Motor Diesel Iveco Camion

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CURSOR SERIESVehicle application

C78

C78 ENT C

C10C10 ENT C

C13C13 ENT C

Technical and Repair manual





F2B Cursor engines Part 1

F3A Cursor engines Part 2

F3B Cursor engines Part 3

CURSOR ENGINES

1CURSOR ENGINES



2 CURSOR ENGINES



The subjects usually dealt with in each section are:Technical data table, Driving torques, Equipment, Diagnostic, Removal and Fitting in place, Repair operations.

Where possible, the same sequence of procedures has been followed for easy reference.Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (seenext page) instead of giving descriptions of some operations or procedures.

Example

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

α

Tighten to torqueTighten to torque + angular value

1∅

∅ 2

3CURSOR ENGINES

SPECIAL REMARKS



4 CURSOR ENGINES

Graph and symbols

RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly ρ Compression ratio

Tighten to torque Tolerance

Weight difference

α

Tighten to torque + angle value Rolling torque

Press or caulk Replacement

Original spare parts

RegulationAdjustment

Rotation

! WarningNote

AngleAngular value

Visual inspectionFitting position check

Preload

MeasurementValue to findCheck

Number of revolutions

Equipment Temperature

Surface for machiningMachine finish bar

Pressure

InterferenceStrained assembly

OversizedHigher than….Maximum, peak

ThicknessClearance

UndersizedLess than….Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

Temperature < 0 °CCold

Winter

Air bleedingTemperature > 0 °CHotSummer



Section

General specifications 1

Fuel 2

Vehicle application 3

General overhaul 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the F2B engine illustrating its features

and working in general.

Section 2 describes the type of fuel feed.

Section 3 relatesto the specific duty and is divided in four sepa-

rate parts:

1. Mechanical part, related to the engine overhaul,

limited to those components with different characteristics

based on the relating specific duty.

2. Electrical part, concerning wiring harness, electrical

and electronic equipment with different characteristicsbased on the relating specific duty.

3. Maintenance planning and specific overhaul.

4. Troubleshooting part dedicated to the operators who,

being entitled to provide technical assistance, shall have simple

and direct instructions to identify the cause of the major incon-

veniences.

Sections 4 and 5 illustrate the overhaul operations of the engi-

ne overhaul on stand and the necessary equipment to execute

such operations.

Part 1

F2B CURSOR ENGINES

1F2B CURSOR ENGINES



2 F2B CURSOR ENGINES



3F2B CURSOR ENGINES

UPDATING

Section Description Page Date of revision






SECTION 1 - GENERAL SPECIFICATIONS 1F2B CURSOR ENGINES

SECTION 1

General Specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODEAND COMMERCIAL CODE 3. . . . . . . . . . . . .

VIEWS OF ENGINE 5. . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 8. . . . . . . . . . . . . . . . . . . . . . . . . .

- Oil pump 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Overpressure valve 9. . . . . . . . . . . . . . . . . . . . .

- Oil pressure control valve (on the base unit) 10. .

- Filter support and heat exchanger 10. . . . . . . . . .

- By-pass valve inside the filter support/heatexchanger assembly 11. . . . . . . . . . . . . . . . . . . . .

- Thermostatic valve 11. . . . . . . . . . . . . . . . . . . . . .

- Engine oil filters 11. . . . . . . . . . . . . . . . . . . . . . . .

COOLING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Water pump 13. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 14. . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGER 14. . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 15. . . . . . . . . . . . . . . . . . . . . .

- Turbocharger HOLSET HY55V 15. . . . . . . . . . . .



2 SECTION 1 - GENERAL SPECIFICATIONS F2B CURSOR ENGINES



CORRESPONDENCE BETWEEN TECHNICAL CODE ANDCOMMERCIAL CODE


Technical Code Commercial Code

F2BE0681A*B... C78 ENT C






LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

47525

47526

Figure 1

VIEWS OF ENGINE




FRONT VIEW

REAR VIEW

47524

47527

Figure 2




TOP VIEW

47528

Figure 3




LUBRICATION

Engine lubrication is obtained with a gear pump driven by the crankshaft via gears.A heat exchanger governs the temperature of the lubricating oil.The oil filter, signalling sensors and safety valves are installed in the intercooler.

LUBRICATION CIRCUIT

86930

Figure 4

Dropping oil

Pressure oil

B. Engine oil sump (auxiliary oil pump version)

C. Auxiliary oil pump




The oil pump (1) cannot be overhauled. On finding any damage, replace the oil pump assembly.

See under the relevant heading for replacing the gear (2) of the crankshaft.

84382 77820

60628

Figure 5

Figure 6

MAIN DATA TO CHECK THE OVERPRESSUREVALVE SPRING

OIL PUMP CROSS-SECTION

1. Overpressure valve — Start of opening pressure 10.1 ± 0.7 bars.

Overpressure valve

Figure 7

190 ± 6N

4 3 , 6 5

3 3 , 5

2 2 , 9 5

324 ± 9N

Oil pump


Print 603.93.141



The oil pressure control valve is located on the left-hand sideof the crankcase.Start of opening pressure 5 bars.

73542

98862

Figure 8

Figure 9

MAIN DATA TO CHECK THE OIL PRESSURECONTROL VALVE SPRING

Oil pressure control valve (on the base unit)

Filter support and heat exchanger

98823

Figure 10

HEAT EXCHANGER The following elements are fitted on the intercooler: 1. Oil pressure sensor for single gauge - 2. Transmitter for low pressure

warning lamp - 3. By-pass valve - 4. Heat valve. Number of intercooler elements: 7




This is a new generation of filters that permit much more thorough filtration as they are able to holder back a greater amount of particles of smaller dimensions than those heldback by conventional filters with a paper filtering element.

These high-filtration devices, to date used only in industrialprocesses, make it possible to:

- reduce the wear of engine components over time;

- maintain the performance/specifications of the oil and thereby lengthen the time intervals between changes.

External spiral winding

The filtering elements are closely wound by a spiral so thateach fold is firmly anchored to the spiral with respect to theothers. This produces a uniform use ofthe element even in theworst conditions such as cold starting with fluids with a highviscosity and peaks of flow. In addition, it ensures uniformdistribution of the flow over the entire length of the filteringelement, with consequent optimization of the loss of load andof its working life.

Mount upstream

To optimize flow distribution and the rigidity of the filteringelement, this has an exclusive mount composed of a strong meshmade of nylon and an extremely strong synthetic material.

Filtering element

Composed of inert inorganic fibres bound with an exclusiveresin to a structure with graded holes, the element ismanufactured exclusively to precise procedures and strictquality control.

Mount downstream

A mount for the filtering element and a strong nylon meshmake it even stronger, which is especially helpful during coldstarts and long periods of use. The performance of the filter remains constant and reliable throughout its working life andfrom one element to another, irrespective of the changes inworking conditions.

Structural parts

The o-rings equipping the filtering element ensure a perfectsealbetween it and the container, eliminating by-pass risks andkeeping filter performance constant. Strong corrosion-proof bottoms and a sturdy internal metal core complete the

structure of the filtering element. When mounting the filters, keep to the following rules:

- Oil and fit new seals.

- Screw down the filters to bring the seals into contact with the supporting bases.

- Tighten the filter to a torque of 35÷40 Nm.

Figure 11

The valve quickly opens at a pressure of: 3 bars.

Thermostatic valve

Start of opening:

- travel 0.1 mm at a temperature of 82 ± 2°C.End of opening:

- travel 8 mm at a temperature of 97°C.

Engine oil filters

By-pass valve inside the filter support/heatexchanger assembly

Figure 12

Figure 13

73545

47447

73546




COOLING

Description

The engine cooling system is of the closed-circuit, forced circulation type.It consists mainly of the following components:

- expansion tank, not supplied (by IVECO);

- a heat exchanger to cool down lubrication oil;

- a water pump with centrifugal system incorporated in the cylinder block;

- fan, not supplied;

- a 2-way thermostat controlling the coolant circulation.

Operation

The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat isopened and from here the coolant flows into the radiator and is cooled down by the fan.The pressure inside the system, due to temperature change, is adequately controlled through the expansion vessel.

Figure 14

92824

Water leaving the thermostat

Water entering the pump Water circulating in the engine




TO THE HEATER

TO BY- PAS S FROM THE HEAD

Figure 15

Figure 16

Figure 17

WATER PUMP SECTION

The water pump consists of: rotor, seal bearing and controlpulley.

Water circulating in the engine

Water issuing from thermostat

Water pump

Thermostat

!Make sure that the pump casing has no cracking or

water leakage; otherwise, replace the entire pump.

THERMOSTAT OPERATION VIEW

44915

45357

45358

Check thermostat operation, in case of doubts, replace it.Start of stroke temperature 84 _C ± 2 _CMinimum stroke 15 mm at 94 _C ± 2 _C

TO EXPANSION TANK

FROM THE HEAD

TO RADIATOR

TO THE HEATER




Figure 18

TURBOCHARGING

The turbocharging system consists of:

- air filter;

- variable geometry turbocharger;

- “intercooler” radiator.

98868

TURBOCHARGING DIAGRAM

TURBOCHARGEROperating principle

The variable geometry turbocharger (VGT) consists of acentrifugal compressor and a turbine, equipped with a mobiledevice which adjusts the speed by changing the area of thepassing section of exhaust gases to the turbine.

Thanks to this solution, gas velocity and turbine speed can behigh even when the engine is idling.

If the gas is made to go through a narrow passage, in fact, itflows faster, so that the turbine rotates more quickly.

The movement of the device, choking the exhaust gas flowingsection, is carried out by a mechanism, activated by apneumatic actuator.

This actuator is directly controlled by the electronic controlunit by a proportional solenoid valve.

The device is in maximum closing condition at idle speed.

At high engine operating speed, the electronic control systemis activated and increases the passing section, in order to allow

the in-coming gases to flow without increasing their speed.

A toroidal chamber is obtained during the casting process in the central body for the passage of the coolant.

Engine exhaust gas

Intake air

Compressed air (hot)

Compressed air (cooled)




Figure 19

TURBOCHARGING


- air filter;



60675


Turbocharger HOLSET HY55VOperating principle

The variable geometry turbocharger (VGT) consists of acentrifugal compressor and a turbine, equipped with a mobiledevice which adjusts the speed by changing the area of thepassing section of exhaust gases to the turbine.

Thanks to this solution, gas velocity and turbine speed can behigh even when the engine is idling.

If the gas is made to go through a narrow passage, in fact, itflows faster, so that the turbine rotates more quickly.

The movement of the device, choking the exhaust gas flowingsection, is carried out by a mechanism, activated by apneumatic actuator.



At high engine operating speed, the electronic control systemis activated andincreases the passing section, in order to allow

the in-coming gases to flow without increasing their speed.

A toroidal chamber is obtained during the casting process in the central body for the passage of the coolant.


Intake air

Engine exhaust gas







SECTION 2 - FUEL 1F2B CURSOR ENGINES

SECTION 2

Fuel

Page

FUEL FEED 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEED SCHEME WITH PUMP MOUNTEDLATERALLY 3. . . . . . . . . . . . . . . . . . . . . . . . . .

FEED SCHEME WITH PUMP MOUNTEDFRONTALLY 4. . . . . . . . . . . . . . . . . . . . . . . . . .


- Feed pump 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injector-pump 6. . . . . . . . . . . . . . . . . . . . . . . . .

- Injector Phases 7. . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 2 - FUEL F2B CURSOR ENGINES



Figure 1

92827

FUEL FEED

Fuel feed is obtained by means of a pump, fuel filter andpre-filter, 6 pump-injectors controlled by the camshaft by means of rockers and by the electronic control unit.

Return circuit

Delivery circuit

FEED SCHEME WITH PUMP MOUNTED LATERALLY

ENGINE FEED SCHEME FOR VEHICLES 4x2 - 4x4 - 6x61. Fuel filter - 2. Pressure control valve (start of opening at 5 bar) - 3. Feed pump - 4. Fuel pre-filter with priming pump -5. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) - 6. Overpressure valve to

return fuel to tank (start of opening at 0.2 bar) - 7. Fitting - 8. Central unit - 9. Heat exchanger - 10. Pump injectors

A. Fuel arriving at injectors - B. Fuel returning to tank - C. Fuel entering from injectors into feed pump




92828

Figure 2

FEED SCHEME WITH PUMP MOUNTED FRONTALLY

Return circuit

Delivery circuit

ENGINE FEED SCHEME FOR VEHICLES 8x8x4 - 8x81. Fuel filter - 2. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) - 3. Feed

pump - 4. Overpressure valve to return fuel to tank (start of opening at 0.2 bar) - 5. Pressure control valve (start of openingat 5 bar) - 6. Fuel pre-filter with priming pump - 7. Fitting - 8. Central unit - 9. Heat exchanger- 10. Pump injectors





92830

Feed pump mounted laterally 1. Overpressure valve - 2. Delivering fuel to injectors -

3. Sucking in fuel - 4. Pressure control valve

92829

Pump performances

Pump rotation speed (rpm)

Minimum flow rate (l/h)

2600

310

600

45

170

12

100

Testconditions

Negative pressureon aspiration (bar)

Pressure on delivery (bar)

Test liquid temperature (˚C)

Test liquid

0.5

5

30

0.3

3

30

0.3

0,3

30

0.3

0.3

30

ISO 4113

Field of use


Overrunning rotation speed (max 5 min) (rpm)

Diesel oil temperature (˚C)

Filtering rate on aspiration

(micron)

Negative pressure on aspiration (bar)

2600

4100 max

-25/+80

30

0.5 max

Pressure control valve

Valve calibration 5 ÷ 5.8

Injectors return valve

Valve calibration 3.4 ÷ 3.8

73547

Figure 3

Feed pump mounted frontally A. Fuel inlet — B. Fuel delivery — C. By-pass nut —

D. Fuel return from the pump-injectors — E. Pressure relief valve — Opening pressure: 5-8 bars

Feed pump

Figure 4

98870

SECTION ON FEED PUMP1. Oil and fuel leaks indicator

Figure 5

Figure 6

Pump performances

Pump rotation spee d (rpm)


4100

310

900

45

250

12

140

6

Testconditions




Test liquid

0.5

5

50

0.3

3

50

0.3

0.3

50

0.3

0.3

20

ISO 4113

Field of use





(micron)


4100

5800 max

-25/+80

0.5 max

-25/+120


Valve calibration


Valve calibration

An overpressure valve is a single-acting valve,calibrated to 0.2÷ 0.3 bar, placed on the piping that returns fuel to tank. Theoverpressure valve prevents fuel duct in cylinder head fromemptying with engine stopped.

5 ÷ 5.8

3.4 ÷ 3.8

Overpressure valve




44908

1. Fuel/oil seal — 2. Fuel/diesel seal — 3. Fuel/exhaust gas seal.

The injector-pump is composed of: pumping element, nozzle,solenoid valve.

Pumping element

The pumping element is operated by a rocker arm governeddirectly by the cam of the camshaft.The pumping element is able to ensure a high delivery pressure. The return stroke is made by means of a returnspring.

Nozzle

Garages are authorized to perform fault diagnosis solely on the entire injection system and may not work inside theinjector-pump, which must only be replaced.A specific fault-diagnosis program, included in the controlunit, is able to check the operation of each injector (itdeactivates one at a timeand checksthe delivery of the other five).Fault diagnosis makes it possible to distinguish errors of anelectrical origin from ones of a mechanical/hydraulic origin.It indicates broken pump-injectors.It is therefore necessary to interpret all the control unit error messages correctly.Any defects in the injectors are to be resolved by replacing

them.

Solenoid valve

The solenoid, which is energized at each active phase of thecycle, via a signal from the control unit, controls a slide valve

that shuts off the pumping element delivery pipe. When the solenoid is not energized, the valve is open, thefuel is pumped but it flows back into the return pipe with thenormal transfer pressure of approximately 5 bars.

When the solenoid is energized, the valve shuts and the fuel,not being able to flow back into the return pipe, is pumpedinto the nozzle at high pressure, causing the needle to lift.The amount of fuel injected depends on the length of time

the slide valve is closed and therefore on the time for which the solenoid is energized.

The solenoid valve is joined to the injector body and cannotbe removed.On the top there are two screws securing the electricalwiring from the control unit.To ensure signal transmission, tighten the screws with a torquewrench to a torque of 1.36 — 1.92 Nm (0.136 — 0.192 kgm).

Figure 7

Injector-pump






1. Fuel valve - 2. Pumping element - 3. Fuel outlet -4. Filling and backflow passage.

60671

Figure 10

Pressure Reduction phaseInjection ceases when the fuel valve (1) opens, at a certainpoint in the down stroke of the pumping element, after thesolenoid valve gets de-energized.

The fuel flows back through the open valve (1), the injector holes and the passage (4) into the cylinder head.

The time for which the solenoid valve stays energized,appropriately calculated by the electronic control unit, is theduration of injection (delivery) and it depends on theworkingconditions of the engine.




SECTION 3 - DUTY-INDUSTRIAL APPLICATION 1F2B CURSOR ENGINES

SECTION 3

Vehicle application

Page

CLEARANCE DATA 3. . . . . . . . . . . . . . . . . . . . .

PART ONE - MECHANICAL COMPONENTS 5

DISMANTLING THE ENGINE ON THE BENCH 7

ASSEMBLING THE ENGINE ON THE BENCH 14.

- Diagram showing the underblock fixing screws tightening order 16. . . . . . . . . . . . . . . . . . . . . . . .

- Fitting the connecting rod-piston assembly into thecylinder liners 17. . . . . . . . . . . . . . . . . . . . . . . . .

- Mounting cylinder head 18. . . . . . . . . . . . . . . . . .

- Fitting engine flywheel 20. . . . . . . . . . . . . . . . . . .

- Fitting camshaft 21. . . . . . . . . . . . . . . . . . . . . . . .

- Fitting pump-injectors 22. . . . . . . . . . . . . . . . . . .

- Fitting rocker-arm shaft assembly 22. . . . . . . . . .

- Camshaft timing 23. . . . . . . . . . . . . . . . . . . . . . .

- Phonic wheel timing 25. . . . . . . . . . . . . . . . . . . .

- Intake and exhaust rocker play adjustment andpre-loading of rockers controlling pump injectors 26

ENGINE COMPLETION 27. . . . . . . . . . . . . . . . . .

PART TWO -ELECTRICAL EQUIPMENT 29. . . . . . . . . . . . .

- Components on the engine F2B 31. . . . . . . . . . .

BLOCK DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . .

- EDC MS 6.2 electronic control unit 33. . . . . . . .

- EDC control unit PIN-OUT -Connector “A” (Engine) 34. . . . . . . . . . . . . . . . .

- EDC control unit PIN-OUT -Connector “B” (Frame area) 35. . . . . . . . . . . . . .

- Pump injector (78247) 36. . . . . . . . . . . . . . . . . .

- Engine coolant temperature sensor (85153) 37. .



2 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F2B CURSOR ENGINES

Page

- Fuel temperature sensor (47042) 38. . . . . . . . . .

- Flywheel pulse transmitter (48035) 39. . . . . . . . .

- Distribution pulse transmitter (48042) 40. . . . . .

- Overfeed pressure transmitter (85154) 41. . . . . .

- Air temperature transmitter on manifold (85155) 42. . . . . . . . . . . . . . . . . . . .

- Pre-post reheat resistor (61121) 43. . . . . . . . . . .

EDC SYSTEM FUNCTIONS 44. . . . . . . . . . . . . . . .

PART THREE - TROUBLESHOOTING 47. . . . . .

PREFACE 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART FOUR - MAINTENANCE PLANNING 57.

MAINTENANCE 59. . . . . . . . . . . . . . . . . . . . . . . . .

- Maintenance services scheme 59. . . . . . . . . . . . .

CHECKS AND/OR MAINTENANCE WORK 60. .

OFF-PLANE OPERATIONS 61. . . . . . . . . . . . . . . .




CLEARANCE DATA

*Type ...

ρ Compression ratio 16 ± 0.8

Max. output kW(HP)rpm

228(310)

2100

Max. torque Nm(kgm)rpm

1115(114)2400

Loadless engineidling

rpm 525 ± 25

Loadless enginepeak

rpm 2760 ± 20

Bore x stroke mmDisplacement cm3

115 x 1257790

SUPERCHARGING

Turbocharger type

Overfedwith aftercooler

HOLSET HY40V with variable geometry

bar

LUBRICATION

Oil pressure(warm engine)

- idling bar - peak rpm bar

Forced by gear pump, relief valve single actionoil filter

1.55

COOLING Water pump controlThermostat- start of opening ºC

LiquidThrough belt

85






PART ONE - MECHANICAL COMPONENTS









Remove the following components:

- alternator (1);

- belt tightener support (2);

- if present, air conditioner compressor (3);

- water pump (5) and pipe;

- fixed backstand (4).

Only models equipped without Intarder

- thermostat unit (6).

73579

87202

Figure 4

Figure 5

Figure 6

Figure 7

Using an appropriate tool (2), operate in the direction of thearrow, and remove the belt (1) driving the water pump,alternator and fan.Take out the screws and remove the electromagneticcoupling (3).

87201

Use the suitable wrench to operate the roller fastening screw(2) on the backstand (3) in the direction shown by the ar-r o w t o s l a c k e n t h e b e l t t e n s i o n i n g ( 1 ) a n d r e -move the belt. Take out the screws and remove the electro-magnetic coupling (3).

The screw (2) cannot be slackened when the threadis left-hand.

Only models equipped with IntarderLoosen straps (2 and 4), then remove pipe (1) from thecylinder head and pipe (3).Remove the fastening screws, then take off thermostat unit

(5).

87203

NOTE




Remove the following components: oil supply lines (1); water cooling supply lines (3); water discharge lines (2); oil returnlines (4); turbocharger (5); exhaust manifold (6).

87204

45254

47566

Figure 8

Figure 9

Figure 10

Block the flywheel rotation with tool 99360351.

Remove screws (4), then disassemble damper flywheel (3).

Remove the screws (2) and the pulley (1).

87205

Figure 11

Unscrew the oil filter (1) by tool 99360314 (2).

Install extractor 99340051 (2) and remove the seal gaskets(1). Unscrew the screws and remove the cover.Disconnect all electric connections and sensors.

87206

Figure 12

Unscrew the screws (1) and remove the entire heat exchanger (2).




Remove the following components: intake manifold (6);support for fuel filter (1); fuel lines (2); fuel pump(3);compressor (4); control unit (5).

47587

45661

86289

47568

Figure 13

Figure 14

Unscrew the screws (2), by using the proper wrench andremove the gear (1) with the phonic wheel.

By means of a properly splined wrench, untighten screws (2)

and remove the transmission gear (1)

84377

Remove the rocker arm cover (1), take off the screws (2) andremove: the cover (3), the filter (5) and the gaskets (4 and 6).Take off the screws (8) and remove the blow-by case (7).

70708

To remove the P.T.O. (if applicable):

- Disconnect the oil pipe (1).- Unscrew the 4 screws (2) and (3).

Figure 15

Figure 16

Figure 17

Figure 18

Unscrew the screws (1); tighten a screw in a reaction hole andremove the shoulder plate (2), remove the sheet gasket.




47569

4525745259

Figure 19

Figure 20

Figure 21

Apply extractor 99340052 (2) and pull out the seal gasket (1).

Untighten the screws (1) and take down the gear box (2).

- Remove the check springs (2) of the exhaust brake lever;

- Untighten the fixing screws (1) of rocker arm shaft.

47568

Stop the engine flywheel (3) rotation by means of tool99360351 (1), untighten the fixing screws (2) and remove theengine flywheel.

73533

- Using tool 99360144 (3), constrain the blocks (4) to therockers (2).

- Apply tool 99360553 (1) to the rocker holder shaft (5)and remove the shaft (5) from the cylinder head.

In sequence, take out the:- if the P.T.O. control gear (1) is present;- idle gear (2);- oil pump gear (3).

Figure 22

Figure 23

Figure 24

1




45266

- Remove injectors (2)

If this operations is difficult, use extractor 99342148 (1). Installplugs 99360177 instead of injectors.

45263

47574

Remove the camshaft and the fixing screws on cylinder heads

- By means of wire ropes, lift the cylinder head (1) andremove seals (2). Rotate the block (1) to the vertical position.

45262

- Remove the piping (1) for exhaust brake pins;

- Untighten screws and remove electric connections (2)from solenoid valves;

- Untighten fixing screws (3) of injector brackets (4).

4

3

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30

86923

86924

Untighten screws (2) and remove the engine oil sump (1) withspacer (3) and seal .The box shows the oil sump mounted on the enginesequipped with supplementary oil pump.

Remove the screws and the rose pipe (1).For engines equipped with supplementary oil pump, remove

the screws and take out strainers (2 and 3).

2




47576

47571

47570

By means of proper and splined wrenches, untighten thescrews (1) and (2) and remove the under-block (3).

Remove the crankshaft (2) with tool 99360500 (1).

Remove the crankshaft half-bearings (1), untighten the screwsand remove oil spray nozzles (2).Takedown cylinder linersas specified in therelative paragraph.

After disassembling the engine, thoroughly cleandisassembled parts and check their integrity.Instructions for main checks and measures are givenin the following pages, in order to determinewhether the parts can be re-used.

47575

Untighten screws (2) fixing the connecting rod cap (3) andremove it. Remove the connecting rod-piston assembly from

the upper side. Repeat these operations for the other pistons.

Figure 31

Figure 32

Figure 33

Figure 34

NOTE




47586

47595

47596

Figure 35

Figure 36

Figure 37

Figure 38

Fix the engine block to the stand 99322230 by means of brackets 99361035.Mount cylinder liners (see Section 4).

Fit the oil spray nozzles (2), so that the dowel coincides with the block hole (3).

Place the half bearings (1) on the main bearings.

Place the half-bearings (1) on the main bearings in theunderblock (2).

Use the suitable equipment (1) to apply silicone LOCTITE5970 (IVECO No. 2995644) as shown in the following figure.

Sealant application diagram

Fit the underblock within 10’of the application of thesealant.

47570

Figure 39

Lubricate the half bearings, then install the crankshaft (2) by means of hoist and hook 99360500 (1).

49021

NOTE

ASSEMBLING THE ENGINE ON THEBENCH




47581

47579

Figure 40

Figure 41

Figure 42

Fit the engine block and use the dynamometric wrench (2) to lock the hexagonal threaded screws(1) to torque 25 Nmon the basis of the diagrams on the following page.

Close the inner screws (1) to 140 Nm torque by means of a dynamometric wrench (3), then with two further angular phases 60° + 60°, using tool 99395216 (4). Tighten again theouter screws (1, Figure 41) with 90° angular closing, using

tool 99395215 (3, Figure 41).

Fit the underblock by means of a suitable hoistand hooks (1).

α

α

49022




44898

FRONT SIDEFourth phase:inner screwsangle closing

(60º)

44897

44899

44898

Figure 43

First phase: outer screws preliminary

tightening

(25 Nm)

FRONT SIDE

FRONT SIDE

FRONT SIDE

Second phase:inner screwspreliminary tightening

(140 Nm)

Fifth phase:outer screwsangle closing

(90º)

44898

FRONT SIDE

Third phase:inner screwsangle closing

(60º)

Diagram showing the underblock fixing screws tightening order




49030

Rotate the cylinder assembly placing it vertically.Lubricate the half-bearings (1) and fit them in the connectingrod and the cap.

Figure 44

Connecting rod-piston assembly

Marking area of ideogram on the pistoncrown

Connecting rod marking area

Figure 45

47593

Fit the connecting rod-piston assemblies (2) into the pistonliners, using the band 99360605 (1). Check the following:

- the openings of the split rings are offset by 120º;

- all pistons belong to the same class, A or B;- ideogram (2, Figure 45), stamped on the piston crown,

is placed towardthe engine flywheel,or thecavity, on thepiston skirt, corresponds to the position of the oil spray nozzles

Fitting the connecting rod-piston assembly intothe cylinder liners

Figure 46

1

2

361831

Not finding it necessary to replace the connectingrod bearings, you need to fit them back in exactly

the same sequence and position as in removal.If they are to be replaced, choose connecting rodbearings based on selection described in Section 4.

Do not make any adjustment on the bearing shells.

Lubricate the half-bearings (1) and fit them in the connectingrod and the cap. The pistons are supplied as spares in class A and can

also be fitted in class B cylinder liners.

NOTE

NOTE

NOTE




47594

Figure 47

Figure 48

Figure 49

Figure 50

Figure 51

Figure 52

Connect the connecting rods to the relative journals, fit theconnection rod caps (1) with half bearings; tighten the fixingscrews (2) of the connecting rod caps to 50 Nm torque (5kgm). Using tool 99395216 (3), further tighten screws with40° angle.

By means of centering ring 99396033 (2), check the exactcover position (1), otherwise act as necessary and tighten thescrews.

Fit the sealing gasket (1), install the fitting tool 99346245 (2)and drive the sealing gasket (1) by screwing nut (3).

Make sure that pistons 1-6 are exactly at the TDC Place thesealing gasket (2) on the block. Fit the cylinder head (1) and

tighten screws as shown in figs. 51, 52 and 53.

Diagram showing the cylinder head fixing screws tighteningorder

- Preliminary tightening by means of a dynamometricwrench (1):1st phase: 50 Nm (5 kgm:

2nd phase: 100 Nm (10 kgm)

45255

45256

α

45266

45267

44900

Mounting cylinder head




Engines without power take-off

Tighten the screws shown in the figure by means of adynamometric wrench, in compliance with the following order and tightening torque:

no. 1 screw M10 x 1.5 x 100 tightening torque 42 Nm

no. 13 screws M12 x 1.75 x 80 tightening torque 63 Nm



Figure 53

Figure 54

Figure 55

45268

- Angle closing by means of tool 99395216 (1):3rd phase: 90° angle4 th phase: 75° angle

Fit the oil pump (4), intermediate gears (2) with rod (1) and tighten screws (3) in two phases:

preliminary tightening 30 Nmangle closing 90°

Apply sealant LOCTITE 5970 IVECO No. 2992644 to thegear box using the proper equipment (1).

The sealer string (1) diameter is to be 1,5 ±

47592

47597

47598

Figure 56

α

Install the gear box within 10’ of the application of the sealant.

α

no. 2 screws M18 x 1.25 x 125 tightening torque24 Nm

:

Engines with power take-off (if available)





84390

no.2screwsM12x1.75x125tighteningtorque63Nm

¬

d no. 8 screw M10 x 1,5 x 120◊ no. 2 screw M10 x 1,5 x 120 (apply to the thread

LOCTITE 275)

Figure 57

0.50.2

NOTE





Second phase:closingto angle of 60° with tool 99395216 (1).

49036

α

Figure 58

Figure 59

The crankshaft has a locating peg that has to couplewith the relevant seat on the engine flywheel.

49037

Figure 60

Position the flywheel (1) on the crankshaft, lubricate the thread of the screws (2) with engine oil and screw themdown. Lock rotation with tool 99360351 (3). Lock thescrews (2) in three phases.First phase: pre-tightening with torque wrench (4) to a

torque of 100 Nm (10 kgm).

If the teeth of the ring gear mounted on the engineflywheel, for starting the engine, are very damaged,replace the ring gear. It must be fitted after heating

the ring gear to a temperature of approx. 200°C.

α

Fitting engine flywheel

Fit the sealing gasket (1), install the fitting tool 99346246 (2)and drive the sealing gasket by screwing the nut (3).

45258

60668

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONSA. Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4. - B. Hole on flywheel with onereferencemark, corresponding to the TDC of pistons 1-6. - C. Hole on flywheel with one reference mark, corresponding

to the TDC of pistons 2-5. - D. Hole on flywheel with two reference marks, position corresponding to 54°.

VIEW OF HOLES:A - B - C

VIEW OF HOLES:D

Figure 61

NOTE

NOTE



Figure 62

Figure 63

Fit the camshaft (4), positioning it observing the referencemarks (→) as shown in the figure.Lubricate the seal (3) and fit it on the shoulder plate (2).Mount the shoulder plate (2) with the sheet metal gasket (1)and tighten the screws (5) to the required torque.

73843

72436

Figure 64

Figure 65

Position the crankshaft with the pistons 1 and 6 at the topdead centre (T.D.C.).This situation occurs when:

1. The hole with reference mark (5) of the engine flywheel(4) can be seen through the inspection window.

2. The tool 99360612 (1), through the seat (2) of the enginespeed sensor, enters the hole (3) in the engine flywheel (4).

If this condition does not occur, turn the engine flywheel (4)appropriately.Remove the tool 99360612 (1).

Replace the idle gear bushing (1) when wear isdetected. After installing the bushing, adjust it to j58.010 ± 0.10 mm.

- Apply gauge 99395215 (1), check and record theposition of the rod (3) for the transmission gear, tighten

the screw (2) to the prescribed torque.

45376

- Remove the transmission gear (1) and tighten screws (2)by means of proper splined wrench, to the prescribed

torque.

45269

Fitting camshaft

NOTE





5

Position the gear (2) on the camshaft so that the 4 slots are

centred with the holes for fixing the camshaft, without fully locking the screws (5).Using the dial gauge with a magnetic base (1), check that theclearance between the gears (2 and 3) is 0.073 — 0.195 mm;if this is not so, adjust the clearance as follows:

- Loosen the screws (4) fixing the idle gear (3).

- Loosen the screw (2, Figure 64) fixing the link rod. Shift the link rod (3, Figure 64) to obtain the requiredclearance.

- Lock the screw (2, Figure 64) fixing the link rod andscrews (4, Figure 64) fixing the idle gear to the required

torque.

44908

Fit the seals (1) (2) (3) on the injectors.

Before refitting the rocker-arm shaft assembly,make sure that all the adjustment screws havebeenfully unscrewed.

Using tool 99360144 (3), fasten the blocks (4) to the rocker arms (2).Apply the tool 99360553 (1) to the rocker arm shaft (5) andmount the shaft on the cylinder head.

73533

Fitting pump-injectors

71775

Fitting rocker-arm shaft assembly

Figure 66

Figure 67

Figure 68

Figure 69

45270

NOTE

Mount:

- The injectors (2) and, using a torque wrench, lock thebracket fixing screws to a torque of 26 Nm.

- The exhaust brake cylinders (1) and (4) and, using a torque wrench, fix them to a torque of 19 Nm.

- The crosspieces (3) on the valve stem, all with the largesthole on the same side.



Apply the tool 99360321 (6) to the gearbox (3).

- Mount the engine brake lever retaining springs (3).- Connect the pipe (2) to the engine brake cylinders (4) and

to the cylinder with the engine brake solenoid valve (1).

Figure 70

Figure 71

Figure 72

45261

Lock the screws (2) fixing the rocker-arm shaft as follows:

- 1st phase: tightening to a torque of 40 Nm(10 kgm) with the torque wrench (1).

- 2nd phase: closing with an angle of 60° using the tool99395216 (3).

60574

71776

71777

Figure 73

Mount the electric wiring (2), securing it on theelectro-injectors with a torque screwdriver (1) to a torqueof 1.36 - 1.92 Nm.

α

The arrow shows the direction of rotation of theengine when running.Using the above-mentioned tool, turn the engineflywheel (1) in the direction of rotation of the engineso as to take the piston of cylinder no.1 toapproximately the T.D.C. in the phase of combustion.This condition occurs when the hole with onereference mark (4), after the hole with tworeference marks (5) on the engine flywheel (1), canbe seen through the inspection window (2).

NOTE

Camshaft timing

Figure 74

SCHEME OF SCREW TIGHTENING SEQUENCESECURING ROCKER ARMS

Screw screws (1 - 2 - 3) until rocker arms are brought tocontact relating seats on cylinder head, tighten the screwsaccording to sequence indicated in figure operating in twosteps as indicated in successive figure.

70567A

3





71774

60573

60575

The exact position of piston no.1 at the T.D.C. is obtainedwhen in the above-described conditions the tool 99360612(1) goes through the seat (2) of the engine speed sensor into

the hole (3) in the engine flywheel (4).If this is not the case, turn and adjust the engine flywheel (4)

appropriately.Remove the tool 99360612 (1).

Set the dial gauge with the magnetic base (1) with the rodon the roller (2) of the rocker arm that governs the injector

of cylinder no.1 and pre-load it by 6 mm.

With tool 99360321 (6, Figure 74), turn the crankshaftclockwise until the pointer of the dial gauge reaches theminimum value beyond which it can no longer fall.

Reset the dial gauge.

Turn the engine flywheel anticlockwise until the dial gauge givesa reading for the lift of the cam of the camshaft of 4.90 ±0.05mm.

The camshaft is in step if at the cam lift values of 4.90 ±0.05 mm

there are the following conditions:

1) the hole marked with a notch (5) can be seen through the inspection window;

2) thetool99360612(1)throughthe seat(2)ofthe enginespeed sensor goes into the hole (3) in the engineflywheel (4).

If you do not obtain the conditions illustrated in Figure 77 anddescribed in points 1 and 2, proceed as follows:

1) loosen the screws (2) securing the gear (1) to thecamshaft and utilize the slots (1, Figure 79) on the gear (2, Figure 79);

2) turn the engine flywheel appropriately so as to bringabout the conditions described in points 1 and 2Figure 77, it being understood that the cam lift must notchange at all;

3) lock the screws (2) and repeat the check as describedabove.

Tighten the screws (2) to the required torque.

77259

Figure 75

Figure 76

Figure 77

Figure 78




71778

When the adjustment with the slots (1) is not enough tomake up the phase difference andthe camshaft turns becauseit becomes integral with the gear (2); as a result, the referencevalue of the cam lift varies, in this situation it is necessary toproceed as follows:

1) lock the screws (2, Figure 78) and turn the engineflywheel clockwise by approx. 1/2 turn;

2) turn the engine flywheel anticlockwise until the dial gaugegives a reading of the lift of the cam of the camshaft of 4.90±0.05 mm;

3) take out the screws (2, Figure 78) and remove the gear (2) from the camshaft.

Turn the flywheel (4) again to bring about the followingconditions:

- a notch (5) can be seen through the inspection window;

- the tool 99360612 (1) insertedto the bottomof the seatof the engine speed sensor (2) and (3) on the flywheel(4).

Phonic wheel timing

Turn the crankshaft by taking the piston of cylinder no. 1 into the compression phase at T.D.C.; turn the flywheel in theopposite direction to the normal direction of rotation by approximately 1/4 of a turn.

Again turn the flywheel in its normal direction of rotationuntil you see the hole marked with the double notch (4)

through the inspection hole under the flywheel housing.Insert tool 99360612 (5) into the seat of the flywheel sensor (6).

Insert the tool 99360613 (2), via theseat of the phase sensor,onto the tooth obtained on the phonic wheel.

Should inserting the tool (2) prove difficult, loosen thescrews(3) and adjust the phonic wheel (1) appropriately so that the

tool (2) gets positioned on the tooth correctly. Go ahead and tighten the screws (3).

Mount the gear (2, Figure 79) with the 4 slots (1, Figure 79)centred with the fixing holes of the camshaft, locking therelevant screws to the required tightening torque.Check the timing of the shaft by first turning the flywheelclockwise to discharge the cylinder completely and then turn

the flywheel anticlockwise until the dial gauge gives a readingof 4.90 ±0.05.Check the timing conditions described in Figure 77.

77259

77260

Figure 79

Figure 80

Figure 81




Clockwisestart-up

and rotation

Adjustingcylinder

valve no.

Adjustingclearance

of cylinder valve no.

Adjustingpre-loadingof cylinder injector no.

