ring (4). Mount the central part at the locking device (3) of the
impeller.
Mount the compressor wheel (2), lubricate the self–
locking nut slightly and tighten it to a tightening
Figure 163 torque of 0.23 kgm by means of a torque wrench (1);
tighten by a further quarter turn and check the pro-
jection of the shaft over the self–locking nut which
should be 0.140 ÷ 0.165 mm.
Check the axial play of the rotary unit.
Mount the compressor and turbine housings and
take care that the reference marks applied during
dismounting cover each other. Mount the locking
plates, tighten the screws and bend the locking
plates.
Lubricate the inner parts of the turbocharger with en-
gine oil after mounting.
33595
Mount sealing ring on the bearing (2), and insert the

thrust bearing (3) on the support; then mount these
to the impeller shaft: the positioning pins (4) must
cover the bores in the thrust bearing.
Mount the sealing ring (1).
Mount the spring at the rear bearing (7, Figure 155)
and spring (8).
Figure 164
33596
Mount the rear bearing (1) on the central part (2): the
reference marks applied during dismounting must
cover each other; mount the locking plates, fix the
screws and bend the locking plates.
EW–5–59
FUEL SYSTEM Figure 167
The fuel system consists of:

- air filter;
- fuel preliminary filter with manual suction pump;
- fuel filter;
- feed pump;
- injection pump PES6A90D410RS2757;
- pipes for high–pressure circuit;
- injection valves.
19195
NOTE – The variable pitch spring (1) is correctly

mounted when it is positioned with its larger pitch
NOTE – Renewal or disassembly of one or more in- turns (2) resting on the spring support cap (3).
jection pipes, from the injection pump to the injec-
tors, involves renewal of all brackets with spring
block, screw and clamp.
Figure 168
INJECTORS
Dismantling
Figure 166
16689
19282
PARTS OF THE INJECTORS

1. Nozzle holder body – 2. Adjusting shim – 3. Calibration
Spring – 4. Cap – 5. Spacer – 6. Nozzle body – 7.
Nozzle retainer nut. Injectors (1) are checked and calibrated by means
of tool 75290284 (2); the calibration value should be
equal to that shown in the table, otherwise the shims
must be replaced. Also ensure that the fluid comes
Tighten the injector in a vice, unscrew the nozzle re- out evenly from all nozzle holes; then check that the
taining nut (7). Remove the nozzle body (6), the nozzle is not dripping at a slighly lower pressure
spacer (5) with the centering pin, the cap (4), the value.
spring (3) and withdraw shim (2) from the nozzle
holder body (1). Check that all the parts are free from
wear or breakage and replace defective parts, if
necessary. To assemble injectors, reverse the dis-
mantling operation sequence. NOTE – For a correct check and calibration pro-
cedure, follow the instructions provided herein.
EW–5–60
INJECTION PUMP PES6A90D410RS2757 Speed governor marking

WITH RSV SPEED GOVERNOR
R = speed governor
S = variable lever ratio
Pump marking
V = continuous adjustment
P = injection pump
E = with independent drive
S = flanged to the engine Speed governor
6 = no. of cylinders
The speed governor is an essential device for the in-
A = pump size jection pump. If this device, which controls the fuel
90 = pumping element diameter in tenths of mm flow, is absent, the engine cannot operate since it
would tend to decelerate until it stops or to acceler-
D = modification letter ate until it destroys itself.
410 = assembly system The speed governor is RSV type. Its purpose is to
R = clockwise rotation keep the rotation speed set by the accelerator pedal
S = equipment letter constant in the entire range, from minimum to maxi-
mum.
2757 = equipment number
Inside the governor there is a control device which
consists of two equal weights.
These weights act through the effect of the centrifu-
gal force and their opening is opposed by a set of op-
The feed pump is mechanically driven by the injec- posite springs with equal stiffness.
tion pump camshaft and has the function of intaking
fuel from the tank and taking it to a sufficiently high Correct spring tension is set at the test bench.
pressure to fill the pumping element. The feed pump
is provided with a settling unit, consisting of a trans-
parent tank 1, and a wire filter, 2. The tank must be
inspected every 50 hours to check that no deposits
are present and cleaned every 300 hours.
The rear part of the injection pump unit contains the High–pressure pumping elements
mechanical speed governor for all “RSV” condi-
tions, which is connected to: The high–pressure pumping elements, one per en-
- The accelerator control lever, 1 gine cylinder, send fuel to the injectors at a pressure
- The suction manifold, 3 through L.D.A. of approximately 260 bar. The pumping elements
must supply the exact quantity of fuel and at the right
- The injection pump camshaft, 4 time. The operation of each single element is de-
- Lubrication is carried out through the engine oil scribed here below:
pipe, 2
- The engine stop lever.
L.D.A. device (delivery adjustment as a func-

