Professional Documents
Culture Documents
Every information, illustration and specification contained in the present manual is based on the most recent informa--
tion available at the time of printing.
NEW HOLLAND reserves the right, to modify the text at any time without prior communication.
NEW HOLLAND
PRINT NO. 604.13.582
Edition – April 2006
2 WE
MOTORI
2
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no--
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example:: T 1 -- 2 -- 3
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min--1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
MOTORI
SECTION 1
DIAGNOSTICS
INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
INDICE
EW--1--3
DIAGNOSTICS
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
YES
(to be continued)
EW--1--4
DIAGNOSTICS
YES
The feeding circuit or injection pump does not Check and blow off.
show air penetration NO
YES
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water NO tank).
YES
YES
YES
Automatic advance variator and electric STOP Check and replace the concerned parts.
device both in working order NO
YES
Fuel pump fed correctly Check and replace (if necessary) the fuel pump.
NO
YES
DIAGNOSTICS
2 ENGINE OVERHEATS
Coolant level correct Check for leaks and restore the level.
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level.
NO
YES
YES
YES
Radiator in working order Wash down thoroughly, check for fluid leaks, re--
NO place (if necessary) the part.
YES
Air filter and circuit piping both in working order Clean or replace faulty parts.
NO
YES
Openings for coolant flow to the head in working Wash down thoroughly.
order NO
EW--1--6
DIAGNOSTICS
YES
YES
YES
Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.
YES
Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.
YES
Feeding circuit in working order Check and make (if necessary) the required re--
NO pairs.
(to be continued)
EW--1--7
DIAGNOSTICS
The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.
YES
YES
YES
YES
YES
Automatic advance variator (in injection pump) in Check and bench--adjust the injection pump.
working order NO
YES
Distributing plunger (in injection pump) in work-- Check and bench--adjust the injection pump.
ing order NO
(to be continued)
EW--1--8
DIAGNOSTICS
Injection pump rate correct Check and bench--adjust the injection pump.
NO
YES
Speed governor (in injection pump) in working Check and bench--adjust the injection pump.
order at all speeds NO
YES
YES
Injection pump with peak adjusting--screw fine-- Fine--tune the peak adjusting--screw.
tuned NO
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.
YES
YES
YES
Correct tie rod length between the accelerator Adjust the tie rod length.
and injection pump NO
EW--1--9
DIAGNOSTICS
YES
YES
Automatic addition device comes into operation Check and replace (if necessary).
NO
YES
YES
YES
YES
Injection pump adjusted as prescribed Check and bench--adjust the injection pump.
NO
(to be continued)
EW--1--10
DIAGNOSTICS
Injection pipes intact Check the condition of pipes and replace them (if
NO necessary).
YES
YES
High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO
YES
YES
YES
(to be continued)
EW--1--11
DIAGNOSTICS
High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO
Excessive oil consumption Check the oil vapour vent and cylinder compres--
YES sion. Overhaul, if necessary, the cylinder head or
engine.
Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine.
NO
Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect--
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.
NO
Knock detected in pistons Check the following items: play between the pis--
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.
(to be continued)
EW--1--12
DIAGNOSTICS
Knock detected in the cylinder head Check the following items: operation play be--
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for excess--
YES ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.
NO
Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace.
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.
NO
Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump.
8 ENGINE STOPS
YES
(to be continued)
EW--1--13
DIAGNOSTICS
YES
YES
YES
Injection pump controls in working order Replace worn parts and adjust.
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
arms.
NO
YES
Speed governor in working order Check and replace (if necessary) the worn parts.
NO
EW--1--14
DIAGNOSTICS
Pressure control valve in working order Check and replace (if necessary).
NO
YES
Oil pump and delivery pipes both in working or-- Check and replace (if necessary).
der NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.
YES
Engine oil SAE viscosity conforming to stan-- Replace the engine oil with equivalent of ad--
dards NO equate viscosity.
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.