1 and 6 at TDC 6 1 5120º 3 4 1

120º 5 2 4

120º 1 6 2

120º 4 3 6

120º 2 5 3

- using an appropriate wrench (4), loosen theadjustment screw until the pumping element is at theend-of-stroke;

- tighten the adjustment screw, with a dynamometricwrench, to 5 Nm tightening torque (0.5 kgm);

- untighten the adjustment screw by 1/2 to 3/4 rotation;

- tighten the locking nut.

FIRING ORDER 1-4-2-6-3-5

The adjustment of clearance between the rockers and rodscontrolling the intake and exhaust valves, as well as theadjustment of pre-loading of the rockers controlling pumpinjectors, must be carried out carefully.

Take the cylinder where clearance must be adjusted to thebursting phase; its valves are closed while balancing thesymmetric cylinder valves.Symmetric cylinders are 1-6, 2-5 and 3-4.

In order to properly operate, follow these instructions anddata specified on the table.

Adjustment of clearance between the rockers and rodscontrolling intake and exhaust valves:

- use a polygonal wrench to slacken the locking nut (1) of the rocker arm adjusting screw (2).

- insert the thickness gauge blade (3);

- tighten or untighten the adjustment screw with theappropriate wrench;

- make sure that the gauge blade (3) can slide with a slightfriction;

- lock the nut (1), by blocking the adjustment screw.

Pre-loading of rockers controlling pump injectors:

- using a polygonal wrench, loosen the nut locking therocker adjustment screw (5) controlling the pumpinjector (6);

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

In order to properly carry out theabove-mentioned adjustments, follow thesequence specified in the table, checking the exactposition in each rotation phase by means of pin99360612, to be inserted in the 11 th hole in eachof the three sectors with 18 holes each.

Figure 82

99272

Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors

NOTE



DIAGRAM FOR THE INSTALLATION OF FAN BELTS - WATER PUMP - ALTERNATOR AND CONDITIONER

COMPRESSOR 1. Alternator - 2. Fan - 3. Water pump - 4. Crankshaft -

5. Conditioner compressor.

ENGINE COMPLETION

Complete the engine by installingor connecting thefollowingcomponents:

- thermostatic unit;

- belt tensioner, water pump, alternator;

- control belt;

- belt tensioner, conditioner compressor;

- control belt.

Figure 83

Figure 84

44921

47564

To install belts (1-3), use the appropriate tools (2-4,) to work on the tensioners, as shown by arrows.

84377

Fit the distribution cover (1).

Fit the blow-by case (7) and its gasket and then tighten thescrews (8) to the prescribed torque.

Install the filter (5) and the gaskets (4 and 6).

The filter (5) operation is unidirectional, thereforeit must be assembled with the two sight supportsas illustrated in the figure.

Fit the cover (3) and tighten the fastening screws (2) to theprescribed torque.

Apply silicone LOCTITE 5970 (IVECO No.2995644) on the blow-by case (7) surface of engines fitted with P.T.O. according to theprocedure described in the following figure.

84392

Apply silicone LOCTITE 5970 (IVECO No. 2995644) on theblow-by case and form a string (2) of ∅ 1.5 ±, as shownin the figure.

Fit the blow-by case (1) within 10’ from sealer application.

Figure 85

Figure 86

0.50.2

NOTE

NOTE

NOTE




- damping flywheel;

- fan;

- compressor;

- fuel pump;

- fuel filter and piping;

- pre-heating resistance;

- intake manifold;

- soundproof shields;

- heat exchanger;

- oil filter, lubricating the gasket;

- rockers caps;

- exhaust manifold;

- turbocharger and its oil and water piping;

- power take-off (P.T.O.) (if any) and related pipes;

- oil level stick and oil vapor vent;

- rotate the engine, then mount the oil strainer (or strainers, if an engine equipped with supplementary oilpump is available).

Automatic tensioners do not require further adjustments after the installation.

86929

Figure 87

- place the gasket (4) on the oil sump (1), position thespacer (3) and fit the sump to the engine block by

tightening screws (2) to the prescribed torque;

- electric connections and sensors;

- remove the engine from the stand and fit the starter;

- fill the engine with the oil quantity required.

Box A shows the oil sump mounted on the engines equippedwith supplementary oil pump.

NOTE




PART TWO -

ELECTRICAL EQUIPMENT







A. Resistance for engine warming - B. Fuel filter clogged signalling switch - C. Fuel temperature sensor - D. Engine rpm sensor on camshaft - E. Starter motor - F. Engine intake air temperature sensor - G. Alternator - H. Boosting pressure sensor -

I. Conditioner compressor - L. EDC (MS6.2) control unit - M. Connector on engine head for connection with injector solenoidvalves - N. Water temperature for EDC (MS6.2) - O. Water temperature sensor - P. Oil pressure transmitter -

Q. Engine speed on flywheel sensor - R. Low oil pressure transmitter.

ENGINE RIGHT-HAND SIDE VIEW

ENGINE LEFT-HAND SIDE VIEW

Figure 1

Figure 2

99286

99287

Components on the engine F2B

(Demonstration)

(Demonstration)




Figure 3

99288

KEYS1. Accelerator pedal position sensor / switch accelerator depressed — 2. Engine coolant temperature sensor — 3. Oversupply air temperature sensor — 4. Fuel temperature sensor — 5. Oversupply air pressure sensor — 6. Input for electronic tachograph

(if available) — 7. Output for electronic revs counter (if available) — 8. E.D.C. system failure warning light — 9. Blink—code button(if available) — 10. Diagnosis connector — 11. CAL L-H line — 12. Pump-injectors — 13. Warning light for pre/post-heating

activated — 14. Remote control switch for pre/post-heating activation — 15. Pre/post-heating resistance — 16. Main remotecontrol switch — 17. Flywheel sensor — 18. Distribution sensor — 19. Cruise Control buttons (if available) — 20. Clutch switch —

21. Primary / secondary brake switch.

BLOCK DIAGRAM




Connector “A” engine

Connector “B” chassis/cabin

EDC MS 6.2 electronic control unit

Figure 4




EDC control unit PIN-OUT - Connector “A” (Engine)

Figure 5


Pin Function

1 - Engine rev sensor

2 - Distribution rev sensor

3 - ---

4 - Air temperature sensor mass5 - Engine coolant temperature sensor mass

6 - Engine oil temperature and fuel temperature sensor ground

7 - ---

8 - ---

9 - ---

10 - Engine oil temperature sensor signal

11 - Fuel temperature sensor signal

12 - Oversupply pressure sensor signal



15 - ---

16 - ---

17 - Boosting pressure sensor ground

18 - ---

19 - ---

20 - ---

21 - Air temperature sensor signal

22 - Engine coolant temperature sensor signal

23 - Oversupply pressure sensor power supply

24 - Injector power supply for cylinders 1 / 2 / 3


26 - Cylinder 4 injector control



29 - ---30 - ---

31 - ---

32 - ---




Colour code

B White

BG Beige

C Orange

23 G Yellow

13 H Grey

L Blue

M Brown

N Black

R Red

24 35 000576t S Pink

V Green

EDC CONTROL UNIT DIAGRAM WITH ELECTRICAL CONNECTIONS TO CONNECTOR “A” Z Purple



EDC control unit PIN-OUT - Connector “B” (Frame area)

Figure 6


Pin Functions1 - Negative direct from battery / blink button — code

2 - Negative direct from battery / blink button — code

3 - Positive from main remote switch

4 - Positive from main remote switch5 - Signal for electronic rev. counter (if available)

6 - Negative for EDC / blink button — code warning light (if available)

7 - CAN line for Multiplex electric system architecture

8 - ---

9 - Engine phase signal for diagnosis connector

10 - Negative for pre-post heating remote switch engagement

11 - CAN - L line for interconnection of the CAN line with control units (if any) available with the application

12 - CAN - H line for interconnection of the CAN line with control units (if any) available with the application

13 - K line for diagnosis connector

14 - ---

15 - Key controlled supply positive

16 - Accelerator pedal position sensor supply 17 - Negative from idler switch

18 - Negative for warning light pre — post heating

19 - ---

20 - Positive from N.C. clutch switch (if available)

21 - Function “RESUME” Cruise Control (if available)

22 - Positive from speed reducer switch (if available)

23 - Accelerator pedal position signal sensor

24 - L line for diagnosis connector

25 - Negative for accelerator pedal, multiple-state switch for torque reducer and negative for engine speed and vehicle

speed sensors

26 - Positive from primary N.C. brake switch

27 - Negative for main remote switch28 - Signal from the multiple-state switch for the torque reducer (if available)

29 - Vehicle speed (D3 tachograph) signal (if available)

30 - PWM line

31 - Positive from N.C. redundant brake switch

32 - Function “SET —“ Cruise Control (if available)

33 - Function “OFF +” Cruise Control (if available)

34 - Function “SET +” Cruise Control (if available)

35 - Negative for accelerator pedal position sensor

WIRING DIAGRAM OF EDC CONTROL UNIT WITH CONNECTIONS TO CONNECTOR ”B”

1

13

24 35 000576t

12

23



Pump injector (78247)

It consists mainly of:

A) Solenoid valve

B) Pumping element

C) Nozzle

These three parts CANNOT be replaced individually and CANNOT be overhauled.

The pumping element, mechanically actuated at every rocker arm cycle, compresses the fuel container in the delivery chamber.

The nozzle, whose composition and operation are similar to those of traditional injectors, is opened by the fuel under pressureand sprays it into the combustion chamber.

A solenoid valve, directly controlled by the electronic control unit, determines delivery according to the control signal.

A casing houses the lower part of the pump injector in the cylinder head.

Figure 7

A

B

C

001694t




TECHNICAL VIEW

8527 000602t

WIRING DIAGRAM

PERSPECTIVE VIEW

000693t

Figure 8


Engine coolant temperature sensor (85153)

This N.T.C. type sensor located on the water outlet sump on the engine head left measures coolant temperature for the various

operating logics with a hot or cold engine and identifies injection enrichment requirements for a cold engine or fuel reduction

requirements for a hot engine.

It is connected to electronic center pins A5/A22.

Sensor behavior as a function of temperature:

- 10 °C 8,10 ÷ 10,77 kOhm+ 20 °C 2,28 ÷ 2,72 kOhm

+ 80 °C 0,29 ÷ 0,364 kOhm

At 60 to 90 _C, voltage at A5 and A22 ranges from 0.6 to 2.4V.

Connector Function Cable colour

2 To EDC center pin A 5 –




Figure 9

Fuel temperature sensor (47042)

Specifications

Supplier BOSCHMax. tightening torque 35 Nm

It is an N.T.C. type sensor positioned on engine lh side fuel filter.It detects fuel temperature value enabling electronic central unit to determine fuel density and volume by rectifying delivery.

TECNICAL VIEW

8527 8528

WIRING DIAGRAM

PERSPECTIVE VIEW

8529 8530

RESISTANCE TREND


Pin Function Cable colour

2 To pin 6 of EDC control unit – 3 To pin 11 of EDC control unit –



HOLES ON FLYWHEEL

TECHNICAL VIEW WIRING DIAGRAM

PERSPECTIVE VIEW

8520

Figure 10

Figure 11

Figure 12

Figure 13


Flywheel pulse transmitter (48035)

Features

Vendor BOSCHTorque 8 ± 2 NmResistance 880 ÷ 920 Ω

This induction type sensor located on the flywheel generates signals obtained from the magnetic flow lines that close through 54holes in three series of 18 in the flywheel.

The electronic center uses this signal to detect the various engine ratings and pilot the electronic rev counter.

The rev counter does not operate in the absence of this signal.

This sensor’s air gap is NOT ADJUSTABLE.




3 Shields –




PERSPECTIVE VIEW 8520REFERENCE ON SOUND WHEEL000606t

Figure 14


Distribution pulse transmitter (48042)

Features


This induction type sensor located on the camshaft generates signals obtained from the magnetic flow lines that close through the6 plus 1 phase teeth of a sound wheel mounted on the shaft.

The electronic center uses the signal generated by this sensor as an injection step signal.

Though electrically identical to engine rpm sensor mounted in the camshaft in is NOT interchangeable with it as it cable is shorter and it features a larger diameter.





3 Shields –



TECHNICAL VIEW

8521

8522

max abosulte pressure 600 kPa

PERSPECTIVE VIEW8523

Figure 15 Figure 16

Figure 17


Overfeed pressure transmitter (85154)

Features

Vendor BOSCHCode B 281022 018Operating pressure range 50 ÷ 400 kPaMaximum torque 10 Nm

This pressure strain gauge transducer located on the intake to the intake manifold downstream the intercooler on the engine left

side measures air overfeed pressure to the intake manifold.This measurement, together with the air temperature sensor finding, enables the electronic center to exactly define the amountof air admitted to the cylinders so as to pilot injectors by adjusting fuel supply, limit noxious emissions and improve fuel consumptionand engine performance.

The sensor is provided with an internal temperature correction electronic circuit to optimize pressure measurement as a functionof admitted air temperature.







TECHNICAL VIEW

8527 8528

WIRING DIAGRAM

PERSPECTIVE VIEW

8529 8530

RESISTANCE BEHAVIOR

Figure 18

Figure 19

Figure 20

Figure 21


Air temperature transmitter on manifold (85155)

Features

Vendor BOSCHMaximum torque 35 Nm

The device must carry Vendor identification, unit part number and manufacture date.

Together with the overfeed pressure sensor, this N.T.C. type sensor located on the intake manifold input downstream the

intercooler on the engine left supplied the electronic center with the parameters required to identify proper air delivery values.






Pre-post reheat resistor (61121)

000025t

A. Pre/ort reheat resistor / 0.7 Ohm

A

Figure 22


This resistor located between the cylinder head and the intake duct is used to heat air in pre/post reheat operations.

By inserting the key switch, when even only one of the water, air or gas oil temperature sensors record less than 10_C, the electroniccenter activates pre/post reheating and switches on the warning light on the cab instrument panel for a variable period according

to temperature, after which the light starts blinking to inform the operator that the engine can be started.The warning light goes off after engine start but the resistor continues being supplied for a variable period of time to complete postreheating.

The operation is cancelled to prevent uselessly discharging the battery if the engine is not started within 20/25 seconds with thewarning light blinking.

When reference temperature is above 10 _C, actuating the ignition key makes the warning light go on for some 2 seconds tocomplete the test and then turns it of to indicate the engine can be started.



EDC SYSTEM FUNCTIONS

The MS6.2 electronic center manages the following main functions:

Fuel injectionAccessory functions such as cruise control, speed limiter, PTO and the likeSelf-diagnosisRecovery

It also enables:

Interfacing with other electronic systems (if any) available on the vehicleDiagnosis

Fuel dosing

Fuel dosing is calculated based on:- accelerator pedal position- engine rpm- quantity of air admitted.The result can be corrected based on:- water temperatureor to prevent:- noise

- fumes- overloads- overheating

Pressure can be adjusted in case of:- engine brake actuation- external device actuation (e.g. speed reducer, cruise control)- serious defects involving load reduction or engine stop.After determining the mass of air introduced by measuring its volume and temperature, the center calculates the correspondingmass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.

Delivery correction based on water temperature

When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating playsare not optimized yet.Fuel injected also tends to condense on cold metal surfaces.Fuel dosing with a cold engine is therefore greater than when hot.

Delivery correction to prevent noise, fumes or overloads

Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center to prevent them.

De-rating

In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

Turbine rpm regulation

Turbine speed is constantly regulated and rectified, if necessary, by operating on geometry variation.




Injection lead electronic control

Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.Lead is corrected as required:- during acceleration- according to water temperatureand to obtain:- reduced emissions, noise abatement and no overload

- better vehicle accelerationHigh injection lead is set at start, based on water temperature.Delivery start feedback is given by injection electro valve impedance variation.

Engine start

Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables

the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawnby the starter motor.

Cold start

Pre-post reheating is activated when even only one of the three water, air or gas oil temperature sensors records a temperatureof below 10 _C. The pre-heat warning light goes on when the ignition key is inserted and stays on for a variable period of timeaccording to temperature, while the intake duct input resistor heats the air, then starts blinking, at which point the engine can be

started.The warning light switches off with the engine revving, while the resistor continues being fed for a variable period of time tocomplete post-heating. The operation is cancelled to avoid uselessly discharging the batteries if the engine is not started within 20÷ 25 seconds with the warning light blinking. The pre-heat curve is also variable based on battery voltage.

Hot start

On inserting the ignition key the warning light goes on for some 2 seconds for a short test and then switches off when all reference temperatures are above 10 _C. The engine can be started at this point.

Run Up

When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),and diagnoses the system.

After Run

At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable themicroprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom)memory to make tem available for the next start (Cf. Run Up).These data essentially consists of:- miscellaneous settings, such as engine idling and the like- settings of some components- breakdown memory The process lasts for some seconds, typically from 2 to 7 according to the amount of data to be stored, after which the ECU sendsa command to the main relay and makes it disconnect from the battery.




Cut-off

It refers to the supply cut-off function during deceleration.

Cylinder Balancing

Individual cylinder balancing contributes to increasing comfort and operability.This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between eachcylinder, to compensate for injector hydraulic tolerances.The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This informationis provided by the entry of the codes for every single injector, by means of the diagnosis instrument.

Synchronization search

The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with thesequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injectionoccurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequenceand start the engine.

In order to reduce the number of connections, and of the cables connecting the injectors, and to consequently reduce the noseon transmitted signal, the central unit is directly mounted on the engine by a heat exchanger enabling its cooling, using spring blockswhich reduce vibrations transmitted from engine.

It is connected to vehicle wiring harness by two 35-pole connectors:connector “A” for components present on the engineconnector “B” for components present on the cab

Internally, there is a pressure ambient sensor use to further improve injection system management.

The central unit is equipped with a much advanced self-diagnosis system and, depending on environmental conditions, is capable to identify and store any faults, even of intermittent type, occurred to the system during vehicle running, ensuring a more correctand reliable repair intervention.

This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before10 seconds at least after engine cutout.

In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdownmemory and the engine operates at lower performance at next start while the EDC warning light stays on.

Repeated procedure interruptions could in fact lead to center damage.




PART THREE - TROUBLESHOOTING






PREFACE

A successful troubleshooting is carried out with thecompetence acquired by years of experience and attending

training courses.

When the user complains for bad efficiency or workinganomaly, his indications must be kept into proper consideration using them to acquire any useful information tofocus the intervention.

After the detection of the existing anomaly, it isrecommended to proceed with the operations of

troubleshooting by decoding the auto-troubleshooting dataprovided by the EDC system electronic central unit.

The continuous efficiency tests of the components connected to, and the check of working conditions of the entire systemcarried out during working, can offer an important diagnosisindication, available through the decoding of the”failure/anomaly” codes issued by blinking of the failure led:

the ”blink-code” (whether programmed).

Please consider that the interpretation of the indications

provided by the blink-code is not sufficient to guarantee thesolution to the existing anomalies.

Using Iveco Motors processing instruments, it is also possible to establish a bi-directional connection with the central unit,by which not only to decoding the failure codes but also inputan enquiry relying on memory files, in order to achieve any further necessary information to identify the origin of theanomaly.

Every time there is a breakdown claim and this breakdown isactually detected, it is necessary to proceed inquiring theelectronic unit in one of the ways indicated and then proceedwith the diagnostic research making trials and tests in order tohave a picture of the working conditions and identify the rootcauses of the anomaly.

In case the electronic device is not providing any indication, itwill be necessary to proceed relying on the experience,adopting traditional diagnosis procedures.

In order to compensate the operators’ lack of experience in this new system, we are hereby providing the USER’sGUIDELINE FOR TROUBLESHOOTING in the followingpages.

The GUIDELINE is composed of three different parts:

- Part 1: Blink Code, relating to the anomalies identified by the gearbox, mainly of electric and electrical nature;

- Part 2: Troubleshooting guide using PT-01 portable tester.Tool identified as IVECO p/n 8093731.

- Part 3: Guideline for troubleshooting without blink code,divided per symptoms, describing all possible anomaliesnot detected by the electronic gearbox, often of mechanical and hydraulic nature.

!

Any kind of operation on the electronic center unitmust be executed by qualified personnel, duly authorized by Iveco Motors.

Any unauthorized tamper will involve decay of after-sales service in warranty.





PART 1EDC MS6.2 SW control unit Blink Table

Blink code EDC warning lamp * Fault

VEHICLE AREA

1.1 GLOWING STEADILY Vehicle speed signal (if available)

1.2 GLOWING STEADILY Torque selector (if available)

1.3 OFF Cruise Control (if available)

1.4 GLOWING STEADILY Accelerator pedal

1.5 OFF Clutch pressure switch (if available)

1.6 GLOWING STEADILY Plausibility of brake pedal signal switches

1.7 OFF Plausibility between accelerator / brake pedal

ENGINE AREA

2.1 OFF Water temperature sensor

2.2 OFF Air temperature sensor

2.3 OFF Fuel temperature sensor

2.4 GLOWING STEADILY Supercharging pressure sensor

2.5 OFF Ambient pressure sensor (inside control unit)

3.5 OFF Battery voltage

INJECTORS

5.1 GLOWING STEADILY Fault on injector cylinder 1






ENGINE RPM SENSORS6.1 GLOWING STEADILY Flywheel sensor

6.2 GLOWING STEADILY Timing gear sensor

6.4 FLASHING Engine over revving

INTERFACES WITH OTHER CONTROL UNITS

7.2 OFF CAN line

7.6 OFF CAN line (ASR control) (if available)

7.7 OFF CAN line (gearbox data control)

CONTROL UNIT

9.1 FLASHING Faulty control unit

9.2 GLOWING STEADILY Incorrect data in EPROM

9.4 GLOWING STEADILY Main relay

9.5 GLOWING STEADILY Incorrect engine stopping procedure

9.6 GLOWING STEADILY Incorrect data recording in control unit

* Blink code warning lamp off = slight error Blink code warning lamp glowing steadily = significant error Blink code warning lamp flashing = serious error



PART 2


B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E

P O S S I B L E R E L A T E D

A N O M A L I E S

R E C O M M E N D E D T E S T S

O R M E A S U R E S

R E M A R K S

1 . 1

O N s t e a d y

F a u l t y

v e h i c l e

s p e e d

s e n s o r . T h

e

t a c h o g r a p h

w o n ’ t

w o r k .

O d d

b e h a v i o u r

o f

t h e

t a c h o g r a p

h

p o i n t e r .

( I f

a v a i l a b l e )

V e h i c l e

s p e e d n o

l o n g e r

r e d u c e d : i t c a n b e e x c e e d e d i n

c a s e o f p o o r r e s i s t a n c e t o

p r o g r e s s i n g . S e r r a t i o n

w i t h

h i g h s p e e d s .

F l i g h t r e c o r d e r d e t e c t s h i g h

t i m e a t l o w

s p e e d . C h e c k c a b l i n g , c o n n

e c t i o n s a n d

c o m p o n e n t .

C o n t r o l u n i t r e p l a c e m e n t v a l u e : 5 k m / h .

1 . 2

O N s t e a d y

F a u l t y

m u l t i p l e - s t a t e

s w i t c h . ( I f

a v a i l a b l e )

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 3

O F F

F a u l t y

C r u i s e

C o n t r o l

s w i t c h e s . ( I f a v a i l a b l e )

T h e C r u i s e C o n t r o l w o n ’ t

w o r k .

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

O r n o n - p l a u s i b l e

s w i t c h

s i g n a l s ( s w i t c h e s

p r e s s e d s i m u l t a n e o u s l y ) .

1 . 4

O N s t e a d y

A c c e l e r a t o r p e d a l : f a u l t y

p o t e n t i o m

e t e r

o r

n o n - p l a u s

i b l e

s i g n a l . O d d

r e a c t i o n

o f e n g i n e w h e n

a c t u a t i n g

t h e a c c e l e r a t o r

p e d a l .

E n g i n e s p e e d c a n b e v a r i e

d b y m e a n s o f t h e C C

( S e t + / S e t - ) s w i t c h . ( I f

a v a i l a b l e )

1 . 5

O F F

F a u l t y c l u t c h s w i t c h . C C

w o n ’ t w o r k . ( I f a v a i l a b l e )

S e r r a t i o n w h e n c h a n g i n g g e a r . C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 6

O N s t e a d y

B r a k e s w

i t c h

p l a u s i b i l i t y .

N o r e a c t i o n a f t e r a c t u a t i n g

t h e C C / P

T O

s w i t c h e s . ( I f

a v a i l a b l e )

T h e C r u i s e c o n t r o l / P T O

w o n ’ t w o r k .

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 7

O F F

B r a k e s w i t c h / a c c e l e r a t o r

p e d a l s e n s o r p l a u s i b i l i t y .

N o r e a c t i o n f r o m t h e s y s

t e m .




B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

2 . 1

O F F

F a u l t y c o o

l a n t t e m p e r a t u r e

s e n s o r . E

x c e s s i v e s t a r t i n g

t i m e i n

c o l d

w e a t h e r

c o n d i t i o n s .

G r e a t e r c o m b u s t i o n

n o i s e

d u e t o h i g h i n j e c t i o n a d v a n c e .

P r e - h e a t i n g r e s i s t o r a c t i v e d i a g n o s i s .

P a r a m e t e r r e a d i n g . C h e

c k c a b l i n g ,

c o n n e c t i o n s a n d c o m p o n e

n t .

N o o v e r h e a t i n g p r o t e c t i o n , r e p l a c e m e n t v a l u e

= 0 ˚

C .

2 . 2

O F F

F a u l t y

b o o s t i n g

a i r

t e m p e r a t u r e s e n s o r .

I f

t h e

s e n s o r

s i g n a l s

a

t e m p e r a t u r e l o w e r

t h a n t h e

a c t u a l o n e , t h e e r r o r i s n o t

s t o r e d

a n d

t h e

e n g i n e

a c h i e v e s b e t t e r p e r

f o r m a n c e ,

y e t w i t h b l a c k s m o k e .


c k c a b l i n g ,


n t .

R e p l a c e m e n t v a l u e = 2 0 ˚

C .

2 . 3

O F F

F a u l t y f u

e l t e m p e r a t u r e

s e n s o r .


c k c a b l i n g ,


n t .

N o i n j e c t i o n r a t e c o r r e c t i o n ; y e t , t h e d r i v e r i s

n o t a w a r e o f i t . R e p l a c e m e n t v a l u e = 3 0 ˚

C .

2 . 4

O N s t e a d y

F a u l t y b o o s t i n g p r e s s u r e

s e n s o r . P o

w e r r e d u c t i o n .

S i g n i f i c a n t b l a c k s m o k e i n

m o m e n t a r y c o n d i t i o n s .

P a r a m e t e r r e a d i n g

m o d

u s : i f t h e

r e p l a c e m e n t v a l u e i s r e a d

w h e n t h e

e n g i n e i s i d l i n g , t h e f a u l t i s

c o n f i r m e d .

R e p l a c e m e n t v a l u e . C u r s o r 8 = 1 , 6 0 0 m b a r ,

C u r s o r 1 0 = 2 , 8 0 0 m b a r .

2 . 5

O F F

F a u l t y a m b i e n t p r e s s u r e

s e n s o r .

C o n t a c t H e l p D e s k f o r r e p

l a c e m e n t ( i f

a n y ) o f t h e c o n t r o l u n i t , o w i n g t o t h e

s e n s o r b e i n g i n t e g r a t e d i n t

o t h e s a m e .

E D C w o r k s w i t h a r e p l a c

e m e n t v a l u e o f 2 8 V .

3 . 5

O F F

T o o l o w b a t t e r y v o l t a g e o r

v o l t a g e r e

c o g n i t i o n f a u l t .

P o s s i b l e

p r e - h e a t i n g

a n d

s t a r t i n g p r o b l e m s .

B a t t e r y t e s t .

5 . x

O N s t e a d y

P r o b l e m

w i t h

i n j e c t i o n

c i r c u i t o n

c y l i n d e r X . T h e

e n g i n e s p

e e d i s r e d u c e d ,

a n d t h e

e n g i n e o p e r a t e d

w i t h 5 c y l i n d e r s .

I f t h e f a u l t i s i n t e r m

i t t e n t , t h e

e n g i n e

s o m e t i m e s

w o r k s

c o r r e c t l y ; s o m e t i m e s , i t d o e s

n o t .

E n g i n e t e s t ( i f t h e f a u l t i s f o u n d ) . C h e c k

c o m p o n e n t , c a b l i n g a n d c o n n e c t i o n s

( h e a d c a b l e i n c l u d e d ) .




B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

6 . 1

O N s t e a d y

F a u l t y f l y w h e e l

s e n s o r .

R e d u c e d e n g i n e s p e e d a n d

p o w e r .

E n g i n e s t a r t i n g m a y t a k e a

l o n g e r t i m e t h a n u s u a l .

F a u l t m e m o r y r e a d i n g b y m

e a n s o f t h e

d i a g n o s i s i n s t r u m e n t . C h e c k

c a b l i n g ,


n t .

6 . 2

O N s t e a d y

D i s t r i b u t i n g s h a f t s e n s o r .


p o w e r .




e a n s o f t h e


c a b l i n g ,


n t .

( 6 . 1 - 6 . 2 )

O N s t e a d y

D i s t r i b u t i n g s h a f t p h o n i c

w h e e l h a s r o t a t e d , d u e t o

l o o s e n e d

s c r e w s .

T h e

e n g i n e w o

n ’ t s t a r t , o r s t o p s

a n d

c a n n o t b e

s t a r t e d

a g a i n .

R e d u c e d p o w e r w i t h e n g i n e

s t a r t e d

( a f t e r t a

k i n g

t h e

m e a s u r e r e c o m m e n

d e d i n t h e

n e x t c o l u m n ) .

D i s c o n n e c t

t h e

d i s t r i b u t i n g

s h a f t

s e n s o r c o n n e c t o r . I f t h e

e n g i n e i s

s t a r t e d , e v e n b y t a k i n g a l o n g e r t i m e

t h a n

u s u a l , t h e

p h o n i c

w h e e l i s

o u t - o f - p h a s e .

6 . 4

B l i n k i n g

T h e e n g i n

e h a s r e a c h e d ( o n

p u l l i n g )

t h e

o u t - o f - r e v

c o n d i t i o n s f o r a n y r e a s o n

w h a t s o e v e r .

F a u l t m e m o r y r e a d i n g . F l i g

h t r e c o r d e r

r e a d i n g t o g e t c o n f i r m a t i o n o f t h e

e n g i n e o u t - o f - r e v c o n d i t i o n .

( 9 . 1 )

B l i n k i n g

F a u l t y

E D C

c o n t r o l

u n i t . T h e e

n g i n e w i l l s t o p o r

w o n ’ t s t a r t .

C o n t a c t H e l p D e s k f o r c

o n t r o l u n i t

r e p l a c e m e n t .

N o d i a g n o s i s c a n b e m a d e . T h i s e r r o r m a y e v e n

n o t b e s t o r e d ; t h i s d e p e n d s o n t h e c o n t r o l u n i t


9 . 2

O N s t e a d y

C o n t r o l

u n i t

f a u l t

( E E P R O M

m e m o r y ) .


p o w e r .

F a u l t y m e m o r y l o s t ; o n l y t h e

d i a g n o s i s o f e x i s t i n g

f a u l t s c a n

b e m a d e .



a n y ) o f t h e c o n t r o l u n i t .

9 . 4

B l i n k i n g

M a i n r e l a y f a u l t y o r l o c k e d

i n

c l o s e d

p o s i t i o n . T h e

E D C w a r n i n g l i g h t r e m a i n s

O N w h e n

t h e k e y i s t u r n e d

t o O F F ; y e t t h e e n g i n e w i l l

s t o p .

E D C p o w e r s u p p l y r e m a i n s

O N a f t e r t h e k e y

h a s b e e n

t u r n e d t o O F F ; d a n g e r o f

b a t t e r y r u n - d o w n .

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

T h e f a u l t w i l l b e s t o r e d o n l y a f t e r t h e n e x t t i m e

t h e e n g i n e i s s t a r t e d .




B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

9 . 5

O N s t e a d y

E C U p o w

e r s u p p l y i s c u t

o u t t o o

o f t e n ( 5 t i m e s ) :

f a u l t y m a i n r e l a y o r e n g i n e

s t o p b y m e a n s o f b a t t e r y

d i s c o n n e c

t

s w i t c h .

R e d u c e d

e n g i n e

m a x .

s p e e d a n d

p o w e r .

C h e c k

m a i n

r e l a y , c a b l i n g

a n d

c o n n e c t i o n s . I n v e s t i g a t e w

h e t h e r t h e

d r i v e r s w i t c h e s t h e e n g i n e

o f f i n o t h e r

w a y s t h a n b y t u r n i n g t h e k

e y .

T h e p r o b l e m w i l l b e s o l v e d b y i t s e l f t h e n e x t

t i m e t h e s w i t c h - o f f p r o c e

d u r e a n d d a t a s t o r i n g

a r e p e r f o r m e d c o r r e c t l y .

9 . 6

O N s t e a d y

E C U s t o

p

t e s t f a i l u r e .


p o w e r .

T h i s i s a t e s t p r o c e d u r e

i n h e r e n t t o t h e c o

n t r o l u n i t

f o r p o w e r s t a g e c o n t r o l . I t

m i g h t s t o r e

o t h e r e r r o r s

c o n c e r n i n g t h e v a r i o u s p o w e r

s t a g e s o f a c t u a t o r s .






PART 3


S I G N A L L E D

A N O M A L Y

B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O S S I B L E

C A U S E

P O S S I B L E

R E L A T E D

A N O M A L I E S

R E C O M M E N D E D

T E S T S O R

M E A S U R E S

R E M A R K S

T h e b a t t e r y g o e s f l a t

q u i c k l y .

-

-

P r e - h e a t i n g

r e s i s t o r

p o w e r e d c o n t i n u o u s l y .

L o c a l o v e r h e a t i n g .

T h e e n g i n e w i l l s t o p o r


-

-

F u e l p r e - f i l t e r c l o g g e d .

D i f f i c u l t s t a r t w h e n t h e

e n g i n e i s e i t h e r h o t o r

c o l d .

-

-

T h e 3 . 5 b a r v a l v e o n

f u e l

r e t u r n i s s t u c k o p e n .

S l i g h t o v e r h e a t i n g .

-

-

E i t h e r 0 . 3 b a r t a n k r e t u r n

v a l v e

o r

r e t u r n p i p i n g

c l o g g e d .

A f t e r t h e n e w v e h i c l e

h a s b e e n d e l i v e r e d , t h e

e n g i n e w i l l s t o p a f t e r a

s h o r t

o p e r a t i o n

t i m e . T h e t a n k h o l d s a

l o t o f f u e l ; a l l t h e r e s t i s

O . K .

-

-

R e v e r s e d t a n k s u c t i o n /

r e t u r n p i p e s .

T h e e n g i n e i s f e d b y t h e

r e

t u r n p i p e , t h e s u c t i o n

o f w h i c h i n t h e t a n k i s

l o

w e r . W h e n t h e p i p e

s u c k s n o

m o r e , t h e

e n g i n e w i l l s t o p .

R e d u c e d

p o w e r

/

d i f f i c u l t

e n g i n e

m a n e u v e r a b i l i t y .

-

-

I n j e c t i o n

s y s t e m

/

t h e

e n g i n e o p e r a t e s w i t h o n e

c y l i n d e r f a i l i n g :

- i n j e c t o r p l u n g e r s e i z u r e ;

- v a l v e r o c k e r a r m s e i z u r e .

O v e r h e a t i n g

E n g i n e t e s t : c y l i n d e r e f f i c i e n c y t e s t . I f

t h

e t r o u b l e i s n o t r e l a t e d t o e l e c t r i c

c o m p o n e n t s ( B l i n k c o d e 5 . x ) , t h e

r o

c k e r a r m h o l d e r s h a f t n e e d s b e

d i s a s s e m b l e d . C h e c k t h e r o c k e r a r m

r o

l l e r a n d b u s h i n g a s w e l l a s t h e

r e

s p e c t i v e c a m .

F u e l

c o n s u m p t i o n

i n c r e a s e .

-

-

A i r f i l t e r c l o g g i n g w i t h

n o

s i g n a l f r o m

t h e w a r n i n g

l i g h t o n t h e i n s t r u m

e n t

b o a r d .

S m o k e .

C

h e c k t h e c a b l i n g , c o n n e c t i o n s a n d

c o m p o n e n t .




S I G N A L L E D

A N O M A L Y

B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O S S I B L E

C A U S E

P O S S I B L E

R E L A T E D

A N O M A L I E S


T E S T S O R

M E A S U R E S

R E M A R K S

T h e e n g i n e d o e s n o t

r e a c h t h e o t h e r s p e e d s

u n d e r l o a d c o n d i t i o n s .

-

-

T h e

b o o s t i n g

p r e s s u r e

s e n s o r p r o v i d e s t o o h i g h

v a l u e s , w h i c h , i n a n y c

a s e ,

f a l l w i t h i n t h e r a n g e .

S m o k e .

T h e d r i v e r f e e l s t h a t t h e

e n g i n e i s n o t w o r k i n g

c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-

I m p a i r e d

h y d r a u l i c

p e r f o r m a n c e o f a n i n j e c

t o r .

E n g i n e t e s t : c h e c k - u p

R e p l a c e t h e i n j e c t o r o f

t h

e c y l i n d e r i n w h i c h

M

o d u s d e t e c t s l o w e r

p e r f o r m a n c e

l e v e l s

( c

o m p a r e d

w i t h

t h e

o t h e r s ) o n l y a f t e r v e r i f y -

i n

g t h a t t h e

c o n t r o l

r o

c k e r a r m a d j u s t m e n t i s

c o r r e c t .



c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-

W r o n g a d j u s t m e n t o f a n

i n j e c t o r c o n t r o l r o c k e r a r m .

E n g i n e t e s t : c h e c k u p .

P e r f o r m c o r r e c t a d j u s t -

m

e n t , t h e n r e p e a t t h e

e n g i n e t e s t .

T h e e n g i n e o p e r a t e s

w i t h

f i v e

c y l i n d e r s ;

n o i s e ( k n o c k ) .

-

-

P l u n g e r s e i z u r e .

P o s s i b l e o v e r h e a t i n g .

E n g i n e t e s t : c y l i n d e r e f f i c i e n c y .


t h

e c y l i n d e r i n w h i c h t h e

d i a g n o s i s i n s t r u m e n t d e -

t e

c t s l o w e r p e r f o r m a n c e

l e

v e l s ( c o m p a r e d w i t h

t h

e o t h e r s ) .


t h e c y l i n d e r i n w h i c h t h e


t e c t s l o w e r p e r f o r m a n c e

l e v e l s ( c o m p a r e d w i t h

t h e o t h e r s ) .

-

-

W r o n g a d j u s t m e n t o f

t h e

i n j e c t o r c o n t r o l r o c k e r a r m

( e x c e s s i v e

t r a v e l )

w i t h

i m p a c t o n t h e p l u n g e r

o n

t h e n o z z l e .

P o s s i b l e m e c h a n i c d a m a g e t o

t h e a r e a s s u r r o u n d i n g t h e

i n j e c t o r .



t h



t e


l e


t h

e o t h e r s ) .


w o n ’ t s t a r t a g a i n .

-

-

P r e s e n c e o f a i r i n t h e

f u e l

s u p p l y c i r c u i t .

I t m i g h t e v e n n o t s w i t c h o f f ; i t

m i g h t

h a v e

o p e r a t i o n

o s c i l l a t i o n s , o r s t a r t , y e t w i t h

d i f f i c u l t y a n d

a f t e r m a k i n g

m a n y a t t e m p t s .

B l e e d a i r .



PART FOUR - MAINTENANCE PLANNING







MAINTENANCEMaintenance services scheme

Programmed maintenance is made up of ”Standard” services, plus a set of operations called ”Extra Plan” operations, as well asfurther operations called ”Temporal” operations.