tion of load)
The L.D.A. device is mounted on the injection

pumps that are normally installed for supercharged
engines: it operates to vary the fuel flow as a function
of the air volume existing in the cylinders.
EW–5–61
Delivery valves Fuel injector units
On each piston there is a one–way delivery valve The fuel injection unit is used to atomize the fuel to
which allows fuel at the injection pressure to flow allow for correct combustion. The injector must cor-
within high–pressure pipes preventing it from flow- rectly send clean fuel into the combustion chamber
ing back. The valve is also used to rapidly reduce with an optimized jet.
pressure in the injection line after the pressure The nozzle is placed inside a support. To allow the
coming from the piston has ceased. A rapid pres- fuel to enter correctly the combustion chamber,
sure decrease is necessary for the injection valve to centering pins are provided which direct the nozzle
snap in order to avoid any leakage of fuel that may inside its support. A ring bracket directs the support
cause coking to be generated on the injector end. within the engine cylinder head.
Pressure control valve assembly
The purpose of the pressure control valve is to main-

tain a pressure of about 1.5 bar in the fuel line. When
this pressure is reached, the pressure control valve
opens allowing the fuel in excess to return to the
tank.
Figure 169
47283
EW–5–62

NOTE:
EW–5–63
IVECO FIAT S.p.A. TEST VALUES IDENTIFICATION CODE

ENGINEERING P.N. C F TECH. C
TESTING DESIGN INJECTION PUMPS 99466259 D E 77–9500
THIS DOCUMENT APPLIES TO INJECTION UNITS
INJECTION PUMP: PES6A90D410RS2757 IVECO REF.: 99459159
SPEED GOVERNOR: RSV425–1075A1C2266–2L MANUFACTURER REF.:
REF : 0400876440
FEED PUMP: FP/KSG 24 AD 205 SUPPLIER: BOSCH
ENGINE: 8065.25.085 IT APPLIES TO THE VARIATIONS: SEE D.B. ENGINES
PRESSURE PIPES (ENGINE): diameter 6 x diameter 1.5
Cyl. No. 1–2–3–4–5–6 L=565 mm
INJECTOR SETTING (ENGINE): bar: 260+12
ENGINE IDLING SPEED WITHOUT LOAD 850 ± 25 RPM.
STATIC SETTING 18±0.5 DEGREES BEFORE T.D.C. WITH PUMPING ELEMENT No. 1
OF INJECTION PUMPIN THE START–OF–DELIVERY POSITION AND PISTON No. 1 OF THE ENGINE ON
THE COMPRESSION STROKE.
TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS CONFORMING TO ISO 4008/1 AND
4008/2 STANDARDS
PIPES IN COMPLIANCE WITH ISO 4093.1 STANDARD (diameter 6x diameter 2 x 600 mm)
INJECTORS IN COMPLIANCE WITH ISO 7440 A11 STANDARD (pellet with calibrated hole)
INJECTOR SETTING bar: 172+3
TEST FLUID IN COMPLIANCE WITH ISO 4113–TEMPERATURE: 38...42 DEGREES C°
SUPPLY PRESSURE bar: 1.5 + 0.3–BURETTE EMPTYING TIME: 30”
PRESSURE RELIEF VALVE SET AT bar: 1.3...1.8
“INJECTION PUMP ADJUSTMENT VALUES”

– “ADJUST UNIFORMITY OF DELIVERY QUANTITIES ON THE BASIS OF THE VALUES IN PARA. 2”
– “THE NUMBERS GIVEN IN BRACKETS SHOULD BE USED ONLY AS TEST VALUES”
1 – START OF DELIVERY 2 – BASIC ADJUSTMENT AND CHECKING