YES
(to be continued)
EW--1--15
DIAGNOSTICS
YES
YES
YES
YES
Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16
DIAGNOSTICS
NOTES
SECTION 2 F4BE0454 -- F4BE0484
INDEX
Engines F4BE0484 . . . . . . . . . . . . . . . . . EW--2--3 Checking the eccentric lift and the
Coding of source engines . . . . . . . . . . EW--2--4 pin alignment . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Main engines features . . . . . . . . . . . . . . EW--2--5 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--60
Torque and rating features . . . . . . . . . . EW--2--7 Replacing the bushings . . . . . . . . . . . . . . EW--2--61
General engines features F4BE0454 . EW--2--8 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Assembling engines play F4BE0454 -- Mounting the tappets – Distributing shaft EW--2--61
specifications . . . . . . . . . . . . . . . . . . . . . EW--2--10
General engines features F4BE0484 . EW--2--16 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Assembling engines play F4BE0484 -- Measuring the journals and crankpins . . EW--2--62
specifications . . . . . . . . . . . . . . . . . . . . . EW--2--18 Replacing the oil pump drive gears . . . . EW--2--65
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--24 Mounting the main bearings . . . . . . . . . . EW--2--65
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25 Measuring the journal assembling play . EW--2--65
Graphic indications and symbols . . . EW--2--26 Checking the drive shaft shoulder play . EW--2--66
General remarks . . . . . . . . . . . . . . . . . . . EW--2--27 Connecting rod--piston assembly . . . EW--2--67
Description of main mechanic
engine components . . . . . . . . . . . . . . . . EW--2--28 Measuring the piston diameter . . . . . . . . EW--2--68
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--28 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Conditions for correct pin/piston
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--2--29 matching. . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--30 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--31 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--70
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--32 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--71
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--33 Checking the connecting rods . . . . . . . . . EW--2--71
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Checking the torsion . . . . . . . . . . . . . . . . . EW--2--71
Valves and valve seats . . . . . . . . . . . . . . . EW--2--35
Checking the flexion . . . . . . . . . . . . . . . . . EW--2--71
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--2--36
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--37 Connecting rod--piston match . . . . . . . . . EW--2--72
Auxiliary component drive . . . . . . . . . . . . EW--2--38 Mounting the piston rings . . . . . . . . . . . . . EW--2--72
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Mounting the connecting rod/piston
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--40 assemblies in the cylinder liners . . . . . . . EW--2--73
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--41 Measuring the crankpin assembling play EW--2--73
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--42 Checking piston protrusion . . . . . . . . . . . EW--2--74
Oil vapour recirculation . . . . . . . . . . . . . . . EW--2--43 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--74
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--44 Distribution gearbox case . . . . . . . . . . . . EW--2--74
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--45 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--2--75
Mechanic injection feeding system . . . . EW--2--46
Injection pump – 1st phase . . . . . . . . . EW--2--76
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . EW--2--46
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--46 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--76
Mechanic fuel pump . . . . . . . . . . . . . . . . . EW--2--47 Flywheel cover case . . . . . . . . . . . . . . . . EW--2--76
Injection assembly . . . . . . . . . . . . . . . . . . . EW--2--48 Mounting the rear seal ring . . . . . . . . . . . EW--2--77
Engine bench--overhaul . . . . . . . . . . . . EW--2--49 Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--77
Disassembling the engine . . . . . . . . . . . . EW--2--49 Replacing the engine flywheel ring gear EW--2--77
Removing the front seal ring . . . . . . . . . . EW--2--51 Injection pump – 2nd phase . . . . . . . . . EW--2--78
Removing the injection pump . . . . . . . . . EW--2--52 Mounting the injection pump –
Removing the rear seal ring . . . . . . . . . . EW--2--53 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--78
Removing the rocker arm assembly Mounting the oil and water pumps . . EW--2--79
and cylinder head . . . . . . . . . . . . . . . . . . . EW--2--55
Monting the front seal ring . . . . . . . . . . . . EW--2--79
Repair work on cylinder cluster . . . . . EW--2--57
Checks and measurements . . . . . . . . . . . EW--2--57 Mounting the oil sump . . . . . . . . . . . . . . EW--2--80
Checking the surface supporting Mounting the water / oil heat
the head on the cylinder cluster . . . . . . . EW--2--58 exchanger . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--59 Removing the valves . . . . . . . . . . . . . . . . EW--2--81
INDEX
ENGINES F4BE0484E
Figure 1
84235
EW--2--4
F 4 B E 0 4 8 4 E * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern:
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 4 = 4--cylinder
Group
Engines
4 = Earthmovers
X Y Y Y Y Y Y Y Y
B F4BE0454B F4BE0484D
E 3922 cm3
74kW 88 kW
F 2100 min--1 2200 min--1
G Direct injection
T.C. T.A.A.
I
(Boosted) (Boosted by intercooler)
A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6
B F4BE0484E
E 3922 cm3
83 kW
F 2000 min--1
G Direct injection
T.A.A.