Normally, no differentiated plans are prescribed in connection with vehicle use. Where a differentiation in terms of ”mission”exists, as many plants are forwarded as many are the ”missions”.

Using recommended lubricants systematically allows for long replacement intervals with relatively contained costs. To suchpurpose, see recommended lubricants summary card.

M = STANDARD SERVICE

”Standard” services are indicated by M = ”Maintenance”.They must be performed at regular kilometre intervals that are normally multiple among one another.

EP = EXTRA PLAN OPERATIONS

Extra plan operations are indicated by EP = ”Extra Plan”.They are services complementary to ”standard” services and areto be performed according to intervals which arenot compatiblewith standard services.

T = TEMPORAL OPERATIONS

They are specific interventions that are exclusively connected to temporal intervals and are to be normally performed inparticular season conditions. To minimise the number of stops for maintenance it is recommended to program extra plan stopsbased on average yearly run matching them as much as possible with predefined kilometre intervals.

To ensure optimum working conditions, the following pages give the checks, inspections and adjustments that need to be madeon the various parts of the vehicle at the required times.

!The kilometre frequency for engine lubrication is in relation to a percentage of sulphur in diesel of under 0.5%.

NOTE: If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.

Use engine oil: ACEA E5 (URANIA LD5)

!- If the vehicle is used very little or anyhow for less than 800 hours/80,000 km a year, the engine oil and filter need

to be replaced every 12 months.

- The drier filter of the pneumatic system anyhow has to be changed each year.

- In case of very low yearly runs, or operativity under 1600 hours/year, gearbox and axle(s) oil must be replacedat least once every two years.

- In case of very low operativity, general greasing must be performed at least once a year.





CHECKS AND/OR MAINTENANCE WORK

Type of operationEvery

80,000 km1600 hours

Every 160,000 km3200 hours



Engine

Change engine oil • • • •

Change engine oil filters • • • •

Change fuel filter • • • •

Check blow-by filter conditions through clogging indicator • • • •

Check control belt conditions • •

EDC system engine check-up by means of diagnosis instrument • •

Check valve clearance and adjust it if needed • •

Change control belt of engine auxiliary parts • •

Change fuel pre-filter • • • •




OFF-PLANE OPERATIONS

Carry out the following operations.

EVERY YEAR

and possibly before winter when a maintenance service is performed, carry out the following operations:

Check antifreeze quantity in engine cooling water

EVERY TWO YEARS

and possibly when a maintenance service is performed, carry out the following operations:

Change engine coolant

Change air filter dry cartridge even if there is no clogging signal

Change engine Blow-by filter cartridge even if there is no clogging signal






SECTION 4 - GENERAL OVERHAUL 1F2B CURSOR ENGINES

SECTION 4

General overhaul

Page

GENERAL CHARACTERISTICS 3. . . . . . . . . . . . .

ASSEMBLY CLEARANCE DATA 5. . . . . . . . . . . .

REPAIR OPERATIONS 11. . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK 11. . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements 11. . . . . . . . . . . . . . .

CYLINDER LINERS 12. . . . . . . . . . . . . . . . . . . . . . .

- Removal of cylinder liners 13. . . . . . . . . . . . . . . .

- Fitting and checking protrusion 13. . . . . . . . . . . .

CRANKSHAFT 14. . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring main journals and crank pins 15. . . . .

- Preliminary measurement of main andbig end bearing shell selection data 16. . . . . . . . .

- Defining the class of diameter of the main journalsand crankpins (Journals with nominal diameter) 18

- Selection of main half-bearings(nominal diameter pins) 19. . . . . . . . . . . . . . . . .

- Selection of main half-bearings (rectified pins) 20

- Selecting the big end bearing shells(journals with nominal diameter) 21. . . . . . . . . .

- Selection of connecting rod half-bearings(rectified pins) 22. . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing the timing control gear and the oil pump 23. . . . . . . . . . . . . . . . . . . . . . .

- Checking main journal installation clearance 23. .

- Checking crankshaft end float 24. . . . . . . . . . . . .

PISTON-CONNECTING ROD ASSEMBLY 25. . . .

- Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring the diameter of the pistons 26. . . . . .

- Conditions for correct gudgeonpin-piston coupling 26. . . . . . . . . . . . . . . . . . . . .



2 SECTION 4 - GENERAL OVERHAUL F2B CURSOR ENGINES

Page

- Piston rings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING ROD 28. . . . . . . . . . . . . . . . . . . . .

- Checking connecting rod alignment 29. . . . . . . . .

- Mounting the connecting rod - piston assembly 29

- Mounting the piston rings 29. . . . . . . . . . . . . . . .

- Fitting the connecting rod-piston assembly into the piston liners 30. . . . . . . . . . . . . . . . . . . .

- Piston protrusion check 30. . . . . . . . . . . . . . . . . .

- Checking assembly clearance of big end pins 31. .

CYLINDER HEAD 31. . . . . . . . . . . . . . . . . . . . . . . .

- Valve removal 31. . . . . . . . . . . . . . . . . . . . . . . . .

- Checking the planarity of the headon the cylinder block 31. . . . . . . . . . . . . . . . . . . .

VALVE 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing deposits and checking the valves 31. . .

VALVE GUIDES 32. . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing of valve guides 33. . . . . . . . . . . . . . . . .

- Replacing - Reaming the valve seats 33. . . . . . . . .

REPLACING INJECTOR HOLDER CASES 33. . . . .

- Removal 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking protrusion of injectors 35. . . . . . . . . . .

TIMING GEAR 36. . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft drive 36. . . . . . . . . . . . . . . . . . . . . . . . .

- Intermediate gear pin 36. . . . . . . . . . . . . . . . . . . .

- Idler gear 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Twin idler gear 36. . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing the bushings 36. . . . . . . . . . . . . . . . . . .

Page

- Check of cam lift and timing systemshaft pins alignment 37. . . . . . . . . . . . . . . . . . . . .

- Bushes 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing camshaft bushes usingbeater 99360487 39. . . . . . . . . . . . . . . . . . . . . . .

- Removing bushes 39. . . . . . . . . . . . . . . . . . . . . . .

- Assembling bushes 39. . . . . . . . . . . . . . . . . . . . . .

VALVE SPRINGS 40. . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting the valves and oil seal ring 40. . . . . . . . . . .

ROCKER SHAFT 41. . . . . . . . . . . . . . . . . . . . . . . . .

- Shaft 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Rocker 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 42. . . . . . . . . . . . . . . . .

- Underblock fixing screws tightening sequence 45.

- Diagram of cylinder head fixing screws tighteningsequence 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of rocker shaft fixing screws tighteningsequence 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of exhaust manifold fixing screws tighteningsequence 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of turbocharger fixing screws and nuts tightening sequence 47. . . . . . . . . . . . . . . . . . . . .

- Diagram of heat exchanger fixing screws tighteningsequence 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of engine oil sump fixing screws tighteningsequence 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of rocker arm cap fixing screws tighteningsequence 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .




GENERAL CHARACTERISTICS

Type F2B

Cycle Diesel 4 strokes

Feeding Turbocharged with aftercooler

Injection Direct

N. of cylinders 6 on-line

∅Diameter mm 115

Stroke mm 125

+ + +.. = Total displacement cm3

7790




Type F2B

A

B

VALVE TIMING

opens before T.D.C. A

closes after B.D.C. B

17°

31°

C

D

opens before B.D.C. D

closes after T.D.C. C

48°

9°

X

For timing check

mmX

mm

Running

mmX

mm

_

_

0.35 to 0.45

0.35 to 0.45

FEED Through fuel pump - Filters

Injection

type Bosch

With electronically regulated injectors PDE 30

pump injectors controlled by overhead camshaft

ozz e type -

Injection order 1 - 4 - 2 - 6 - 3 - 5

bar Injection pressure bar

Injector calibration bar

1500

-




ASSEMBLY CLEARANCE DATA

Type F2B

CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS

mm

∅ 1 Cylinder sleeve boreupper

∅ 1lower

130.200 to 130.225

128.510 to 128.535

Cylinder liners:

L

outer diameter:upper

∅ 2lower

130.161 to 130.186

128.475 to 128.500

∅2 length L

Cylinder sleeve -

crankcase bore upper lower

0.014 to 0.0640.010 to 0.060

Outside diameter ∅ 2

Cylinder sleeve

∅ 3 inside diameter ∅3 A* 115.000 to 115.012

X

inside diameter ∅3 B* 115.010 to 115.022

Protrusion X 0.035 to 0.065

* Available dia. class

Pistons:

X measuring dimension X 18

outside diameter ∅ 1 A• 114.888 to 114.900

∅2 outside diameter ∅ 1 B•• 114.898 to 114.910

outside diameter ∅ 246.010 to 46.018

114.898 to 114.910

• Class A pistons supplied as spares.•• Class B pistons are fitted in production only and

are not supplied as spares.

Piston - cylinder sleeve 0.100 to 0.124

Piston diameter ∅ 1 _

X

Pistons protrusion X 0.32 to 0.99

3∅ Gudgeon pin ∅ 3 45.994 to 46.000

Gudgeon pin - pin housing 0.010 to 0.024




Type mm

MAHLE MONDIAL FEDERAL MOGOL

1X X1* 2.71 to 2.74 2.71 to 2.74

X2 Piston ring grooves X2 2.55 to 2.57 2.55 to 2.57

3X

X3 4.02 to 4.04 4.02 to 4.04

*measured on ∅ of 112 mm

Piston rings: trapezoidal seal S1* 2.575 to 2.595

12

SS

lune seal S2 2.470 to 2.490

3S milled scraper ringwith slits and internalspr ng

*measured on ∅ of 112 mm

. to .

1 0.115 to 0.165

Piston rings -grooves 2

0.070 to 0.095

3 0.030 to 0.065

Piston rings _

X1

2X

Piston ring end gap incylinder liners:

X1 0.35 to 0.50

X2 0.70 to 0.95

X3 0.30 to 0.60

1

Small end bush housingØ1 49.975 to 50.000

∅ 2

Big end bearinghousing Ø2

1Selection classes Ø2 2

3

nominal value 77.000 to 77.030

77.000 to 77.01077.010 to 77.02077.020 to 77.030

∅ 4 Small end bush diameter

outside ∅4 50.055 to 50.080∅ 3

inside ∅3 46.015 to 46.030

S

Big end bearing shell SRedGreenYellow

2.000 to 2.0102.011 to 2.0202.021 to 2.030

Small end bush - housing 0.055 to 0.105

Piston pin - bush 0.015 to 0.036

Big end bearing shells 0.127 - 0.254 - 0.508

Connecting rod weight g.

A 2890 to 2920

Class B 2921 to 2950

C 2951 to 2980




F2Bype

mm

XMeasuring dimension X 125

Max. connecting rodaxis misalignment

tolerance 0.08

1 2∅∅

Main journals ∅1- class 1- class 2- class 3

Crankpins ∅2- class 1- class 2- class 3

nominal value 82.910 to 82.94082.910 to 82.91982.920 to 82.92982.930 to 82.940

nominal value 72.915 to 72.94572.915 to 72.92472.925 to 72.93472.935 to 72.945

S 1 S 2

Main bearing shells S1

RedGreenYellowD

3.000 to 3.0103.011 to 3.0203.021 to 3.030

Big end bearing shells S2RedGreenYellowD

2.000 to 2.0102.011 to 2.0202.021 to 2.030

3∅

Main bearing housings ∅3- class 1- class 2- class 3

nominal value 89,000 ÷ 89,03089,000 ÷ 89,00989,010 ÷ 89,01989,020 ÷ 89,030

Bearing shells - ◊main journals

0.040 to 0.098 - 0.040 to 0.110 **

Bearing shells - ◊big ends 0.035 to 0.093 - 0.035 to 0.083 **

Main bearing shells 0.127 - 0.254 - 0.508


X1

Main journal, thrust bearing X1 39.96 to 40.00

X2

Main bearing housing, thrust bearing X2 32.94 to 32.99

X 3Thrust washer halves X3 3.38 to 3.43

Driving shaft shoulder 0.11 to 0.30

1 2 Alignment 1 - 2

Ovality 1 - 2

Taper 1 - 2

≤ 0.05

_0.010

0.010

D Fitted in production only and not supplied as spares.◊ provided with spare: * = standard —0.127; ** = 0.254 — 0.508.




11Print603.93.141

Type F2B

CYLINDER HEADS - VALVE TRAIN mm

∅ 1

Valve guide housingsin cylinder head∅1 12.980 to 12.997

2∅

∅ 2 8.023 to 8.038

∅ 3

Valve guide∅ 3 13.012 to 13.025

Valve guides - housings

in the cylinder heads

0.015 to 0.045

Valve guide _

∅ 4 Valves:

7.970 to 7.985

α 60° 30′ ± 7′ 30″

∅ 4 7.970 to 7.985

α α 45° + 15′

Valve stem and its guide 0.038 to 0.068

Housing in head for valveseat

∅1 41.985 to 42.020

∅ 1 ∅1 40.985 to 41.020

Outside diameter of valve

2∅ seat; angle of valve seat in

cylinder head:

∅ 2 42.060 to 42.075α 60° - 30’

α ∅ 2 41.060 to 41.075α 45° - 30′

Recessing of valve

0.5 to 0.8

X X 1.6 to 1.9

etween va veseat and head 0.040 to 0.090




Type F2B

mm

Valve outside springheight:

free height H 63.6

H H 1 under a load of:H2 N 454 ± 22 H1 49.5

N 840 ± 42 H2 34.5

X

Injector protrusion X 0.7

∅∅∅

Camshaft bush housingfitted in the cylinder head:1 ⇒ 7 Ø 80.000 to 80.030

∅

∅

∅1

2

3

Camshaft journal diameter:1 ⇒ 7 Ø 75.924 to 75.940

∅ Camshaft bushing outer

diameter: ∅ 80.090 to 80.115

∅ Camshaft bushing

inner diameter: ∅ 75.990 to 76.045

Bushings and housings inengine block

0.060 to 0.115

Bushings and journals 0.050 to 0.121

Cam lift:

8.07

H 7.63

8.80 to 8.82

∅ 1

Rocker shaft ∅ 137.984 to 38.000




Type F2B

mm

Bushing housing in rocker arms

41.000 to 41.016

53.000 to 53.019

∅

42.000 to 42.016

Bushing outer diameter for rocker arms:

41.097 to 41.135

∅ 53.105 to 53.156

42.066 to 42.091

Bushing inner diameter for rocker arms:

38.025 to 38.041

∅ 50.025 to 50.041

38.015 to 38.071

Between bushings andhousings

0.081 to 0.135

0.086 to 0.156

0.050 to 0.091

Between rocker arms andshaft

0.025 to 0.057

-

0.015 to 0.087

O1

O2

Engine brake control lever

Eccentric pin outer diameter ∅1

Rocker arms shaft seat ∅2

49.984 ÷ 50.000

38.025 ÷ 38.041





45150 99278

47533

Figure 5

Figure 6

CYLINDER LINERS MAIN DATA

DETAIL “X”

“A“ = Selection class marking area

Figure 7

47534

BLOCK WITH CYLINDER LINERS

A 115.000 to 115.012 mmB 115.010 to 115.022 mm

Selection class

A

CYLINDER LINERS




47577

77812

16798

35012

Figure 8

Figure 9

Figure 10

Place details 99360706 (1 and 2) and plate 99360724 (4) as

shown in the figure, by making sure that the plate (4) isproperly placed on the cylinder liners.Tighten the screw nut (1) and remove the cylinder liner (3)from the block.

Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);lubricate lower part of liner and install it in the cylinder unitusing the proper tool.

Check cylinder barrel protrusion with tool 99360334(1-2-3-4) and tighten screw (1) to 170 Nm.

With dial gauge 99395603 (5) placed on base 99370415 (6).Measure the cylinder barrel protrusion compared to thecylinder head supporting plane, it must be 0.035 to 0.065 mm

(Figure 11); otherwise replace the adjusting ring (1, Figure 9)fitted with spare parts having different thickness.

When the installation is completed, block the cylinder liners

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

Fitting and checking protrusion

(Demonstration)

Figure 11

CYLINDER LINER PROTRUSION

49017

The adjustment ring (1) is supplied as spare parts in the following thicknesses: 0.08 mm - 0.10 mm - 0.12mm.

Figure 12

Removal of cylinder liners

NOTE






MEASURING CRANK PINS

During grinding, pay attention to journal andcrank pins valuesspecified in figures 14 and 15.

47536

Figure 16

Figure 17

MEASURING THE MAIN JOURNALS

Before grinding the crank pins using a micrometer (1),measure the main journals and the crank pins (2) and decide,on the basis of the undersizing of the bearings, the finaldiameter to which the pins are to be ground.

It is advisable to enter the values found in a table(Figure 18).

All journals and crank pins must also be ground to the same undersizing class, in order to avoid any alteration to shaft balance.

Figure 18

Fill in this table with the measurements of the main journals and the crank pins.

MAIN JOURNALS

36061

Ø MIN.Ø MAX.

Ø MIN.Ø MAX.

CRANK PINS

Measuring main journals and crank pins

47535

NOTE NOTE




Preliminary measurement of main and big end bearing shell selection data

For each of the journals of the crankshaft, it is necessary to carry out the following operations:

MAIN JOURNALS:

- Determine the class of diameter of the seat in thecrankcase.

- Determine the class of diameter of the main journal.

- Select the class of the bearing shells to mount.

CRANKPINS:

- Determine the class of diameter of the seat in theconnecting rod.

- Determine the class of diameter of the crankpin.


DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE

On the front of the crankcase, two sets of numbers are marked in the position shown.

- The first set of digits (four) is the coupling number of the crankcase with its base.

- The following seven digits, taken singly, are the class of diameter of each of the seats referred to.

- Each of these digits may be 1, 2 or 3.

47535

89.000 to 89.009

89.010 to 89.019

89.020 to 89.030

Figure 19 CLASS MAIN BEARING HOUSING

NOMINAL DIAMETER






Defining the class of diameter of the main journals and crankpins (Journals with nominal diameter)

Main journals and crankpins: determining the class of diameter of the journals.Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 21 at top):

- The first number, of five digits, is the part number of the shaft.

- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the statusof the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins

they refer to.

- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows thestatus of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of themain journals they refer to.

Figure 21

72.915 to 72.924

72.925 to 72.934

72.935 to 72.945

CLASS CRANKPIN

NOMINAL DIAMETER

82.910 to 82.919

82.920 to 82.929

82.930 to 82.940

CLASS MAIN JOURNALS

NOMINAL DIAMETER




Selection of main half-bearings (nominal diameter pins)

After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, incompliance with the following table:

STD.

1 2 3

1

2

3

green

green

red

red

red

red

green

green

green

green

red

red

green

green

green

green

red

red

Figure 22




green/black

Selection of main half-bearings (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing typerequired for this undersizing.

-0.127

1 2 3

82.78482.793

green/black

green/black

green/black

green/black

green/black

green/black

red/black

red/black

green/black green/black

green/black

red/black

red/black

red/black

red/black

red/black

red/black

82.794

82.803

82.80482.814

1

2

3

red/black =3.063 to 3.073 mm

green/black =

3.063 to 3.073 mm

-0.254

1 2 3

82,66682,686 red red red

red red red

red =3.127 to 3.137 mm

-0.508

1 2 3

82.41282.432 red red red

red red red

red =

3.254 to 3.264 mm

Figure 23




Figure 24Selecting the big end bearing shells(journals with nominal diameter)

There are three markings on the body of the connecting rodin the position shown in the view from ”A”:

1

2

3

The number, indicating the class of diameter of the bearingshell seat may be 1, 2 o 3.

Determine the type of big end bearing to fit on each journalby following the indications in the table (Figure 25). 47557

VIEW FROM “A”

STD.

1 2 3

1

2

3

green

green

red

red

red

red

red

red

green green

green green

green

green green

green

red

red

Class

Figure 25

Letter indicating the class of weight:

A = 2890 to 2920 g.B = 2921 to 2950 g.C = 2951 to 2980 g.

Number indicating the selection of the diameter of thebig end bearing seat:

1 = 77.000 to 77.010 mm2 = 77.011 to 77.020 mm3 = 77.021 to 77.030 mm

Numbers identifying the cap-connecting rod coupling.




green/black

Selection of connecting rod half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearingsidentified according to the relative table.

-0.127

1 2 3

72.78972.798

green/black

green/black

green/black

green/black

green/black

green/black

red/black

red/black


green/black

red/black

red/black

red/black

red/black

green/black

green/black

72.79972.808

72.80972.818

1

2

3


green/black =

2.063 to 2.073 mm

-0.254

1 2 3

72.67172.680 red green green

red green green

red

2.127 to 2.137 mm

green =

2.138 to 2.147 mm

-0.508

1 2 3


red green green

red red green

red red green

72.42772.437 red red green

red red green

red =

2.254 to 2.264 mm

green =

2.265 to 2.274 mm

72.68172.691

Figure 26








Make sure the piston does show any trace of seizing, scoring,

cracking; replace as necessary.

49023

47580

Figure 36

Figure 37

PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ringwith spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston

Removal of the piston split rings (2) using the pliers99360184

(1).

Removal

Pistons are equipped with three elastic rings: a sealing ring, a

trapezoidal ring and a scraper ring.Pistons are grouped into classes A and B for diameter.

49024

Figure 38

Remove the piston pin split rings (2) using the round tipped

pliers (1).

PISTON-CONNECTING ROD ASSEMBLY




49025 32618

49026

Figure 39

Figure 40

Figure 41

Figure 42

Remove the piston pin (1).If removal is difficult use the appropriate beater.

Measuring the diameter of the pistons

Measuring the gudgeon pin diameter (1) with a micrometer (2).

Conditions for correct gudgeon pin-pistoncoupling

Lubricate the pin (1) and the relevant housing on the pistonhubs with engine oil; piston must be inserted with a slightfinger pressure and it should not come out by gravity.

47584

Using a micrometer (2), measure the diameter of the piston(1)to determine the assembly clearance;the diametershouldbe measured at the specified value.




Drawing No. 500388370

MAIN DATA ON PISTONS, AND PISTONS RINGS

* Values are determined on ∅ of 112 mm.

16552

3513

Figure 43

Check the thickness of the piston ring (2) using a micrometer (1).

The sealing ring (2) of the 1º cavity is trapezoidal. Clearance“X” between the sealing ring and its housing is measured by placing the piston (1) with its ring in the cylinder barrel (3),so that the sealing ring is half-projected out of the cylinder barrel.

Piston rings

77816

16552

Check the clearance between the sealing rings (2) and therelative piston housings (1) using a thikness gauge (3).

36134

Check the opening between the ends of the sealing rings (1),using a thickness gauge (2), entered in the cylinder barrel (3).If the distance between ends is lower or higher than the valuerequired, replace split rings.

Figure 44

Figure 45

Figure 46

Figure 47






Check the torsion of the connecting rod (5) by comparing two points (A and B) of the pin (3) on the horizontal planeof the axis of the connecting rod.Position the mount (1) of the dial gauge (2) so that thispre-loads by approx. 0.5 mm on the pin (3) at point A andzero the dial gauge (2). Shift the spindle (4) with theconnecting rod (5) and compare any deviation on theopposite side B of the pin (3): the difference between A and

B must be no greater than 0.08 mm.

Check the bending of the connecting rod (5) by comparing two points C and D of the pin (3) on the vertical plane of theaxis of the connecting rod.Position the vertical mount (1) of the dial gauge (2) so that

this rests on the pin (3) at point C.Swing the connecting rod backwards and forwards seeking

the highest position of the pin and in this condition zero thedial gauge (2).Shift the spindle (4) with the connecting rod (5) and repeat

the check on the highest point on the opposite side D of thepin (3). The difference between point C and point D must beno greater than 0.08 mm.

61696

Checking axis alignment

Check the alignment of the axes of the connecting rods (1)with device 99395363 (5), proceeding as follows:

- Fit the connecting rod (1) on the spindle of the tool99395363 (5) and lock it with the screw (4).

- Set the spindle (3) on the V-prisms, resting theconnecting rod (1) on the stop bar (2).

Figure 50

Figure 51

Figure 52

Figure 53

To fit the piston rings (1) on the piston (2) use the pliers99360184 (3).The rings need to be mounted with the word ”TOP” (4)facing upwards. Direct the ring openings so they arestaggered 120° apart.

Mounting the connecting rod - piston assembly

Carry out the steps for removal described on pages 25 and

26 in reverse order.

!The connecting rod screws can be reused as long as

the diameter of the thread is not less than 13.4 mm.

Mounting the piston rings

Checking torsion

61694

Checking bending

61695

49029

Checking connecting rod alignment




4903047593

Figure 54

Figure 55

Figure 56

Fit the half-bearings (1), selected as described on pages 52 to

58, both on the connecting rod and on the stand.

- all pistons belong to the same class, A or B;

- ideogram stamped on the piston crown is placed toward the engine flywheel, or the cavity, on the piston cover,corresponds to the position of the oil spray nozzles.

61831

Connecting rod-piston assembly

Marking area on the piston crown of ideogramspecifying the assembly position and theselection class

Connecting rod marking area (see Figure 48).

1

2

3

Fit the connecting rod-piston assemblies (1) into the pistonliners (2) using band 99360605 (1, Figure 56). Check thefollowing:

- the openings of the split rings are offset by 120°;

As spares, class A pistons are provided and can befitted also to cylinder barrels belonging to class B.

Piston protrusion check

Once assembly is complete, check piston protrusion fromcylinder barrels: it must be 0.32-0.69 mm.

Fitting the connecting rod-piston assemblyinto the piston liners

NOTE




Install the connecting rod caps (1) with half-bearings; tighten

the connecting rod cap fixing screws (2) to 50 Nm (5 kgm) torque. By tool 99395216 (3), tighten the screws further at40° angle.Remove the caps and check the clearance by comparing thewidth of the calibrated wire with the scale calibration on theenvelope containing the wire.

CYLINDER HEAD

Before dismounting the cylinder head, check its hydraulic tightness by using suitable tooling; in case of leaks not causedby either retainer caps or threaded caps, replace the cylinder head.

47594

47583

36159

48625

Figure 57

Figure 58

Figure 59

Figure 60

Valve removal

Install and fix tool 99360264 (2) with bracket (4); tighten by lever (1) until cotters are removed (3); remove the tool (2)and theupperplate (5), the spring (6) and the lower plate (7).Repeat the operation on all the valves. Turn the cylinder headupside down and remove the valves (8).

The planarity (1) is checked using a ruler (2) and a thiknessgauge (3). If deformations exist, surface the head usingproper surface grinder; the maximum amount of material tobe removed is 0.2 mm.

VALVE

Removing deposits and checking the valves

Remove carbon deposits using the metal brush supplied.Check that the valves show no signs of seizure or cracking.Check the diameter of the valve stem using a micrometer (see Figure 61) and replace if necessary.

Checking assembly clearance of big end pins

To check the clearance proceed as follows:

Connect the connecting rods to the relative main journals,place a length of calibrated wire on the latter.

α Checking the planarity of the head on thecylinder block

(Demonstration)

After leveling, make sure that valve sinking andinjector protrusion are as described in the relativeparagraph.

NOTE

In case of caps dismounting/replacement, apply sealant Loctite 270 on to the caps.

NOTE

Before dismounting cylinder head valves, number the valves in order to remount them in the sameposition that was found on dismounting in the casewhere they should not to be overhauled or replaced. Intake valves are distinguished fromexhaust valves in that they have a recess located at

the centre of valve mushroom.

NOTE




47509

Figure 61

Figure 62

INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES

* Values to be obtained after installing the valve guides.

VALVE GUIDES

*

MAIN DATA - VALVES AND VALVE GUIDES

* Values to be obtained after installing the valve guides

92841

Check, by means of a micrometer, that valve stem diametersare as specified; if necessary, grind the valves seat with agrinder, removing the minimum quantity of material.




41032

45634

Figure 63

Figure 64

Remove valve guides by means of tool 99360288.Install by means of tool 99360288 equipped with part99360294, which determines the exact installation positionof valve guides into the cylinder heads; if they are notavailable, install the valve guides in the cylinder head so that

they project out by mm 16.3 to 16.7 (Figure 62).After installing the valve guides, smooth their holes with

sleeker 99390310.

Ream the valve seats (2) on cylinder head using tool99305019 (1).

After reaming the valve seats, use tool 99370415, to makesure that the valve position, with respect to the cylinder headsurface, is the following:

- -0.5 to -0.8 mm (recessing) of exhaust valves;

- -1.6 to 1.9 mm (recessing) of discharge valves.

To replace the injector case (2), act as follows:

- thread the case (2) with tool 99390804 (1).

Replacing of valve guides REPLACING INJECTOR HOLDER CASESRemoval

Replacing - Reaming the valve seats

To replace the valve seats, remove them using theappropriate tool.

Valve seats must be reamed whenever valves or valve guides are replaced or ground.

1

2

A

NOTE




45633

Figure 65

Figure 66

Figure 67

- Remove any residue (1), with tool 99390772 (2), from the cylinder head groove.

1

2

- Fasten extractor 99342149 (2) to case (3), by tightening the nut (1), and pull out the case from cylinder head.

45631

1

2

3

45635

- Lubricate sealing rings (3) and fit them to the case (4);fix tool 99360554 (2) to the cylinder head by means of bracket A, install the new case, tighten the screw (1),upsetting the case lower part.

1

2

4

3

A

45632

Figure 68

- Adjust the casing hole (3) with borer 99394043 (1) and

guide bushing 99394014 (2).

1

2

3

A




45636

47585

Figure 69

Figure 70

- Through miller 99394041 (1) andbushing 99394014 (2),ream the injector seat in the case (3), check the injector protrusion from the cylinder head plane which must be

0.7 mm.

Using dial gauge (1), check the protrusion of the injector (2)which must be 0.7 mm.

Checking protrusion of injectors

1

2

3

A

44909

Figure 71

INSTALLATION DIAGRAM FOR INJECTOR CASE




TIMING CONTROL COMPONENT PARTS1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -

5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear - 8. Drive shaft driving gear.

86925

86927

99283

Rated assembling play between idler gear bushings and pins:0.040 ÷ 0.080 mm.

TIMING GEARCamshaft drive

Intermediate gear pin

86926

Idler gear

Twin idler gear

Replacing the bushings

Bushings can be replaced when they are worn. Put up thebushing, then grind it so as to bring it to a dimension of ∅58.010 ± 0.10 mm.

Bushings must be forced into gears by following thedirection of the arrow: they must be positioned at

the level shown in the figures.

Figure 72

Figure 73

Figure 74

Figure 75

NOTE






The bush surfaces must not show any sign of seizing or scoring; if they do replace them.

47504

47508

Figure 79

Figure 80

MAIN DATA - CAMSHAFT AND TOLERANCESThe surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the

shaft and the relative bushes.

MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS* Bush inner diameter after installation

Bushes

Measure the bush inner diameters with a baremeter and replace them, if the value measured exceeds the tolerance value.To take down and fit back the bushes, use the proper tool

99360487.


TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity ⊥

POSITION Concentricity or coaxial alignment

OSCILLATION Circular oscillation

IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝



Figure 81

71721A B C D E F D L G H D I

A. Drift with seat for bushings to insert/extract. - B. Grub screw for positioning bushings. - C. Reference mark to insertseventh bushing correctly. - D. Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks). - E. Guide bushing. -F. Guide line. - G. Guide bushing to secure to the seventh bushing mount. - H. Plate fixing yellow bushing to cylinder head.

- I. Grip. - L. Extension coupling.

Figure 82

71725

The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, 1.The bushings are extracted from the front of the single seats.Removal does not require the drift extension for bushings 5,6 and 7 and it is not necessary to use the guide bushing.For bushings 1, 2, 3 and 4 it is necessary to use the extensionand the guide bushings.Position the drift accurately during the phase of removal.

Removing bushes

Figure 83

Assembling bushes

1 Position the bushing to insert on the drift (A) making thegrub screw on it coincide with the seat (B) (Figure 81) on

the bushing.2 Position the guide bushing (E) and secure the guide

bushing (G) (Figure 81) on the seat of the 7 th bushingwith the plate (H).

3 While driving in the bushing, make the referencemark(F)match the mark (M). In this way, when it is driven home,

the lubrication hole on the bushing will coincide with theoil pipe in its seat.The bushing is driven home when the 1st red referencemark (D) is flush with the guide bushing (G).

Assemble the drift together with the extension.

To insert bushings 1, 2, 3, 4 and 5, proceed as follows:

71723

Figure 84

To insert the bushing (6), proceed as follows:

- Unscrew the grip (I) and the extension (N).

- Position the extension (N) and the guide bushing (E) asshown in the figure.

- Repeat steps 1, 2, 3.

Rear

Rear

77795

Replacing camshaft bushes using beater 99360487




70000

99374

87051

86290

MAIN DATA TO CONTROL EXHAUST AND

DISCHARGE VALVE SPRING

- fit springs (6) and the upper plate (5);

- apply tool 99360264 (2) and block it with bracket (4); tighten the lever (1) until cotters are installed (3),remove tool (2).

VALVE SPRINGS

Fitting the valves and oil seal ring

71724

To insert bushing (7), proceed as follows:


- Refit the guide (G) fromthe inside as shown in the figure.

- Position the bushing on the drift (A) and bring it closeup to the seat, making the bushing hole match thelubrication hole in the head. Drive it home.

The 7 th

bushing is driven inwhen the reference mark (C)is flush with the bushing seat.

Before assembly, the flexibility of the valve springs has to bechecked with the tool 99305047.Compare the load and elastic deformation data with thoseof the new springs given in the following figure.

Rear

Figure 85

Figure 86

Figure 87

Figure 88

Figure 89

Lubricate the valve stem and insert the valves in therespective valve guides; fit the lower caps (1). Use tool99360329 to fit the oil seal (2) on the valve guides (3) of theexhaust valves; then, to fit the valves, proceed as follows.

Free spring height

Valve closed

Valve open

6 3 . 6

4 9 . 5

3 4 . 5

N 454 ± 22

N 840 ± 42

Where valves should not have been overhauled or

replaced, remount them according to thenumbering that was performed during mounting.Intake valves are distinguished from exhaust valvesin that they have a recess located at the centre of valve mushroom.

NOTE




44925

The camshaft cams directly control rockers: 6 for injectors and 12 for valves.Injectors and intake valves control rocker arms are keyed on rocker arms shaft directly. Exhaust intake valves control rocker armsare keyed on rocker arms shaft putting in between the levers with engine brake control eccentric pin.Rockers slide directly on the cam profiles via rollers. The other end acts on a bar directly supported by the two valves stems.A padis placed between the rockeradjusting screw andthe bar. Twolubrication holes areobtainedinsidethe rockers. The rocker shaft practically covers the whole cylinder head; remove it to have access to all the underlying components.

Figure 90

44914

44912

44913

Figure 91

Figure 92

Figure 93

PUMP INJECTOR ROCKER

EXHAUST VALVES ROCKER

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

DISCHARGE VALVE ROCKER

Rocker

SECTION A-A SECTION B-B



Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.