.1 Test pressure bar :25...27 .1 Speed rpm :1075
.2 Pre–lift (from B.D.C.) mm :2.25...2.35 Pressure on LDA hPa :900
(±0.1) Rod stroke mm :12.9±0.05
Average delivery cm 3 :10.2±1
.3 Rod stroke mm :9...12
per 100 shots :(±3)
.4 Direction of rotation :clockwise
Max. imbalance cm3 :0.35 (0.8)
.5 Pump injection order:
.2 Speed rpm :425
1–5–3–6–2–4
Rod stroke mm :6.6±0.1
.6 Nozzle sequence :
Average delivery cm3 :1.3±0.2
0–60–120=180–240–300
per 100 shots :(±0.45)
.7 Tolerance :±30’ (45) Max. imbalance cm 3 :0.55 (0.9)
.8 Start of delivery cyl. no. :1
EW–5–64

IVECO FIAT S.p.A. TEST VALUES IDENTIFICATION C.
ENGINEERING P.N.. C F TECH. C.
3 – SPRING PIN AXIAL STROKE 7 – CURVE FOR GOVERNOR DEFLECTION AT
.1 Speed rpm : IDLING SPEED
Stroke mm : .1 Control lever position from
.2 Speed rpm : horizontal axis degrees :78±4
Stroke mm : Adjustment:
.3 Speed rpm : .2 Speed rpm :425
Stroke mm :6.6
Stroke mm :
Check:
.4 Speed rpm’ :
.3 Speed rpm :100
Stroke mm : Stroke mm :19.5
.5 Speed rpm : .4 Speed rpm :425
Stroke mm : Stroke mm :7.1±0.1
4 – SPRING PIN POSITION CHECK .5 Stroke mm :2
.1 Loose control lever position Speed rpm :555±30
(excluding internal and external .6 Speed rpm :
control lever stops) Stroke mm :
.2 Speed rpm :800 .7 Rod stroke linearity
Rod stroke mm :0.5±0.2 Speed rpm :
5 – DELIVERY AT FULL LOAD 8 – ADJUSTING MATCHING
Speed rpm :1075 .1 Mechanical travel of the
device mm :
Pressure on LDA hPa :900
.2 Control lever at max. position
Rod stroke mm :12.9±0.05
Average delivery per .3 Pressure on LDA hPa :900
1000 shots cm3 :102±1 .4 Speed rpm :1075
Max. imbalance cm3 :3.5 (8) Stroke mm :12.9±0.05
.5 Speed rpm :700
Stroke mm :12.95±0.1
6 – CURVE FOR GOVERNOR DEFLECTION AT .6 Speed rpm :500
MAXIMUM Stroke mm :11.3±0.05
.1 Control lever position from horizontal .7 Speed rpm :
axis for “RSV” deg. :108±4 Stroke mm :
with pressure on LDA hPa :900 .8 Speed rpm :
.2 Control lever adjustment point Stroke mm :
“RQ”
9 – ADJUSTING AND CHECKING THE
Speed rpm : EXCESS FUEL DEVICE
Stroke mm : Adjustment:
Adjustment Speed rpm :500
.3 Stroke mm :11,9 .1 Pressure on LDA hPa :900
Speed rpm :1120±5 Stroke mm :12.95±0.1
Verifica .2 Pressure on LDA hPa :0
.4 Stroke mm :4 Stroke mm :11.3±0.1
Speed rpm :1165±15 .3 Pressure on LDA hPa :470
.5 Stroke mm :0.85±0.55 Stroke mm :11.7±0.05
Check:
Speed rpm :1340
Speed rpm :
.4 Pressure on LDA hPa :
Stroke mm :
EW–5–65
IVECO FIAT S.p.A. TEST VALUES IDENTIFICATION CODE