I (Boosted by intercooler)
A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--7
Figure 2
Torque - Nm
Rating - kW
Torque Rating
84279
EW--2--8
Bore mm 102
Stroke mm 120
Max. rating kW 74
min --1 2100
F4BE0454B
Type
*D601 *D602
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
FEEDING
Bosch--type injection VE4 / 12 F 1100 L
Start of delivery mm 1
Injection sequence 1 -- 3 -- 4 -- 2
F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Measurement dimension X --
F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
∅1 43.637 to 43.663
X 0.104 to 0.840
Valve seats --
EW--2--14
F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
7.239
EW--2--15
F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Tappets --
∅1
Bore mm 102
Stroke mm 120
Max. rating kW 83 88
min --1 2000 2200
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
Ambra Master gold HSP REFUELLING
15W40
-- engine sump + filter litres 12 5
12.5
10W30
FEEDING
VE4 / 12 F 1100 L
Bosch--type injection
Start of delivery mm 1
Injection sequence 1 -- 3 -- 4 -- 2
Position of pistons
0.28 to 0.52
from crankcase X
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Measurement dimension X --
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm
Valvese:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
∅1 43.637 to 43.663
X 0.104 to 0.840
Valve seats --
EW--2--22
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
7.239
EW--2--23
F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm
∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Tappets --
∅1
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st phase
p 50 ± 6 (5 ± 0.6)
2nd p
phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90°
Connecting g rod cap
p fastening
g screws 1st p
phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
TOOLS
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Joint for pressure control in the cylinders (use with 380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and depression measuring
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Diesel engine cylinder compression control device
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380000228)
380002730 Engine PMS positioning tool
EW--2--26
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
EW--2--27
GENERAL REMARKS
Figure 3
84236
1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump drive belt – 6. Automatic belt stretcher – 7. Fixed guide pulley – 8. Fixed guide pulley – 9. Fan
pulley – 10. In--line injection pump – 11. Cold start air heater – 12. Blow--by
Figure 4
88233
EW--2--28
Figure 5
2
7 3
86605
EW--2--29
Drive shaft
It is made of steel and rests on five induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
Inside the drive shaft are the lubricating oil ducts.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
The second main half bearing is equipped with a
flywheel and auxiliary component drive pulley.
shoulder to restrain the drive shaft end play.
Parts (1) and (2) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 6
84207
1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 7
84038
EW--2--31
Pistons
Figure 8
84039
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1 and 2, trapezoidal in shape and with ce-
Three slots (piston ring seats) are provided: the first ramic chrome coating.
one and the second one are obtained from a cast-- Ring 3, with double scraper ring shoe with inner
iron insert with trapezoidal section. spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 9
84040
EW--2--32
Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.
Figure 10
70164
84238
EW--2--33
Valve control
Figure 11
84239
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--34
Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);
Figure 12
84240
Figure 13
S 1
84241
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 14
84242
Valve guides
Figure 15
INTAKE EXHAUST
84046
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 16
84048
EW--2--38
Figure 17
84243
1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
EW--2--39
Lubrication
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the crank-
lowing components: case, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure control valve built into the oil filter
case front part, controlled by the straight--tooth adapter;
gear force--fitted on the drive shaft shank; - by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.
Figure 18
84244
Heat exchanger
Figure 19
84051
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter
EW--2--41
Oil pump
Figure 20
84052
Figure 21
70150
Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2) (fitted onto the oil
case by means of an aluminium plate (3), Figure 22. sump leading profile) enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 22
84245
Figure 23
84246
The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--2--43
Figure 24
114063
EW--2--44
Cooling
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.
Figure 25
84247
Water flowing out of the thermostat Water flowing into the pump
Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 26
84058
Figure 27
84059
EW--2--46
84060
Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.
Figure 29
84248
EW--2--47
Figure 30
84249
1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank
Figure 31
84250
Injection assembly
Figure 32
84251
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--49
84252 84254
Drain the engine oil by taking the cap off the sump - disconnect the engine oil vapour recovery pipe
and the oil filling cap off the head cover. from blow--by (1);
Remove the fan unit from the fan pulley. - take off tappet covers (4);
In order to be able to fit bracket 380000995 (which - disconnect electric wiring (8);
fastens the engine to the overhaul stand) to the - take off fuel filter (9);
crankcase, it is necessary to:
- take off intake manifold (3);
- remove electric wiring (1).
- take off container (2);
- take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
Figure 34
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 36;
- take off fuel filter support (6).
Figure 36
84253
In order to be able to fit bracket 380000995 to the
crankcase on the right side, it is necessary to re-
move:
- the starter motor (3);
- the bracket (2) fastening the oil return pipe (1);
- the oil return piping (1) relative to turbine;
- oil pipes (4) and (5) from heat exchanger unit
(6). 70126
Secure the engine to rotary stand 380000978. Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
- take off turbine lubrication delivery pipe (7);
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--50
Figure 37 Figure 40
84255
Figure 38
Figure 41
84256
Figure 39
84258
84068
Figure 43 Figure 45
84259 78257
Unscrew fastening screws (1) from pulley (2). Apply the proper tension rod (3) of tool 380000996 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
EW--2--52
Figure 46 Figure 48
84260
IMPORTANT -- Oil pump (1) cannot be recondi- IMPORTANT -- Carefully store the L--shaped
tioned. spacer with the pump body.