MAIN DATA OF THE ROCKER ARM SHAFT

79171

Shaft

Figure 94

Figure 95

92822

LEVER WITH ENGINE BRAKE CONTROLECCENTRIC PIN

ROCKER SHAFT





TIGHTENING TORQUES

TORQUE

Nm kgm

Under-basement fastening screws to cylinder block (see Figure 96) ♦Outer screws First stage : pre-tightening M10x1.25 25 2.5

Inner screws Second stage : pre-tightening M16x2 140 14

Inner screws Third stage : angle closing M16x2 60°Inner screws Fourth stage : angle closing M16x2 60°Outer screws Fifth stage : angle closing M10x1,5 90°Pipe union for piston cooling nozzle M12X1.5 35 ± 2 3.5 ± 0.2

Intercooler fastening screws to cylinder block ♦ (see Figure 101)pre-tightening

tightening11.5 ± 3.5

19 ± 31.15 ± 0.35

1.9 ± 0.3

Plug 125 ± 15 12.5 ± 1.5

Spacer and oil sump fastening screws (see Figure 102) 41.5 ± 3.5 4.1 ± 0.3

Gearcase fastening screws to cylinder block M10X1.25 41.5 ± 3.5 4.1 ± 0.3

M12X1.75 63 ± 7 6.3 ± 0.7

M8X1.25 23.5 ± 1.5 2.3 ± 0.1

Cylinder head fastening screw: (see Figure 97)First stage pre-tightening 50 5Second stage pre-tightening 100 10Third stage angle closing 90°Fourth stage angle closing 75°Rocker arm shaft fastening screw ♦ (see Figure 98)

First stage pre-tightening 40 4

Second stage angle closing 60°Locknut for rocker arm adjusting screw ♦ 39 ± 5 3.9 ± 5

Screws for injector fastening brackets ♦ 36.5 3.65

Shoulder plate fastening screws to head ♦ 20 ± 2 2 ± 0.2

Engine support bracket fastening screws to cylinder head 74 ± 8 7.4 ± 0.8

Gear fastening screws to camshaft: ♦First stage pre-tightening 50 5

Second stage angle closing 50°Phonic wheel fastening screws to distribution gear 8.5 ± 1.5 0.8 ± 0.1

Exhaust pipe fastening screws • (see Figure 99)pre-tightening

tightening35 ± 570 ± 5

3.5 ± 0.57 ± 0.5

Engine brake actuator cylinder fastening screws 19 ± 3 1.9 ± 0.3

Connecting rod cap fastening screws: ♦First stage pre-tightening 50 5

Second stage angle closing 40°Engine flywheel fastening screws: ♦ M16x1.5x58

First stage pre-tightening 100 10Second stage angle closing 60°Engine flywheel fastening screws: ♦ M16x1.5x110

First stage pre-tightening 100 10Second stage angle closing 120°Flywheel pulley fastening screws to crankshaft : ♦


Second stage angle closing 50°

♦ Lubricate with oil MOLYKOTE before assembly

• Lubricate with graphitized oil before assembly




TORQUE

Nm kgm

Damper flywheel fastening screws: ♦ 115 ± 15 11.5 ± 1.5

Idler gear pin fastening screws: ♦



Idle gear link rod fastening screw 24.5 ± 2.5 2.4 ± 0.2

Oil pump fastening screw 24.5 ± 2.5 2.4 ± 0.2

Oil pump suction rose fastening screw 24.5 ± 2.5 2.4 ± 0.2

Front cover fastening screw to cylinder block ♦ 19 ± 3 1.9 ± 0.3

Control unit fastening screw to cylinder block ♦ 19 ± 3 1.9 ± 0.3

Supply pump fastening screw to gearcase ♦ 19 ± 3 1.9 ± 0.3

Fuel filter support fastening screw to cylinder head 24.5 ± 2.5 2.4 ± 0.2

M16x2 screw securing engine support to gears box ♦



Turbo-compressor fastening screws and nuts • (see Figure 100)pre-tightening

tightening35 ± 546 ± 2

3.5 ± 0.54.6 ± 0.2

Water pump fastening screw to cylinder block 24.5 ± 2.5 2.4 ± 0.2

Pulley fastening screw to hub 55 ± 5 5.5 ± 0.5

Rocker arm cover fastening screws (see Figure 103) 9 0.9

Thermostat box fastening screws to cylinder head 24.5 ± 2.5 2.4 ± 0.2

Automatic tightener fastening screws to cylinder block 45 ± 5 4.5 ± 0.5

Fixed tightener fastening screws to cylinder block 105 ± 5 10.5 ± 0.5

Fan support fastening screws to cylinder block 24.5 ± 2.5 2.4 ± 0.2

Starter fastening screws 44 ± 4 4 ± 0.4

Air heater on cylinder head 50 ± 5 5 ± 0.5

Air compressor fastening screw to cylinder head 74 ± 8 7.4 ± 0.8

Air compressor control gear fastening nut 170 17 ± 1

Hydraulic power steering pump gear fastening nut 46.5 ± 4.5 4.6 ± 0.4

Air conditioner compressor fastening screw to support 24.5 ± 2.5 2.4 ± 2.5

Air conditioner compressor support fastening screw to cylinder block 44 ± 4 4.4 ± 0.4

Alternator support fastening screw to cylinder block 44 ± 4 4.4 ± 0.4

Alternator bracket fastening screw to cylinder block 24.5 ± 2.5 2.4 ± 0.2 Water pipe unions 35 3.5

Water temperature sensor 32.5 ± 2.5 3.2 ± 0.2

♦ Lubricate with oil MOLYKOTE before assembly

• Lubricate with graphitized oil before assembly





44898

FRONT SIDE Front phase:

angle tighteningof inner screws

60º

44897

44899

44898

Figure 96

First phase:preliminary tightening

of outer screws(25 Nm)

FRONT SIDE

FRONT SIDE

Second phase:preliminary

tightening of inner screws

(140 Nm)

Fifth phase:angle tighteningof outer screws

90º

44898

FRONT SIDE Third phase:

angle tighteningof inner screws

60º

FRONT SIDE

Underblock fixing screws tightening sequence




44900

Figure 97

Figure 98

Diagram of exhaust manifold fixing screws tightening sequence

45359

Diagram of cylinder head fixing screws tightening sequence

18

6 3 2 7 6 3 4 7 6 3 2 7

54852854 11

Figure 99

70567A

Diagram of rocker shaft fixing screws tightening sequence




455361

Figure 100

Figure 101

Diagram of engine oil sump fixing screws tightening sequence

45362

Diagram of heat exchanger fixing screws tightening sequence

1

8

12 11 10 3

913

14

4 5 6 7 2

Figure 102

SEQUENCE: Preliminary tightening 4 - 3 - 1 - 2Tightening 1 - 4 - 2 - 3

45360

Diagram of turbocharger fixing screws and nuts tightening sequence




Figure 103

Diagram of rocker arm cap fixing screws tightening sequence

45363

17 14 13 1 4 5 8

18

19

20

16 15 12 2 3 6 7

11

10

9




SECTION 5 - TOOLS 1F2B CURSOR ENGINES

SECTION 5

Tools

Page

TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 5 - TOOLS F2B CURSOR ENGINES




TOOLS

TOOL NO. DESCRIPTION

8093731 Tester PT01

99305019 Full-optional tool-kit to rectify valve seat

99305047 Equipment for spring load check

99322230 Rotary telescopic stand

99340051 Extractor for crankshaft front gasket

99340052 Extractor for crankshaft rear gasket




TOOLS


99340205 Percussion extractor

99342148 Injector extractor

99342149 Extractor for injector-holder

99346245 Tool to install the crankshaft front gasket

99346246 Tool to install the crankshaft rear gasket

99348004 Universal extractor for 5 to 70 mm internal components




TOOLS


99350072 Box wrench for transmission gear support fixing screws

99350074 Box wrench for block junction bolts to the underblock

99360144 Skid retaining tools (12+6) for rocker arm adjusting screws during

rocker arm shaft removal/ refitting

99360177 Injector housing plug

99360184 Pincers for removing and refitting circlips and pistons

(105-160 mm)

99360264 Tool to take down-fit engine valves




TOOLS


99360288 Tool to remove valve guide

99360292 Tool to install gasket on valve guide

99360294 Tool to drive valve guide

99360314 Tool to remove cartridge filters

99360321 Tool to rotate engine flywheel

99360334 Tool for checking cylinder barrel projection.




TOOLS


99360335 Cylinder barrel compression cap (to be used with 99360334)

99360351 Tool to stop engine flywheel

99360487 Tool to take down and fit back camshaft bushes

99360500 Tool to lift crankshaft

99360551 Bracket to take down and fit engine flywheel

99360558 Tool to lift and transport rocker shaft




TOOLS


99360585 Balance for lifting and handling engine

99360605 Belt to insert piston in cylinder liner (60 - 125 mm)

99360612 Engine flywheel timing pin

99360613 Tool for timing of phonic wheel on timing gear

99360703 Tool to stop cylinder liners

99360706 Tool to extract cylinder liners




TOOLS


99360724 Tool to extract the cylinder liners (to be used with 99360723)

99361035 Brackets fixing the engine to rotary stand 99322230

99365054 Tool for injector holder heading

99370415 Tool to detect cylinder liner projections

(use with 99395603)

99378100 Tool for printing engine identification plates (to be used with

special punches)

99378101 *99378102

99378105

99378106

Punches (A * - B - E - F ) for printing engine identificationplates (to be used with 99378100)




TOOLS


99389834 Dynamometric screwdriver to calibrate screws for injector solenoid valve

99390310 Valve guide sleeker

99390772 Tool to remove residues from injector holder

99390804 Tool to thread injector holders to be extracted

99394014 Guide bush (to be used with 99394041 or 99394043)

99394041 Cutter to rectify injector holder housing (to be used with

99394015)




TOOLS


99394043 Reamer to rectify injector holder lower side (to be used with99394015)

99395215 Gauge for centre distance check between camshaft and idle gear

99395216 Measuring pair for angular tightening with 1/2” and 3/4” square

couplings

99395363 Complete square to check connecting rod squaring

99395603 Dial gauge (0 - 5 mm)

99395687 Reaming gauge (50-178 mm)




TOOLS


99396033 Centering ring of crankshaft front cap



APPENDIX 1F2B CURSOR ENGINES

Appendix

Page

SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . .



2 APPENDIX F2B CURSOR ENGINES



Particular attention shall be drawn on some precautions thatmust be followed absolutely in a standard working area andwhose non fulfillment will make any other measure uselessor not sufficient to ensure safety to the personnel in-chargeof maintenance.

Be informed and inform personnel as well of the laws in forceregulating safety, providing information documentationavailable for consultation.

- Keep working areas as clean as possible, ensuringadequate aeration.

- Ensure that working areas are provided with emergency boxes, that must be clearly visible and always providedwith adequate sanitary equipment.

- Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnelmust be trained on intervention methods and priorities.

- Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequateindications of the emergency exit lines.

- Smoking in working areas subject to fire danger must bestrictly prohibited.

- Provide Warnings throughout adequate boards signalingdanger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.

- Do not execute any intervention if not provided withnecessary instructions.

- Do not use any tool or equipment for any differentoperation from the ones they’ve been designed andprovided for: serious injury may occur.

- In case of test or calibration operations requiring enginerunning, ensure that the area is sufficiently aerated or

utilize specific vacuum equipment to eliminate exhaustgas. Danger: poisoning and death.

SAFETY PRESCRIPTIONSStandard safety prescriptions

Prevention of injury

- Do not wear unsuitable cloths for work, with flutteringends, nor jewels such as rings and chains when workingclose to engines and equipment in motion.

- Wear safety gloves and goggles when performing thefollowing operations:- filling inhibitors or anti-frost- lubrication oil topping or replacement- utilization of compressed air or liquids under pressure(pressure allowed: ≤ 2 bar)

- Wear safety helmet when working close to hangingloads or equipment working at head height level.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- Use protection cream for hands.

- Change wet cloths as soon as possible

- In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections.Ensure that hands and feet are dry and execute workingoperations utilizing isolating foot-boards. Do not carry out working operations if not trained for.

- Do not smoke nor light up flames close to batteries and to any fuel material.

- Put the dirty rags with oil, diesel fuel or solvents inanti-fire specially provided containers.

During maintenance

- Never open filler cap of cooling circuit when the engineis hot. Operating pressure would provoke high

temperature with serious danger and risk of burn. Waitunit the temperature decreases under 50ºC.

- Never top up an overheated engine with cooler andutilize only appropriate liquids.

- Always operate when the engine is turned off: whether particular circumstances require maintenanceintervention on running engine, be aware of all risksinvolved with such operation.

- Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

- Keep the engine clean from oil tangles, diesel fuel and or chemical solvents.

- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areasaerated. Whenever necessary wear safety mask.

- Do not leave rags impregnated with flammablesubstances close to the engine.

- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

- Do not utilize fast screw-tightening tools.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on theelectrical system.

- Disconnect batteries from system aboard to load themwith the battery loader.

- After every intervention, verify that battery clamppolarity is correct and that the clamps are tight and safe

from accidental short circuit and oxidation.- Do not disconnect and connect electrical connections

in presence of electrical feed.

- Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquidor air under pressure. Take all necessary precautionsbleeding and draining residual pressure or closing dumpvalves. Always wear adequate safety mask or goggles.Non fulfillment of these prescriptions may cause seriousinjury and poisoning.






Section


Fuel 2


General overhaul 4

Tools 5



Section 1 describes the F3A engine illustrating its features




rate parts:










veniences.



such operations.

Part 2

F3A CURSOR ENGINES

1F3A CURSOR ENGINES



2 F3A CURSOR ENGINES



3F3A CURSOR ENGINES

UPDATING




4 F3A CURSOR ENGINES



SECTION 1 - GENERAL SPECIFICATIONS 1F3A CURSOR ENGINES

SECTION 1


Page


VIEWS OF ENGINE 5. . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 8. . . . . . . . . . . . . . . . . . . . . . . . . .

- Oil pump 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


- Oil pressure control valve 10. . . . . . . . . . . . . . . .

- Heat exchanger for engine versions

with double filter 10. . . . . . . . . . . . . . . . . . . . . . .

- Heat exchanger for engine versionswith single filter 11. . . . . . . . . . . . . . . . . . . . . . . .

- By-pass valve 12. . . . . . . . . . . . . . . . . . . . . . . . . .



COOLING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Description 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Water pump 14. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 15. . . . . . . . . . . . . . . . . . . . . .

- Turbocharger HOLSET HY55V 15. . . . . . . . . . . .



2 SECTION 1 - GENERAL SPECIFICATIONS F3A CURSOR ENGINES






F3A0681D*B... C10 ENT C






LEFT-HAND SIDE VIEW


73529

73526

Figure 1

VIEWS OF ENGINE




FRONT VIEW

REAR VIEW

73528

73527

Figure 2




TOP VIEW

73834

Figure 3




Figure 4

LUBRICATION

Engine lubrication is obtained with a gear pump driven by the crankshaft via gears.A heat exchanger governs the temperature of the lubricating oil.It houses two oil filters, indicator sensors and safety valves.

60672

LUBRICATION CIRCUIT

Oil falling

Oil under pressure

B - to cylinders 1 - 2 - 3C - to cylinder 4D - to cylinders 5 - 6




The oil pump (1) cannot be overhauled. On finding any

damage, replace the oil pump assembly.See under the relevant heading for replacing the gear (2) of

the crankshaft.

60560 73540

73541

Figure 5

Figure 6

MAIN DATA TO CHECK THE OVERPRESSUREVALVE SPRING

OIL PUMP CROSS-SECTION

1. Overpressure valve — Start of opening pressure 10.1 ±0.7 bars.

Overpressure valve

Figure 7

1

Oil pump





73542 73543

Figure 8

Figure 9

Figure 10


HEAT EXCHANGER The heat exchanger is fitted with: 1. Oil temperature sensor - 2. Oil pressure sensor for pressure gauge - 3. Transmitter for

low pressure warning lamp - 4. By-pass valve - 5. Heat valve. Number of elements 9.

Oil pressure control valve

Heat exchanger for engine versions with

double filter

78950




HEAT EXCHANGER The following elements are fitted on the intercooler: 1. Transmitter for low pressure warning lamp - 2. By-pass valve -3. Oil temperature sensor - 4. Oil pressure sensor for single gauge - 5. Heat valve. Number of intercooler elements: 7.

Heat exchanger for engine versions with single filter

77818

Figure 11









The filtering elements are closely wound by a spiral so thateach fold is firmly anchored to the spiral with respect to theothers. This produces a uniform use of the element even in

the worst conditions such as cold starting with fluids with ahigh viscosity and peaks of flow. In addition, it ensures uni-form distribution of the flow over the entire length of thefiltering element, with consequent optimization of the loss of load and of its working life.

Mount upstream

To optimize flow distribution and the rigidity of the filtering el-ement, this has an exclusive mount composed of a strong meshmade of nylon and an extremely strong synthetic material.

Filtering element

Composed of inert inorganic fibres bound with an exclusiveresin to a structure with graded holes, the element is manu-factured exclusively to precise procedures and strict quality control.

Mount downstream


Structural parts

The o-rings equipping the filtering element ensure a perfectseal between it and the container, eliminating by-pass risksand keeping filter performance constant. Strong corrosion-proof bottoms and a sturdy internal metal core complete thestructure of the filtering element.

When mounting the filters, keep to the following rules:

- Oil and fit new seals.

- Screw down the filters to bring the seals into contactwith the supporting bases.

- Tighten the filter to a torque of 35-40 Nm.

73545

47447

73546

Figure 12

Figure 13

Figure 14


Thermostatic valve

Start of opening:

- travel 0.1 mm at a temperature of 82 ±2°C.

End of opening:


Engine oil filters

By-pass valve




COOLING

Description

The engine cooling system is of the closed-circuit, forced circulation type.It consists mainly of the following components:

- expansion tank, not supplied (by IVECO);



- fan, not supplied;


Operation

The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to thecylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the

thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan.The pressure inside the system, due to temperature change, is adequately controlled through the expansion vessel.

Figure 15

99248

A/B outlet/inlet for vehicle heater C inlet from the expansion vessel

D/E outlet from the radiator and the thermostat body for expansion vessel inlet

Water flowing out of the thermostat


Water flowing into the pump

(Demonstration)




60631

Figure 16

Figure 17

Figure 18

Thermostat

The water pump is composed of: impeller, bearing, seal anddriving pulley.

Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.

CROSS-SECTION OF THE WATER PUMP

View of thermostat operation

60747


TO THEEXPANSION

TUB

FROMTHE ENGINE

TO THEBY PASS


60748

TO THERADIATOR

TO THEEXPANSION

TUB

TO THEBY PASSFROM

THE ENGINE

Check the thermostat works properly; replace it if in doubt.Temperature of start of travel 84°C ±2°C.Minimum travel 15 mm at 94°C ±2°C.

TO THERADIATOR

Water pump

NOTE




Figure 19

TURBOCHARGING


- air filter;



60675


Turbocharger HOLSET HY55VOperating principle

The variable geometry turbocharger (VGT) consists of acentrifugal compressor and a turbine, equipped with amobile device which adjusts the speed by changing the areaof the passing section of exhaust gases to the turbine.

Thanks to this solution, gas velocity and turbine speed canbe high even when the engine is idling.

If the gas is made to go through a narrow passage, in fact,it flows faster, so that the turbine rotates more quickly.

The movement of the device, choking the exhaust gasflowing section, is carried out by a mechanism, activated by a pneumatic actuator.



At high engine operating speed, the electronic controlsystem is activated and increases the passing section, inorder to allow the in-coming gases to flow withoutincreasing their speed.

A toroidal chamber is obtained during the casting processin the central body for the passage of the coolant.


Intake air

Engine exhaust gas








SECTION 2 - FUEL 1F3A CURSOR ENGINES

SECTION 2

Fuel

Page

FEEDING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SUPPLY DIAGRAM 4. . . . . . . . . . . . . . . . . .

- Fuel pump 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injector-pump 5. . . . . . . . . . . . . . . . . . . . . . . . .

- Injector Phases 6. . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 2 - FUEL F3A CURSOR ENGINES



Figure 1

1. Valve for return circuit, starts opening at 3.5 bars - 2. Valve for return circuit, starts opening at 0.2 bars.

71738

FEEDING

Fuel is supplied via a fuel pump, filter and pre-filter, 6pump-injectors governed by the camshaft via rocker armsand by the electronic control unit.

Return circuit

Supply circuit




81817

Figure 2

1. Temperature sensor - 2. Bleed valve - 3. Secondary fuel filter - 4. By-pass valve (0.3 ÷ 0.4 bar) - 5. Fuel supply pump -6. Integrated valve (3.5 bar) - 7. Pressure relief valve (5 bar) - 8. Fuel tank - 9. Priming pump - 10. Primary fuel filter -11. Check valve (opening 0.1 bar) - 12. Heater - 13. Electronic control unit - 14. Fuel return union with valve built in

(0.2 bar) - 15. Pump-injectors.

FUEL SUPPLY DIAGRAM

(Demonstration)




73547

44908

73548

Figure 3

Figure 4

Figure 5

A. Fuel inlet — B. Fuel delivery — C. By-pass nut — D. Fuel return from the pump-injectors —

E. Pressure relief valve — Opening pressure: 5-8 bars.

CROSS-SECTION OF THE FUEL PUMP1. Oil and fuel leakage indicator.

Injector-pump

1. Fuel/oil seal — 2. Fuel/diesel seal — 3. Fuel/exhaust gas seal.


Pumping element

The pumping element is operated by a rocker arm governeddirectly by the cam of the camshaft.The pumping element is able to ensure a high delivery pressure. The return stroke is made by means of a returnspring.

Nozzle

Garages are authorized to perform fault diagnosis solely on the entire injection system and may not work inside theinjector-pump, which must only be replaced.A specific fault-diagnosis program, included in the controlunit, is able to check the operation of each injector (itdeactivates one at a time and checks the delivery of the other five).Fault diagnosis makes it possible to distinguish errors of anelectrical origin from ones of a mechanical/hydraulic origin.It indicates broken pump-injectors.It is therefore necessary to interpret all the control unit error messages correctly.Any defects in the injectors are to be resolved by replacing

them.

Solenoid valve


that shuts off the pumping element delivery pipe. When the solenoid is not energized, the valve is open, thefuel is pumped but it flows back into the return pipe with thenormal transfer pressure of approximately 5 bars.

When the solenoid is energized, the valve shuts and the fuel,not being able to flow back into the return pipe, is pumpedinto the nozzle at high pressure, causing the needle to lift.The amount of fuel injected depends on the length of time

the slide valve is closed and therefore on the time for which the solenoid is energized.

The solenoid valve is joined to the injector body and cannotbe removed.On the top there are two screws securing the electricalwiring from the control unit.To ensure signal transmission, tighten the screws with a torquewrench to a torque of 1.36 — 1.92 Nm (0.136 — 0.192 kgm).

Fuel pump




1. Fuel valve - 2. Pumping element - 3. Fuel outlet -

4. Filling and backflow passage.

60669

Figure 6

Injector Phases

Filling phaseDuring the filling phase the pumping element (2) runs up to

the top position.After passing the highest point of the cam, the rocker armroller comes near the base ring of the cam.The fuel valve (1) is open and fuel can flow into the injector via the bottom passage (4) of the cylinder head.Filling continues until the pumping element reaches its toplimit.

Injection phaseThe injection phase begins when, at a certain point in thedown phase of the pumping element, the solenoid valve getsenergized and the fuel valve (1) shuts.

The moment delivery begins, appropriately calculated by theelectronic control unit, depends on the working conditionsof the engine.

The cam continues with the rocker arm to push the pumpingelement (2) and the injection phase continues as long as thefuel valve (1) stays shut.



60670

Figure 7






60671

Figure 8



The time for which the solenoid valve stays energized,appropriately calculated by the electronic control unit, is theduration of injection (delivery) andit depends on the workingconditions of the engine.







SECTION 3 - VEHICLE APPLICATION 1F3A CURSOR ENGINES

SECTION 3

Vehicle application

Page

CLEARANCE DATA 3. . . . . . . . . . . . . . . . . . . . .


DISMANTLING THE ENGINE ON THE BENCH 7


- Diagram of tightening sequence of crankcase basefixing screws 16. . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod - piston assembliesin cylinder liners 17. . . . . . . . . . . . . . . . . . . . . . .






- Camshaft timing 23. . . . . . . . . . . . . . . . . . . . . . .



COMPLETING ENGINE ASSEMBLY 27. . . . . . . . .


- Components on the engine F3A 31. . . . . . . . . . .

BLOCK DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . .




- Pump injector (78247) 36. . . . . . . . . . . . . . . . . .




2 SECTION 3 - VEHICLE APPLICATION F3A CURSOR ENGINES

Page



- Distribution pulse transmitter (48042) 40. . . . . .

- Overfeed pressure transmitter (85154) 41. . . . . .

- Air temperature transmitter on manifold (85155) 42. . . . . . . . . . . . . . . . . . . .

- Pre-post reheat resistor (61121) 43. . . . . . . . . . .



PREFACE 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


MAINTENANCE 59. . . . . . . . . . . . . . . . . . . . . . . . .

CHECKS AND/OR MAINTENANCE WORK 60. .

OFF-PLANE OPERATIONS 61. . . . . . . . . . . . . . . .




CLEARANCE DATA

Type F3A0681D*B...

ρ Compression ratio 17 ± 0.8


316(430)

2100


1900(194)

1050 ÷ 1590

Loadless engineidling rpm

550 ± 25

Loadless engine

peak rpm 2550 ± 20


125 x 14010300

SUPERCHARGING

Turbocharger type HOLSET HY55V with variable geometry

bar

LUBRICATION




1.55

COOLING By centrifugal pump, regulating thermostat, viscostatic fan,

radiator and heat exchanger

Water pump control By belt

Thermostat N. 1

initial opening ~84ºC ±2 °C

maximum opening 94ºC ±2 °C













- soundproofing shield (1);

- all the pipes connecting the compressor;

60481

60483

60482

60484

60485

60486

On the engine right-hand side

- diesel cartridge filter (1);

- power steering system tank (2);

- electric connections;

- compressor (1) fitted with power steering pump (2);

- remove the air conditioner control belt (1) using a fit tool(3) and acting in the direction shown by the arrow;

- disassemble the air conditioner (2) fitted with the enginesupport.

- oil pressure controlling valve (1).

On the engine left-hand side

- engine support (1);

DISMANTLING THE ENGINE ON THEBENCH

Before fixing the engine on the rotary stand 99322230remove the following components:

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6




73582

Figure 7

Secure the engine to the rotary stand 99322030 with the brackets 99361036 (1).




87256

87257

60490

60491

Figure 8

Figure 9

Figure 10

Figure 11

Use a suitable wrench to act on the belt-stretcher (2) roller fastening screw in the direction shown by the arrow, so as toloosen belt (1) tension, then take off the belt.

In the same way (if present) operate the backstand (4) andremove the belt (3).

Remove the following components:- thermostat unit (5) fitted with turbine actuator pressure

sensor;- alternator (1);- electro-magnetic joint (7);- water pump (6) and piping;- automatic belt tightener support (2);- fixed belt tightener (8);- remove the screws (11), the spacer (10), the damper fly-

wheel (9) and the pulley (12).- disconnect all the electric connections and the sensors.If present, remove:

- the climate control system compressor (3);

- the automatic backstand (4).

Fit the extractor 99340053 (2) and remove the enginecrankshaft seal gasket (1), remove the cover (3).

Remove the following components: water outlet line (2); oildelivery line (4); actuator air line (3); water delivery line (6);oil return line (7); turbocharger (5); exhaust manifold (1).

60492

Unscrew the oil filters (1) using the tool 99360314.

Figure 12




60494

60493 85480

60496

60497

- Unscrew the screws (1) and remove the heat exchanger (4);

- unscrew the screws (2) and remove the water line (3).

Remove the following components: fuel filter support (1); fuelpump (2) and lines; starter (3); engine starting button support(4); PWN valve air filter (5); suction manifold (6) fitted withresistance for engine pre-heating; control unit (7).

- Unscrew the screws (2) and remove the gear (1) fittedwith phonic wheel.

- Unscrew the screws (1); tighten one screw in a reactionhole and remove the shoulder plate (2), remove thesheet

gasket.

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

70708

To remove the P.T.O. (if applicable):

- Disconnect the oil pipe (1).

- Unscrew the 4 screws (2) and (3).

Remove the rocker arm cover (1), take off the screws (2) andremove: the cover (3), the filter (5) and the gaskets (4 and 6).Take off the screws (8) and remove the blow-by case (7).

Figure 18




60498

60500

60499

60501

60511

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Unscrew the screws (2)and remove the transmission gear(1).

Stop the engine flywheel (3) rotation by means of tool99360351 (1), unscrew the fixing screws (2) and remove theengine flywheel.

Apply the extractor 99340054 (2) and pull out the sealgasket (1).

Unscrew the screws (1) and take down the gearbox (2).

- Release the check springs (3) of the exhaust brake lever.

- Unscrew the screws and cut-out solenoid valve electricconnections (1).

- Remove exhaust brake pins (4) and slave cylinder (6)pipes (5).

- Unscrew the screws (2) fixing the rocker arm shaft.

In sequence, take out the:- if the P.T.O. control gear (1) is present;- idle gear (2);- oil pump gear (3).

71709

Figure 24




73533

60514

60513

60515

60516

60517

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30

Using tool 99360144 (3), constrain the blocks (4) to therockers (2).Apply tool 99360553 (1) to the rocker holder shaft (5) andremove the shaft (5) from the cylinder head.

- Unscrew the screws (2) fixing the brackets (3) andremove the injectors (1).

- Unscrew the screws (4) and remove the exhaust brakepins (5).

- Unscrew the screws and remove the slave cylinder (6).

- Fit the plugs 99360180 (1) instead of injectors.

- Remove the camshaft (2).

- Unscrew the fixing screws on the cylinder head (3).

- By means of metal ropes, lift the cylinder head (1).

- Remove the seal (2)

Unscrew the screws (2) and remove the engine oil sump (1)fitted with spacer (3) and seal.

Unscrew the screws and remove suction rose (1).




60519

60518

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Untighten screws (2) fixing the connecting rod cap (3) andremove it. Remove the connecting rod-piston (1) assembly

from the upper side. Repeat these operations for the other pistons.

By means of proper and splined wrenches, untighten the

screws (1) and (2) and remove the under-block.

47574

Rotate the block (1) to the vertical position.

47570

Using tool 99360500 (1), remove the crankshaft (2).

47571

Remove the main bearing shells (1), unscrew the screws and take out the oil nozzles (2).Remove the cylinder liners as described under the relevantsubheading.

After disassembling the engine, thoroughly cleandisassembled parts and check their integrity.Instructions for main checks and measures are givenin the following pages, in order to determinewhether the parts can be re-used.

!Keep the big end bearing shells in their respectivehousings and/or note down their assembly positionsince, if reusing them, they will need to be fitted in theposition found upon removal.

Note down the assembly position of the top andbottom main bearing shells since, if reusing them,

they will need to be fitted in the position found uponremoval.

NOTE

NOTE




47586

47595

60632

Figure 36

Figure 37

Figure 38

Figure 39


Fix the engine block to the stand 99361036 by means of brackets 99322230.Mount cylinder liners (see Section 4).

Mount the oilnozzles (2), making the grub screw coincide with the hole (3) in the crankcase.

Place the half-bearings (1) on the main bearings in theunderblock (2).

Apply silicone LOCTITE 5699 IVECO N. 45500253 with thesuitable equipment (1) on the engine block as shown in thefollowing figure.

Sealant application diagram.

Fit the underblock within 10’ of the application of the sealant.

47570

Figure 40

Lubricate the half bearings, then install the crankshaft (2) by means of hoist and hook 99360500 (1).

49021

Not finding it necessary to replace the mainbearings, you need to fit them back in exactly thesame sequence and position as in removal. If to bereplaced, select the main bearings according to theselection described in the ”Main bearing andconnecting rod bearing selection” chapter.

Arrange the bearing shells (1) on the main bearing housings.

NOTE

NOTE




60559

47581

47579

Figure 41

Figure 42

Figure 43

Mount the crankcase base and using a torque wrench (2), tighten the outside hex grooved screws (1) to a torque of 30 Nm following the sequence shown on page 16.

Using a torque wrench (3), tighten the inside screws (1) to a torque of 120 Nm. Then tighten them to an angle of 90° and45° with tool 99395216 (4) with another two phases.Regrind the outside screws (1, Figure 42) with closure to an

angle of 60° using tool 99395213 (4).

Mount the crankcase base (1) using appropriate tackle andhooks.

α

α


Print 603.93.331



60593

FRONT SIDE stage 4:

angleinner

screws

(45º)

60592

60594

Figure 44

stage 1:pretighteningouter screws

(30 Nm)

FRONT SIDE

FRONT SIDE

FRONT SIDE

stage 2:pretighteniginner screws

(120 Nm)

stage 5:angleouter

screws

(60º)

FRONT SIDE stage 3:

angleinner

screws

(90º)

60593

60593

DIAGRAM OF TIGHTENING SEQUENCE OF CRANKCASE BASE FIXING SCREWS

Diagram of tightening sequence of crankcase base fixing screws




2

3

449030

Turn the cylinder block, setting it upright.

Lubricate the pistons, piston rings and insidethe cylinder liners.

With the aid of the clamp 99360605 (1) mount the connectingrod — piston assemblies (2) in the cylinder liners according toFigure 46. Check that:

- The number of each connecting rod corresponds to thecap coupling number.

- The symbol (2, Figure 46) punched on the top of thepistons faces the engine flywheel or the recess in thepiston skirt tallies with the position of the oil nozzles.

60615

Figure 45

Connecting rod — piston assembly.

Area of punch marking on the top of thepiston with the symbol for the mountingposition and selection class.

Area of connecting rod punch marking.

Figure 46

60616

Fitting connecting rod - piston assembliesin cylinder liners

Figure 47

1

2

3

Not finding it necessary to replace the connectingrod bearings, you need to fit them back in exactly

the same sequence and position as in removal.If they are to be replaced, choose connecting rodbearings based on selection described in Section 4.Lubricate the bearing shells (1 and 3) and fit themon the connecting rod (2) and on the cap (4).

Do not make any adjustment on the bearing shells. The pistons are supplied as spares in class A andcan

also be fitted in class B cylinder liners.

NOTE

NOTE NOTE




Figure 48

Figure 49

Figure 50

Figure 51

Figure 52

Using the centring ring 99396035 (2), check the exact positionof the cover (1). If it is wrong, proceed accordingly and lock

the screws (3).

Key on the gasket (1), mount the key 99346250 (2) and,screwing down the nut (3), drive in the gasket (1).

Check that the pistons 1-6 are exactly at the T.D.C.Put the gasket (2) on the crankcase.Mount the cylinder head (1) and tighten the screws as shownin Figs. 52 - 53 - 54.

Diagram of the tightening sequence of the screws fixing thecylinder head.

- Pre-tightening with the torque wrench (1):1st phase: 60 Nm (6 kgm).2nd phase: 120 Nm (12 kgm).

60563

60564

60515

60565

61270

!Lubricate the thread of the screws with engine oilbefore assembly.





Apply LOCTITE 5970 IVECO n˚ 2992644 silicone on the gear housing, using appropriate tools (1), as shown in the figure.The sealer string (1) diameter is to be 1,5 ±

Using a torque wrench, tightenthe highlighted screws with thefollowing sequence and tightening torques:

4 screws M12 x 1.75 x 35 63 Nm

10 screws M12 x 1.75 x 100 63 Nm

1 screw M12 x 1.75 x 120 63 Nm

2 screws M12 x 1.75 x 70 63 Nm

Figure 53

Figure 54

Figure 55

60566

- Closing to angle with tool 99395216 (1):3rd phase: angle of 120°.4 th phase: angle of 60°.

Mount the oil pump (4), the intermediate gears (2) together with the link rod (1) and lock the screws (3) in two phases:pre-tightening 30 Nm.closing to angle 90°.

47592

60567

60633

Figure 56

Figure 57

α

Key on the gasket (1), mount the keying device 99346251 (2)and, screwing down the nut (3), drive in the gasket.

!Mount the gear housing within 10 min. of applying thesealant.

α

60568

2 screws M12 x 1.75 x 193 63 Nm:

0.50.2






72436

Figure 61

Figure 62

Figure 63

Figure 64

Positionthe crankshaft with the pistons 1 and 6 at the top deadcentre (T.D.C.).

This situation occurs when:



If this condition does not occur, turn the engine flywheel (4)appropriately.

Remove the tool 99360612 (1).

- Fit the idle gear (1) back on and lock the screws (2) to therequired torque.

60571

- Apply the gauge 99395219 (1). Check and adjust thepositionof the linkrod (3) for the idle gear. Lockthe screw(2) to the required torque.

60570

Fit the camshaft (4), positioning it observing the referencemarks (→) as shown in the figure.

Lubricate the seal (3) and fit it on the shoulder plate (2).

Mount the shoulder plate (2) with the sheet metal gasket (1)and tighten the screws (5) to the required torque.

73843

Fitting camshaft




60572

Figure 65

Figure 66

Position the gear (2) on the camshaft so that the 4 slots arecentred with the holes for fixing the camshaft, without fully locking the screws (5).Using the dial gauge with a magnetic base (1), check that the

clearance between the gears (2 and 3) is 0.073 — 0.195 mm;if this is not so, adjust the clearance as follows:




torque.

Figure 67

44908


Before refitting the rocker-arm shaft assembly, makesure that all the adjustment screws have been fully unscrewed.


73533

5



Mount:



Figure 68

99284

NOTE





Apply the tool 99360321 (7) and the spacer 99360325 (6) to the gearbox (3).



Figure 69

Figure 70

Figure 71

45261


- 1st phase: tightening to a torque of 100 Nm (10 kgm) with the torque wrench (1);


60574

71776

71777

Figure 72

Mount the electric wiring (2), securing it on theelectro-injectors with a torque screwdriver (1) to a torque of 1.36 - 1.92 Nm.

α


NOTE

Camshaft timing

Figure 73



70567A




71774

60573

60575

Figure 74

Figure 75

Figure 76

Figure 77




Set the dial gauge with the magnetic base (1) with the rod on the roller (2) of the rocker arm that governs the injector of cylinder no.1 and pre-load it by 6 mm.

With tool 99360321 (7) Figure 72, turn the crankshaftclockwise until the pointer of the dial gauge reaches theminimum value beyond which it can no longer fall.


Turn the engine flywheel anticlockwise until the dial gauge givesa reading for the lift of the cam of the camshaft of 4.44 ±0.05 mm.

The camshaft is in step if at the cam lift values of 4.44 ±0.05 mm there are the following conditions:

1) the holemarked witha notch (5) can beseen through theinspection window;

2) the tool99360612(1) through the seat (2) of the enginespeed sensor goes into the hole (3) in the engineflywheel (4).


1) loosen the screws (2) securing the gear (1) to the camshaftand utilize the slots (see Figure 78) on the gear (1);

2) turn the engine flywheel appropriately so as to bring about the conditions described in points 1 and 2 Figure 76, itbeing understood that the cam lift must not change at all;



77259




71778

72436

Figure 78

When the adjustment with the slots (1) is not enough to makeup the phase difference and the camshaft turns because itbecomes integral with the gear (2); as a result, the referencevalue of the cam lift varies, in this situation it is necessary toproceed as follows:

1) lock the screws (2, Figure 77) and turn the engine flywheelclockwise by approx. 1/2 turn;


3) take out the screws (2, Figure 77) and remove the gear (1)from the camshaft.



- the tool 99360612 (1) inserted to the bottom of the seatof the engine speed sensor (2) and (3).

77260

Phonic wheel timing


Again turn the flywheel in its normal direction of rotation untilyou see the hole marked with the double notch (4) through

the inspection hole under the flywheel housing. Insert tool99360612 (5) into the seat of the flywheel sensor (6).

Insert the tool 99360613 (2), via the seat of the phase sensor,onto the tooth obtained on the phonic wheel.

Should inserting the tool (2) prove difficult, loosen the screws(3) and adjust the phonic wheel (1) appropriately so that the


Mount the gear (2) Figure 78 with the 4 slots (1) centred with the fixing holes of the camshaft, locking the relevant screws to the required tightening torque.Check the timing of the shaft by first turning the flywheelclockwise to discharge the cylinder completely and then turn


Figure 79

Figure 80




Clockwisestart-up

and rotation

Adjustingcylinder

valve no.

Adjustingclearance



1 and 6 at TDC 6 1 5120º 3 4 1

120º 5 2 4

120º 1 6 2

120º 4 3 6

120º 2 5 3

- using an appropriate wrench (4),loosen the adjustmentscrew until the pumping element is at theend-of-stroke;

- tighten the adjustment screw, with a dynamometricwrench, to 5 Nm tightening torque (0.5 kgm);

- untighten the adjustment screw by 1/2 to 3/4 rotation;

- tighten the locking nut.


The adjustment of clearance between the rockers and rodscontrolling the intake and exhaust valves, as well as theadjustment of pre-loading of the rockers controlling pumpinjectors, must be carried out carefully.

Take the cylinder where clearance must be adjusted to thebursting phase; its valves are closed while balancing thesymmetric cylinder valves.Symmetric cylinders are 1-6, 2-5 and 3-4.

In order to properly operate, follow these instructions anddata specified on the table.

Adjustment of clearance between the rockers and rodscontrolling intake and exhaust valves:

- use a polygonal wrench to slacken the locking nut (1) of

the rocker arm adjusting screw (2).- insert the thickness gauge blade (3);

- tighten or untighten the adjustment screw with theappropriate wrench;

- make sure that the gauge blade (3) can slide with a slightfriction;

- lock the nut (1), by blocking the adjustment screw.

Pre-loading of rockers controlling pump injectors:

- using a polygonal wrench, loosen the nut locking therocker adjustment screw (5) controlling the pumpinjector (6);

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

In order to properly carry out the above-mentionedadjustments, follow the sequence specified in the

table, checking the exact position in each rotationphase by means of pin 99360612, to be inserted in

the 11 th hole in each of the three sectors with 18holes each.

Figure 81

99272


NOTE



Apply silicone LOCTITE 5699 IVECO No. 45500253 on theblow-by case and form a string (2) of ∅ 1,5 ±, as shownin the figure.



The filter (5) operation is unidirectional, thereforeit must be assembled with the two sight supports asillustrated in the figure.

Mount rocker arms cover; for tightening, see Section 4.Fit the blow-by case (7) and its gasket and then tighten thescrews (8) to the prescribed torque.Install the filter (5) and the gaskets (4 and 6).

60665

Figure 82

Figure 83

- Set the gasket (4) on the oil sump (1). Position the spacer (3) and mount the sump on the engine crankcase,screwing the screws (2) to the required torque.

COMPLETING ENGINE ASSEMBLY

Complete the engine by fitting or hooking up the followingparts:

- thermostat assembly;

- automatic tensioner, water pump, alternator;

- drive belt.

ASSEMBLY DIAGRAM OF FAN — WATER PUMP — ALTERNATOR DRIVE BELT

1. Alternator — 2. Electromagnetic coupling — 3. Water pump — 4. Crankshaft

Figure 84

60578

- damper flywheel;

- electromagnetic coupling;

Figure 85

Apply silicone LOCTITE 5699 IVECO n˚ 45500253on the blow-by case (7) surface of engines fittedwith P.T.O. according to the procedure describedin the following figure.

85480

85481

0.50.2

.

NOTE

NOTE

NOTE




COMPRESSOR CONTROL BELTASSEMBLY DIAGRAM

1. Crankshaft - 2. Air conditioner compressor

Assemble:

- air conditioner compressor automatic belt tightener;

- control belt.

When assembling the belts (1-3) operate on the belt tighteners using fit tools (2-4), acting in the direction shown by the arrows.

Figure 86

60579

Belt tighteners are automatic and do not needfurther adjustment after assembly.

Figure 87

73580

The fittings of the cooling water and lubricating oilpipes of the turbocharger have to be tightened toa torque of:

- 35 ±5 Nm, water pipe fittings;

- 55 ±5 Nm, oil pipe female fitting;

- 20-25 Nm, oil pipe male fitting.