ENGINEERING P.N. C F TECH. C.
10 – REVERSAL POINT 13 – IDLING SPEED DELIVERY TEST
.1 Operating the control lever .1 Speed rpm :425
from MIN. to MAX. Stroke mm :7.1±0.1
with the solenoid energized Average delivery per cm3 :13±2
Speed rpm : 1000 shots :(±4.5)
Stroke mm : Max. imbalance cm3 :5.5 (9)
.2 Operating the control lever .2 Speed rpm :100
from MIN. to MAX. Stroke mm :* min.
Pressure on LDA hPa : 14 – STARTING DELIVERY TEST
Speed rpm : (With rod cover plug fitted to pump housing and
Stroke mm : with solenoid energized, if any)
11 – DELIVERY PATTERN
.1 Pressure on LDA hPa :900 Control lever position at max..
Speed rpm :1075 Speed rpm :100
Average delivery per cm3 :102±1 Average delivery for cm 3 :84±7.5
1000 shots (±3) 1000 shots :(±10)
Max. imbalance cm3 :3.5 (8)
.2 Pressure on LDA hPa :0
Speed rpm :500 NOTES:
Average delivery per cm3 :90±1 1) ENTRIES WITH NO ALPHANUMERIC VALUES
1000 shots (±3) REFER TO DIFFERENT INJECTION PUMP
Max. imbalance cm3 : TYPES.
.3 Pressure on LDA hPa :900 2) FOLLOW INSTRUCTIONS GIVEN ON THE
Speed rpm :700 IVECO TECHNICAL PUBLICATIONS AND
Average delivery per cm3 :98±2 TRAINING MANUAL No. 603.42.273 TO CARRY
1000 shots (±4) OUT A CORRECT INJECTION PUMP ADJUST-
Max. imbalance cm3 : MENT AT THE ELECTRICAL TEST BENCH.
.4 Pressure on LDA hPa :
Speed rpm :
Average delivery per cm3 :
1000 shots
Max. imbalance cm3 :
12 – SETTING GOVERNOR CUT–IN SPEED
Pressure on LDA hPa :900
Control lever position at max.
Stroke mm :11.9
Speed rpm :1120±5
SECTION 6 EX135–EX215
RECHARGE AND START–UP
CONTENTS
STARTER MOTOR . . . . . . . . . . . . . . . . . . EW–6–3 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . EW–6–9
Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW–6–3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW–6–9
Magneti Marelli MT67CB–4kW . . . . . . . . EW–6–4 Bosch NL1 28V 10/55A . . . . . . . . . . . . . EW–6–9
Test and checks on the vehicle TEST AND CHECKS ON THE VEHICLE EW–6–11
Current absorption test . . . . . . . . . . . . . . . EW–6–5
Maximum output test . . . . . . . . . . . . . . . . EW–6–11
Voltage drop test on the circuit . . . . . . . . EW–6–5
Pressure drop test on the circuit . . . . . . . EW–6–11
Excessive voltage drop test on the
circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–5 Voltage drop test on the earth
Starter motor earth test . . . . . . . . . . . . . . EW–6–6 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–12
Voltage drop test on the solenoid Voltage regulator calibration
contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–6 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . EW–6–7 Alternator belt tensioning . . . . . . . . . . . . . EW–6–12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–7 Disassembly and bench test . . . . . . . . . . EW–6–13
Bench test . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–13
EW–6–3
RECHARGE AND START–UP EX135–EX215

STARTER MOTOR
MARELLI MT67CB–24V–4Kw
Quick diagnosis
Fault Possible causes Remedy
Insufficient torque 1. Flat batteries Restore
2. Oxidised or loose circuit Check connections

connections at battery and
starter motor
3. Inefficient brushes Check the sliding
length and pressure
of brushes
4. Shorted field Change the windings
windings
5. Armature cut off Change the armature
or shorted
6. Ovalised commutator Lathe grind
or replace
Sufficient torque 1. Faulty free wheel or Replace
but engine fails electromagnet
to start
Pinion does not engage 1. Ring gear bevelled Restore
EW–6–4
Magneti Marelli MT 67CB 24V 4kW

Type 4–pole series motor, electromagnet–driven meshing fork
Direction of rotation clockwise
Rated voltage 24V
Power 4kW
3820 3821
WIRING DIAGRAM CONNECTION
6,5
19
26,8+0,8
43,2 +0,8
21282 3823
CHARACTERISTIC CURVES PINION ADJUSTMENT
1. PINION CONTROL
ELECTROMAGNET
1 2. INDUCTORS
3. DRIVE SIDE SUPPORT
4. STARTER MOTOR
SUPPORT
3 2
5. FRAME
6. BRUSH HOLDER
4 7. COVER
8. MESHING FORK
5 AND PINION
9. ARMATURE
8
9
924
EXPLODED VIEW
EW–6–5
Test and checks on the vehicle Figure 1