84073
84071
Prior to removing the injection pump, take off the fly- - Remove cover (1) from gear covering case (2).
wheel locking tool described in Figure 42. - Lock the engine flywheel as described in
Rotate the drive shaft until it reaches the condition of Figure 42.
1° cylinder at top dead centre. - Loosen nut (3) securing the injection pump drive
Such condition is obtained when (after removing the gear (4).
closing plug), by pushing pin 380002730 (1) shown
by the arrow, it is housed in its own seat obtained on
distributing shaft drive gear (2).
EW--2--53
Figure 50 Figure 52
84261
84076
Loosen the three nuts (2) (4) (5) securing the injection Screw two pins (2) of adequate length into drive shaft
pump (1) to the flywheel covering case (3), then take holes (3).
the pump out of its housing by means of tool
380000979 through proper application to gear (4) in Remove tool 380000990 (2, Figure 51).
Figure 49.
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
Figure 51 Figure 53
84075 78258
Remove screws (3) securing engine flywheel (4) to the Apply tool 380000981 (3) on drive shaft rear shank
drive shaft. (5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2).
EW--2--54
Figure 54 Figure 57
78257
84077
86470
Remove screws (2) and take off rear cover (1). APPLICATION WITH ROSE PIPE IN REAR
POSITION
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. Remove screws (1) and (4) and take off oil suction
strainer (5).
Remove screws (2) and take off stiffening plate (3).
Figure 56 Figure 59
84278 70156
Turn the engine upside down, remove screws (2), Remove screws (1) and take off gear (3) from distrib-
take off both plate (3) and oil sump (1). uting shaft (2).
EW--2--55
84085
84081 Remove screws (2) and take off timing gear case (1).
For each cylinder, remove rocker arm assembly (1),
loosen adjusting nuts (3), unscrew registers (2) and
remove screws (4).
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter.
Figure 61
87006 Figure 64
Remove screws (1) securing the head to the crank-
case.
Figure 62
70158
87007
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
EW--2--56
Figure 65 Figure 68
70159
Remove screws (1) and take off bed caps (2). 70162
Figure 69
70160
Figure 67
Figure 70
70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000362(1) and a hoist. crankcase.
EW--2--57
Figure 71 Figure 72
70165 70166
Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
70167
70170
Valve gear
Distributing shaft
Figure 76
70169
70171
Bushings Figure 78
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.
70172
Figure 79
sec. A-A
70173
70174 70176
To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000991 (2) and handle 380000999 (3) to remove seats of the crankcase.
and reassemble the bushings.
Tappets
Figure 81 Figure 83
84053 70164
MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
EW--2--62
Figure 84 Figure 86
70238 70180
Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.
Drive shaft
Measuring the journals and crankpins
Figure 87
Figure 85
70182
70179
Figure 88
70181
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--64
Figure 89
70183
Figure 90
84275
EW--2--65
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 91 Figure 93
70184 70161
Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
70185 70186
Figure 95 Figure 97
70187 70189
Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
70188 70190
- 3rd phase with tool 380001001 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60° ± 5°. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--67
Figure 99
70191
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--2--68
Figure 102
84095
MAIN DATA ABOUT PISTON IN APPLICATION WITH INTERCOOLER
86471
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 61 mm far
from the piston skirt base.
EW--2--69
84097 84100
Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 106
Figure 109
84098
84101
CONNECT-
70194 ING ROD
WEIGHT
NO.
Connecting rods
Figure 111
70196
* Dimension of inner diameter to be obtained after - By a letter (on the connecting rod body) which
driving into the connecting rod small--end and refacing indicates the weight class of the factory--as-
by means of a reamer. sembled connecting rod:
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure
better match. Material removal is not permitted.
Therefore, it is recommended not to remove
knurls.
EW--2--71
61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ∼ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.
61696
Check parallelism of the axles of the connecting rods
(1) with a suitable device (5) as follows:
- mount connecting rod (1) on tool (5) spindle, then
secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--72
84103 84093
The following reference data are engraved on the pis- Use pliers 380000986 (3) to fit piston rings (1) on pis-
ton crown: ton (2).
1. Spare part number and design modification The rings must be mounted with the writing “TOP”
number; facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
2. Date of manufacture;
by 120°.
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin- IMPORTANT -- Spare piston rings are supplied in
der liner. the following dimensions:
Figure 117 -- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;
Figure 120
84104
Connect piston (2) to connecting rod (4) by means of
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5)
stamped on connecting rod (4) can be seen as shown
in the figure.
Figure 118
70200
Mount half bearings (1) both on the connecting rod
and the cap.