- oil dipstick;

- oil suction strainer;

- electrical connections and sensors;

- replenish the engine with the required amount of oil;

- remove the engine from the rotary stand and take off thebrackets (99361036) fixing the engine.

NOTE

NOTE

- damper flywheel;

- fan;

- compressor;

- fuel pump;

- fuel filter and pipes;- preheating resistance;

- intake manifold;

- sound deadening guards;

- heat exchanger;

- oil filter, by lubricating the gasket;

- rocker arms cover;

- exhaust manifold;

- turbocharger and relating water and oil pipes;

- power take-off (P.T.O., if present), and relating pipes;

- oil level rod and oil vapours vent;

- rotate engine and mount oil rose pipe; or rose pipes, incase of engine with additional oil pump.




PART TWO -













Figure 1

Figure 2

99370

99371

Components on the engine F3A

(Demonstration)

(Demonstration)




Figure 3

99372

KEYS

1. Accelerator pedal position sensor / switch accelerator depressed — 2. Engine coolant temperature sensor — 3. Oversupply air temperature sensor — 4. Fuel temperature sensor — 5. Oversupply air pressure sensor — 6. Input for electronic tachograph




BLOCK DIAGRAM







Figure 4





Figure 5


Pin Function1 - Engine rev sensor


3 - ---



7 - ---

8 - ---

9 - ---






15 - ---

16 - ---


18 - ---

19 - ---

20 - ---









29 - ---30 - ---

31 - ---

32 - ---




Colour code

B White

BG Beige

C Orange

23 G Yellow

13 H Grey

L Blue

M Brown

N Black

R Red

24 35 000576t S Pink

V Green





Figure 6








8 - ---






14 - ---




19 - ---







speed sensors




30 - PWM line







1

13

24 35 000576t

12

23





A) Solenoid valve

B) Pumping element

C) Nozzle






Figure 7

A

B

C

001694t




TECHNICAL VIEW

8527 000602t

WIRING DIAGRAM

PERSPECTIVE VIEW

000693t

Figure 8








- 10 °C 8,10 ÷ 10,77 kOhm+ 20 °C 2,28 ÷ 2,72 kOhm

+ 80 °C 0,29 ÷ 0,364 kOhm







Figure 9


Specifications



TECNICAL VIEW

8527 8528

WIRING DIAGRAM

PERSPECTIVE VIEW

8529 8530

RESISTANCE TREND






HOLES ON FLYWHEEL


PERSPECTIVE VIEW

8520

Figure 10

Figure 11

Figure 12

Figure 13



Features









3 Shields –





Figure 14


Distribution pulse transmitter (48042)

Features



The electronic center uses the signal generated by this sensor as an injection step signal.Though electrically identical to engine rpm sensor mounted in the camshaft in is NOT interchangeable with it as it cable is shorter and it features a larger diameter.





3 Shields –







000025t

A. Pre/ort reheat resistor / 0.7 Ohm

A

Figure 22


Pre-post reheat resistor (61121)

This resistor located between the cylinder head and the intake duct is used to heat air in pre/post reheat operations.

By inserting the key switch, when even only one of the water, air or gas oil temperature sensors record less than 10_C, the electronic

center activates pre/post reheating and switches on the warning light on the cab instrument panel for a variable period according to temperature, after which the light starts blinking to inform the operator that the engine can be started.

The warning light goes off after engine start but the resistor continues being supplied for a variable period of time to complete postreheating.

The operation is cancelled to prevent uselessly discharging the battery if the engine is not started within 20/25 seconds with thewarning light blinking.

When reference temperature is above 10 _C, actuating the ignition key makes the warning light go on for some 2 seconds tocomplete the test and then turns it of to indicate the engine can be started.






It also enables:


Fuel dosing








De-rating










Engine start



Cold start



Hot start


Run Up


After Run



















VEHICLE AREA

1.1 GLOWING STEADILY Vehicle speed signal (if available)


1.3 OFF Cruise Control (if available)


1.5 OFF Clutch pressure switch



ENGINE AREA







INJECTORS











7.2 OFF CAN line

7.6 OFF CAN line (ASR control)


CONTROL UNIT


9.2 GLOWING STEADILY Incorrect data in EPROM

9.4 GLOWING STEADILY Main relay






PART 2


B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

1 . 1

O N s t e a d y

F a u l t y

v e h i c l e

s p e e d

s e n s o r . T h

e

t a c h o g r a p h

w o n ’ t

w o r k .

O d d

b e h a v i o u r

o f

t h e

t a c h o g r a p

h

p o i n t e r .

( I f

a v a i l a b l e )

V e h i c l e

s p e e d n o

l o n g e r




w i t h



t i m e a t l o w


e c t i o n s a n d

c o m p o n e n t .


1 . 2

O N s t e a d y

F a u l t y


s w i t c h . ( I f

a v a i l a b l e )

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 3

O F F

F a u l t y

C r u i s e

C o n t r o l



w o r k .

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .


s w i t c h



1 . 4

O N s t e a d y


p o t e n t i o m

e t e r

o r

n o n - p l a u s

i b l e

s i g n a l . O d d

r e a c t i o n


a c t u a t i n g


p e d a l .



( S e t + / S e t - ) s w i t c h . ( I f

a v a i l a b l e )

1 . 5

O F F




c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 6

O N s t e a d y

B r a k e s w

i t c h



t h e C C / P

T O


a v a i l a b l e )



C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 7

O F F




t e m .




B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

2 . 1

O F F

F a u l t y c o o


s e n s o r . E


t i m e i n

c o l d

w e a t h e r



n o i s e




c k c a b l i n g ,


n t .


= 0 ˚

C .

2 . 2

O F F

F a u l t y

b o o s t i n g

a i r


I f

t h e

s e n s o r

s i g n a l s

a


t h a n t h e


s t o r e d

a n d

t h e

e n g i n e


f o r m a n c e ,



c k c a b l i n g ,


n t .


C .

2 . 3

O F F

F a u l t y f u


s e n s o r .


c k c a b l i n g ,


n t .



C .

2 . 4

O N s t e a d y


s e n s o r . P o





m o d

u s : i f t h e


w h e n t h e


c o n f i r m e d .


C u r s o r 1 0 = 2 , 8 0 0 m b a r .

2 . 5

O F F


s e n s o r .





o t h e s a m e .



3 . 5

O F F


v o l t a g e r e


P o s s i b l e


a n d



5 . x

O N s t e a d y

P r o b l e m

w i t h

i n j e c t i o n

c i r c u i t o n


e n g i n e s p


a n d t h e




i t t e n t , t h e

e n g i n e

s o m e t i m e s

w o r k s


n o t .







B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

6 . 1

O N s t e a d y


s e n s o r .


p o w e r .




e a n s o f t h e


c a b l i n g ,


n t .

6 . 2

O N s t e a d y



p o w e r .




e a n s o f t h e


c a b l i n g ,


n t .

( 6 . 1 - 6 . 2 )

O N s t e a d y



l o o s e n e d

s c r e w s .

T h e

e n g i n e w o


a n d

c a n n o t b e

s t a r t e d

a g a i n .


s t a r t e d

( a f t e r t a

k i n g

t h e


d e d i n t h e


D i s c o n n e c t

t h e


s h a f t


e n g i n e i s


t h a n

u s u a l , t h e

p h o n i c

w h e e l i s


6 . 4

B l i n k i n g

T h e e n g i n


p u l l i n g )

t h e

o u t - o f - r e v




h t r e c o r d e r



( 9 . 1 )

B l i n k i n g

F a u l t y

E D C

c o n t r o l

u n i t . T h e e




o n t r o l u n i t





9 . 2

O N s t e a d y

C o n t r o l

u n i t

f a u l t

( E E P R O M

m e m o r y ) .


p o w e r .



f a u l t s c a n

b e m a d e .




9 . 4

B l i n k i n g


i n

c l o s e d



O N w h e n



s t o p .



h a s b e e n



C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .






B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

9 . 5

O N s t e a d y

E C U p o w


o u t t o o

o f t e n ( 5 t i m e s ) :



d i s c o n n e c

t

s w i t c h .

R e d u c e d

e n g i n e

m a x .

s p e e d a n d

p o w e r .

C h e c k

m a i n


a n d


h e t h e r t h e


o f f i n o t h e r


e y .





9 . 6

O N s t e a d y

E C U s t o

p



p o w e r .



n t r o l u n i t


m i g h t s t o r e












S I G N A L L E D

A N O M A L Y

B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O S S I B L E

C A U S E

P O S S I B L E

R E L A T E D

A N O M A L I E S


T E S T S O R

M E A S U R E S

R E M A R K S




-

-

T h e

b o o s t i n g

p r e s s u r e



a s e ,


S m o k e .



c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-

I m p a i r e d

h y d r a u l i c


t o r .



t h


M



l e v e l s

( c

o m p a r e d

w i t h

t h e


i n

g t h a t t h e

c o n t r o l

r o


c o r r e c t .



c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-





m




w i t h

f i v e

c y l i n d e r s ;


-

-





t h



t e


l e


t h

e o t h e r s ) .







-

-


t h e


( e x c e s s i v e

t r a v e l )

w i t h


o n

t h e n o z z l e .



i n j e c t o r .



t h



t e


l e


t h

e o t h e r s ) .



-

-


f u e l



m i g h t

h a v e

o p e r a t i o n





B l e e d a i r .








Print603.93.331

Out of plan operations are interventions complementary to standard services.They are maintenance operations to be carried out at regular time or mileage intervals and concern optional components thatare not present on all models.Important! The correlation between kilometres and months only applies in cases where the distance travelled by the vehiclecorresponds roughly to the specified average annual mileage. This is indicated only in order to suggest a hypothetical maintenance

programme,. Note that the time intervals specified for Extra Plan operations are to be adhered to regardless of the actual mileagecovered.

The kilometre frequency for engine lubrication is in relation to a percentage of sulphur in diesel of under 0.5%.NOTE: If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.

Use engine oil: ACEA E4 (URANIA FE 5 W 30)ACEA E3/E5 (URANIA LD5)

- If class ACEA E3 engine oil is used, the engine oil and filters must be changed every 100,000 km.

- If class ACEA E2 engine oil is used, the engine oil and filters must be changed every 50,000 km.

- In the case of very low annual mileage of less than 150,000 km/year, the engine oil and filters must be changedevery 12 months.

- If mineral oil is used in the gearbox, the interval between gearbox oil changes is to be reduced to 150,000 km.

- In the case of very low annual mileage of less than 150,000 km/year, the engine oil and filters must be changedat least every 2 years.

- If mineral oil is used in the axle with disc brakes, the interval between oil changes is to be reduced to 200,000 kmas for the axle with drum brakes.

- In the case ofvery low annual mileage of less than 150,000km/year, the oil in axles with disc brakes must bechanged

at least every 3 years.- In the case of very low annual mileage of less than 150,000 km/year, the oil in axles with drum brakes must be

changed at least once every 2 years.

- The filter dryer of the pneumatic system must in any case be renewed every year.

- In the case of very low annual mileage, general greasing must be carried out at least once a year.

- In the case of very low annual mileage, change the anti-pollen filters at least once a year.

- Premature clogging of the air cleaner is generally due to the operating conditions. The filter should therefore berenewed whenever clogging is signalled by the sensor regardless of the prescribed time interval, which should inany case be respected in the absence of any specific indications.

NOTE

NOTE






Type of operation Every

150,000 kmEvery

300,000 km

Engine

Change engine oil • •

Change engine oil filters • •

Check state of blow-by filter (with clogging indicator) • •

Check miscellaneous drive belts • •


Change miscellaneous drive belts •

Chassis and mechanical assemblies

Change fuel pre-filter (if available) • •








SECTION 4 - GENERAL OVERHAUL 1F3A CURSOR ENGINES

SECTION 4

General overhaul

Page



REPAIR OPERATIONS 11. . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK 11. . . . . . . . . . . . . . . . . . . . . . .


CYLINDER LINERS 12. . . . . . . . . . . . . . . . . . . . . . .

- Removing cylinder liners 13. . . . . . . . . . . . . . . . .

- Fitting and checking protrusion 13. . . . . . . . . . . .

CRANKSHAFT 14. . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring the main journals and crankpins 15. . .

- Preliminary measurement of main and big endbearing shell selection data 16. . . . . . . . . . . . . . .

- Selecting the main and big end bearing shells 17.


- Selecting the main bearing shells(Journals with nominal diameter) 19. . . . . . . . . .

- Selecting the main bearing shells(ground journals) 20. . . . . . . . . . . . . . . . . . . . . . .


- Selecting big end bearing shells(ground journals) 22. . . . . . . . . . . . . . . . . . . . . . .

- Replacing the timing gear and oil pump 23. . . . .

- Checking main journal assembly clearance 23. . .


PISTON CONNECTING ROD ASSEMBLY 25. . . .

- Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .




2 SECTION 4 - GENERAL OVERHAUL F3A CURSOR ENGINES

Page

- Conditions for correct gudgeonpin-piston coupling 26. . . . . . . . . . . . . . . . . . . . . .

- Piston rings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS 28. . . . . . . . . . . . . . . . . . . .

- Bushings 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking connecting rods 29. . . . . . . . . . . . . . . .

- Mounting the connecting rod — piston assembly 30


- Fitting the big end bearing shells 30. . . . . . . . . . .

- Fitting connecting rod - piston assembliesin the cylinder liners 31. . . . . . . . . . . . . . . . . . . . .

- Checking piston protrusion 31. . . . . . . . . . . . . . .

- Checking crankpin assembly clearance 32. . . . . . .

CYLINDER HEAD 32. . . . . . . . . . . . . . . . . . . . . . . .

- Removing valves 32. . . . . . . . . . . . . . . . . . . . . . . .

- Checking the planarity of the head on thecylinder block 32. . . . . . . . . . . . . . . . . . . . . . . . . .

- Valves 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing deposits and checking the valves 32. . .

- Valve seats 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve-stem andassociated valve guide 34. . . . . . . . . . . . . . . . . . .

- Replacing valve guides 34. . . . . . . . . . . . . . . . . . .

- Replacing injector cases 34. . . . . . . . . . . . . . . . . .

- Checking injector protrusion 36. . . . . . . . . . . . . .

TIMING GEAR 37. . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft drive 37. . . . . . . . . . . . . . . . . . . . . . . . .

Page

- Idler gear and pin 37. . . . . . . . . . . . . . . . . . . . . . .

- Twin intermediate gear and pin 37. . . . . . . . . . . .


- Check of cam lift and timing system shaft pinsalignment 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bushings 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing camshaft bushings with drift 99360499 40

- Dismounting the bushings 40. . . . . . . . . . . . . . . .

- Mounting the bushings 40. . . . . . . . . . . . . . . . . . .

- Valve springs 41. . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting valves and oil seal 42. . . . . . . . . . . . . . . . .

ROCKER SHAFT 42. . . . . . . . . . . . . . . . . . . . . . . . .

- Shaft 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Rocker arms 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE 44. . . . . . . . . . . . . . . . . .

- Diagrams of tightening sequence for screws

fixing crankcase base 47. . . . . . . . . . . . . . . . . . . .

- Diagram of cylinder head fixing screws tighteningsequence 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of exhaust manifold fixing screws tighteningsequence 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of turbocharger fixing screws and nuts tightening sequence 48. . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence for heat exchanger screws 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence for engine oil sumpscrews 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence for screws fixingrocker cover 49. . . . . . . . . . . . . . . . . . . . . . . . . .





Type F3A

Cycle 4-stroke Diesel engine

Fuel feed TurbochargedInjection Direct

No. of cylinders 6 in line

∅

Bore mm 125

Stroke mm 140

+ + +.. = Total displacement cm3 10300

Compression ratio 17 0.8




Type F3A

A

B

VALVE TIMING



16°

32°

C

D



50°

9°

X

For timing check

mmX

mm

Running

mmX

mm

-

-

0.35 to 0.45

0.45 to 0.55

FEED Through fuel pump - filters

Injection

type: Bosch



ozz e type _

Injection order 1 - 4 - 2 - 6 - 3 - 5



1500

290





Type F3A

CYLINDER BLOCK ANDCRANKMECHANISM COMPONENTS

mm

∅1Bores for cylinder liners:

upper ∅1

lower

142.000 to 142.025

140.000 to 140.025

Cylinder liners:

L

external diameter:upper

∅2lower

141.961 to 141.986

139.890 to 139.915

∅2 length L -

Cylinder liners -crankcase bores

upper lower

0.014 to 0.0640.085 to 0.135

External diameter ∅2 -

Cylinder sleeve

∅3inside diameter ∅3A* 125.000 to 125.013

Xinside diameter ∅3B* 125.011 to 125.024


* Selection class

Pistons:∅1 measuring dimension X 18

X external diameter ∅1AF 124.881 to 124.893

external diameter ∅1BFF 124.892 to 124.904∅ 2 pin bore ∅2 50.010 to 50.018

Piston - cylinder sleeveA*B*

0.107 to 0.1320.096 to 0.131

* Selection class

Piston diameter ∅1 -

X


3∅ Gudgeon pin ∅3 49.994 to 50.000


F Class A pistons supplied as spares.FF

Class B pistons are fitted in production only and are not supplied as spares.






F3Aype

mm


Max. connecting rod

axis misalignment tolerance

0.08

1 2∅∅

Main journals ∅1- nominal- class 1- class 2- class 3

Crankpins ∅2- nominal- class 1- class 2- class 3

92.970 to 93.00092.970 to 92.97992.980 to 92.98992.990 to 93.000

82.970 to 83.00082.970 to 82.97982.980 to 82.98982.990 to 83.000

S 1 S 2 Main bearing shells S1RedGreenYellow*

2.965 to 2.9742.975 to 2.9842.985 to 2.995

Big end bearing shells S2RedGreenYellow*

1.970 to 1.9801.981 to 1.9901.991 to 2.000

3∅

Main bearing housings ∅3- nominal- class 1- class 2- class 3

99.000 to 99.03099.000 to 99.00999.010 to 99.01999.020 to 99.030

Bearing shells -

main journals 0.050 to 0.090

Bearing shells -big ends

0.040 to 0.080



X1


X2



Crankshaft end float 0.10 to 0.30

1 2 Alignment 1 - 2

Ovalization 1 - 2

Taper 1 - 2

≤ 0.025

-0.010

0.010

* Fitted in production only and not supplied as spares




Type F3A

CYLINDER HEAD - VALVE TRAIN mm

∅ 1


2∅

Valve uide ∅2 9.015 to 9.030

∅ 3

∅3 15.012 to 15.025


in the cylinder heads 0.015 to 0.045

Valve guide 0.2 - 0.4

∅ 4 Valves:

∅4α

8.960 to 8.97560° 30′ ± 7′ 30″

α

∅4α

8.960 to 8.97545° 30’ ± 7′ 30″


Valve seat inhead

∅1 44.185 to 44.220

∅ 1 ∅1 42.985 to 43.020


2∅ seat; angle of valve seatin cylinder head:

44.260 to 44.275

α 60° - 30’

α 43.060 to 43.075

α 45° - 30′

XRecessin of valve

0.65 to 0.95

X X 1.8 to 2.1

Between valveseat and head 0.040 to 0.090. .




Table 1

F3Aype

mm

Valve spring height:

free height H 75

H H 1 under a load of:H2 N 500 ±25 H1 61

N 972 ±48 H2 47.8

X

Injector protrusion X 0.14 to 1.4

∅∅∅

Camshaft bushing housingin the cylinder head:1 ⇒ 7 Ø 88.000 to 88.030

∅

∅

∅1

2

3

Camshaft bearing journals:1 ⇒ 7 Ø 82.950 to 82.968

∅ Outer diameter of

camshaft bushings: ∅88.153 to 88.183

∅ Inner diameter of

camshaft bushings: ∅ 83.018 to 83.085

Bushings and housingsin the cylinder head

0.123 to 0.183

Bushings and bearing journals 0.050 to 0.135

Cam lift:

9.30

H 9.45

11.21

∅ 1

Rocker shaft ∅1 41.984 to 42.000







60600

Figure 5

Figure 6

CYLINDER LINERS MAIN DATA

DETAIL “X”

“Y“ - Selection class marking area

Figure 7

BLOCK WITH CYLINDER LINERS

A 125.000 to 125.013 mmB 125.011 to 125.024 mm

Selection class

60598

60601

CYLINDER LINERS




47577

16798

60521

Figure 8

Figure 9

Figure 10

Figure 11

Place details 99360706 (2) and plate 99360726 (4) as shownin the figure, by making sure that the plate (4) is properly

placed on the cylinder liners.Tighten the screw nut (1) and remove the cylinder liner (3)from the block.

Always replace water sealing rings (3, 4 and 5).Install the adjustment ring (1) on the cylinder liner (2);lubricate lower part of liner and install it in the cylinder unitusing the proper tool.

Check the protrusion of the cylinder liners, using tool99360472 (2) and tightening screw (1) to 225 Nm torque.

Using a dial gauge (3), measure the cylinder liner protrusion,from the cylinder head supporting surface, it must be 0.045

to 0.075 (Figure 11); otherwise, replace the adjustment ring(1, Figure 9) supplied as spare parts having different

thicknesses.

When the installation is completed, block the cylinder liners(1) to the block (2) with studs 99360703 (3).

Fitting and checking protrusion

Figure 12

CYLINDER LINER PROTRUSION49017

The adjustment ring (1) is supplied as spare parts in thefollowing thicknesses: 0.08 mm - 0.10 mm - 0.12 mm.

60520

0.045 to 0.075

Removing cylinder liners

NOTE

(Demonstration)




60604

60602

Figure 13

Figure 14

X. Detail of main journals connections Y. Detail of crank pins connections

MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGSCheck the condition of the journals and the big end pins; there must no be signs of scoring,

ovalization or excessive wear. The data given refer to the normal diameter of the pins.

60603

Upper main journal half bearings

Lower main journal half bearings

Figure 15

BUFF

GROUNDGROUND

GROUND

BUFF

36.7137.00

2.9652.995

45.7545.80

2.9652.995

3.383.43

92.97093.000 131.122

131.147

45.9546.00

82.97083.000

36.7537.00

2.9652.995

45.7545.80

2.9652.995

3.383.43

1 0 8

1.6

R 5

R 3.7 to 4

9 t o 1 2

0.8 ±0.3 0.8 ±0.3

1 0 8

R 5

R 4.2 to 4.5

9 t o 1 2

0.3 0.3

CRANKSHAFT








MAIN JOURNALS:




CRANKPINS:





On the front of the crankcase, two sets of numbers are marked in the position shown.


- The following seven digits, taken singly, are the class of diameter of each of the seats referred to.


47535

99.000 to 99.009

99.010 to 99.019

99.020 to 99.030


NOMINAL DIAMETER




To obtain the required assembly clearances, the main and big end bearing shells need to be selected as describedhereunder.

This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,can have different classes from one journal to another).

red

red/black

green

green/black

STD

1.970 to 1.980

1.981 to 1.990

+0.127

2.033 to 2.043

2.044 to 2.053

+0.254

2.097 to 2.107

2.108 to 2.117

+0.508

2.224 to 2.234

2.235 to 2.244

Depending on the thickness, the bearing shells are selectedin classes of tolerance marked by a coloured sign (red-green

— red/black — green/black).

The following tables give the specifications of the main andbig end bearing shells available as spares in the standard sizes(STD) and in the permissible oversizes (+0.127, +0.254,+0.508).


Figure 20

yellow*

yellow/black*

1.991 to 2.000

red

red/black

green

green/black

STD

2.965 to 2.974

2.975 to 2.984

+0.127

3.028 to 3.037

3.038 to 3.047

+0.254

2.097 to 2.107

2.108 to 2.117

+0.508

2.224 to 2.234

2.235 to 2.244

yellow*

yellow/black*

2.985 to 2.995

2.054 to 2.063

3.048 to 3.058

Selecting the main and big end bearing shells

NOTE






Selecting the main bearing shells (Journals with nominal diameter)

After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells to use according to the following table:

STD.

1 2 3

1

2

3

green

green

red

red

red

red

green

green

green

green

red

red

green

green

green

green

green

green

Figure 22




green/black

Selecting the main bearing shells (ground journals)

If the journals have been ground, the procedure described so far cannot be applied.In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only typeof bearing shell envisaged for the relevant undersizing.

-0.127

1 2 3

99.84399.852

green/black

green/black

green/black

green/black

green/black

green/black

red/black

red/black


green/black

red/black

red/black

red/black

red/black

green/black

green/black

99.853

99.862

99.86399.873

1

2

3

red/black =mm 3.028 to 3.037

green/black =

mm 3.028 to 3.047

-0.254

1 2 3

99.72699.746 red red red

red red red

red =mm 3.237 to 3.247

-0.508

1 2 3

93.46893.508 red red red

red red red

red =

mm 3.219 to 3.229

Figure 23





There are three markings on the body of the connecting rodin the position shown in the view from ”A”:


A = 3973 to 4003 g.B = 4004 to 4034 g.C = 4035 to 4065 g.


1 = 87.000 to 87.010 mm2 = 87.011 to 87.020 mm3 = 87.021 to 87.030 mm


1

2

3



VIEW FROM “A”

STD.

1 2 3

1

2

3

green

green

red

green

red

red

red

green

green green

green green

green

green green

green

red

red

Class

Figure 25




Figure 26

green/black

Selecting big end bearing shells (ground journals)

If the journals have been ground, the procedure described so far cannot be applied.In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of thecrankpins and to mount the bearing shells identified with the relevant table.

-0.127

1 2 3

82.84382.852

green/black

green/black

green/black

green/black

green/black

green/black

green/black

red/black


green/black

red/black

red/black

green/black

red/black

green/black

green/black

82.85382.862

82.86382.873

1

2

3


green/black =

2.033 to 2.043 mm

-0.254

1 2 3


red green green

red =

2.097 to 2.107 mm

green =

2.108 to 2.117 mm

-0.508

1 2 3


red green green

red red green

red red green


red red green

red =

2.224 to 2.234 mm

green =

2.235 to 2.244 mm

82.73682.746




Arrange the bearing shells (1) on the main bearing housingsin the crankcase base (2).Check the assembly clearance between the main journals of

the crankshaft and their bearings, proceeding as illustrated on

the following pages.

Using the tackle and hook 99360500 (1), mount thecrankshaft (2).

When fitting the gear (1) on the crankshaft (2), heat it for nolonger than 2 hours in an oven at a temperature of 180 °C.After heating the gear (1), fit it on the shaft by applying a loadof 6000 N to it, positioning it at the distance shown inFigure 27.After cooling, the gear must have no axial movement under a load of 29100 N.If changing the pin (3), after fitting it on, check it protrudesfrom the crankshaft as shown in the figure.

73534

47579

47578

49021

Mount the oil nozzles (2), making the grub screw match thehole (3) on the crankcase.Arrange the bearing shells (1) on the main bearing housings.

Replacing the timing gear and oil pump

Check that the toothing of the gear is neither damaged nor worn; if it is, take it out with an appropriate extractor andreplace it.

Checking main journal assembly clearance

Figure 27

Figure 28

Figure 29

Figure 30




- Lubricate the internal screws (1) with UTDM oil and tighten them with a torque wrench (3) to a torque of 120 Nm, using tool 99395216 (4), to an angle of 90 °,following the diagram of Figure 33.

Set two journals of the crankshaft (2) parallel to thelongitudinal axis, a section of calibrated wire. Usingappropriate hooks and tackle, mount the crankcase base (1).

60559

47579

47578

47588

60593

Figure 31 Figure 32

Figure 33

Figure 34

Figure 35

- Remove the crankcase base.

The clearance between the main bearings and their journals ismeasured by comparing the width taken on by the calibratedwire (2) at the point of greatest crushing with the graduatedscale on the case (1) containing the calibrated wire.The numbers on the scale give the clearance of the couplingin millimetres. If you find the clearance is not as required,replace the bearing shells and repeat the check.

FRONT SIDE

DIAGRAM OF SEQUENCE FOR TIGHTENING THE SCREWS FIXING THE BOTTOM CRANKCASE BASETO THE CRANKCASE

Checking crankshaft end float

α

End float is checked by placing a magnetic dial gauge (2) on the crankshaft (1), as shown in the figure. If the value obtainedis higher than specified, replace the rear thrust half-bearingsand repeat this check.




Make sure the piston does show any trace of seizing, scoring,cracking; replace as necessary.

60608

60607

Figure 36

Figure 37


1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring -6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.


(1).

Removal

Pistons are equipped with three elastic rings: a sealing ring, a trapezoidal ring and a scraper ring.

Pistons are grouped into classes A and B for diameter.

49024

Figure 38


pliers (1).





49025 32618

49026

Figure 39

Figure 40

Figure 41

Figure 42






47584

Using a micrometer (2), measure the diameter of the piston(1) to determine the assembly clearance; the diameter has tobe measured at the value X shown:

1

2




MAIN DATA OF THE PISTON, SUPPLIED BY MONDIAL PISTON, PISTON RINGS AND PIN

* Values are determined on ∅ of 120 mm.

16552

3513

Figure 43

Figure 44

Check the thickness of the piston ring (2) using a micrometer (1).

The sealing ring (2) of the 1st cavity is trapezoidal. Clearance“X” between the sealing ring and its housing is measured by placing the piston (1) with its ring in the cylinder barrel (3),so that the sealing ring is half-projected out of the cylinder barrel.

Piston rings

78904

60610

Check the clearance between the sealing rings (2) and therelative piston housings (1) using a thikness gauge (3).

36134

Check the opening between the ends of the sealing rings (1),using a thickness gauge (2), entered in the cylinder barrel (3).If the distance between ends is lower or higher than the valuerequired, replace split rings.

Figure 45

Figure 46

Figure 47




47557

44927

Figure 48

Figure 49

MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Values to be obtained after installing the bush.

DIAGRAM OF THE CONNECTING RODMARKS

Letter indicating the weight class:

A = 3973 to 4003 g.B = 4004 to 4034 g.C = 4035 to 4065 g.

Number indicating the selection of diameter for the big end bearing housing:

1 = 87.000 to 87.010 mm2 = 87.011 to 87.020 mm3 = 87.021 to 87.030 mm

Numbers identifying cap-connecting rod coupling.

1

2

3

Data concerning the class section of connecting rod housingand weight are stamped on the big end.

When installing connecting rods, make sure they all belong to the same weight class. VIEW FROM “A”

54.00054.030

54.08554.110

50.019*50.035*

49.99450.000

1.9702.000

87.00087.030

CONNECTING RODS

NOTE




73535

Figure 50

Figure 51

Check the bushing in the small end has not come loose andshows no sign of scoring or seizure; replace it if it does.The bushing (2) is removed and fitted with a suitable drift (1).

When driving it in, make absolutely sure that the holes for the

oil to pass through in the bushing and small end coincide.Using a boring machine, rebore the bushing so as to obtaina diameter of 50.019 — 50.035.

Checking connecting rods

61696


Check the alignment of the axes of the connecting rods (1)with device 99395363 (5), proceeding as follows:Fit the connecting rod (1) on the spindle of the tool99395363 (5) and lock it with the screw (4).Set the spindle (3) on the V-prisms, resting the connectingrod (1) on the stop bar (2).

Check the torsion of the connecting rod (5) by comparing two points (A and B) of the pin (3) on the horizontal planeof the axis of the connecting rod.

Position the mount (1) of the dial gauge (2) so that thispre-loads by approx. 0.5 mm on the pin (3) at point A andzero the dial gauge (2). Shift the spindle (4) with theconnecting rod (5) and compare any deviation on theopposite side B of the pin (3): the difference between A andB must be no greater than 0.08 mm.

Figure 52

61694

Check the bending of the connecting rod (5) by comparing two points C and D of the pin (3) on the vertical plane of theaxis of the connecting rod.Position the vertical mount (1) of the dial gauge (2) so that

this rests on the pin (3) at point C.Swing the connecting rod backwards and forwards seeking

the highest position of the pin and in this condition zero thedial gauge (2).Shift the spindle (4) with the connecting rod (5) and repeat

the check on the highest point on the opposite side D of thepin (3). The difference between point C and point D must beno greater than 0.08 mm.

Figure 53

Checking bending

Bushings




73536

74052

60614

Figure 54

Figure 55

Figure 56

The piston (1) has to be fitted on the connecting rod (2) so

that the graphic symbol (4), showing the assembly positionin the cylinder liner, and the punch marks (3) on theconnecting rod are observed as shown in the figure.

Fit the pin (2) and fasten it on the piston(1) withthe split rings(3).

To fit the piston rings (1) on the piston (2) use the pliers99360184 (3).

The rings need to be mounted with the word ”TOP” (4)facing upwards. Direct the ring openings so they arestaggered 120° apart.

Mounting the piston rings

49030

Fit the bearing shells (1), selected as described under theheading ”Selecting the main and big end bearing shells”, onboth the connecting rod and the cap.

If reusing bearing shells that have been removed, fit themback into their respective seats in the positions markedduring removal.

Figure 57

12

3

Fitting the big end bearing shells

Mountingthe connecting rod — piston assembly




60615

Fitting connecting rod - piston assembliesin the cylinder liners

With the aid of the clamp 99360605 (1, Figure 58), fit theconnecting rod — piston assembly (2) in the cylinder liners,according to the diagram of Figure 59, checking that:

- The openings of the piston rings are staggered 120° apart.

- The pistons are all of the same class, A or B.

- The symbol punched on the top of the pistons faces theengine flywheel, or the recess in the skirt of the pistons

tallies with the oil nozzles.

60616

Figure 58

Figure 59

The pistons are supplied as spares in class A and canbe fitted in class B cylinder liners.

ASSEMBLY DIAGRAM OF CONNECTING ROD — PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod — piston assembly — 2. Area of punch marking on the top of the piston,symbol showing assembly position and selection class — 3. Connecting rod punch mark area.

Checking piston protrusion

On completing assembly, check the protrusion of the pistonsfrom the cylinder liners; it must be 0.23 — 0.53 mm.

NOTE




Mount the connecting rod caps (1) together with the bearingshells. Tighten the screws (2) fixing the connecting rod caps

to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),further tighten the screws with an angle of 60°.

CYLINDER HEAD

Before removing the cylinder head, check it is leakproofusingappropriate equipment. Replace the cylinder head if there isany leakage.

47594

47583

36159

48625

Figure 60

Figure 61

Figure 62

Figure 63

Removing valves

Install and fix tool 99360261 (2) with bracket (4); tighten by lever (1) until cotters are removed (3); remove the tool (2)and the upper plate (5), the spring (6) and the lower plate (7).Repeat the operation on all the valves.Turn the cylinder head upside down and remove the valves (8).

The planarity (1) is checked using a ruler (2) and a thiknessgauge (3). If deformations exist, surface the head using proper

surface grinder; the maximum amount of material to beremoved is 0.3 mm.

ValvesRemoving deposits and checking the valves

Remove carbon deposits using the metal brush supplied.Check that the valves show no signs of seizure or cracking.Check the diameter of the valve stem using a micrometer (see Figure 64) and replace if necessary.

To check the clearance proceed as follows.Connect the connecting rods to the relative main journals,place a length of calibrated wire on the latter.

α

Checking the planarity of the head on thecylinder block

(Demonstration)

After this process, you need to check the valverecessing and injector protrusion.

Remove the caps and determine the clearance by comparing the width of the calibrated wire with the graduated scale on the case containing the calibrated wire.Upon final assembly: check the diameter of the thread of thescrews (2), it must be no less than 13.4 mm; if it is, change

the screw. Lubricate the crankpins and connecting rod

bearings. Tighten the screws (2) as described above.

The thread of the screws (2), before assembly, has to be lubricated with engine oil.

NOTE

NOTE

Checking crankpin assembly clearance


Print603.93.141



MAIN DATA OF VALVES AND VALVE GUIDES

* Measurement to be made after driving in the valve guides

Check with a micrometer that the diameter of the valvestems is as indicated. If necessary, grind the valve seats witha grinding machine, removing as little material as possible.

Figure 64

60617

Valve seats

Regrinding — replacing valve seats

The valve seats are reground whenever the valvesor valve guides are ground and replaced.

41032

Check the valve seats (2). If you find any slight scoring or burns, regrind them with tool 99305019 (1) according to theangles shown in Figure 64 and Figure 66. If it is necessary toreplace them, using the same tool and taking care not to

affect the cylinder head, remove as much material as possiblefrom the valve seats so that, with a punch, it is possible toextract them from the cylinder head.

Heat the cylinder head to 80 — 100°C and, using a drift, fit in the new valve seats (2), chilled beforehand in liquid nitrogen.Using tool 99305019 (1), regrind the valve seats according

to the angles shown in Figure 66.

After regrinding the valve seats, using tool 99370415 and dialgauge 99395603, check that the position of the valves inrelation to the plane of the cylinder head is:

- -0.65 to -0.95 mm (recessing) intake valves;

- -1.8 to -2.1 mm (recessing) exhaust valves.

Figure 65

73537

Figure 66

MAIN DATA OF VALVE SEATS

1. Intake valve seat — 2. Exhaust valve seat.

1 2

NOTE




60619

To replace the injector case (2), proceed as follows:

- Thread the case (2) with tool 99390804 (1).

Checking clearance between valve-stem andassociated valve guide

Using a dial gauge with a magnetic base, check the clearancebetween the valve stem and the associated guide. If theclearance is too great, change the valve and, if necessary, thevalve guide.

The valve guides are removed with the drift 99360481.They are fitted with the drift 99360481 equipped with part99360295.Part 99360295 determines the exact position of assembly of

the valve guides in the cylinder head. If they are not available,you need to drive the valve guides into the cylinder head so

they protrude by 30.8-31.2 mm.After driving in the valve guides, rebore their holes with thesmoother 99390311.

Replacing valve guides

73538


Figure 67

Figure 68

Replacing injector cases

Removal




60621

- Using the tool 99390772 (2) removeany residues (1)leftin the groove of the cylinder head.

- Screw the extractor 99342149 (2) into the case (3).Screw down the nut (1) and take the case out of thecylinder head.

60620

60622

- Lubricate the seals (3) and fit themon the case (4).Using tool 99365056 (2) secured to the cylinder head withbracket A, drive in the new case, screwing down thescrew (1) upsetting the bottom portion of the case.

60623

- Using the reamer99394041 (1-2), rebore the hole in the

case (3).

Figure 69

Figure 70

Figure 71

Figure 72


Assembly



60624

47585

Check injector protrusion (2) with the dial gauge (1).The protrusion must be 1.14 to 1.4 mm.

Checking injector protrusion

71720

INJECTOR CASE ASSEMBLY DIAGRAM

Figure 73

- Using grinder 99394041 (1-2), ream the injector seat in the case (3), check the injector protrusion from thecylinder head plane which must be 1.14 to 1.4 mm.

Figure 74

Figure 75




86925

86934TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear

- 8. Drive shaft driving gear.


Idler gear and pin

87258

Twin intermediate gear and pin


Gear bushings shown on Figures 127/2 - 90 can be replacedwhen they are worn. Put up the bushing, then bore it toobtain the diameter shown on Figure 77 or Figure 78.

The bushing must be driven into the gear by following the direction of the arrow and setting the latter to thedimension shown on Figure 77 or Figure 78.

Rated assembling play between gear bushings and pins:Figure 77 — 0.040 ÷ 0.080 mmFigure 78 — 0.045 ÷ 0.085 mm.

Figure 76

Figure 77

Figure 78

NOTE




47506

47505

47507

Figure 79

Figure 80

Figure 81

Check of cam lift and timing system shaft pins alignment

When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must notexceed 0.035 mm. If misalignment exceeds this value, replace the shaft.

In order to check installation clearance, measure bush inner diameter andcamshaft pin (1) diameter; the real clearance is obtainedby their difference.

If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2).