Current absorption test
To carry out the current absorption test proceed as
follows:
- connect the clips of the main cables to the battery
terminals observing their polarity (Figure 1);
- connect the inductive clip to the positive cable
observing its polarity and the direction indicated
by the arrow on the clip;
- position the test selector on ”INT” (internal);
- prevent the engine from starting and operate the
starter motor for 15 seconds
Read the voltage and current values:
- voltage cannot fall below 19.5V, if two 12–V
series batteries are used;
- the value of the current absorbed by the starter 3839
motor cannot exceed about three times the bat-
tery capacity in Ah. CURRENT ABSORPTION TEST
If these two conditions are satisfied, the starter Figure 2
motor is efficient.
Voltage drop test on the circuit
To carry out the voltage drop test on the circuit pro-
ceed as follows:
- connect the positive clip to the 30 mark of the
starter motor and the negative clip to its frame
(Figure 2);
- position the test selection on ”EST” (external);
starter motor.
Check that the voltage, read on the digital voltmeter
at starting, varies within 0.5V with respect to the
value read in the previous test (current absorption
test). If this happens, the circuit and connections are
satisfactory. 3840
Excessive voltage drop test on the circuit VOLTAGE DROP TEST ON CIRCUIT AND
To carry out the excessive voltage drop test on the CONNECTIONS
circuit proceed as follows: Figure 3
- connect the positive clip of the external volt-
meter cable to the positive terminal of the battery
and the clip of the negative cable to the 30 ter-
minal in the starter motor (Figure 3);
- position the test selector on ”EST” (external);
starter motor.
Check that the voltage read on the digital voltmeter
does not exceed 0.5V. If it does not, the circuit is effi-
cient.
3841
VOLTAGE DROP TEST ON THE CIRCUIT

EW–6–6
Figure 4 Starter motor earth test

To carry out the starter motor earth test proceed as
follows:
- connect the negative cable of the external volt-
meter to the negative terminal of the battery and
the voltmeter cable to the starter motor frame
(Figure 4);
starter motor.
Look at the voltage value on the digital voltmeter: it
must not exceed 0.25V if the solenoid contacts are
efficient.
3842
STARTER MOTOR EARTH TEST
Figure 5
Voltage drop test on the solenoid contacts

To carry out the voltage drop test on the solenoid
contacts proceed as follows:
- position the external voltmeter cables on the
solenoid contacts observing their polarity
(Figure 5);
starter motor.
3843 Check that the voltage value on the digital voltmeter
does not exceed 0.25V with efficient contacts.
PRESSURE DROP TEST ON THE SOLENOID
CONTACTS
EW–6–7
In addition to the above tests, to find a fault in the If a visual inspection shows that the armature mani-
starter motor, it is possible to perform bench tests fold requires grinding, due to eccentricity, use a
with appropriate test equipment. hard–steel tool for turning.
It is necessary to make use of the manufacturer’s If the windings are removed, mark the pole pieces.
data to compare them with the results found. Lightly heat the new windings and assemble them
Disassembly making reference to the marks put during the disas-
sembly operation.
Clamp the starter motor in the vice provided with If you have to carry out checks by a tester, lean the
lead vice caps. Disassemble the motor proceeding pole frame on a working level that is insulated from
as described below. both the bench earth and the ground.
Replace all relays with worn or damaged working
contacts.
Special attention must be paid during the armature
insulation test.
Vibrations in the steel reed on the armature pack
indicate a shorted armature or inaccurate mica re-
NOTE – To facilitate some disassembly operations moval. If the mica removal is accurately carried out,
only use a plastic hammer. a perfect U shape must be obtained.
Assembly
Remove the control relay and put aside the com-
pensation plate. During assembly, make sure that the armature (pro-
vided with brushes) rotates freely.
Remove the brush holder support making sure not
to damage the winding terminals. Check that the brushes correcly slide in their seats
and check the spring pressure on the brushes (1.2
When disassembly is completed, wash the disas- Kg).
sembled parts using only liquids for electrical com-
ponents: benzine, solvents, trichlorethylene. Also check the spring on the engagement bar.
Lubricate the bright parts with anticorrosive oils and
slighly grease the pinion with a specific grease.
NOTE – Due to their volatility, it is absolutely necess-

ary to observe the safety standards relating to flam-
mable liquids; furthemore, it is necessary to use pro-
tective glasses and gloves.
Accurately dry the washed parts with compressed