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 123
Figure 121
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 124
Figure 122
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 125
84040
70206 70208
- Take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
Figure 127 Figure 129
70207
84106 84107
SCHEME FOR REAR GEARBOX CASE FASTEN- Turn drive shaft (4) and distributing shaft (2) in such
ING SCREW TIGHTENING SEQUENCE a direction that when mounting driven gear (1) on the
Reassemble case to the crankcase. distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.
Valve timing
Figure 131 Figure 133
70211 70213
Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--76
84108
Force--fit gear (1) transmitting the motion to the pump,
then fasten nut (2) by hand.
84071
Flywheel cover case
Bring cylinder 1 to the top dead centre. This condition
occurs when pin 380002730 (1) (shown by an arrow) Figure 137
is housed in the seat available on the distributing shaft
drive gear (2).
84109
84110 84111
SCHEME FOR FLYWHEEL COVER CASE Check the clutch disc supporting surface and turn it if
FASTENING SCREW TIGHTENING SEQUENCE scoring is detected.
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
taken off, then fasten them to the specified torque. NOTE -- The rated thickness of the engine flywheel
is 51 mm.
Screws:
- M12 x 1.75 x 100 80 ± 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 ± 20 Nm Check the condition of ring gear (2) teeth. If breaks or
- M16 x 1.50 x 100 200 ± 20 Nm excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 140) by using a
- M12 x 1.75 x 78 80 ± 10 Nm normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.
Mounting the rear seal ring
70216 84076
Apply part (5) of tool 380000984 on drive shaft rear Screw down two pins (2) of adequate length into the
shank (6), secure it by means of screws (4) and force-- shaft holes (3), then remove the engine flywheel (1)
fit the new seal ring (3) on the same. by means of suitable harnesses and a hoist.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--78
84075 84115
Apply tool 380000990 (2) to the flywheel cover case Torque--tighten nut (1) by means of torque wrench (2).
(1) to stop engine flywheel (4) rotation.
Tighten screws (3) fastening engine flywheel (4) to the
Figure 145
drive shaft.
Figure 143
α 84116
Figure 146
84114
Figure 147
70223
Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5205 onto the same.
70220
Figure 151
Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 148
70224
Figure 149
70225
84278
86601
Mount oil sump (1) and apply plate (3) on the same.
APPLICATION WITH ROSE PIPE IN FRONT
POSITION Fasten screws (2) and tighten them to the specified
torque.
Figure 154 Screws:
- M10 x 1.50 x 70 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 100 70 ± 5 Nm
- M10 x 1.50 x 90 70 ± 5 Nm
86470
84280
70227
Force--fit pulley (1) complete with spacer (2) onto the
Place gasket (1) on oil sump (2). drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (4) to the front cover by means
of screws (3).
EW--2--81
84175 84281
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support (3).
gasket (1), heat exchanger (2), a new gasket (3), and
Fasten screws (2) without torque--tightening them.
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Figure 159
84176
Lubricate seal ring (1) with engine oil, then position it Cylinder head
on oil pipe coupling (2).
Removing the valves
Fit oil pipe coupling (2) to support (4).
Figure 162
Place a new seal ring (3) in the crankcase housing.
Figure 160
84179
84282 87008
Take off oil seals (1) fitted to the valve stems. Remove the thermostat unit (2) and brackets (1) and
(4).
To remove the valves, properly turn the head upside
down. Remove the cover (3) of the intake manifold.
INTAKE EXHAUST
84181 84183
In addition to the head dimensions, the exhaust The plane of the supporting surface of head (1) to cyl-
valves differ from intake valves in that they are inder cluster is checked by means of a ruler (2) and
equipped with a supplementary notch (1) obtained on a thickness gauge (3).
the stem for intake valves. The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
EW--2--83
84284
84187
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). Check by reading the scorings
parator (1) placed as shown. Assembling play must and burns, use the tool (1) over it again according to
be equal to 0.039 to 0.079 mm. the tilting values indicated on the Figure 174.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
EW--2--85
Figure 174
EXHAUST INTAKE
87009
Figure 175
EXHAUST INTAKE
87010
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same proper tool (1, Figure 173) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of the proper tool, according to the values shown in Figure 174.
EW--2--86
87008
84192
Apply sealant LOCTITE 5205 between cover (3) and
cylinder head, then tighten the screws to the specified
After the reconditioning operations, verify, by means torque.
of base 380001000 (2) and comparator 380001004 Mounting the thermostat unit (2) and brackets (1) and
(1), that valve hollow (3) corresponds to the specified (4), then tighten the screws to the specified torque.
value.
Figure 179
Valve springs
Figure 177
84282
Lubricate the valve stem and insert into the respective
valve guide according to the position marked upon
disassembling.
Mount seal rings (1) onto the valve guide.