1




The bush surfaces must not show any sign of seizing or scoring; if they do replace them.

60626

60627

Figure 82

Figure 83

MAIN DATA - CAMSHAFT AND TOLERANCESThe surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing

or scoring, replace the shaft and the relative bushes.

MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT HOUSINGS ON CYLINDER HEAD* Bush inner diameter after installation

Bushings

Measure the bush inner diameters with a baremeter and replace them, if the value measured exceeds the tolerance value.To take down and fit back the bushes, use the proper tool

99360499.

Camshaft


‘

TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity ⊥

POSITION Concentricity or coaxial alignment

OSCILLATION Circular oscillation

IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝



77795

71721

Figure 84

Figure 85

A = Drift with seat for bushings to insert/extract.B = Grub screw for positioning bushings.C = Reference mark to insert seventh bushing correctly.D = Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks).E = Guide bushing.F = Guide line.G = Guide bushing to secure to the seventh bushing mount.H = Plate fixing bushing G to cylinder head.I = Grip.L = Extension coupling.


To insert bushings 1, 2, 3, 4 and 5, proceed as follows:4 position the bushing to insert on the drift (A) making the

grub screw on it coincide with the seat (B) (Figure 84) on the bushing.

5 position the guide bushing (E) and secure the guidebushing (G) (Figure 84) on the seat of the 7 th bushingwith the plate (H).

6 while driving in the bushing, make the reference mark (F)match the mark (M). In this way, when it is driven home,


71725

Figure 86


Dismounting the bushings Mounting the bushings

Front

Rear

A B C D E F D L G H D I

Replacing camshaft bushings with drift 99360499




71723

71724

Figure 87

Figure 88








- Position the bushing on the drift (A) and bring it closeup to the seat, making the bushing hole match thelubrication hole in the head. Drive it home.The 7 th bushing is driven in when the reference mark (C)is flush with the bushing seat.

Front

Rear

Front

Rear

70000

Figure 89

Figure 90

MAIN DATA TO CHECK THE SPRINGFOR INTAKE AND EXHAUST VALVES

Valve springs


49034

Free spring height

Valve closed

Valve open

500 ± 25

972 ± 48 7 5

6 1 4 7 , 8




44925

The cams of the camshaft control the rocker arms directly: 6 for the injectors and 12 for the valves.

The rocker arms run directly on the profiles of the cams by means of rollers.

The other end acts on a crosspiece that rests on the stem of the two valves.

There is a pad between the rocker arm adjustment screw and the crosspiece.

There are two lubrication ducts inside the rocker arms.

The length of the rocker arm shaft is basically the same as that of the cylinder head. It has to be detached to be able to reach

all the parts beneath.

Figure 91

Fitting valves and oil seal Figure 92

ROCKER SHAFT

Figure 93

Lubricate the valve stem and insert the valves in therespective valve guides; fit the lower caps (1). Use tool

99360329 to fit the oil seal (2) on the valve guides (3) of theexhaust valves; then, to fit the valves, proceed as follows.

87051

86290

- Mount the springs (6) and the top plate (5).

- Fit the tool 99360263 (2) and secure it with the bracket(4). Screw down the lever (1) to be able to fit on thecotters (3). Take off the tool (2).




73539

Figure 94

44914

44912 44913

Figure 95

Figure 96 Figure 97

PUMP INJECTOR ROCKER ARMS

INTAKE VALVE ROCKER ARMS

Check the surfaces of the bushings, which must show nosigns of scoring or excessive wear; if they do, replace therocker arm assembly.

EXHAUST VALVE ROCKER ARMS

Rocker arms




4 2 , 0 1 5

4 2 , 0 7 1

4 2 , 0 2 5

4 2 , 0 4 1

5 6 , 0 3 0

5 6 , 0 4 9

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.


Shaft





Print603.93.331

TIGHTENING TORQUE

PART TORQUE

Nm kgm

Capscrews, undercrankcase to crankcase (see Figure 98) ♦

M12x1.75 outer screws Stage 1: pretightening 30 3

M 17x2 inner screws Stage 2: pretightening 120 12

Inner screws Stage 3: angle 90°

Inner screws Stage 4: angle 45°

Outer screws Stage 5: angle 60°

Piston cooling nozzle union ♦ 35 ± 2 3.5 ± 2

Capscrews, heat exchanger to crankcase ♦ (see Figure 102)pretightening

tightening11.519

1.15

1.9

Spacer and oil sump capscrews ♦ (see Figure 103)pretightening

tightening3845

3.84.5

M 12x1.75 screws, gear case to crankcase ♦ 63 ± 2 6.3 ± 0.7

Cylinder head capscrews (see Figure 99) ♦

Stage 1: pretightening 60 6

Stage 2 pretightening 120 12

Stage 3: angle 120°

Stage 4: angle 60°

Air compressor capscrews 100 10

Rocker shaft capscrew ♦


Stage 2: angle 60°

Locknut, rocker adjusting screw ♦ 39 ± 5 3.9 ± 0.5

Capscrews, injector securing brackets ♦ 26 2.6

Capscrews, thrust plates to head ♦ 19 1.9

Screw fastening the engine supporting bracket to the cylinder headStage 1: pretightening 120 12

Stage 2: angle 45°

Screw fastening the engine supporting bracket to the flywheel case


Stage 2: angle 60°

Camshaft gear capscrews ♦


Stage 2: angle 60°

Screw fixing phonic wheel to timing system gear ♦ 8.5 ± 1.5 0.8 ± 0.1

Exhaust manifold capscrews • (see Figure 100)

pretightening tightening

40 ± 570 ± 5

4 ± 0.57 ± 0.5

Capscrews, exhaust brake actuator cylinder ♦ 19 1.9

Capscrews, connecting rod caps ♦


Stage 2: angle 60°

Engine flywheel capscrews ♦


Stage 2: angle 60°

Stage 3: angle 30°

♦ Before assembly, lubricate with engine oil

D Before assembly, lubricate with graphitized oil




PART TORQUE

Nm kgm

Screws fixing damper flywheel: ♦

First phase pre-tightening 70 7

Second phase closing to angle 50°

Screws fixing intermediate gear pins: ♦

First phase pre-tightening 30 3Second phase closing to angle 90°

Screw fixing connecting rod for idle gear 25 ± 2.5 2.5 ± 0.2

Screws fixing oil pump 25 ± 2.5 2.5 ± 0.2

Screw fixing suction strainer and oil pump pipe to crankcase 25 ± 2.5 2.5 ± 0.2

Screws fixing crankshaft gasket cover 25 ± 2.5 2.5 ± 0.2

Screws fixing fuel pump/filter 37 ± 3 3.7 ± 0.3

Screw fixing control unit mount to crankcase 19 ± 3 1.9 ± 0.3

Screw fixing fuel pump to flywheel cover box 19 ± 3 1.9 ± 0.3

Screw fixing thermostat box to cylinder head 19 ± 3 1.9 ± 0.3

Screw fixing rocker cover (see Figure 15) 8.5 ± 1.5 0.8 ± 0.1

Screws and nuts fixing turbocharger • (see Figure 12)pre-tightening

tightening33.5 ± 7.5

46 ± 23.3 ± 0.74.6 ± 0.2

Screws fixing water pump to crankcase 25 ± 2.5 2.5 ± 0.2

Screws fixing spacer/pulley to fan 30 ± 3 3 ± 0.3

Screw fixing automatic tensioner to crankcase 50 ± 5 5 ± 0.5

Screw fixing fixed tensioner to crankcase 105 ± 5 10.5 ± 0.5

Screws fixing fan mount to crankcase 100 ± 5 10 ± 0.5

Screws fixing starter motor 74 ± 8 7.4 ± 0.8

Screws fixing air heater to cylinder head 37 ± 3 3.7 ± 0.3Screw fixing air compressor 74 ± 8 7.4 ± 0.8

Nut fixing gear driving air compressor 170 ± 10 17 ± 10

Screw fixing automatic tensioner for belt driving air-conditioningcompressor to crankcase 26 ± 2 2.6 ± 0.2

Screw fixing alternator bracket to crankcase L = 35 mmL = 60 mmL = 30 mm

30 ± 344 ± 4

24.5 ± 2.5

3 ± 0.34.4 ± 0.42.4 ± 0.2

Screws fixing hydraulic power steering pump 46.5 ± 4.5 4.65 ± 0.45

Screws fixing air-conditioner compressor to mount 24.5 ± 2.5 2.5 ± 0.25

Screws fixing guard 24.5 ± 25 2.5 ± 0.25

Filter clogging sensor fastening 55 ± 5 5.5 ± 0.5

♦ Before assembly, lubricate with engine oilD Before assembly, lubricate with graphitized oil




PART TORQUE

Nm kgm

Pressure transmitter fastener 8 ± 2 0.8 ± 0.2

Water/fuel temperature sensor fastener 32.5 ± 2.5 3.2 ± 0.2

Thermometric switch/transmitter fastener 23 ± 2.5 2.5 ± 0.2

Air temperature transmitter fastener 32.5 ± 2.5 3.2 ± 0.2

Pulse transmitter fastener 8 ± 2 0.8 ± 0.2

Injector-pump connections fastener 1.36 ± 1.92 0.13 ± 0.19

Screw fixing electric cables 8 ± 2 0.8 ± 0.2

Screw fixing electric cables 8 ± 2 0.8 ± 0.2

Exhaust brake solenoid valve fastener 32 3.2

PWM solenoid valve fastener 9 ± 1 0.9 ± 0.1

Motor propulsor

M14x70/80 screw securing front and rear elastic blocks to chassis 192.5 ± 19.5 19.2 ± 1.9

M16x130 screw securing front and rear elastic blocks to engine 278 ± 28 27.8 ± 2.8

M18x62 flanged HEX screw for front engine block Pre-tightening 1st step 120 12

Angle closing 2nd step 45˚

M14x60 socket cheese-head TC screw for front engine block

Pre-tightening 1st step 60 6


Flanged HEX screw for rear engine block

Pre-tightening 1st step 100 10


♦ Before assembly, lubricate with engine oilD Before assembly, lubricate with graphitized oil



60593

FRONT SIDE stage 4:

angle, inner screws

45º

60592

60594

60593

Figure 98

stage 1:

pretightening,outer screws

(30 Nm)

FRONT SIDE

FRONT SIDE

stage 2:pretightenig, inner

screws

(120 Nm)

60º

stage 5:angle, outer

screws

60593

FRONT SIDE stage 3:

angle, inner screws

90º

FRONT SIDE

Diagrams of tightening sequence for screws fixing crankcase base




60580

Figure 99

Figure 100

Figure 101

Diagram of exhaust manifold fixing screws tightening sequence

SEQUENCE: Pretightening 4 - 3 - 1 - 2Tightening 1 - 4 - 2 - 3

60581

60582

Diagram of cylinder head fixing screws tightening sequence

Diagram of turbocharger fixing screws and nuts tightening sequence




60666

Figure 102

Figure 103

Diagram of tightening sequence for engine oil sump screws

60583

Diagram of tightening sequence for heat exchanger screws

Stage 1 from 1 to 16.

Stage 2 from 17 to 32

Figure 104

Diagram of tightening sequence for screws fixing rocker cover

73587

NOTE







SECTION 5 - TOOLS 1F3A CURSOR ENGINES

SECTION 5

Tools

Page

TOOLS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 5 - TOOLS F3A CURSOR ENGINES




TOOLS


8093731 Tester PT01


99305047 Spring load tester

99322230 Rotary telescopic stand (range 2000 daN, torque 375 daNm)






TOOLS











TOOLS


99360144 Tools (12 + 6) holding rocker adjustment screw blocks whenremoving/refitting the rocker shaft

99360180 Injector housing protecting plugs (6)

99360184 Pliers for assembling and disassembling piston split rings

(105-106 mm)


(to be used with special plates)

99360262 Plate for take down-fit engine valves

(to be used with 99360261)

99360295 Tool to fit back valve guide (to be used with 99360481)




TOOLS


99360314 Tool to remove oil filter (engine)

99360321 Tool to rotate engine flywheel (to be used with 99360325)

99360325Spacer (to be used with 99360321)


99360334 Compression tool for checking the protrusion of cylinder liners

(to be used with 99370415-99395603 and special plates)

99360336 Spacer (to be used with 99360334)




TOOLS


99360337 Cylinder liner compression plate(to be used with 99360334-99360336)


99360481 Tool to remove valve guide







TOOLS


99360553 Tool for assembling and installing rocker arm shaft

99360585 Swing hoist for engine disassembly assembly


99360612 Tool for positioning engine P.M.S.






TOOLS


99360706 Tool to extract cylinder liners (to be used with specific rings)

99360726 Ring (125 mm) (to be used with 99360706)



99370415 Base supporting the dial gauge for checking cylinder liner

protrusion (to be used with 99395603)

99378100 Tool for printing engine identification plates(to be used with special punches)




TOOLS


99378102 Punches (B) for printing engine identification plates(to be used with 99378100)

99378104 Punches (D) for printing engine identification plates


99389834 Torque screwdriver for calibrating the injector solenoid

valve connector check nut


99390772 Tool for removing injector holding case deposits

99390804 Tool for threading injector holding cases to be extracted





TOOLS


99390805 Guide bush (to be used with 99390804)


99394041 Cutter to rectify injector holder housing


99394043 Reamer to rectify injector holder lower side


99395216 Measuring pair for angular tightening with 1/2”

and 3/4” square couplings

99395218 Gauge for defining the distance between the centres

of camshaft and transmission gear




TOOLS



99395603 Dial gauge (0 - 5 mm)

99395687 Reaming gauge (50 - 178 mm)

99396035 Centering ring of crankshaft front gasket cap



APPENDIX 1F3A CURSOR ENGINES

Appendix

Page




2 APPENDIX F3A CURSOR ENGINES








- Organize and displace specific exit points to evacuate

the areas in case of emergency, providing for adequateindications of the emergency exit lines.









- Do not wear unsuitable cloths for work, with flutteringends, nor jewels such as rings and chains when workingclose to engines and equipment in motion.

- Wear safety gloves and goggles when performing thefollowing operations:- filling inhibitors or anti-frost- lubrication oil topping or replacement- utilization of compressed air or liquids under pressure(pressure allowed: ≤ 2 bar)

- Wear safety helmet when working close to hangingloads or equipment working at head height level.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- Use protection cream for hands.

- Change wet cloths as soon as possible

- In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections.Ensure that hands and feet are dry and execute workingoperations utilizing isolating foot-boards. Do not carry out working operations if not trained for.

- Do not smoke nor light up flames close to batteries and to any fuel material.

- Put the dirty rags with oil, diesel fuel or solvents inanti-fire specially provided containers.

During maintenance







- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areasaerated. Whenever necessary wear safety mask.

- Do not leave rags impregnated with flammablesubstances close to the engine.

- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

- Do not utilize fast screw-tightening tools.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on theelectrical system.

- Disconnect batteries from system aboard to load themwith the battery loader.

- After every intervention, verify that battery clamppolarity is correct and that the clamps are tight and safe

from accidental short circuit and oxidation.- Do not disconnect and connect electrical connections

in presence of electrical feed.

- Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquidor air under pressure. Take all necessary precautionsbleeding and draining residual pressure or closing dumpvalves. Always wear adequate safety mask or goggles.Non fulfillment of these prescriptions may cause seriousinjury and poisoning.

APPENDIX 3F3A CURSOR ENGINES



- Respect of the Environment shall be of primary importance: all necessary precautions to ensurepersonnel’s safety and health shall be adopted.

- Be informed and inform the personnel as well of laws inforce regulating use and exhaust of liquids and engineexhaust oil. Provide for adequate board indications and

organize specific training courses to ensure thatpersonnel is fully aware of such law prescriptions and of basic preventive safety measures.

- Collect exhaust oils in adequate specially providedcontainers with hermetic sealing ensuring that storage ismade in specific, properly identified areas that shall beaerated, far from heat sources and not exposed to firedanger.

- Handle the batteries with care, storing them in aeratedenvironment and within anti-acid containers. Warning:battery exhalation represent serious danger of intoxication and environment contamination.

Respect of the Environment- Avoid incorrect tightening or out of couple. Danger:incorrect tightening may seriously damage engine’scomponents, affecting engine’s duration.

- Avoid priming from fuel tanks made out of copper alloysand/or with ducts not being provided with filters.

- Do not modify cable wires: their length shall not bechanged.

- Do not connect any user to the engine electricalequipment unless specifically approved by Iveco.

- Do not modify fuel systems or hydraulic system unlessIveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correctworking and duration.

For engines equipped with electronic gearbox:

- Do not execute electric arc welding without havingpriory removed electronic gearbox.

- Remove electronic gearbox in case of any interventionrequiring heating over 80ºC temperature.

- Do not paint the components and the electronicconnections.

- Do not vary or alter any data filed in the electronicgearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty andfurthermore may affect engine correct working andduration.

4 APPENDIX F3A CURSOR ENGINES



Section


Fuel 2


General overhaul 4

Tools 5



Section 1 describes the F3B engine illustrating its features




rate parts:










veniences.



such operations.

Part 3

F3B CURSOR ENGINES

1F3B CURSOR ENGINES






3F3B CURSOR ENGINES

UPDATING








SECTION 1


Page


VIEWS OF ENGINE 5. . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 8. . . . . . . . . . . . . . . . . . . . . . . . . .

- Oil pump 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


- Additional oil pump 9. . . . . . . . . . . . . . . . . . . . .

- Oil pressure control valve 10. . . . . . . . . . . . . . . .

- Heat exchanger 10. . . . . . . . . . . . . . . . . . . . . . . .

- By-pass valve 11. . . . . . . . . . . . . . . . . . . . . . . . . .



COOLING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Water pump 13. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 14. . . . . . . . . . . . . . . . . . . . . .

- Turbocharger HOLSET HX 50W 15. . . . . . . . . .

- Turbocharger HOLSET HY 55 V 16. . . . . . . . . . .









F3BE0681A*D... C13 ENT C






LEFT-HAND SIDE VIEW


71695

73526

Figure 1

VIEWS OF ENGINE




FRONT VIEW

REAR VIEW

71696

71694

Figure 2




TOP VIEW

73530

Figure 3






The oil pump (1) cannot be overhauled. On finding any

damage, replace the oil pump assembly.

See under the relevant heading for replacing the gear (2) of the crankshaft.

86937 73540

Figure 5

Figure 6

Figure 7

MAIN DATA TO CHECK THE OVERPRESSURE

VALVE SPRING

Overpressure valve

Figure 8

OIL PUMP CROSS-SECTION1. Overpressure valve — Start of opening pressure 10.1 ±

0.7 bars

73541 86938

SUPPLEMENTARY OIL PUMP SECTION

Additional oil pump

Oil pump





73542

73558

Figure 9

Figure 10

Figure 11


HEAT EXCHANGER The heat exchanger is fitted with: A. Oil filter clogging indicator — B. Oil temperature transmitter —

C. Oil pressure transmitter — D. Filter bypass valve — E. Thermostat — Number of heat exchanger elements: 11.

Oil pressure control valve

Heat exchanger

73559

73543









The filtering elements are closely wound by a spiral so thateach fold is firmly anchored to the spiral with respect to theothers. This produces a uniform use of the element even in

the worst conditions such as cold starting with fluids with ahigh viscosity and peaks of flow. In addition, it ensures uni-form distribution of the flow over the entire length of thefiltering element, with consequent optimization of the loss of load and of its working life.

Mount upstreamTo optimize flow distribution and the rigidity of the filtering el-ement, this has an exclusive mount composed of a strong meshmade of nylon and an extremely strong synthetic material.

Filtering element

Composed of inert inorganic fibres bound with an exclusiveresin to a structure with graded holes, the element is manu-factured exclusively to precise procedures and strict quality control.

Mount downstream


Structural parts

The o-rings equipping the filtering element ensure a perfectseal between it and the container, eliminating by-pass risksand keeping filter performance constant. Strong corrosion-proof bottoms and a sturdy internal metal core complete thestructure of the filtering element.

When mounting the filters, keep to the following rules:- Oil and fit new seals.

- Screw down the filters to bring the seals into contactwith the supporting bases.

- Tighten the filter to a torque of 35-40 Nm.

73545

47447

73546

Figure 12

Figure 13

Figure 14


Thermostatic valve

Start of opening:

- travel 0.1 mm at a temperature of 82 ±2°C.End of opening:


Engine oil filters

By-pass valve




Figure 15

92843

COOLING


Water entering the pump Water circulating in the engine

COOLING CIRCUIT VERSION WITHOUT INTARDER

DescriptionThe engine cooling system works with forced circulationinside closed circuit and can be connected to an additionalheater (if any) and to the intarder intercooler.It consists mainly of the following components:

- an expansion reservoir whose plug (1) incorporates twovalves — discharge and charge — controlling the systempressure;

- a coolant level sensor;

- an engine cooling unit to dissipate the heat taken by thecoolant from the engine through the intercooler;



- an electric fan;


OperationThe water pump is actuated by the crankshaft through apoli-V belt and sends coolant to the cylinder block, especially

to the cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat is opened and from here thecoolant flows into the radiator and is cooled down by the fan.The pressure inside the system depending on the

temperature variation is controlled by the discharge andcharge valves incorporated in the expansion reservoir fillingplug (1).The discharge valve has a double function:

- keepthe system under light pressure in order to raise the

coolant boiling point;- discharge the pressure surplus in the atmosphere as a re-

sult of the coolant high temperature.

The charge valve makes it possible to transfer the coolantfrom the expansion reservoir to the radiator when adepression is generated inside the system as a result of thecoolant volume reduction depending on the fall in thecoolant temperature.Discharge valve opening:

D 1st breather 0.9 bar

D 2nd breather 1.2 bar

Charge valve opening -0.03 bar

+0.2-0.1

+0.2-0.1

+0-0.02




60631

Figure 16

Figure 17

Figure 18

Thermostat

The water pump is composed of: impeller, bearing, seal anddriving pulley.

!Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.

CROSS-SECTION OF THE WATER PUMP

View of thermostat operation

60747


TO THEEXPANSION

TUB

FROMTHE ENGINE

TO THEBY PASS


60748

TO THERADIATOR

TO THEEXPANSION

TUB

TO THEBY PASSFROM

THE ENGINE

Check the thermostat works properly; replace it if in doubt.Temperature of start of travel 84°C ±2°C.Minimum travel 15 mm at 94°C ±2°C.

TO THERADIATOR

Water pump





Intake air

Engine exhaust gas


Figure 19

98869


TURBOCHARGING

The turbocharging system is composed of:

- an air filter;

- one turbocharger with pressure relief valve, or, as analternative, variable geometry valve, depending on thepower required by vehicle application;

- an “intercooler” radiator.




The turboblower is of the type equipped with pressure relief valve.It is essentially made up of:

- a central body which incorporates a shaft supported by bushings at the opposite ends of which the turbineimpeller and the compressor rotor are fitted;

- a turbine body and a compressor body, both of whichmounted on the central body end;

- an overpressure relief valve fitted to the turbine body.The function of this valve is to choke the exhaust gasoutlet, by conveying part of the gas directly into theexhaust pipe, when the boosting pressure downstream

the compressor reaches the calibration value.

71766

Figure 20

Turbocharger HOLSET HX 50W

(pressure relief valve)




CROSS-SECTION OF TURBOCHARGER

1. Air delivery to the intake manifold - 2. Compressor - 3. Air inlet - 4. Actuator - 5. Exhaust gas flow-rate adjustment ring -6. Exhaust gas inlet - 7. Exhaust gas outlet - 8. Turbine - 9. Exhaust gas flow-rate control fork

86942

Figure 21

71734

CROSS-SECTION OF MAXIMUM FLOW

71733

CROSS-SECTION OF MINIMUM FLOW

Figure 22

Figure 23

Turbocharger HOLSET HY 55 V

(variable geometry)

Working principle

The variable geometry turbocharger (VGT) is composed of a centrifugal compressor and a turbine equipped with amobile device that, by changing the area of cross-section of

the passage of the exhaust gases going to the turbine, governs

the speed.

Thanks to this solution, it is possible to keep the speed of thegases and turbine high even when the engine is running atlowspeed.

By making the gases pass through small cross-sections, they flow faster, so that the turbine turns faster as well.

The movement of the device changing the cross-section of the flow of exhaust gases is accomplished with a mechanismoperated by a pneumatic actuator.

This actuator is controlled directly by the electronic controlunit via a proportional solenoid valve.

This device is most closed at low speed.At high engine speeds, the electronic control system increases

the cross-section of the passage to permit the incoming gases to flow without increasing their speed too much.

Cast in the central body there is a toroidal chamber for thecoolant to pass through.




Figure 24

60754

60753

1. Slide guide - 2. Compressor - 3. Slide rods - 4. Compressor fan - 5. Lubrication bushings -6. Exhaust gas flow-rate adjustment ring - 7. Exhaust gas fan - 8. Gas exhaust body - 9. Locking rings -

10. Oil delivery - 11. Oil outlet - 12. Actuator drive shaft

Figure 25




Figure 26

71762

1. Slide guide - 3. Slide rod - 11. Oil outlet - 12. Actuator drive shaft -

13. Actuator - 14. Exhaust gas flow-rate control fork

Figure 27

71763





SECTION 2

Fuel

Page

FEEDING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Scheme with pump mounted laterally 3. . . . . . .

- Scheme with pump mounted frontally 4. . . . . . .


- Feed pump 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injector-pump 6. . . . . . . . . . . . . . . . . . . . . . . . .

- Injector Phases 7. . . . . . . . . . . . . . . . . . . . . . . . .






Figure 1

1. Fuel filter - 2. Pressure control valve (start of opening at 5 bar) - 3. Feed pump - 4. Fuel pre-filter with priming pump -5. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) - 6. Overpressure valve to

return fuel to tank (start of opening at 0.2 bar) - 7. Fitting - 8. Central unit - 9. Heat exchanger- 10. Pump injectors


92846

FEEDING

Fuel is supplied via a fuel pump, filter and pre-filter, 6pump-injectors governed by the camshaft via rocker armsand by the electronic control unit.

Return circuit

Supply circuit

Scheme with pump mounted laterally




Figure 2

1. Fuel filter - 2. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) - 3. Feedpump - 4. Overpressure valve to return fuel to tank (start of opening at 0.2 bar) - 5. Pressure control valve (start of opening

at 5 bar) - 6. Fuel pre-filter with priming pump - 7. Fitting - 8. Central unit - 9. Heat exchanger- 10. Pump injectors


92847

Return circuit

Supply circuit

A

B

Scheme with pump mounted frontally




92830

Engine feed pump mounted laterally 1. Overpressure valve - 2. Delivering fuel to injectors -

3. Sucking in fuel - 4. Pressure control valve

92829

Pump performances



2600

310

600

45

170

12

100

Testconditions




Test liquid

0.5

5

30

0.3

3

30

0.3

0,3

30

0.3

0.3

30

ISO 4113

Field of use





(micron)


2600

4100 max

-25/+80

30

0.5 max


Valve calibration 5 ÷ 5.8


Valve calibration 3.4

÷ 3.8

73547

Figure 3

Engine feed pump mounted frontally A. Fuel inlet — B. Fuel delivery — C. By-pass nut —

D. Fuel return from the pump-injectors — E. Pressure relief valve — Opening pressure: 5-8 bars

Feed pump

Figure 4

98870

SECTION ON FEED PUMP1. Oil and fuel leaks indicator

Figure 5

Figure 6

Pump performances

Pump rotation spee d (rpm)


4100

310

900

45

250

12

140

6

Testconditions




Test liquid

0.5

5

50

0.3

3

50

0.3

0.3

50

0.3

0.3

20

ISO 4113

Field of use





(micron)


4100

5800 max

-25/+80

0.5 max

-25/+120


Valve calibration


Valve calibration

An overpressure valve is a single-acting valve,calibrated to 0.2÷ 0.3 bar, placed on the piping that returns fuel to tank. Theoverpressure valve prevents fuel duct in cylinder head fromemptying with engine stopped.

5 ÷ 5.8

3.4 ÷

3.8

Overpressure valve




44908

Figure 7

Injector-pump

1. Fuel/oil seal — 2. Fuel/diesel seal — 3. Fuel/exhaust gas seal


The amount of fuel injected depends on the length of time the slide valve is closed and therefore on the time for which the solenoid is energized.

The solenoid valve is joined to the injector body and cannotbe removed.

On the top there are two screws securing the electricalwiring from the control unit.

To ensure signal transmission, tighten the screws with a torquewrench to a torque of 1.36 — 1.92 Nm (0.136 — 0.192 kgm).

If this job is done with the engine on the vehicle,before removing the injectors-pump drain off thefuel contained in the pipes in the cylinder head by unscrewing the delivery and return fittings on thecylinder head.

Pumping element

The pumping element is operated by a rocker arm governeddirectly by the cam of the camshaft.

The pumping element is able to ensure a high delivery pressure. The return stroke is made by means of a returnspring.

Nozzle

Garages are authorized to perform fault diagnosis solely on the entire injection system and may not work inside theinjector-pump, which must only be replaced.

A specific fault-diagnosis program, included in the control unit,is able to check the operation of each injector (it deactivatesone at a time and checks the delivery of the other five).

Fault diagnosis makes it possible to distinguish errors of anelectrical origin from ones of a mechanical/hydraulic origin.

It indicates broken pump-injectors.

It is therefore necessary to interpret all the control unit error messages correctly.

Any defects in the injectors are to be resolved by replacing them.

Solenoid valve


that shuts off the pumping element delivery pipe.

When the solenoid is not energized, the valve is open, thefuel is pumped but it flows back into the return pipe with thenormal transfer pressure of approximately 5 bars.

When the solenoid is energized, the valve shuts and the fuel,not being able to flow back into the return pipe, is pumped

into the nozzle at high pressure, causing the needle to lift.

NOTE

0 411 700 002 XXXXXX XXXX X

868 USA /

87060

Figure 8

For each injector replaced, connect to diagnosis station and,when required by the program, enter the code that is printedon the injector (→) in order to reprogram the central unit.

When checking the clearance of the rocker arms,it is important to check the injector-pump pre-load.

NOTE





4. Filling and backflow passage

60669

Figure 9

Injector Phases

Filling phaseDuring the filling phase the pumping element (2) runs up to

the top position.After passing the highest point of the cam, the rocker armroller comes near the base ring of the cam.The fuel valve (1) is open and fuel can flow into the injector via the bottom passage (4) of the cylinder head.Filling continues until the pumping element reaches its toplimit.

Injection phaseThe injection phase begins when, at a certain point in thedown phase of the pumping element, the solenoid valve getsenergized and the fuel valve (1) shuts.

The moment delivery begins, appropriately calculated by theelectronic control unit, depends on the working conditionsof the engine.

The cam continues with the rocker arm to push the pumpingelement (2) and the injection phase continues as long as thefuel valve (1) stays shut.



60670

Figure 10






60671

Figure 11



The time for which the solenoid valve stays energized,appropriately calculated by the electronic control unit, is theduration of injection (delivery) and it depends on theworkingconditions of the engine.





SECTION 3

Vehicle application

Page

CLEARANCE DATA 3. . . . . . . . . . . . . . . . . . . . .


STRIPPING THE ENGINE ON THE BENCH 7. . .


- Diagram of tightening sequence of crankcase basefixing screws 17. . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod - piston assemblies incylinder liners 18. . . . . . . . . . . . . . . . . . . . . . . . .


- Fitting engine flywheel box 20. . . . . . . . . . . . . . .





- Timing of timing system shaft 24. . . . . . . . . . . . .



COMPLETING ENGINE ASSEMBLY 28. . . . . . . . .


- Components on the engine F3B 33. . . . . . . . . . .

BLOCK DIAGRAM 34. . . . . . . . . . . . . . . . . . . . . . .







Page

- Pump injector (78247) 38. . . . . . . . . . . . . . . . . . .




- Distribution pulse sensor (48042) 43. . . . . . . . . .

- Overfeed pressure sensor (85154) 44. . . . . . . . .

- Air temperature sensor on manifold (85155) 45.

- Pre/post-heating resistance (61121) 46. . . . . . . .



PREFACE 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


MAINTENANCE 63. . . . . . . . . . . . . . . . . . . . . . . . .

- Maintenance services scheme 63. . . . . . . . . . . . .

- Checks and/or maintenance work 64. . . . . . . . . .

- off-plane operations 65. . . . . . . . . . . . . . . . . . . . .




CLEARANCE DATA

Type F3BE0681A*D001

ρ Compression ratio 16.5 ± 0.8


397(540)

1550 ÷ 1900


2350(240)

1000 ÷ 1600

Loadless engineidling rpm

525 ± 25

Loadless engine

peak rpm 2250 ± 20


135 x 15012880

SUPERCHARGING

Turbocharger type

with intercooler Direct injection

HOLSET HX50WHOLSET HY55V

bar

LUBRICATION




1.55

COOLING By centrifugal pump, regulating thermostat, viscostatic fan,

radiator and heat exchanger

Water pump control By belt

Thermostat N. 1

initial opening 84 ± 2 °C

maximum opening 94 ± 2 °C













- The sound-deadening guard (1).

- The pipes connecting the compressor.

60481

60483

60482

60484

60485

60486

On the right-hand side of the engine

- The fuel cartridge filter (1).

- The hydraulic power steering tank (2).

- The electrical connections.

- The compressor (1) together with the power steering

pump (2).

- Using the right tool (3), turn it in the direction shown by the arrow and remove the air-conditioner drive belt (1).

- Remove the air-conditioner (2) together with the enginemounting.

- The oil pressure adjustment valve (1).

- The engine mounting (1).

STRIPPING THE ENGINE ON THE BENCH

Before securing the engine on the rotary stand 99322230,remove the following parts:

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

On the left-hand side of the engine




73582

Figure 7

Secure the engine to the rotary stand 99322030 with the brackets 99361036 (1).Remove the electric wiring by disconnecting it from the sensors and the electric actuators.

(Demonstration)







98863

Figure 13

Figure 14

Disconnect the pipes (3 and 4) from the V.G.T controlsolenoid valves.

Remove the thermostatassembly (1) together with the V.G.T.control solenoid valve (2).

71707

Figure 15

Remove the following components: water delivery pipe (5);water outlet pipe (1); actuator control air pipe (2); oil delivery pipes (3); oil return pipes (4); turbo-compressor unit (6);exhaust manifold (7).

Figure 16

60490

Apply extractor 99340053 (2) andtake out the crankshaft seal

(1); now remove the flange (3).

(Version without Intarder)

Figure 17

98864

Disconnect the pipes (3 and 6) from the V.G.T controlsolenoid valves. Remove the water inlet/outlet pipe assembly (1) together with the V.G.T. control solenoid valve (2).

(Version with Intarder)

Figure 18

60492

Use tool 99360314 to slacken the oil filters (1).

(Version without Intarder)

60493

- Slacken the screws (1) and remove the intercooler (4);

- Slacken the screws (2) and remove the water pipe (3).




Figure 19

Figure 20

Figure 21

(Version with Intarder)

70708

The remove the P.T.O. (if fitted):

- disconnect the oil pipe (1);

- slacken the 4 screws (2) and (3).

- Slacken the screws (1) and remove the intercooler (4);

- slacken the screws (2) and remove the thermostat (3).

60494

Remove the following components: fuel filter support (1); fuelpump (2) and relevant pipes; starter (3); support for enginestarting buttons (4); PWN valve air filter (5); suction manifold(6) with engine preheating resistor; engine control unit (7);

72674

60575

60497

- Slacken the screws (2) and remove the gear (1) together with the phonic wheel.

- Slacken the screws (1); drive one of them in a torque holein order to remove the shoulder plate (2) and extract the

metal sheet gasket.

Figure 22

Figure 23

Figure 24

85480

Remove the rocker arm cover (1), take off the screws (2) andextract the cover (3), the filter (5) and the gaskets (4 and 6).Remove the screws (8) and the blow-by case (7).



60498

60500

60499

60501

60511

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

Unscrew the screws (2) and remove the idle gear (1).

With the engine flywheel locking tool 99360351 (1) fitted,unscrew the fixing screws (2). Take off the tool (1) andextract

the flywheel (3).

Fit on the extractor 99340054 (2) and extract the gasket (1).

Unscrew the screws (1) and remove the gearbox (2).

- Unhook the engine brake lever retaining springs (3).- Unscrew the screws (1) to disconnect the electrical

connections from the electro-injectors.- Unscrew the screws (6) securing the injector wiring to the

head.- Electricallydisconnect the engine brake solenoid valve (8).- Take out the pipes (5 and 7) supplying the engine brake

cylinders (4).- Unscrew the screws (2) fixing the rocker arm shaft.- Unscrew the screws (6) to take out the head injector

wiring. The wiring has to be extracted from the front.

71709

Figure 30

In sequence, take out the:

- control gear P.T.O. (1), if fitted;- idle gear (2);- oil pump (3).

4




5

73533

60514

60513

60515

86931

86932

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Figure 36

Using tool 99360144 (3), constrain the blocks (4) to therockers (2). Apply tool 99360553 (1) to the rocker holder shaft (5) and remove the shaft (5) from the cylinder head.

- Unscrew the screws (2)fixing the brackets (3) andextract the injectors (1).

- Unscrew the screws (4) and take out the engine brakecylinders (5).

- Unscrew the screws and take out the cylinder with thesolenoid valve of the engine brake (6).

- Insert the plugs 99360180 (1) in place of the injectors.

- Extract the camshaft (2).

- Unscrew the screws fixing the cylinder head (3).

- Using metal ropes, lift the cylinder head (1).

- Take off the gasket (2).

Take off screws (2), then remove engine oil sump (1)complete with spacer (3) and seal gasket.The box shows the oil sump mounted on the enginesequipped with supplementary oil pump.

Remove the screws and take off strainer (1).For engines equipped with supplementary oil pump, remove

the screws and take out strainers (2 and 3).




60519

60518

Figure 37

Figure 38

Figure 39

Figure 40

Figure 41

Untighten screws (2) fixing the connecting rod cap (3) and

remove it. Remove the connecting rod-piston (1) assembly from the upper side. Repeat these operations for the other pistons.

Using an appropriate wrenchand the hex wrenchunscrew the

screws (1) and (2) and take off the crankcase base.

47574

Turn the crankcase (1) upright.

47570

Using tool 99360500 (1), remove the crankshaft (2).

47571

After removing the engine, you need to clean theremoved parts thoroughly and check their integrity.The following pages give the instructions for making

the checks and the main measurements to make todetermine whether the parts can be reused.

Keep the big end bearing shells in their respectivehousings and/or note down their assembly positionsince, if reusing them, they will need to be fitted in

the position found upon removal.

Note down the assembly position of the top andbottom main bearing shells since, if reusing them,

they will need to be fitted in the position foundupon removal.

NOTE

NOTE

NOTE

Extract the main bearing shells (1), unscrew the screws and take out the oil nozzles (2).Dismount cylinder liners as described in Section 4.





47586

47595

Figure 42

Figure 43

Figure 44

Figure 45


Using the brackets 99361036, secure the crankcase to thestand 99322230.Mount cylinder liners as described in Section 4.

Mount the oil nozzles (2), making the grub screw coincide with the hole (3) in the crankcase.

Arrange the bearing shells (1) on the main bearing housings.

Arrange the bearing shells (1) on the main bearing housingsin the crankcase base (2).

Apply LOCTITE 5970 (IVECO No. 2992644) silicone on thecrankcase using the appropriate tools (1) as shown in

Figure 46.

47570

Lubricate the bearing shells then mount the crankshaft (2)

using the tackle and hook 99360500 (1).

49021

Not finding it necessary to replace the main bearings,you need to fit them back in exactly the samesequence and position as in removal.If to be changed, choose the main bearings according

to the procedure in chapter “Selection of mainbearings and connecting rod bearings”.