air (at about 4 bars) and clean rags.
Make sure that the parts are not worn or damaged; NOTE – Avoid any oil and grease on the manifold.
replace all defective parts.
NOTE – On a periodical basis, it is necessary to re-

place brushes, sealing gaskets, washers, the Grower Pay special attention when assemblying the brush
washers, the pinion locking nut on the armature shaft. holder support not to damage the winding terminals.
EW–6–8
Figure 6 Power curve. Power depends on two quantities:

torque and revolving speed.
Power is null when the motor operates loadless and
when the motor is blocked.
Maximum power is at the vertex of the curve.
Nominal power is usually measured at 2/3 of the
curve.
Torque curve. Torque is null when the motor oper-

ates loadless, maximum when the motor is blocked.
Speed curve. The revolving speed curve is maxi-

mum when the motor is loadless, null when the
motor is blocked.
22649
Voltage curve. The voltage curve depends on the
BENCH TEST status of the batteries at the bench and is a function
of the current absorbed by the starter motor.
If the values measured at the bench highly differ
from test data, the motor is defective.
When assembly is completed, check that the pinion
runs freely by operating the engagement relay; also Repeat the disassembly sequence and check each
make sure that the armature rotates freely. single part.
Special attention must be paid to the polarity
jumpers of the brushes. Also check the winding ter-
minals with regard to both the brushes and the con-
trol and engagement relays.
Make sure that the winding terminals are not, or run
the risk of being caused by vibrations, to be short cir-
cuited with the pole frame, the armature or the brush
holder.
Bench test
Firmly fix the starter motor (provided with the mani-
fold side protection cover) to the test bench with the
appropriate fastening chains.
Connect the power cables to the corresponding ter-
minals in the starter motor observing their polarity.
If the values highly differ from the data shown on the
characteristic curves, disassemble the starter motor
and check each single part again.
NOTE – Bench test values also depend on the bat-

tery charge and capacity and on the duration of the
test (which must be as short as possible).
EW–6–9

ALTERNATOR
BOSCH NL1–28V–10/55A
2817
Quick diagnosis
Fault Possible causes Remedy
Failing to charge 1. Charging circuit cut off Check the connections of the
(warning light, fuse, charging circuit, clean and
connector, etc.) tighten the terminals on alter-
nator and battery
2. Inefficient voltage regulator Replace the component
3. Rotor winding cut off Replace the component
4. Worn brushes Replace the component
Insufficient charging 1. Belt slack Tension correctly

2. Faulty voltage regulator Replace the component
3. Rotor rings or brushes ex- Replace the component
cessively worn
4. Shorted diodes Replace the component
5. Shorted stator or rotor wind- Replace the component
ings
Overcharging 1. Circuit connections loose Check the connections at the

terminals and leads of bat-
teries, starter motor and alter-
nator
2. Inefficient voltage regulator Replace the component
3. Earth defective Check earth connections
EW–6–10
Bosch NL1 28V 10/55A

Type three–phase, claw–type rotor, 11–diode rectifier and electronic voltage regulator
Direction of rotation (drive side) clockwise
Current output at 6,000 rpm 55A
Rated voltage 28V
2822 3862
WIRING DIAGRAM CONNECTION
2820 2819
CURRENT OUTPUT CHARACTERISTIC VOLTAGE REGULATOR CHARACTERISTIC

CURVES CURVE
8 9 1. NUT AND WASHERS

2. FAN
3. SCREW
7 23
6 21 4. SUPPORT
4 5. BALL BEARING
5 6. PLATE
22 7. KEY
18
8. ROTOR
2 3 25 9. RING
10. BALL BEARING
24 11. O–RING
1 12. SCREW
20 13. STATOR
14. SCREW WITH WASHER
19 15. RECTIFIER
12 16. BUSHING
14 17. SUPPORT
17 18. GROMMETS
19. NUTS
20. GASKET
15 16 21. CONDENSER
11 22. WASHER
10
13 23. SCREW
24. BRUSH HOLDER REGULATOR
25. SCREW
924
EXPLODED VIEW
EW–6–11
Figure 7 TEST AND CHECKS ON THE VEHICLE