84193
Figure 180
MAIN DATA FOR INTAKE AND EXHAUST VALVE
SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of the proper tool. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.
84113 84209
Verify that the cylinder head attaching plane and the Prior to inserting the pushrods, verify their state of
crankcase attaching plane are both clean. preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
Do not spoil the cylinder head gasket. not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
IMPORTANT -- Prior to reusing the cylinder head they are interchangeable.
fastening screws, verify that they do not show Rocker arm assembly
traces of wear or deformations; otherwise, replace
them. Figure 184
84195
87006 84196
Mount the cylinder head on the crankcase by fastening MAIN DATA OF ARBOUR--ROCKER ARM
screws (1) without torque--tightening them. Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--88
84197
84285
Scheme of cylinder head fastening screw tightening
sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201
87012
- Mount exhaust manifold (2).
- Mount turbine (1) by means of screws (3).
- Mount water temperature sensor (4).
86604
The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5205 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
87011
84255
Mount the injector feeding pipe assembly (1). Mount Mount the injection pump (6) injector feeding pipes
the pipes for fuel discharge (2) from injectors, by using (5), then secure brackets (1), (2) and (3) fastening the
gaskets (3) and by tightening screws (4). pipe assembly onto the cylinder head.
Mount priming pump (4).
EW--2--90
84253
87038
- Mount tappet covers (1).
- Mount the starter motor (3).
- Mount container control unit (2).
- Mount turbine lubricating oil return piping (1) with
- Mount fuel filter support (3). its respective fastening bracket (2).
- Mount fuel filter (7). - Mount turbine lubricating oil delivery pipe (7) and
- Attach quick coupling pipes (4), (8) and (10) by fol- engine oil pipes (4) and (5) to water / oil heat ex-
lowing the indications given in Figure 196. changer unit (6).
- Mount electric wiring (5) and (6).
- Mount L.D.A. system piping (9).
- Connect the engine oil vapour recovery pipe to
blow--by (11).
87013
70126
84288
84258
84082
Mount Poli--V belt (5) on pulley (7), drive shaft pulley,
guide pulleys (6), water pump (4) and on alternator
(2); then, stretch the belt by acting on automatic belt Remove injectors (2) by means of tool 380000982 (1)
stretcher (3). and take them off the cylinder head.
EW--2--92
84081
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2).
84201
Remove screws (4) and dismount rocker arm assem-
bly (1) made up of the rocker arm support and ar-
Mount a new seal ring (2) lubricated with petrolatum bours, then take off valves.
and a new seal washer (3) on injector (1). Reassembling
Mount the injectors on their seats on the cylinder Verify that the tappet adjusters are unscrewed to pre-
head, then tighten them by means of a torque wrench. vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
torque of 36 Nm.
Ad just the tappets as described above.
Figure 204
84290
84200
Ad just the play between the rocker arms and the FIRING ORDER 1--3--4--2
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
Adjusting cylinder
1 3 4 2
The operation play is: valve no.
Adjusting clearance
-- ± 0.05 mm of cylinder valve no.
4 2 1 3
– intake valves: 0.25 ± 0.05 mm
-- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
Valve timing
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 207
84210
EW--2--94
Check priming of the injection pump Turn the engine shaft counter clockwise of a few de-
grees and then turn again in the opposite direction un-
til the P.M.S. is determined.
Figure 208
In this position, on the comparator (2) you will read the
pumping element pre--lift value prescribed.
Turn the pump counter clockwise if the stroke is lower,
or clockwise if the stroke is higher until the stroke pre-
scribed is achieved.
Then lock the pump with the fixing nuts to the couple
prescribed.
88141
Turn the engine shaft unit the piston of the 1st cylinder
near the P.M.S. and close the relevant valves (com-
pression stage).
Assemble tool 380000977 (1) and with the compara-
tor (2) in the seat of the injector of the 1str cylinder,
preload the comparator (2).