NOTE




Figure 46

60559

47581

47579

Figure 47

Figure 48

Figure 49

Using a torque wrench (2), tighten the outside hex groovedscrews (1) to a torque of 30 Nm, following the diagramsgivenon the following page.

Using a torque wrench (3), tighten the inside screws (1) to a torque of 120 Nm. Then tighten them to an angle of 60° and55° with tool 99395216 (4) with another two phases.Regrind the outside screws (1, Figure 48) with closure to anangle of 60° using tool 99395216 (4).

Mount the crankcase base (1) using appropriate tackle andhooks.

60632

Sealant application diagram.

Mount the crankcase base within 10 min. of applying the sealant.

α

α

NOTE




60593

FRONT SIDE Fourth phase:

closing inside ìscrews to angle

55º

60592

60594

Figure 50

First phase:

pre-tighteningoutside screws

30 Nm

FRONT SIDE

FRONT SIDE

FRONT SIDE

Second phase:pre-tighteninginside screws

120 Nm

Fifth phase:closing outsidescrews to angle

60º

FRONT SIDE Third phase:

closing insidescrews to angle

60º

60593

60593





49030

Lubricate the bearing shells (1 and 3) and fit them on theconnecting rod (2) and on the cap (4).

60615

Figure 51

Connecting rod — piston assembly

Area of punch marking on the top of thepiston with the symbol for the mountingposition and selection class.

Area of connecting rod punch marking

Figure 52

60616

Turn the cylinder block, setting it upright.Lubricate the pistons, piston rings andinside the cylinder liners.

With the aid of the clamp 99360605 (1) mount the connectingrod — piston assemblies (2) in the cylinder liners according toFigure 52. Check that:

- The number of each connecting rod corresponds to thecap coupling number.

- The symbol (2, Figure 52) punched on the top of thepistons faces the engine flywheel or the recess in thepiston skirt tallies with the position of the oil nozzles.

Fitting connecting rod - piston assemblies incylinder liners

Figure 53

1

2

3

Not finding it necessary to replace the connectingrod bearings, you need to fit them back in exactlythesame sequence and position as in removal.

If to be changed, choose the main bearings according to the procedure in chapter “Selection of mainbearings and connecting rod bearings”.

Do not make any adjustment on the bearing shells.

The pistons are supplied as spares in class A and canalso be fitted in class B cylinder liners.

NOTE

NOTE

NOTE



47594

Figure 54

Figure 55

Figure 56

Figure 57

Figure 58

Figure 59

Connect the connecting rods to the relevant pins of thecrankshaft, mount the connecting rod caps (1) together with thebearing shells. Tighten the screws (2) fixing the connecting rodcaps to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),

tighten the screws further with an angle of 60°.

Using the centring ring 99396035 (2), check the exact positionof the cover (1). If it is wrong, proceed accordingly and lock

the screws (3).

Key on the gasket (1), mount the key 99346250 (2) and,screwing down the nut (3), drive in the gasket (1).

Check that the pistons 1-6 are exactly at the T.D.C.Put the gasket (2) on the crankcase.Mount the cylinder head (1) and tighten the screws as shownin Figs. 58, 59 and 60.

Diagram of the tightening sequence of the screws fixing thecylinder head.

- Pre-tightening with the torque wrench (1):1st phase: 60 Nm (6 kgm).2nd phase: 120 Nm (12 kgm).

60563

60564

α

60515

60565

61270

Beforereusing the screws (2), measure the diameter of the thread; it must be no less than 13.4 mm; if itis, change the screw.Lubricate the thread of the screws with engine oil

before assembly. Lubricate the thread of the screws with engine oilbefore assembly.

NOTE

NOTE



Montaje de la culata



Using a torque wrench, tighten the highlighted screws with thefollowing sequence and torque:

4 screws M12 x 1.75 x 35 56 to 70 Nm

10 screws M12 x 1.75 x 100 56 to 70 Nm

1 screw M12 x 1.75 x 12056 to 70 Nm

2 screws M12 x 1.75 x 70 56 to 70 Nm

Figure 60

Figure 61

Figure 62

60566

- Closing to angle with tool 99395216 (1):3rd phase: angle of 90°

4 th phase: angle of 45° for screws 4, 5, 12, 13, 20, 215 th phase: angle of 65° for screws 1, 2, 3, 6, 7, 8, 9, 10,

11, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26.

Mount the oil pump (5), the middle gears (2) together with the link rod (1) and the PTO driving gear (3).Tighten the screws (4) to the required torque.

Apply LOCTITE 5970 (IVECO No. 2995644) silicone on thegearbox using appropriate tools (1) as shown in the figure.

47592

71773

60633

Figure 63

Figure 64

α

Key on the gasket (1), fit the key 99346251 (2) and, screwingdown the nut (3), drive in the gasket.

Mount the gearbox within 10 min. of applying thesealant.

α

60568

2 s cr ew s M1 2 x 1 .7 5 x 1 93 56 to 70 Nm:Fitting engine flywheel box

NOTE




49036

60668

Figure 65

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

C = Hole on flywheel with one reference mark,corresponding to the TDC of pistons 2-5.

D = Hole on flywheel with two reference marks, positioncorresponding to 54°.

A = Hole on flywheel with one reference mark,corresponding to the TDC of pistons 3-4.

B = Hole on flywheel with one reference mark,corresponding to the TDC of pistons 1-6.

VIEW OFHOLES:

A — B — C

VIEW OFHOLE:

D

49037

Figure 66

α

If the teeth of the ring gear mounted on the engineflywheel, for starting the engine, are very damaged,replace the ring gear. It must be fitted after heating

the ring gear to a temperature of approx. 200°C.

The crankshaft has a locating peg that has to couplewith the relevant seat on the engine flywheel.

Position the flywheel (1) on the crankshaft, lubricate the

thread of the screws (2) with engine oil and screw them down.Lock rotation with tool 99360351 (3). Lock the screws (2) in

three phases.First phase: pre-tightening with torque wrench (4) to a torqueof 120 Nm (12 kgm).

Second and third phase: closing to angle of60° + 30° withtool99395216 (1).

Figure 67

Fitting engine flywheel

α

NOTE

NOTE




72436

Figure 68

Figure 69

Figure 70

Figure 71

Positionthe crankshaft with the pistons 1 and 6 at the top deadcentre (T.D.C.).

This situation occurs when:



If this condition does not occur, turn the engine flywheel (4)appropriately.

Remove the tool 99360612 (1).

- Fit the idle gear (1) back onand lock the screws (2) to therequired torque.

60571

- Apply the gauge 99395219 (1). Check and adjust thepositionof the link rod (3) for the idle gear.Lock the screw(2) to the required torque.

60570

Fit the camshaft (4), positioning it observing the referencemarks (→) as shown in the figure.

Lubricate the seal (3) and fit it on the shoulder plate (2).

Mount the shoulder plate (2) with the sheet metal gasket (1)and tighten the screws (5) to the required torque.

73843

Fitting camshaft




60572

Figure 72

Figure 73

Position the gear (2) on the camshaft so that the 4 slots arecentred with the holes for fixing the camshaft, without fully locking the screws (5).Using the dial gauge with a magnetic base (1), check that the

clearance between the gears (2 and 3) is 0.073 — 0.195 mm;if this is not so, adjust the clearance as follows:




torque.

Figure 74

44908


Before refitting the rocker-arm shaft assembly, makesure that all the adjustment screws have been fully unscrewed.


73533

5



Figure 75

NOTE

71775

Mount:


- The exhaust brake cylinders (1) and (4) and, using a torque wrench, fix them to a torque of 19 Nm.





Apply the tool 99360321 (6) to the gearbox (3).



Figure 76

Figure 77

Figure 78

45261


- 1st phase: tightening to a torque of 40 Nm (10 kgm) with the torque wrench (1).


60574

71776

71777

Figure 79

Mount the electric wiring (2), securing it on theelectro-injectors with a torque screwdriver (1) to a torque of 1.36 - 1.92 Nm.

α


NOTE

Timing of timing system shaft

Figure 80



70567A

6





71774

60573

60575

Figure 81

Figure 82

Figure 83

Figure 84




Set the dial gauge with the magnetic base (1) with the rod on the roller (2) of the rocker arm that governs the injector of cylinder no.1 and pre-load it by 6 mm.

With tool 99360321 (7) Figure 79, turn the crankshaftclockwise until the pointer of the dial gauge reaches theminimum value beyond which it can no longer fall.


Turn the engine flywheel anticlockwise until the dial gauge givesa reading for the lift of the cam of the camshaft of4.44 ±0.05 mm.

The camshaft is in step if at the cam lift values of 4.44 ±0.05 mm there are the following conditions:

1) the holemarked witha notch (5) can be seen through theinspection window;

2) the tool 99360612 (1) through the seat (2) of the enginespeed sensor goes into the hole (3) in the engineflywheel (4).


1) loosen the screws (2) securing the gear (1) to the camshaftand utilize the slots (see Figure 85) on the gear (1);

2) turn the engine flywheel appropriately so as to bring about the conditions described in points 1 and 2 Figure 83, itbeing understood that the cam lift must not change at all;



77259




71778

Figure 85

When the adjustment with the slots (1) is not enough to makeup the phase difference and the camshaft turns because itbecomes integral with the gear (2); as a result, the referencevalue of the cam lift varies, in this situation it is necessary toproceed as follows:

1) lock the screws (2, Figure 84) and turn the engine flywheelclockwise by approx. 1/2 turn;


3) take out the screws (2, Figure 84) and remove the gear (1)from the camshaft.

77260

Phonic wheel timing


Again turn the flywheel in its normal direction of rotation untilyou see the hole marked with the double notch (4) through

the inspection hole under the flywheel housing. Insert tool99360612 (5) into the seat of the flywheel sensor (6).

Insert the tool 99360613 (2), via the seat of the phase sensor,onto the tooth obtained on the phonic wheel.

Should inserting the tool (2) prove difficult, loosen the screws(3) and adjust the phonic wheel (1) appropriately so that the


Mount the gear (2) Figure 85 with the 4 slots (1) centred with the fixing holes of the camshaft, locking the relevant screws to the required tightening torque.Check the timing of the shaft by first turning the flywheelclockwise to discharge the cylinder completely and then turn


Figure 86

Figure 87

77259



- tool 99360612 (1), through seat (2)of engine rpmsensor,is fitted into hole (3) present on engine flywheel (4).




Clockwisestart-up

and rotation

Adjustingcylinder

valve no.

Adjustingclearance



1 and 6 at TDC 6 1 5120º 3 4 1

120º 5 2 4

120º 1 6 2

120º 4 3 6

120º 2 5 3

- Lock the adjusting screw to a torque of 5 Nm (0.5 kgm)by means of a torque wrench.

- Back off the adjusting screw 1/2 to 3/4 turn.

- Tighten the lock nut.


Adjustment of clearances between rockers and valve studsand preloading of pump injector rockers should be carried outwith extreme care.Bring the cylinder under examination to the firing stage, thevalves of this cylinder remain closed while the valves of theother cylinder in the pair can be adjusted.The cylinder pairs are 1-6,2-5,3-4.Strictly adhere to directions and data given on the table below.

Adjusting clearances between rockers andintake/exhaust/valve studs:

- Use a box wrench to loosen the adjusting screw lockingnut (1).

- Insert the feeler gauge blade (3).- By using proper wrench, screw or unscrew rocker arm

adjusting screw (2);

- Ensure the feeler gauge blade (3) can slide between theparts concerned with a slight friction.

- Hold the screw still while tightening the nut (1).

Setting pump-injector rocker preloading:

- Use a box wrench to loosen the nut fastening theadjusting screw for rocker arm (5) controllingpump-injector (6).

- With a suitable wrench (4) tighten the adjusting screwuntil the pumping element reaches its-end-of-strokepoint.

ADJUSTING INTAKE/EXHAUST ROCKERS AND INJECTION

In order to properly carry out the above-mentionedadjustments, follow the sequence specified in the

table, checking the exact position in each rotationphase by means of pin 99360612, to be inserted in

the 11 th hole in each of the three sectors with 18holes each.

Figure 88

60577


NOTE





The filter (5) operation is unidirectional, therefore itmust be assembled with the two sight supports asillustrated in the figure.

Fit the distribution cover (1).Fit the blow-by case (7) and its gasket and then tighten thescrews (8) to the prescribed torque.Install the filter (5) and the gaskets (4 and 6).

60665

Figure 89

Figure 90

- Mount the strainer (or strainers).

- Set the gasket (4) on the oil sump (1). Position the spacer (3) and mount the sump on the engine crankcase,

screwing the screws (2) to the required torque.

COMPLETING ENGINE ASSEMBLY

Complete the engine by fitting or hooking up the followingparts:

- thermostat assembly;

- automatic tensioner, water pump, alternator;

- drive belt.

ASSEMBLY DIAGRAM OF FAN — WATER PUMP — ALTERNATOR DRIVE BELT

1. Alternator — 2. Electromagnetic coupling — 3. Water pump — 4. Crankshaft

Figure 91

60578

- damper flywheel;

- joint for viscous-static fan.

Figure 92

Apply silicone LOCTITE 5970 (IVECO No.2995644) on the blow-by case (7)surface of enginesfitted with P.T.O. according to the proceduredescribed in the following figure.

85480

Apply silicone LOCTITE 59709 (IVECO No. 2995644) on theblow-by case and form a string (2) of ∅ 1,5 ± as shown in

the figure.

85481

0.50.2

.

NOTE

NOTE

NOTE




COMPRESSOR CONTROL BELTASSEMBLY DIAGRAM

1. Crankshaft - 2. Air conditioner compressor

Assemble:

- air conditioner compressor automatic belt tightener;

- control belt.

When assembling the belts (1-3) operate on the belt tighteners using fit tools (2-4), acting in the direction shown by the arrows.

Figure 93

60579

Belt tighteners are automatic and do not needfurther adjustment after assembly.

Figure 94

60667

The fittings of the cooling water and lubricating oilpipes of the turbocharger have to be tightened toa torque of:

- 35 ±5 Nm, water pipe fittings;

- 55 ±5 Nm, oil pipe female fitting;

- 20-25 Nm, oil pipe male fitting.

- starter motor;

- fuel pump;

- hydraulic power steering tank;

- fuel filter and pipes;

- pre-heating element;

- intake manifold;

- heat exchanger;

- oil filters, lubricating the seals;

- exhaust manifold;- turbocharger and associated water and oil pipes;

- power take-off (PTO) and associated pipes.

- oil dipstick;

- electrical connections and sensors;

- replenish the engine with the required amount of oil;

- remove the engine from the rotary stand and take off thebrackets (99361036) fixing the engine.

NOTE

NOTE







PART TWO -













Figure 1

Figure 2

99370

99371

(Demonstration)

(Demonstration)


Components on the engine F3B



Figure 3

101609

KEYS

1. Accelerator pedal position sensor / switch accelerator depressed — 2. Engine coolant temperature sensor — 3. Oversupply air temperature sensor — 4. Fuel temperature sensor — 5. Oversupply air pressure sensor — 6. Input for electronic tachograph




BLOCK DIAGRAM







Figure 4





Figure 5


Pin Function1 - Engine rev sensor


3 - ---



7 - ---

8 - ---

9 - ---






15 - ---

16 - ---


18 - ---

19 - ---

20 - ---









29 - ---30 - ---

31 - ---

32 - ---




Colour code

B White

BG Beige

C Orange

23 G Yellow

13 H Grey

L Blue

M Brown

N Black

R Red

24 35 000576t S Pink

V Green





Figure 6








8 - ---






14 - ---




19 - ---







speed sensors




30 - PWM line







1

13

24 35 000576t

12

23





A) Solenoid valve

B) Pumping element

C) Nozzle






Figure 7

A

B

C

001694t




Figure 8

Pump-injector replacement

If the operation is carried out when the engine is on the vehicle, before removing the pump-injectors drain the fuel in

the cylinder head pipes by releasing the delivery and return pipe unions on the cylinder head.

In an emergency, when the Modus is not available, it is possible to replace 1 injector without the control unit recognition.

Connect to the MODUS station for each replaced injector and, when required by the programme, enter the control unit

re-programming code stamped on the injector

0 4 11 7 0 0 0 0 2

X X X X X X X X X X X

8 6 8 U S A /

61487

When inspecting the rocker arm clearance, check also the pump-injector preload.




TECHNICAL VIEW

8527 000602t

WIRING DIAGRAM

PERSPECTIVE VIEW

000693t

Figure 9








- 10 °C 8,10 ÷ 10,77 kOhm+ 20 °C 2,28 ÷ 2,72 kOhm

+ 80 °C 0,29 ÷ 0,364 kOhm







Figure 10


Specifications



TECNICAL VIEW

8527 8528

WIRING DIAGRAM

PERSPECTIVE VIEW

8529 8530

RESISTANCE TREND






HOLES ON FLYWHEEL


PERSPECTIVE VIEW

8520

Figure 11

Figure 12

Figure 13

Figure 14



Features









3 Shields –





Figure 15


Distribution pulse sensor (48042)

Features



The electronic center uses the signal generated by this sensor as an injection step signal.

Though electrically identical to engine rpm sensor mounted in the camshaft in is NOT interchangeable with it as it cable is shorter and it features a larger diameter.





3 Shields –



TECHNICAL VIEW

8521

8522

max abosulte pressure 600 kPa

PERSPECTIVE VIEW8523

Figure 16 Figure 17

Figure 18


Overfeed pressure sensor (85154)

Features

Vendor BOSCHCode B 281022 018Operating pressure range 50 ÷ 400 kPaMaximum torque 10 Nm

This pressure strain gauge transducer located on the intake to the intake manifold downstream the intercooler on the engine left

side measures air overfeed pressure to the intake manifold.This measurement, together with the air temperature sensor finding, enables the electronic center to exactly define the amountof air admitted to the cylinders so as to pilot injectors by adjusting fuel supply, limit noxious emissions and improve fuel consumptionand engine performance.

The sensor is provided with an internal temperature correction electronic circuit to optimize pressure measurement as a functionof admitted air temperature.







TECHNICAL VIEW

8527 8528

WIRING DIAGRAM

PERSPECTIVE VIEW

8529 8530

RESISTANCE BEHAVIOR

Figure 19

Figure 20

Figure 21

Figure 22


Air temperature sensor on manifold (85155)

Features

Vendor BOSCHMaximum torque 35 Nm

The device must carry Vendor identification, unit part number and manufacture date.

Together with the overfeed pressure sensor, this N.T.C. type sensor located on the intake manifold input downstream the

intercooler on the engine left supplied the electronic center with the parameters required to identify proper air delivery values.






Pre/post-heating resistance (61121)The resistance is ~ 0,7 Ohm.

Such resistance is placed between the cylinder head and the suction manifold. It is used to heat up air during pre/post-heatingoperations.

When the ignition key is inserted, should any one of the temperature sensors — water, air, gas oil — detect a value below 10°C, the electronic control unit will activate pre/post-heating and turn on the relevant dashboard warning light for a variable timedepending on the temperature.

After that time, the warning light starts blinking thus informing the driver that the engine can be started.

When the engine is running the warning light goes off, while the resistance is being fed for a certain time as a result of post-heating.

If the engine is not started, with the warning light flashing, in 20 / 25 seconds, the operation is cancelled to prevent draining thebattery.

On the contrary, if reference temperatures are over 10°C, when the ignition key is inserted the warning light comes on for about2 seconds and carries out the test and then goes out to signal that the engine can be started.

Figure 23

001256t







It also enables:


Fuel dosing








De-rating










Engine start



Cold start



Hot start


Run Up


After Run


Speed regulator

The electronic speed regulator has both regulator characteristics:

- minimum and maximum

- all rotation speeds.

It remains stable within the ranges where conventional mechanical regulators become inaccurate.




Cut-off

It refers to the supply cut-off function during deceleration.

Cylinder Balancing

Individual cylinder balancing contributes to increasing comfort and operability.Thisfunction enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between eachcylinder, to compensate for injector hydraulic tolerances.The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This informationis provided by the entry of the codes for every single injector, by means of the diagnosis instrument.

Synchronization search

The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with thesequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injectionoccurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequenceand start the engine.

In order to reduce the number of connections, and of the cables connecting the injectors, and to consequently reduce the noseon transmitted signal, the central unit is directly mounted on the engine by a heat exchanger enabling its cooling, using spring blockswhich reduce vibrations transmitted from engine.

It is connected to vehicle wiring harness by two 35-pole connectors:connector “A” for components present on the engineconnector “B” for components present on the cab

Internally, there is a pressure ambient sensor use to further improve injection system management.

The central unit is equipped with a much advanced self-diagnosis system and, depending on environmental conditions, is capable to identify and store any faults, even of intermittent type, occurred to the system during vehicle running, ensuring a more correctand reliable repair intervention.

This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before10 seconds at least after engine cutout.

In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdownmemory and the engine operates at lower performance at next start while the EDC warning light stays on.

Repeated procedure interruptions could in fact lead to center damage.














PREFACE

A successful troubleshooting is carried out with thecompetence acquired by years of experience and attending

training courses.

When the user complains for bad efficiency or workinganomaly, his indications must be kept into proper consideration using them to acquire any useful information tofocus the intervention.

After the detection of the existing anomaly, it isrecommended to proceed with the operations of

troubleshooting by decoding the auto-troubleshooting dataprovided by the EDC system electronic central unit.

The continuous efficiency tests of the components connected to, and the check of working conditions of the entire systemcarried out during working, can offer an important diagnosisindication, available through the decoding of the”failure/anomaly” codes issued by blinking of the failure led:

the ”blink-code” (whether programmed).

Please consider that the interpretation of the indications

provided by the blink-code is not sufficient to guarantee thesolution to the existing anomalies.

Using Iveco Motors processing instruments, it is also possible to establish a bi-directional connection with the central unit,by which not only to decoding the failure codes but also inputan enquiry relying on memory files, in order to achieve any further necessary information to identify the origin of theanomaly.

Every time there is a breakdown claim and this breakdown isactually detected, it is necessary to proceed inquiring theelectronic unit in one of the ways indicated and then proceedwith the diagnostic research making trials and tests in order tohave a picture of the working conditions and identify the rootcauses of the anomaly.

In case the electronic device is not providing any indication, itwill be necessary to proceed relying on the experience,adopting traditional diagnosis procedures.

In order to compensate the operators’ lack of experience in this new system, we are hereby providing the USER’sGUIDELINE FOR TROUBLESHOOTING in the followingpages.

The GUIDELINE is composed of three different parts:

- Part 1: Blink Code, relating to the anomalies identified by the gearbox, mainly of electric and electrical nature;

- Part 2: Troubleshooting guide using PT-01 portable tester.Tool identified as IVECO p/n 8093731.

- Part 3: Guideline for troubleshooting without blink code,divided per symptoms, describing all possible anomaliesnot detected by the electronic gearbox, often of mechanical and hydraulic nature.

!

Any kind of operation on the electronic center unitmust be executed by qualified personnel, duly authorized by Iveco Motors.

Any unauthorized tamper will involve decay of after-sales service in warranty.







VEHICLE AREA

1.1 GLOWING STEADILY Vehicle speed signal


1.3 OFF Cruise Control


1.5 OFF Clutch pressure switch



ENGINE AREA







INJECTORS











7.2 OFF CAN line

7.6 OFF CAN line (ASR control)


CONTROL UNIT


9.2 GLOWING STEADILY Incorrect data in EPROM9.4 GLOWING STEADILY Main relay






PART 2


B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

1 . 1

O N s t e a d y

F a u l t y

v e h i c l e

s p e e d

s e n s o r . T h

e

t a c h o g r a p h

w o n ’ t

w o r k .

O d d

b e h a v i o u r

o f

t h e

t a c h o g r a p

h

p o i n t e r .

( I f

a v a i l a b l e )

V e h i c l e

s p e e d n o

l o n g e r




w i t h



t i m e a t l o w


e c t i o n s a n d

c o m p o n e n t .


1 . 2

O N s t e a d y

F a u l t y


s w i t c h . ( I f

a v a i l a b l e )

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 3

O F F

F a u l t y

C r u i s e

C o n t r o l



w o r k .

C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .


s w i t c h



1 . 4

O N s t e a d y


p o t e n t i o m

e t e r

o r

n o n - p l a u s

i b l e

s i g n a l . O d d

r e a c t i o n


a c t u a t i n g


p e d a l .



( S e t + / S e t - ) s w i t c h . ( I f

a v a i l a b l e )

1 . 5

O F F




c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 6

O N s t e a d y

B r a k e s w

i t c h



t h e C C / P

T O


a v a i l a b l e )



C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .

1 . 7

O F F




t e m .




B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

2 . 1

O F F

F a u l t y c o o


s e n s o r . E


t i m e i n

c o l d

w e a t h e r



n o i s e




c k c a b l i n g ,


n t .


= 0 ˚

C .

2 . 2

O F F

F a u l t y

b o o s t i n g

a i r


I f

t h e

s e n s o r

s i g n a l s

a


t h a n t h e


s t o r e d

a n d

t h e

e n g i n e


f o r m a n c e ,



c k c a b l i n g ,


n t .


C .

2 . 3

O F F

F a u l t y f u


s e n s o r .


c k c a b l i n g ,


n t .



C .

2 . 4

O N s t e a d y


s e n s o r . P o





m o d

u s : i f t h e


w h e n t h e


c o n f i r m e d .


C u r s o r 1 0 = 2 , 8 0 0 m b a r .

2 . 5

O F F


s e n s o r .





o t h e s a m e .



3 . 5

O F F


v o l t a g e r e


P o s s i b l e


a n d



5 . x

O N s t e a d y

P r o b l e m

w i t h

i n j e c t i o n

c i r c u i t o n


e n g i n e s p


a n d t h e




i t t e n t , t h e

e n g i n e

s o m e t i m e s

w o r k s


n o t .







B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

6 . 1

O N s t e a d y


s e n s o r .


p o w e r .




e a n s o f t h e


c a b l i n g ,


n t .

6 . 2

O N s t e a d y



p o w e r .




e a n s o f t h e


c a b l i n g ,


n t .

( 6 . 1 - 6 . 2 )

O N s t e a d y



l o o s e n e d

s c r e w s .

T h e

e n g i n e w o


a n d

c a n n o t b e

s t a r t e d

a g a i n .


s t a r t e d

( a f t e r t a

k i n g

t h e


d e d i n t h e


D i s c o n n e c t

t h e


s h a f t


e n g i n e i s


t h a n

u s u a l , t h e

p h o n i c

w h e e l i s


6 . 4

B l i n k i n g

T h e e n g i n


p u l l i n g )

t h e

o u t - o f - r e v




h t r e c o r d e r



( 9 . 1 )

B l i n k i n g

F a u l t y

E D C

c o n t r o l

u n i t . T h e e




o n t r o l u n i t





9 . 2

O N s t e a d y

C o n t r o l

u n i t

f a u l t

( E E P R O M

m e m o r y ) .


p o w e r .



f a u l t s c a n

b e m a d e .




9 . 4

B l i n k i n g


i n

c l o s e d



O N w h e n



s t o p .



h a s b e e n



C h e c k

c a b l i n g ,

c o n n e c

t i o n s

a n d

c o m p o n e n t .






B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O

S S I B L E

C

A U S E


A N O M A L I E S


O R M E A S U R E S

R E M A R K S

9 . 5

O N s t e a d y

E C U p o w


o u t t o o

o f t e n ( 5 t i m e s ) :



d i s c o n n e c

t

s w i t c h .

R e d u c e d

e n g i n e

m a x .

s p e e d a n d

p o w e r .

C h e c k

m a i n


a n d


h e t h e r t h e


o f f i n o t h e r


e y .





9 . 6

O N s t e a d y

E C U s t o

p



p o w e r .



n t r o l u n i t


m i g h t s t o r e









PART 3


S I G N A L L E D

A N O M A L Y

B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O S S I B L E

C A U S E

P O S S I B L E

R E L A T E D

A N O M A L I E S


T E S T S O R

M E A S U R E S

R E M A R K S

T h e b a t t e r y g o e s f l a t

q u i c k l y .

-

-

P r e - h e a t i n g

r e s i s t o r

p o w e r e d c o n t i n u o u s l y .

L o c a l o v e r h e a t i n g .



-

-

F u e l p r e - f i l t e r c l o g g e d .

D i f f i c u l t s t a r t w h e n t h e

e n g i n e i s e i t h e r h o t o r

c o l d .

-

-

T h e 3 . 5 b a r v a l v e o n

f u e l

r e t u r n i s s t u c k o p e n .

S l i g h t o v e r h e a t i n g .

-

-

E i t h e r 0 . 3 b a r t a n k r e t u r n

v a l v e

o r

r e t u r n p i p i n g

c l o g g e d .

A f t e r t h e n e w v e h i c l e

h a s b e e n d e l i v e r e d , t h e

e n g i n e w i l l s t o p a f t e r a

s h o r t

o p e r a t i o n

t i m e . T h e t a n k h o l d s a

l o t o f f u e l ; a l l t h e r e s t i s

O . K .

-

-

R e v e r s e d t a n k s u c t i o n /

r e t u r n p i p e s .

T h e e n g i n e i s f e d b y t h e

r e

t u r n p i p e , t h e s u c t i o n

o f w h i c h i n t h e t a n k i s

l o

w e r . W h e n t h e p i p e

s u c k s n o

m o r e , t h e

e n g i n e w i l l s t o p .

R e d u c e d

p o w e r

/

d i f f i c u l t

e n g i n e

m a n e u v e r a b i l i t y .

-

-

I n j e c t i o n

s y s t e m

/

t h e

e n g i n e o p e r a t e s w i t h o n e

c y l i n d e r f a i l i n g :

- i n j e c t o r p l u n g e r s e i z u r e ;

- v a l v e r o c k e r a r m s e i z u r e .

O v e r h e a t i n g

E n g i n e t e s t : c y l i n d e r e f f i c i e n c y t e s t . I f

t h

e t r o u b l e i s n o t r e l a t e d t o e l e c t r i c

c o m p o n e n t s ( B l i n k c o d e 5 . x ) , t h e

r o

c k e r a r m h o l d e r s h a f t n e e d s b e

d i s a s s e m b l e d . C h e c k t h e r o c k e r a r m

r o

l l e r a n d b u s h i n g a s w e l l a s t h e

r e

s p e c t i v e c a m .

F u e l

c o n s u m p t i o n

i n c r e a s e .

-

-

A i r f i l t e r c l o g g i n g w i t h

n o

s i g n a l f r o m

t h e w a r n i n g

l i g h t o n t h e i n s t r u m

e n t

b o a r d .

S m o k e .

C

h e c k t h e c a b l i n g , c o n n e c t i o n s a n d

c o m p o n e n t .




S I G N A L L E D

A N O M A L Y

B L I N K

C O D E

E D C

W A R -

N I N G

L I G H T

P O S S I B L E

C A U S E

P O S S I B L E

R E L A T E D

A N O M A L I E S


T E S T S O R

M E A S U R E S

R E M A R K S




-

-

T h e

b o o s t i n g

p r e s s u r e



a s e ,


S m o k e .



c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-

I m p a i r e d

h y d r a u l i c


t o r .



t h


M



l e v e l s

( c

o m p a r e d

w i t h

t h e


i n

g t h a t t h e

c o n t r o l

r o


c o r r e c t .



c o r r e c t l y

l i k e

i t d i d

b e f o r e .

-

-





m




w i t h

f i v e

c y l i n d e r s ;


-

-





t h



t e


l e


t h

e o t h e r s ) .







-

-


t h e


( e x c e s s i v e

t r a v e l )

w i t h


o n

t h e n o z z l e .



i n j e c t o r .



t h



t e


l e


t h

e o t h e r s ) .



-

-


f u e l



m i g h t

h a v e

o p e r a t i o n





B l e e d a i r .



PART FOUR - MAINTENANCE PLANNING








Programmed maintenance is made up of ”Standard” services, plus a set of operations called ”Extra Plan” operations, as well asfurther operations called ”Temporal” operations.

Normally, no differentiated plans are prescribed in connection with vehicle use. Where a differentiation in terms of ”mission”exists, as many plants are forwarded as many are the ”missions”.

Using recommended lubricants systematically allows for long replacement intervals with relatively contained costs. To suchpurpose, see recommended lubricants summary card.

M = STANDARD SERVICE

”Standard” services are indicated by M = ”Maintenance”.They must be performed at regular kilometre intervals that are normally multiple among one another.

EP = EXTRA PLAN OPERATIONS

Extra plan operations are indicated by EP = ”Extra Plan”.They are services complementary to ”standard” services and areto be performed according to intervals which arenot compatiblewith standard services.

T = TEMPORAL OPERATIONS

They are specific interventions that are exclusively connected to temporal intervals and are to be normally performed inparticular season conditions. To minimise the number of stops for maintenance it is recommended to program extra plan stopsbased on average yearly run matching them as much as possible with predefined kilometre intervals.

To ensure optimum working conditions, the following pages give the checks, inspections and adjustments that need to be madeon the various parts of the vehicle at the required times.

!The kilometre frequency for engine lubrication is in relation to a percentage of sulphur in diesel of under 0.5%.

NOTE: If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.

Use engine oil: ACEA E5 (URANIA LD5)

!- If the vehicle is used very little or anyhow for less than 800 hours/80,000 km a year, the engine oil and filter need

to be replaced every 12 months.

- The drier filter of the pneumatic system anyhow has to be changed each year.

- In case of very low yearly runs, or operativity under 1600 hours/year, gearbox and axle(s) oil must be replacedat least once every two years.

- In case of very low operativity, general greasing must be performed at least once a year.






Type of operation Every

150,000 kmEvery

300,000 km

Engine

Change engine oil • •

Change engine oil filters • •

Check state of blow-by filter (with clogging indicator) • •

Check miscellaneous drive belts • •


Change miscellaneous drive belts •

Chassis and mechanical assemblies

Change fuel pre-filter (if available) • •




OFF-PLANE OPERATIONS

EVERY 100.000 Km

and possibly when a maintenance operation is carried out

23 Change fuel filter

In the initial period at 150,000 km and then every 300,000 km


22 Check and adjust valve clearance and injectors

Every year — Before winter


4 Check the antifreeze percentage in the engine cooling water

Every two year


7 Change engine coolant

13 Change cartridge and clean air filter container (1)

24 Change Blow-by filter

(1) Early air filter clogging is usually due to environmental conditions. For this reason, the filter should be changed if clogging issignalled by the related sensor, regardless of the prescriptions that shall be observed if no specific indications have beenprovided.







SECTION 4

General overhaul

Page



ENGINE OVERHAUL 11. . . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK 11. . . . . . . . . . . . . . . . . . . . . . .


- Cylinder liners 12. . . . . . . . . . . . . . . . . . . . . . . . .

- Removing cylinder liners 13. . . . . . . . . . . . . . . . .

- Assembly and checking protrusion 13. . . . . . . . .

- Crankshaft 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring the main journals and crankpins 15. . .

- Preliminary measurement of main and big endbearing shell selection data 16. . . . . . . . . . . . . . .

- Selecting the main bearing and big endbearing shells 17. . . . . . . . . . . . . . . . . . . . . . . . . .


- Selecting the main bearing shells(Journals with nominal diameter) 19. . . . . . . . . .

- Selecting the main bearing shells (ground journals) 20


- Selecting big end bearing shells(ground journals) 22. . . . . . . . . . . . . . . . . . . . . . .

- Replacing the timing control gear and the oil pump 23

- Checking main journal installation clearance 23. .


PISTON CONNECTING ROD ASSEMBLY 25. . . .

- Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Page


- Conditions for correct gudgeonpin-piston coupling 26. . . . . . . . . . . . . . . . . . . . . .

- Piston rings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rod 28. . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods bushings 29. . . . . . . . . . . . . . . .

- Checking connecting rods 29. . . . . . . . . . . . . . . .

- Mounting the connecting rod — piston assembly 30


- Fitting the big end bearing shells 30. . . . . . . . . . .

- Fitting connecting rod - piston assemblies in the cylinder liners 31. . . . . . . . . . . . . . . . . . . . . . .

- Checking piston protrusion 31. . . . . . . . . . . . . . .

- Checking crankpin assembly clearance 32. . . . . . .

CYLINDER HEAD 32. . . . . . . . . . . . . . . . . . . . . . . .

- Dismounting the valves 32. . . . . . . . . . . . . . . . . .

- Checking head bearing surface on cylinder block 32

- Decarbonizing and checking valves 33. . . . . . . . .

- Valve seats 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing of valve guides 34. . . . . . . . . . . . . . . . .

- Replacing - Reaming the valve seats 34. . . . . . . . .

- Removing injector holder cases 34. . . . . . . . . . . .

- Assembly 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking injector protrusion 36. . . . . . . . . . . . . .

CAMSHAFT 37. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment 37. . . . . . . . .

- Timing system bushings 38. . . . . . . . . . . . . . . . . .

- Replacing camshaft bushes usingbeater 99360499 39. . . . . . . . . . . . . . . . . . . . . . .

Page

- Removal 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Assembly 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SPRINGS 40. . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting the valves and oil seal ring 40. . . . . . . . . . .

ROCKER SHAFT 41. . . . . . . . . . . . . . . . . . . . . . . . .

- Shaft 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Rocker 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING GEAR 42. . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft drive 42. . . . . . . . . . . . . . . . . . . . . . . . .

- Idler gear and pin 42. . . . . . . . . . . . . . . . . . . . . . .

- Twin intermediate gear and pin 42. . . . . . . . . . . .


TIGHTENING TORQUE 43. . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of crankcasebase fixing screws 46. . . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of exhaustmanifold fixing screws 47. . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of exhaustmanifold fixing screws 47. . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of screws and nutsfixing turbocharger on exhaust manifold 47. . . . .

- Diagram of tightening sequence of heat exchanger fixing screws 48. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of engineoil sump fixing screws 48. . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence for screwsfixing rocker cover 48. . . . . . . . . . . . . . . . . . . . . .

- Diagram of tightening sequence of screws fixinggearbox to crankcase 49. . . . . . . . . . . . . . . . . . . .





Type F3B

Cycle 4-stroke Diesel engine

Fuel feed Overfed with aftercooler Injection Direct

No. of cylinders 6 in line

∅

Bore mm 135

Stroke mm 150

+ + +.. = Total displacement cm3 12880




Type F3B

A

B

VALVE TIMING



17°

30°

C

D



50°

9°

X

For timing check

mmX

mm

Running

mmX

mm

-

-

0.35 to 0.45

0.45 to 0.55

FEED Through fuel pump - filters

Injection

type: Bosch



ozz e type _

Injection order 1 - 4 - 2 - 6 - 3 - 5



1500

290 ± 12





Type F3B

CYLINDER BLOCK ANDCRANKMECHANISM COMPONENTS

mm

∅1Bores for cylinder liners:

upper ∅1

lower

153.500 to 153.525

152.000 to 152.025

Cylinder liners:

L

external diameter:upper

∅2lower

153.461 to 153.486

151.890 to 151.915∅2 length L -

Cylinder liners -crankcase bores

upper lower

0.014 to 0.0390.085 to 0.135

External diameter ∅2 -

Cylinder sleeve

∅3inside diameter ∅3A* 135.000 to 135.013

Xinside diameter ∅3B* 135.011 to 135.024


* Selection class

* Under a load of 800 N

Pistons:∅1 measuring dimension X 20

X external diameter ∅1AF 134.881 to 134.893

external diameter ∅1BFF 134.892 to 134.894∅ 2 pin bore ∅2 54.010 to 54.018

Piston - cylinder sleeveA*B*

0.107 to 0.1320.107 to 0.132

* Selection class

Piston diameter ∅1 -

X


3∅ Gudgeon pin ∅3 53.994 to 54.000


F Class A pistons supplied as spares.FF Class B pistons are fitted in production only and are not supplied as spares.




ypemm

1X X1* 3.445 to 3.475X2 Piston ring grooves X2 3.05 to 3.073X X3

* measured on ∅ of 130 mm5.02 to 5.04

Piston rings: trapezoidal seal S1* 3.296 to 3.364

12

SS

lune seal S2 2.970 to 2.990

3S milled scraper ringwith slits and internalspr ng

* measured on ∅ of 130 mm

. .