Maximum output test
NOTE – Never operate a motor with the charging cir-

cuit electrical connections disconnected or slackened
from the battery terminals.
To carry out the maximum output test on the vehicle

proceed as follows:
- connect the cable clips of equipment ”Electrical
equipment test” Ref. 99309003 to the battery
terminals observing their polarity;
- position the test selector to INT (internal);
- insert the inductive clip on the alternator main
cable observing its polarity and the direction of
3866 the arrow on the clip;
- start the motor and accelerate it;
MAXIMUM OUTPUT TEST
- operate the load rheostat lever until the value
Figure 8 read on the ammeter is equal to the alternator
max. output;
- press the ammeter connection button with the
inductive clip.
Read the battery voltage value and the alternator
charging current. These values must be equal, with-
in 10%, with regard to the charging current.
Voltage must comply with the Manufacturer’s ca-
libration values.
If the alternator output values are low and the “defec-
tive diode” light (DEFECT), located between the two
digital indicators, lights up, this may be due to a de-
fective diode or an interrupted alternator field.
Pressure drop test on the circuit
To carry out the voltage drop test on the circuit pro-
3867
ceed as follows:
PRESSURE DROP TEST ON THE CHARGING - connect the main cables of the vehicle to the bat-
CIRCUIT teries observing their polarity;
Figure 9 - connect the external voltmeter with the negative
clip to the POSITIVE terminal of the battery and
connect the positive clip to either 30 or B+ on the
alternator;
- position the test selector on EST (external);
- connect the inductive clip to the alternator cable
observing its polarity and the direction of the
arrow;
- accelerate until current output is equal to 10A.
Read the voltmeter value: it must not exceed 0.6V if
the circuit and related connections are efficient.
3868
VOLTAGE DROP TEST ON THE EARTH

CIRCUIT
EW–6–12
Voltage drop test on the earth circuit Figure 10

To carry out the voltage drop test on the earth circuit
proceed as follows:
- connect the main cables to the batteries observ-
ing their polarity;
- connect the external voltmeter with the negative
clip to the alternator body and the positive clip to
the negative terminal of the battery;
- position the selector on EST (external);
arrow;
- accelerate until current output is equal to 10A.
Check that the voltmeter value is zero, if the connec-
tions are satisfactory.
Voltage regulator calibration test 3869
To carry out the voltage regulator calibration test VOLTAGE REGULATOR CALIBRATION TEST
proceed as follows:
- connect the external voltmeter cables to the bat- Figure 11
tery terminals observing their polarity;
- position the selector on EST (external);
arrow;
- start the motor and accelerate it until the am-
meter value is slightly below 8A.
Check that the voltmeter value corresponds to the
Manufacturer’s value.
Alternator belt tensioning
To put under tension the alternator belt, proceed as
follows:
- loosen the fastening nuts of the alternator sup-
port and tensioning bracket (see Figure 11);
- insert a lever between the alternator and the 3870
motor so that the control belt is appropriately
stretched;
ALTERNATOR BELT TENSIONING
- tighten the 2 alternator fastening nuts, closing
first the nut relevant to the adjustment slot;
- make sure that the belt, which is put under ten-
sion in the medium section, bends by about 10
mm.
EW–6–13
Figure 12 Accurately dry the washed parts with compressed