Figure 209
87720
INDEX
Engine F4BE0684 . . . . . . . . . . . . . . . . . . EW--3--3 Injection assembly with mechanical
Engine coding . . . . . . . . . . . . . . . . . . . . . EW--3--4 on line pump engine F4BE0684B . . . . . . EW--3--39
Main engine features . . . . . . . . . . . . . . . EW--3--5 Injection assembly with rotary pump
engines F4BE0684M . . . . . . . . . . . . . . . . EW--3--39
Torque and rating features . . . . . . . . . . EW--3--6
Engine bench--overhaul . . . . . . . . . . . . EW--3--40
Main engine features . . . . . . . . . . . . . . . EW--3--7
Disassembling the engine . . . . . . . . . . . . EW--3--40
Assembling play -- specifications . . . EW--3--9
Tightening torque . . . . . . . . . . . . . . . . . . EW--3--15 Removing the front seal ring . . . . . . . . . . EW--3--42
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--16 Removing the injection pump . . . . . . . . . EW--3--43
Graphic indications and symbols . . . EW--3--17 Removint the rear seal ring . . . . . . . . . . . EW--3--45
General remarks . . . . . . . . . . . . . . . . . . . EW--3--18 Removing the rocker arm assembly
and cylinder head . . . . . . . . . . . . . . . . . . . EW--3--46
Description of main mechanic
engine components . . . . . . . . . . . . . . . . EW--3--19 Repair work on cylinder cluster . . . . . EW--3--48
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--19 Checks and measurements . . . . . . . . . . . EW--3--48
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--20 Checking the surface supporting
the head on the cylinder cluster . . . . . . . EW--3--49
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--3--20
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--21
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--3--50
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--22
Checking the eccentric lift and the
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--3--23
pin alignment . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--3--24
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--51
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--3--25
Replacing the bushings . . . . . . . . . . . . . . EW--3--52
Valves and valve seats . . . . . . . . . . . . . . . EW--3--26
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--52
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--3--27
Mounting the tappets – Distributing shaft EW--3--52
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--3--28
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--53
Auxiliary component drive . . . . . . . . . . . . EW--3--29
Measuring the journals and crankpins . . EW--3--53
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--30
Replacing the oil pump drive gears . . . . EW--3--56
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--3--31
Mounting the main bearings . . . . . . . . . . EW--3--56
Oil pressure regulation valve . . . . . . . . . . EW--3--31
Measuring the journal assembling play . EW--3--56
By--pass valve . . . . . . . . . . . . . . . . . . . . . . EW--3--31
Checking the drive shaft shoulder play . EW--3--57
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--32
Connecting rod--piston assembly . . . EW--3--58
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--33
Measuring the piston diameter . . . . . . . . EW--3--59
Oil vapour recirculation . . . . . . . . . . . . . . . EW--3--34
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--35
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--3--36 Conditions for correct pin/piston
matching . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--36
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Mechanic injection feeding system . . . . EW--3--37
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--61
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . EW--3--37
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--62
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--37
Checking the connecting rods . . . . . . . . . EW--3--62
Engine F4BE0684B mechanical
feed pump . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Checking the torsion . . . . . . . . . . . . . . . . . EW--3--62
Engine F4BE0684M mechanical Checking the flexion . . . . . . . . . . . . . . . . . EW--3--62
feed pump . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Connecting rod--piston match . . . . . . . . . EW--3--63
Characteristics . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Mounting the piston rings . . . . . . . . . . . . . EW--3--63
INDEX
ENGINE F4BE0684
Figure 1
84034
EW--3--4
ENGINE CODING
F 4 B E 0 6 8 4 B * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 6 = 6--cylinder
Engine
group
4 = Earthmovers
X Y Y Y Y Y Y Y Y
B F4BE0684B F4BE0684M
E 5883 cm3
118 kW
F 2150 min--1
* up to frame Nr. 2831 -- ** from frame Nr. 2832
• up to frame Nr. 0978 -- •• from frame Nr. 0979
G Direct injection
T.A.A.
I (Boosted by intercooler)
A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--3--6
Figure 2
Torque - Nm
Rating - kW
Torque Rating
84277
EW--3--7
Bore mm 102
Stroke mm 120
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
start of opening: °C 81 ± 2
Ambra Master gold HSP REFUELLING
15W40
-- engine sump + filter litres 16.9
10W30
FEEDING VE6/12F
PES 6A
Bosch--type injection 1075 1046
Start of delivery mm 1
Position of pistons --
from crankcase X
--
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Measurement dimension X --
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--7 0.044 to 0.106
n. 2--3--4--5--6 0.039 to 0.111
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
∅1 43.637 to 43.663
∅2 47.063 to 47.089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 1.00 to 1.52
X 1.00 to 1.52
Valve seats --
EW--3--13
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
7.239
EW--3--14
F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
∅2
Outer diameter of
tappet collar:
∅3
∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Tappets --
∅1
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
nd
2 p phase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st pphase 50 ± 6 (5 ± 0.6)
2nd pphase 80 ± 6 (8 ± 0.6)
rd
3 phase 90° ± 5°
Connecting g rod cap g 1st p
p fastening phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
TOOLS
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Joint for pressure control in the cylinders (use with 380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000997 Comparator holding tool for in line injection pump timing, engine F4BE0684B (use with
380001005)
380000998 Manual pump for pressure and depression measuring
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Diesel engine cylinder compression control device
380001084 Comparator holding tool for rotary injection pump timing, engine F4BE0684M (use with
380001005)
380002730 Engine PMS positioning tool
EW--3--17
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
EW--3--18
GENERAL REMARKS
Figure 3
84035
1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump Poly--V drive belt – 6. Automatic belt stretcher – 7. Fixed guide pulley – 8. Damper flywheel –
9. Fixed guide pulley – 10. Diesel oil filters – 11. In--line injection pump (F4BE0684B engine) –
12. Blow--by -- 13. Cold start air heater
EW--3--19
Figure 4
2
7 3
86605
EW--3--20
Drive shaft
It is made of steel and rests on seven induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
Inside the drive shaft are the lubricating oil ducts. wheel mounting hub.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley. The penultimate main half bearings are equipped
with a shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 5
84037
1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear --
4. Flywheel attachment hub
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 6
84038
EW--3--22
Pistons
Figure 7
84039
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1° and 2°, trapezoidal in shape and with
Three slots (piston ring seats) are provided: the first ceramic chrome coating.