1 0.81 to 0.179

Piston rings - grooves 2 0.060 to 0.100

3 0.030 to 0.070

Piston rings -

X1

2X

Piston ring end gapin cylinder liners

X1 0.40 to 0.55

X2 0.65 to 0.80

X3 0.40 to 0.75

1∅Small end bush housing Ø1

59.000 to 59.030

∅ 2

Big end bearing housing Ø2

- Class 1- Class 2- Class 3

-

94.000 to 94.01094.011 to 94.02094.021 to 94.030

∅4Small end bush diameter outside ∅4

59.085 to 59.110

inside ∅3 54.019 to 54.035

S

Big end bearing shell SRedGreenYellow

1.965 to 1.9751.976 to 1.9851.986 to 1.995

Small end bush - housing 0.055 to 0.110

Piston pin - bush 0.019 to 0.041

Big end bearing -

Connecting rod weight g.

A 4661 to 4694

Class B 4695 to 4728

C 4729 to 4762




F3Bype

mm


Max. connecting rodaxis misalignment

tolerance 0.08

1 2∅∅

Main journals ∅1- rated value- class 1- class 2- class 3

Crankpins ∅2- rated value- class 1- class 2- class 3

99.970 to 100.00099.970 to 99.97999.980 to 99.989

99.990 to 100.000

89.970 to 90.00089.970 to 89.97989.980 to 89.98989.990 to 90.000

S 1 S 2 Main bearing shells S1RedGreenYellow*

3.110 to 3.1203.121 to 3.1303.131 to 3.140

Big end bearing shells S2RedGreenYellow*

1.965 to 1.9751.976 to 1.9851.986 to 1.995

3∅ Main bearing housings ∅3 106.300 to 106.330

Bearing shells -

main journals 0.060 to 0.100

Bearing shells -big ends

0.050 to 0.090



X1


X2



Crankshaft end float 0.10 to 0.30

1 2 Alignment 1 - 2

Ovalization 1 - 2

Taper 1 - 2

≤ 0.025

0.010

0.010





Type F3B

CYLINDER HEAD - VALVE TRAIN mm

∅ 1


2∅

Valve guide ∅2 10.015 to 10.030

∅ 3

∅3 16.012 to 16.025


in the cylinder heads 0.015 to 0.045

Valve guide -

∅ 4 Valves:

∅4α

9.960 to 9.97560° 30′ ± 7′ 30″

α

∅4α

9.960 to 9.97545° 30’ ± 7′ 30″


Valve seat inhead

∅1 49.185 to 49.220

∅ 1 ∅1 46.985 to 47.020


2∅ seat; angle of valve seat

in cylinder head:

49.260 to 49.275

α 60° - 30’

α 47.060 to 47.075

α 45° - 30′

XRecessing of valve

0.54 to 0.85

X X 1.75 to 2.05

etween va veseat and head 0.040 to 0.090. .




Table 2

F3Bype

mm

Valve spring height:

free height H 72,40

H H 1 under a load of:H2 575 ± 28 N H1 58

1095 ± 54 N H2 45

X

Injector protrusion X 0.53 to 1.34

∅∅∅

Camshaft bushing housingin the cylinder head:1 ⇒ 7 Ø 88.000 to 88.030

∅

∅

∅1

2

3

Camshaft bearing journals:1 ⇒ 7 Ø 82.950 to 82.968

∅ Outer diameter of

camshaft bushings: ∅88.153 to 88.183

∅ Inner diameter of

camshaft bushings: ∅ 83.018 to 83.085

Bushings and housingsin the cylinder head

0.123 to 0.183

Bushings and bearing journals 0.050 to 0.135

Cam lift:

9.30

H 9.30

11.216

∅ 1

Rocker shaft ∅1 41.984 to 42.000





A = Selection class Ø 135.000 to 135.013 mmB = Selection class Ø 135.011 to 135.024 mmX = Selection class marking area

On finding maximum wear greater than 0.150 mm or maximum ovalization of 0.100 mm compared to the valuesshown in the figure, you need to replace the cylinder liner asno grinding, facing or reconditioning is permitted.

ENGINE OVERHAULCYLINDER BLOCK Checks and measurements

Internal diameter of the cylinder liners is checked for ovalization, taper and wear, using a bore dial (1) centesimalgauge 99395687 (2) previously reset to ring gauge (3),diameter 135 mm.

If a 135 mm ring gauge is not available use amicrometer caliper.

A = Ø 153.500 to 153.525 mmB = Ø 152.000 to 152.025 mmC = Ø 153.461 to 153.486 mmD = Ø 151.890 to 151.915 mm

The diagram shown in the figure gives the outside diameter of the cylinder liner and inside diameter of its seat.

The cylinder liners can, if necessary, be extracted and fittedseveral times in different seats.

34994

60595

60597

Figure 1

Figure 2

Figure 3

Figure 4

1 = 1st measurement2 = 2nd measurement3 = 3rd measurement

The measurements have to be made on each single cylinder liner at three different heightsand on two levels (A-B) at right

angles to each other as shown in Figure 2.

(Demonstration)

The cylinder liners are supplied as spare parts withselection class ”A”.

60596

x

NOTE

NOTE

Once engine dismounting has been completed, accurately clean cylinders-block assembly.

Accurately check that no cracks are present on engine block.

Check machining plugs conditions. If plugs are rusty or whenever any doubt arises about plugs tightness, replaceplugs.

On plugs mounting, apply sealant Loctite 270 on plugs.




71710

Figure 5

Figure 6

MAIN CYLINDER LINER DATA

DETAIL “X”

“Y“ - Selection class marking area

Figure 7

CRANKCASE ASSEMBLY WITH CYLINDER LINERS

A 125.000 to 125.013 mmB 125.011 to 125.024 mm

Selection class

60598

Cylinder liners

71710




47577

16798

60521

Figure 8

Figure 9

Figure 10

Figure 11

Position the parts 99360706 (2) and the plate 99360728 (4)as shown in the figure, checking that the plate (4) rests on the

cylinder liner correctly.Screw down the nut of screw (1) and extract the cylinder liner (3) from the crankcase.

Always replace the water seals (3, 4 and 5).Fit the adjustment ring (1) on the cylinder liner (2). Lubricate

the bottom of it and mount it in the cylinder assembly using the appropriate tool.

Check the protrusion of the cylinder liners with tool 99360334(2) and tightening the screw (1) to a torque of 225 Nm.

Using the dial gauge 99395603 supplied as standard with thedial gauge base 99370415 (3), check that the protrusion of

the cylinder liner over the supporting face of the cylinder head is 0.045 - 0.075 mm (Figure 11); if this is not so, replace

the adjustment ring (1) (Figure 9), supplied as a spare partwith several thicknesses.

On completing assembly, lock the cylinder liners (1) to thecrankcase (2) with the pins 99360703 (3).

Assembly and checking protrusion

Figure 12

CYLINDER LINER PROTRUSION49017

!The adjustment ring (1) is supplied as a spare partwith the following thicknesses: 0.08 mm - 0.10 mm- 0.12 mm - 0.14 mm.

60520

0.045 to 0.075

Removing cylinder liners






MEASURING CRANKPINS

When grinding, pay the utmost attention to the values of theunions of the main journals and of the crankpins given inFigure 14 and Figure 15.

47535

47536

Figure 16

Figure 17

MEASURING THE MAIN JOURNALS

Before grinding the journals, use a micrometric gauge (1) tomeasure the journals of the shaft (2) and establish, on thebasis of the undersizing of the spare bearing shells, to whatdiameter it is necessary to reduce the journals.

It is advisable to note the measurements in a table(Figure 17).

All the main journals and crankpins should alwaysbe ground to the same undersizing class so as not

to alter the balance of the shaft.

Figure 18

Table for noting down the measurements of the main journals and crankpins of the crankshaft.

MAIN JOURNALS

36061

∅ MIN.∅ MAX.

∅ MIN.∅ MAX.

CRANKPINS

Measuring the main journals and crankpins

NOTE NOTE






MAIN JOURNALS:




CRANKPINS:





On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 19 at top).


- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 19 at bottom).


47535

106.300 to 106.309

106.310 to 106.319

106.320 to 106.330


NOMINAL DIAMETER




To obtain therequiredassembly clearances, the main bearing and bigend bearing shells have to be selected as describedhereunder.

This operation makes it possible to identify the most suited bearing shells for each of the journals of the shaft (the bearing shells

may even have different classes for different pins).

red

red/black

green

green/black

STD

1.965 to 1.975

1.976 to 1.985

+0.127

2.028 to 2.038

2.039 to 2.048

+0.254

2.092 to 2.102

2.103 to 2.112

+0.508

2.219 to 2.229

2.230 to 2.239

Depending on the thickness, the bearing shells are selectedin classes of tolerance marked by a colour (red-green -red/black - green/black).

Figure 20 gives the specifications of the main bearing and bigendbearing shells availableas spare parts in the standard sizes(STD) and in the permissible oversizes (+0.127, +0.254,+0.508).

Figure 20

red

red/black

green

green/black

STD

3.110 to 3.120

3.121 to 3.130

+0.127

3.173 to 3.183

3.184 to 3.193

+0.254

3.237 to 3.247

+0.508

3.364 to 3.374

Big end bearing shells

Main bearing shells

Selecting the main bearing and big end bearing shells

NOTE




Defining the class of diameter of the main journals and crankpins (Journals with nominal diameter)

Main journals and crankpins: determining the class of diameter of the journals.Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 21 at top):

- The first number, of five digits, is the part number of the shaft.

- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the statusof the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins

they refer to (Figure 21 at top).

- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows thestatus of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of themain journals they refer to (Figure 21 at bottom).

Figure 21

89.970 to 89.979

89.980 to 89.989

89.990 to 90.000

CLASS CRANKPIN

NOMINAL DIAMETER

99.970 to 99.979

99.980 to 99.989

99.990 to 100.000

CLASS MAIN JOURNALS

NOMINAL DIAMETER




Selecting the main bearing shells (Journals with nominal diameter)

After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells to use according to the following table:

STD.

1 2 3

1

2

3

green

green

red

red

red

red

green

green

green

green

red

red

green

green

green

green

green

green

Figure 22




green/black

Selecting the main bearing shells (ground journals)

If the journals have been ground, the procedure described so far cannot be applied.In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only typeof bearing shell envisaged for the relevant undersizing.

-0.127

1 2 3

99.84399.852

green/black

green/black

green/black

green/black

green/black

green/black

red/black

red/black


green/black

red/black

red/black

red/black

red/black

green/black

green/black

99.853

99.862

99.86399.873

1

2

3

red/black =3.173 to 3183 mm

green/black =

3.184 to 3.193 mm

-0.254

1 2 3

99.72699.746 red red red

red red red

red =3.237 to 3.247 mm

-0.508

1 2 3

99.46899.508 red red red

red red red

red =

3.364 to 3.374 mm

Figure 23





There are three markings on the body of the connecting rodin the position indicated as ”A”:


A = 4661 to 4694 g.B = 4695 to 4728 g.C = 4729 to 4762 g.


1 = 94.000 to 94.010 mm2 = 94.011 to 94.020 mm3 = 94.021 to 94.030 mm


1

2

3



VIEW FROM “A”

STD.

1 2 3

1

2

3

green

green

red

red

red

red

red

red

green green

green green

green

green green

green

green

green

CLASS

Figure 25




Figure 26

green/black

Selecting big end bearing shells (ground journals)

If the journals have been ground, the procedure described so far cannot be applied.In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of thecrankpins and to mount the bearing shells identified with the relevant table.

-0.127

1 2 3

89.84389.852

green/black

green/black

green/black

green/black

green/black

green/black

red/black

red/black


green/black

red/black

red/black

red/black

red/black

green/black

green/black

89.85389.862

89.86389.873

1

2

3


green/black =

2.039 to 2.048 mm

-0.254

1 2 3


red green green

red =

2.092 to 2.102 mm

green =

2.103 to 2.112 mm

-0.508

1 2 3


red green green

red red green

red red green


red red green

red =

2.219 to 2.229 mm

green =

2.230 to 2.239 mm

89.73689.746




Install the half-bearings (1) on the main bearings in theunderblock (2).Check the installation clearance between the main journalsand the relative bearings as follows:

Using the hoist and hook 99360500 (1) mount the drivingshaft (2).

When fitting gear (1) onto drive shaft (2), the gear must beheated for 2 hours max. in a furnace, at a temperature nothigher than 180˚C.Let them cool down after the installation.

If changing the pin (3), after fitting it on, check it protrudesfrom the crankshaft as shown in the figure.

49020

47579

47578

49021

Figure 27

Figure 28

Figure 29

Figure 30

Install the oil spray nozzles (2) and have the dowel coincidewith the block hole (3).

Install the half-bearings (1) on the main bearings.

Replacing the timing control gear and the oilpump

Check that the teeth of the gears are not damaged or worn,otherwise remove them using the appropriate extractor.

Checking main journal installation clearance

1

2




- Lubricate the internal screws (1) with UTDM oil and tighten them with a torque wrench (3) to a torque of 120 Nm, using tool 99395216 (4), to an angle of 60 °,following the diagram below.

Set two journals of the crankshaft (2) parallel to thelongitudinal axis, a section of calibrated wire. Usingappropriate hooks and tackle, mount the crankcase base (1).

60559

47579

47578

47588

60593

Figure 31 Figure 32

Figure 33

Figure 34

Figure 35

- Remove the crankcase base.

The clearance between the main bearings and their journalsis measured by comparing the width taken on by thecalibrated wire (2) at the point of greatest crushing with thegraduated scale on the case (1) containing the calibratedwire.The numbers on the scale give the clearance of the couplingin millimetres. If you find the clearance is not as required,replace the bearing shells and repeat the check.

FRONT SIDE

DIAGRAM OF SEQUENCE FOR TIGHTENING THE SCREWS FIXINGTHE BOTTOM CRANKCASE BASE TO THE CRANKCASE

Checking crankshaft end float

α

The end float is checked by setting a dial gauge (1) 99395603with a magnetic base on the crankshaft (2) as shown in thefigure. If you find the clearance to be greater than as required,replace the rear main bearing shells carrying the thrustbearings and repeat the clearance check.




Make sure the piston does show any trace of seizing, scoring,cracking; replace as necessary.

60608

60607

Figure 36

Figure 37


1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring -6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.


(1).

Removal

Pistons are equipped with three elastic rings: a sealing ring, a trapezoidal ring and a scraper ring.

Pistons are grouped into classes A and B for diameter.

49024

Figure 38


pliers (1).





1

2

49025 32618

49026

Figure 39

Figure 40

Figure 41

Figure 42






71714

Using a micrometer (2), measure the diameter of the piston(1) to determine the assembly clearance; the diameter has tobe measured at the value X shown:




MAIN DATA OF THE PISTON, PISTON RINGS AND PIN

* The measurement is made on the Ø of 130 mm.

16552

3513

Figure 43

Figure 44

Figure 45

Check the thickness of the piston ring (2) with a micrometer (1).

The seal (2) of the 1st slot has a V shape. The clearance ”X”between the seal and its seat is measured by setting thepiston (1) with the ring in the cylinder liner (3) so that theseal comes half out of the cylinder liner.

Piston rings

73555

60610

Figure 46

Check the clearance between the seals (2) and their seats on the piston (1) with a feeler gauge (3).

36134

Figure 47

Using a feeler gauge (2), check the opening between the endsof the seals (1) inserted in the cylinder liner (3).If you find the distance between the ends is less than or greater than as required, replace the piston rings.




47957

71716

Figure 48

Figure 49

MAIN DATA OF THE BUSHING, CONNECTING ROD, PIN AND BEARING SHELLS

* Measurement to be made after driving in the bushing.

Connecting rod punch markings


A = 4661 to 4694 g.B = 4695 to 4728 g.C = 4729 to 4762 g.

Number indicating the selection of the diameter of the big end bearing seat:

1 = 94.000 to 94.010 mm2 = 94.011 to 94.020 mm3 = 94.021 to 94.030 mm

Number indicating the selection of diameter for the big end bearing housing:

1

2

3

Punched on the big end of the connecting rod are the datarelating to the section in classes relating to the connectingrod seats and the weights.

On assembling the connecting rods, check they are all of the same class of weight. VIEW FROM “A”

54.00054.030

54.08554.110

50.019*50.035*

49.99450.000

1.9702.000

87.00087.030

Connecting rod

NOTE




Check the torsion of the connecting rod (5) by comparing

two points (A and B) of the pin (3) on the horizontal planeof the axis of the connecting rod.Position the mount (1) of the dial gauge (2) so that thispre-loads by approx. 0.5 mm on the pin (3) at point A andzero the dial gauge (2). Shift the spindle (4) with theconnecting rod (5) and compare any deviation on theopposite side B of the pin (3): the difference between A andB must be no greater than 0.08 mm.

Check the bending of the connecting rod (5) by comparing two points C and D of the pin (3) on the vertical plane of theaxis of the connecting rod.Position the vertical mount (1) of the dial gauge (2) so that thisrests on the pin (3) at point C.Swing the connecting rod backwards andforwardsseeking thehighest position of the pin and in this condition zero the dialgauge (2). Shift the spindle (4) with the connecting rod (5) andrepeat the check on the highest point on the opposite side Dof the pin (3). The difference between point C and point D

must be no greater than 0.08 mm.

6169561696


Check the alignment of the axes of the connecting rods (1)with device 99395363 (5), proceeding as follows:

Fitthe connecting rod (1) on the spindle of the tool 99395363(5) and lock it with the screw (4).

Set the spindle (3) on the V-prisms, resting the connecting rod(1) on the stop bar (2).

Figure 50

Figure 51

Figure 52

Checking torsion

61694

Checking bending

Checking connecting rods

73535

Check the bushing in the small end has not come loose andshows no sign of scoring or seizure; replace it if it does.The bushing (2) is removed and fitted with a suitable drift (1).

When driving it in, make absolutely sure that the holes for theoil to pass through in the bushing and small end coincide.Using a boring machine, rebore the bushing so as to obtaina diameter of 54.019 — 54.035.

Figure 53

Connecting rods bushings





12

3

73536

74052

60614

49030

Figure 54

Figure 55

Figure 56

Figure 57

The piston (1) has to be fitted on the connecting rod (2) so that the graphic symbol (4), showing the assembly positionin the cylinder liner, and the punch marks (3) on theconnecting rod are observed as shown in the figure.

Fit the pin (2) and fasten it on the piston(1) withthe split rings(3).

To fit the piston rings (1) on the piston (2) use the pliers99360184 (3).The rings need to be mounted with the word ”TOP” (4)facing upwards. Direct the ring openings so they arestaggered 120° apart.

Fit the bearing shells (1), selected as described under the

heading ”Selecting the main and big end bearing shells”, onboth the connecting rod and the cap.If reusing bearing shells that have been removed, fit themback into their respective seats in the positions markedduring removal.

Mounting theconnecting rod— piston assembly Mounting the piston rings

Fitting the big end bearing shells



60616

Figure 58

Figure 59

ASSEMBLY DIAGRAM OF CONNECTING ROD — PISTON ASSEMBLY IN CYLINDER LINER 1. Connecting rod — piston assembly — 2. Area of punch marking on the top of the piston,

symbol showing assembly position and selection class — 3. Connecting rod punch mark area

Fitting connecting rod - piston assemblies inthe cylinder liners

With the aid of the clamp 99360605 (1, Figure 58), fit theconnecting rod — piston assembly (2) in the cylinder liners,according to the diagram of Figure 59, checking that:

- The openings of the piston rings are staggered 120 °

apart.

- The pistons are all of the same class, A or B.

- The symbol punched on the top of the pistons faces theengine flywheel, or the recess in the skirt of the pistons

tallies with the oil nozzles.

The pistons are supplied as spares in class A and canbe fitted in class B cylinder liners.

60615

Checking piston protrusion

On completing assembly, check the protrusion of the pistonsfrom the cylinder liners; it must be 0.12 — 0.42 mm.

NOTE




Checking head bearing surface on cylinder block

Mount the connecting rod caps (1) together with the bearingshells. Tighten the screws (2) fixing the connecting rod caps

to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),further tighten the screws with an angle of 60°.

47594

47583

36159

Figure 60

Figure 61

Figure 62

Mount and secure the tool 99360263 (2) with the bracket(4). Screw down with the device 99360261 (1) to be able toremove the cotters (3). Take out the tool (2) and extract the

top plate (5), spring (6) and bottom plate (7).Repeat this process on all the valves.

Turn over the cylinder head and take out the valves (8).

Check the supporting surface (1) of the head on the cylinder block with a rule (2) and a feeler gauge (3). If you find any deformation, level the head on a surface grinder; maximumamount of material that can be removed 0.2 mm.

Checking crankpin assembly clearance

To measure the clearance, carry out the followingoperations.Connect the connecting rods to the relevant journals of thecrankshaft, placing a length of calibrated wire on the journals.

α

(Demonstration)

After this process, you need to check the valverecessing and injector protrusion.

Remove the caps and determine the clearance by comparing the width of the calibrated wire with the graduated scale on the case containing the calibrated wire.Upon final assembly: check the diameter of the thread of thescrews (2), it must be no less than 13.4 mm; if it is, change thescrew. Lubricate the crankpins and connecting rod bearings.Tighten the screws (2) as described above.

The thread of the screws (2), before assembly, has to be lubricated with engine oil.

NOTE

CYLINDER HEAD

Before dismounting cylinder head, check cylinder head for hydraulic seal by proper tooling; in case of leaks not causedby cup plugs or threaded plugs, replace cylinder head.

In case of plugs dismounting/replacement, onmounting, apply sealant Loctite 270 on plugs.

NOTE

Dismounting the valves

Before dismounting cylinder head valves, number them in view of their remounting in the positionobserved on dismounting should they not have tobe overhauled or replaced.

Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.

NOTE

NOTE




MAIN DATA OF VALVES AND VALVE GUIDES


71718

73555

Figure 63

Figure 64

Check with a micrometer that the diameter of the valvestems is as indicated. If necessary, grind the valve seats witha grinding machine, removing as little material as possible.

1 2

MAIN DATA OF VALVE SEATS1. Intake valve seat — 2. Exhaust valve seat

The valve seats are reground whenever the valvesor valve guides are ground and replaced.

Valve seats

NOTE

48625

Decarbonizing and checking valves

Remove the carbon deposits on the valves with a wire brush.Check that the valves show no signs of seizure or crackingand check with a micrometer that the valve stem diameter comes within the required values (see Figure 64); replacethevalves if it does not.

Figure 65




41032

60619

Figure 66

Figure 67

Remove valve guides by means of tool 99360143.Install by means of tool 99360143 equipped with part99360296, which determines the exact installation positionof valve guides into the cylinder heads; if they are notavailable, install the valve guides in the cylinder head so that

they project out by mm 30.8 to 31.2 (Figure 65).After installing the valve guides, smooth their holes with

sleeker 99390330.

Check the valve seats (2). If you find any slight scoring or burns, regrind them with tool 99305019 (1) according to theangles shown in Figure 65. If it is necessary to replace them,using the same tool and taking care not to affect the cylinder head, remove as much material as possible from the valveseats so that, with a punch, it is possible to extract them from

the cylinder head.

Heat the cylinder head to 80 — 100°C and, using a drift, fit in the new valve seats (2), chilled beforehand in liquid nitrogen.Using tool 99305019 (1), regrind the valve seats according

to the angles shown in Figure 65.

After regrinding the valve seats, using tool 99370415 and dialgauge 99395603, check that the position of the valves inrelation to the plane of the cylinder head is:

- -0.54 - -0.85 mm (recessing) intake valves

- -1.75 - -2.05 mm (recessing) exhaust valves.

To replace the injector case (2), act as follows:

- thread the case (2) with tool 99390804 (1).

Replacing of valve guides Removing injector holder cases

Replacing - Reaming the valve seats

To replace the valve seats, remove them using theappropriate tool.

!Valve seats must be reamed whenever valves or valve guides are replaced or ground.




60621

- Using the tool 99390772 (2) removeany residues (1)leftin the groove of the cylinder head.

- Screw the extractor 99342149 (2) into the case (3).Screw down the nut (1) and take the case out of thecylinder head.

60620

60622

- Lubricate the seals (3) and fit themon the case (4).Using tool 99365056 (2) secured to the cylinder head withbracket A, drive in the new case, screwing down thescrew (1) upsetting the bottom portion of the case.

60623

- Using the reamer99394041 (1-2), rebore the hole in the

case (3).

Figure 68

Figure 69

Figure 70

Figure 71

Assembly




60624

47585

Check injector protrusion (2) with the dial gauge (1).The protrusion must be 0.52 - 1.34 mm.

Checking injector protrusion

71720

INJECTOR CASE ASSEMBLY DIAGRAM

Figure 72

- Using the milling cutter 99394043 (1-2), regrind theinjector seat in the case (3).

Figure 73

Figure 74




47506

47505

47507

Figure 75

Figure 76

Figure 77

CAMSHAFTChecking cam lift and pin alignment

When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must notexceed 0.030 mm. If misalignment exceeds this value, replace the shaft.

In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtainedby their difference.

If clearance exceeds 0.135 mm, replace bushes and, if necessary, the camshaft.

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on page20.

1




The surface of the bushings must show no sign of seizing or scoring; replace them if they do.Measure the inside diameter of the bushings with a bore

gauge.

60626

60627

Figure 78

Figure 79

MAIN DATA OF THE CAMSHAFT AND TOLERANCESThe surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth.

Whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings.

MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD* Bushing inside diameter after driving in

Timing system bushings

If you find a higher value than the tolerance, replace them.To remove and fit the bushings, use the appropriate drift99360499.


TOLERANCES FEATURE SUBJECT OF TOLERANCE SYMBOL

DIRECTION Perpendicularity ⊥

POSITION Concentricity or coaxiality

SWING Circular oscillation

CLASS OF IMPORTANT ASCRIBED TO PRODUCT CHARACTERISTICS SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝



Figure 80

71721A B C D E F D L G H D I

A. Drift with seat for bushings to insert/extract. - B. Grub screw for positioning bushings. - C. Reference mark to insertseventh bushing correctly. - D. Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks). - E. Guide bushing. -F. Guide line. - G. Guide bushing to secure to the seventh bushing mount. - H. Plate fixing yellow bushing to cylinder head.

- I. Grip. - L. Extension coupling.

Figure 81


Removal

Figure 82

Assembly

1 Position the bushing to insert on the drift (A) making thegrub screw on it coincide with the seat (B) (Figure 80) on

the bushing.2 Position the guide bushing (E) and secure the guide

bushing (G) (Figure 80) on the seat of the 7 th bushingwith the plate (H).

3 While driving in the bushing, make the referencemark(F)match the mark (M). In this way, when it is driven home,



To insert bushings 1, 2, 3, 4 and 5, proceed as follows:

71723

Figure 83





Rear

Rear

77795

71725

Replacing camshaft bushes using beater 99360499




70000

87051

86290

MAIN DATA TO CONTROL EXHAUST AND

DISCHARGE VALVE SPRING

- fit springs (6) and the upper plate (5);

- apply tool 99360263 (2) and block it with bracket (4); tighten the lever (1) until cotters are installed (3),remove tool (2).

VALVE SPRINGS

Fitting the valves and oil seal ring

71724




- Position the bushing on the drift (A) and bring it closeup to the seat, making the bushing hole match thelubrication hole in the head. Drive it home.

The 7 th

bushing is driven inwhen the reference mark (C)is flush with the bushing seat.


Rear

Figure 84

Figure 85

Figure 86

Figure 87

Figure 88

Lubricate the valve stem and insert the valves in therespective valve guides; fit the lower caps (1). Use tool99360329 to fit the oil seal (2) on the valve guides (3) of theexhaust valves; then, to fit the valves, proceed as follows.

99375

Free spring

Valve closed

Valve open 7 3 . 4 0

5 9 4 6

N 575 ± 28

N 1095 ± 54

Where valves should not have been overhauled or

replaced, remount them according to thenumbering that was performed during mounting.Intake valves are distinguished from exhaust valvesin that they have a recess located at the centre of valve mushroom.

NOTE




The camshaft cams directly control rockers: 6 for injectors and 12 for valves.The rocker arms controlling injectors and intake valves are directly keyed on rocker arms shaft.The rocker arms controlling exhaust valves are keyed on rocker arms shaft putting in between the levers with engine brakecontrol cam pin.Rockers slide directly on the cam profiles via rollers.The other end acts on a bar directly supported by the two valves stems.A pad is placed between the rocker adjusting screw and the bar.Two lubrication holes are obtained inside the rockers.The rocker shaft practically covers the whole cylinder head; remove it to have access to all the underlying components.

Figure 89

71728

71729 71730

Figure 90

Figure 91

Figure 92PUMP INJECTOR ROCKER

EXHAUST VALVES ROCKER

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

rocker.

DISCHARGE VALVE ROCKER

Rocker

SECTION A-A

SECTION B-B

SECTION A-A

SECTION B-B

SECTION A-A

SECTION

B-B

Check for shaft surface not to show traces of seizing, scoring or wear. Otherwise, replace the shaft.


73557

Shaft

Figure 93

Figure 94

44925

ROCKER SHAFT

92842




TIMING CONTROL COMPONENT PARTS1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -

5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear - 8. Drive shaft driving gear.

86925


Figure 95

Figure 96

Figure 97

Idler gear and pin

Twin intermediate gear and pin


Bushings (2) can be replaced when they are worn. Put up thebushing, then bore it to obtain the diameter shown onFigure 96 or Figure 97.

The bushing must be driven into the gear by following the direction of the arrow and setting the latter to thedimension shown on Figure 96 or Figure 97.

Rated assembling play between gear bushings and pins:Figure 96 — 0.045 ÷ 0.075 mmFigure 97 — 0.045 ÷ 0.085 mm.

86933

86934

NOTE





TIGHTENING TORQUE

TORQUE

Nm kgm

Screws fixing crankcase base to crankcase (see Figure 98) ♦

Outside screws M12x1.75 First phase: pre-tightening 30 (3)

Inside screws M18x2 Second phase: pre-tightening 120 (12)

Inside screws Third phase: closing to angle 60°

Inside screws Fourth phase: closing to angle 55°

Outside screws Fifth phase: closing to angle 60°

Piston cooling nozzle union ♦ 35 ±2 (3,5 ±0,2)

Screws fixing heat exchanger to crankcase ♦ (see Figure 102)

pre-tightening 11.5 ±3.5 (1.15 ±0.35)

tightening 19 ±3 (1.9 ±0.3)

Screws fixing suction strainer to crankcase base ♦ 24.5 ±2.5 (2.4 ±0.25)

Screws fixing oil sump spacer ♦ (see Figure 103)

pre-tightening 38 (3.8)

tightening 45 (4.5)

Screws fixing gearbox to crankcase M12x1.75 ♦ (see Figure 105) 63 ±7 (6.3 ±0.7)Screws fixing control unit to crankcase base ♦ 24 ±2.5 (2.4 ±0.25)

Screws fixing cylinder head (see Figure 99) ♦

First phase pre-tightening 60 (6)

Second phase pre-tightening 120 (12)

Third phase closing to angle 90°

Fourth phase closing to angle screws no. 4 - 5 - 12 - 20 - 21 45°

Fifth phase closing to angle screws no. 1 - 2 - 3 - 6 - 7 - 8 - 9 - 10 - 11-14 - 15 - 16 - 17 - 18 - 19 - 22-23 - 24 - 25 - 26

65°

Screws fixing rocker arm shaft ♦



Lock nut for rocker arm adjustment screw ♦ 39 ±5 (3.9 ±0.5)

Screws for injector brackets ♦ 26 (2.6)

Screws fixing plastic cover 8.5 ±1.5 (0.85 ±0.15)

Screws fixing shoulder plate to head ♦ 19 ±3 (1.9 ±0.3)

Screws fixing engine mount bracket to cylinder head


Second phase closing to angle 45º

♦ Before assembly, lubricate with UTDM oil

• Before assembly, lubricate with graphitized oil




TORQUE

Nm kgm

Screws fixing engine mount bracket to flywheel casing



Screws fixing camshaft gear ♦

First phase pre-tighteningirst 60 (6)Second phase closing to angle 60°

Screws fixing phonic wheel on camshaft gear 8.5 ±1.5 (0.85 ±0.15)

Screws fixing exhaust manifold • (see Figure 100)

pre-tightening 32.5 (3.2)

tightening 45 (3.2)

Screws fixing engine brake actuator cylinder ♦ 19 (1.9)

Screws fixing connecting rod cap ♦



Screws fixing engine flywheel ♦



Third phase closing to angle 30°

Screws fixing damper flywheel ♦



Screws fixing middle gear pins ♦



Screws fixing idle gear adjustment connecting rod: 24.5 ±2.5 (2.45 ±0.25)

Screws fixing oil pump 24.5 ±2.5 (2.45 ±0.25)

Screws fixing crankshaft gasket front cover 24.5 ±2.5 (2.45 ±0.25)

Screws fixing fuel pump / filter mount 19 (1.9)Screw fixing control unit mount 19 ±3 (1.9 ±0.3)

Screws and nuts fixing turbocharger • (see Figure 101)

pre-tightening 35 (3.5)

tightening 46 (4.6)

Screw fixing thermostat assembly 19 ±3 (1.9 ±0.3)

Screws fixing water pump 25 (2.5)

Screws fixing fan hub to spacer 30 (3)

Screw fixing fan spacer to pulley 30 (3)

Screws fixing fan mount to crankcase 100 (10)

Screw fixing automatic tensioner to air-conditioner 26 ±3 (2.6 ±0.3)

Screw fixing automatic tensioner to alternator mount 50 ±5 (5 ±0.5)

Screws fixing fixed pulley for auxiliary member drive belt to crankcase 105 ±5 (10.5 ±0.5)

Screws fixing starter motor 74 ±4 (7.4 ±0.4)

Screws fixing air heater 30 ±3 (3 ±0.3)

Screws fixing air compressor 74 ±4 (7.4 ±0.4)






TORQUEPART

Nm kgm

Nut fixing air compressor gear ♦ 170 ±10 (17 ±1)

Screws fixing alternator: M 10x1,5 l = 35 mm 30 ±3 (3 ±0.3)

M 10x1,5 l = 60 mm 44 ±4 (4.4 ±0.4)

Screws fixing hydraulic power steering pump 46.5 ±4.5 (4.65 ±0.45)

Screws fixing air-conditioner compressor to the mount 24.5 ±2.5 (2.5 ±0.25)

Screws fixing guard 24.5 ±2.5 (2.5 ±0.25)

Filter clogging sensor fixing 55 ±5 (5.5 ±0.5)

Water / fuel temperature sensor fixing 35 (3.5)

Transmitter / thermometric switch fixing 25 (2.5)

Air temperature transmitter fixing 35 (3.5)

Pulse transmitter fixing 8 ±2 (0.8 ±0.2)

Fixing connections to injector 1.36 ±1.92 (0.13 ±0.19)

Fixing engine brake solenoid valve 32 (3.2)

Heater fastening screw 12.5 ± 2.5 1.2 ± 0.2

Engine propulsor

M14X70/80 screw securing front and rear spring blocks to chassis 192.5 ±

19.5 19.2 ±

1.9M16X130 screw securing front and rear spring blocks to engine 278 ± 28 27.8 ± 2.8

M18X62 flanged hex screw for front engine block:



M14X60 socket cheese-head screw for front engine block:



Flanged hex screw for rear engine block:







60593

FRONT SIDE

Fourth phase:closing inside

screws to angle

55º

60592

60594

60593

Figure 98

First phase:pre-tightening

outside screws

30 Nm

FRONT SIDE

FRONT SIDE

Second phase:pre-tightening

inside screws120 Nm

Fifth phase:closing outsidescrews to angle

60º

60593

FRONT SIDE

Third phase:closing inside

screws to angle

60º

FRONT SIDE





60580

Figure 99

Figure 100

Figure 101

Diagram of tightening sequence of exhaust manifold fixing screws

Diagram of tightening sequence of screws and nuts fixing turbocharger on exhaust manifold

60581

60582

Diagram of tightening sequence of exhaust manifold fixing screws




60666

Figure 102

Figure 103

Diagram of tightening sequence of engine oil sump fixing screws

60583

Diagram of tightening sequence of heat exchanger fixing screws

Figure 104

Diagram of tightening sequence for screws fixing rocker cover

73554




60633

Tightening sequence

4 screws M12 x 1.75 x 35

10 screws M12 x 1.75 x 100

1 screw M12 x 1.75 x 120

2 screws M12 x 1.75 x 70

2 screws M12 x 1.75 x 193:

Figure 105

Diagram of tightening sequence of screws fixing gearbox to crankcase








SECTION 5

Tools

Page

TOOLS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







TOOLS


8093731 Tester PT01


99305047 Spring load tester

99322230 Rotary telescopic stand (range 2000 daN, torque 375 daNm)






TOOLS











TOOLS



99360144 Tools (12 + 6) holding rocker adjustment screw blocks whenremoving/refitting the rocker shaft

99360180 Injector housing protecting plugs (6)

99360184 Pliers for assembling and disassembling piston split rings

(105-106 mm)


(to be used with special plates)

99360263 Plate for take down-fit engine valves





TOOLS


99360296 Tool to fit back valve guide (to be used with 99360481)

99360314 Tool to remove oil filter (engine)

99360321 Tool to rotate engine flywheel (to be used with 99360325)

99360325Spacer (to be used with 99360321)


99360334 Compression tool for checking the protrusion of cylinder liners

(to be used with 99370415-99395603 and special plates)




TOOLS


99360336 Spacer (to be used with 99360334)

99360338 Cylinder liner compression plate

(to be used with 99360334-99360336)








TOOLS


99360553 Tool for assembling and installing rocker arm shaft

99360585 Swing hoist for engine disassembly assembly


99360612 Tool for positioning engine P.M.S.






TOOLS


99360706 Tool to extract cylinder liners (to be used with specific rings)

99360728 Ring (125 mm) (to be used with 99360706)



99370415 Base supporting the dial gauge for checking cylinder liner

protrusion (to be used with 99395603)

99378100 Tool for printing engine identification plates(to be used with special punches)




TOOLS


99378101*99378103•

99378105H

Punches (B) for printing engine identification plates(to be used with 99378100)

99389834 Torque screwdriver for calibrating the injector solenoid

valve connector check nut


99390772 Tool for removing injector holding case deposits

99390804 Tool for threading injector holding cases to be extracted


99390805 Guide bush (to be used with 99390804)




TOOLS



99394041 Cutter to rectify injector holder housing


99394043 Reamer to rectify injector holder lower side


99395216 Measuring pair for angular tightening with 1/2”

and 3/4” square couplings

99395219 Gauge for defining the distance between the centres

of camshaft and transmission gear





TOOLS


99395603 Dial gauge (0 - 5 mm)

99395687 Reaming gauge (50 - 178 mm)

99396035 Centering ring of crankshaft front gasket cap




Appendix

Page




2 APPENDIX F3B CURSOR ENGINES








- Organize and displace specific exit points to evacuate

the areas in case of emergency, providing for adequateindications of the emergency exit lines.









During maintenance







- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas


Documents

Motor Diesel Iveco Camion