air (at about 4 bars) and clean rags.
Make sure that the parts are not worn or damaged.
Any damaged, shorted or worn parts, as well as
brushes, sealing gaskets and washers, must be re-
placed.
Carry out the checks with a tester, placing the parts
on a working plane that is insulated from the bench
earth or the ground.
Special care must be taken when performing stator
and rotor insulation tests. If rotor insulation between
the slip rings and the poles is insufficient, replace the
rotor.
Insulation between any phase and the stator pack
must be perfect: otherwise replace it.
The power diodes must be checked one by one, with
2829
both forward and reverse bias.
If abnormal values are found, the rectifier must be
BENCH TEST
replaced.
To locate a fault in a generator (alternator) in con- Also the energizing winding must be checked using
firmation of the diagnosis previously carried out on an ohmmeter; if any abnormal values are found, the
the vehicle, it is necessary to perform bench tests. rotor must be replaced.
These consist of eliminating the fault(s), when the al- If the bearings must be replaced, they have to be re-
ternator is detached from the vehicle or the motor, by placed with other greaseproof bearings.
special test equipment and the Manufacturer’s data.
If a visual check finds that the rotor slip rings have
Disassembly and bench test grooves or are excessively worn, the rotor must be
Lock the alternator pulley in the vice provided with replaced.
lead vice caps. Disassemble the alternator in accord- Assembly
ance with the instructions provided here below.
During the assembly operations, after having care-
fully welded the phases, check for the good insula-
tion of the 30 or B+ terminals. Also check the O–ring
NOTE – To facilitate some disassembly operations
seal in the support seat on the rectifier side.
only use a plastic hammer.
Lubricate the rotor shaft and assemble the support
on drive side fixing the alternator with the tie rods.
After the pulley has been extracted, remove the When assembly is completed, check that the motor
washer, the fan, the key and the spacer. rotates freely and check the insulation of the 30 or
Extract the brush holder carefully, not to damage it. B+ terminal.
Remove the tie rods with their washers, extract the If, during the test, the values are considerably differ-
support on the rectifier side by beating with the ent from the characteristic curve, disassemble again
plastic hammer on the rotor shaft. and repeat the checks.
Extract the rotor by beating, always with the plastic
hammer, on the support edge, rectifier side. NOTE – The bench test values highly depend on the
battery charge and capacity and on the duration of the
Carefully unweld the three phases using pliers, in test, which must be as short as possible.
order to discharge some heat and therefore over-
heating.
When this operation is completed, wash rapidly the
parts using only liquids for electrical components:
solvent benzine, trichlorethylene.
NOTE – Due to their volatility, it is absolutely necess-

ary to observe the safety standards relating to flam-
mable liquids; furthemore, it is necessary to use pro-
tective glasses and gloves.

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– EXCAVATORS

WORKSHOP MANUAL Ex 215

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.832

- Be sure to thoroughly read this manual for correct FIAT-HITACHI S.p.A.

• Please refer to the materials listed below in addition

SERVICE MANUAL COMPOSITION

• The complete service manual consists of four

BOOK PART NUMBER

Consecutive page number for each group

Group number (if exist)

! This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 Mpa (250 kgf/cm2, 3560 psi)

Main engine troubles:

1 THE ENGINE DOES NOT START

Glow plug working Substitute.

Injection pump efficient Check and calibrate.

Fuel filters clear Replace.

2 THE ENGINE OVERHEATS

Water pump working correctly Check and replace the group.

Thermostat efficient Replace.

Radiator efficient Flush carefully, check for leakage, replace if

Air filter and piping efficient Clean or replace damaged parts.

Cylinder head seal efficient Replace.

Fan working correctly Replace.

3 THE ENGINE LACKS POWER

Fuel filters efficient Replace, following the procedure described in

Thermostat efficient Replace.

Fuel pump efficient Replace.

Injectors efficient Check and register.

Turbosupercharger working correctly Repair or replace the group.

L.D.A. circuit and device working correctly Check.

4 THE EXHAUST FUMES ARE BLACK OR

Air filter efficient Replace.

Glow plug efficient Replace.

Automatic spark lead governor working Check and replace if necessary.

Injectors efficient Overhaul and register as described.

Injection pump adjusted correctly Check thesetting as described in the appropriate

L.D.A. device efficient Check the setting of the L.D.A. device

THE EXAUST FUMES ARE GREY

Thermostat working properly Replace.

Injectors working properly Check and calibrate as described in S.I. 1094.

6 THE EXHAUST FUMES ARE BLUE

Excessive oil consumption Check: air–oil bath filter; cylinder compression.

7 ENGINE KNOCKS OR FUNCTIONS

8 THE ENGINE STOPS

Fuel in the tank Fill tank and, if necessary, flush.

Fuel filters efficient Replace.

Fuel supply circuit efficient Check the pipes and flush.

Engine timing correct Calibrate.

9 THE ENGINE EXCEEDS THE MAXIMUM

Speed regulator working correctly

10 OIL PRESSURE TOO LOW OR TOO HIGH

Pressure valve working correctly Check and replace if necessary.

Bearings efficient. Replace the bearings and if necessary grind the

11 EXCESSIVE FUEL CONSUMPTION

Air filter efficient Replace.

Injectors calibrated correctly Check and calibrate.

Injection pump calibrated correctly Check and calibrate in the workshop.

L.D.A. device efficient Calibrate the L.D.A. device.

REMOVAL & INSTALLATION

EX135 ENGINE REMOVAL & INSTALLATION

Park the machine on a level surface and lower the