one and the second one are obtained from a cast-- Piston ring 3°, with double scraper ring shoe with
iron insert with trapezoidal section. inner spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 8
84040
EW--3--23
Distributing shaft
The distributing shaft rests on seven supports in the A. Intake valve control
crankcase.
B. Exhaust valve control
The rear support has a steel bushing lined with anti--
friction material, assembled with interference: there The distributing shaft is controlled directly by the
are 2 control eccentrics for each cylinder. drive shaft by means of straight--tooth gears.
Figure 9
70164
84041
EW--3--24
Valve control
Figure 10
84042
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--3--25
Cylinder head
The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injectors (6); - intake manifold (2) with seat for cold start air
- thermostat (5); heater (3).
Figure 11
84043
84044
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 13
84045
Valve guides
Figure 14
INTAKE EXHAUST
84046
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 15
84047
Figure 16
84048
Figure 17
84049
1. Water pump -- 2. Alternator -- 3. Automatic belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan
pulley
EW--3--30
Lubrication
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the engine
lowing components: crankcase, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure control valve built into the oil filter
case front part, controlled by the straight--tooth adapter;
gear force--fitted on the drive shaft shank; - by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.
Figure 18
84050
Heat exchanger
Figure 19
84051
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter
107419 70482
Oil pump
Figure 22
84052
Figure 23
70150
Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2), fitted onto the oil
case by means of an aluminium plate (3), Figure 25. sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 24
84054
Figure 25
84055
The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--3--34
Figure 26
114063
EW--3--35
Cooling
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components:
- heat exchanger, used to cool the lubricating oil; - thermostat, used to regulate coolant flow.
Figure 27
84057
Water recirculating
EW--3--36
Figure 28
79458
84058
Figure 29
84059
EW--3--37
84060
Fuel filters
The support (2) incorporates: fuel temperature sen- Maximum working pressure: 5 bar.
sor (1), heater resistors (4), air bleeding screws (3) Working temperature: --25 °C to + 90 °C.
and filter (5).
Degree of filtration of cartridge: 10 micron.
Figure 32
84061
EW--3--38
Figure 33
84062
1. Injection pump -- 2. Fuel outflow to the filter -- 3. Fuel pump -- 4. Fuel inflow from the tank --
5. Manual control lever
Volumetric pump, assembled on the left side of the Priming at 60 rpm : max 28 cycles
engine, supplies the injection pump. It is controlled Unitary displacement 60 rpm: ∼10 cm3
by the camshaft. Static pressure at 1800 rpm: 0,47÷0.61 bar
Minimum capacity at 600 rpm: 111.3 L/h
Minimum capacity at rpm: 127.3 L/h
Figure 34
84250
84063
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Injector 5
fuel pipe -- 6. Injector 6 fuel pipe -- 7. Pipe for fuel discharge from injectors -- 8. Connector for pipe
measuring the pressure inside the L.D.A. intake manifold -- 9. Injection pump -- 10. Injector
86495
ENGINE BENCH--OVERHAUL
Disassembling the engine
- Disconnect electric wiring; - for engine F4BE0684B
- drain the engine oil by taking the cap off the sump disconnect injector feed pipes (7) from injection
and the oil filling cap off the head cover; pump (9); remove the brackets fastening pipe (2),
(5) and (15) unit on the cylinder head;
- fit bracket 380000995 (which fastens the engine
to the overhaul stand) to the crankcase; - for engine F4BE0684B
take off injection pump (10) lubrication pipes;
- disconnect the engine oil vapour recovery pipe
from blow--by (4); - disconnect quick--coupling pipes (8) and (14) by
following the indications given in Figure 39;
- take off tappet covers (6);
- take off fuel filters (12);
- take off intake manifold unit (1);
- for engine F4BE0684B - take off fuel filter support (13).
disconnect the piping from L.D.A. system (3); - take off oil level check piping (11).
Figure 37
84064
Figure 38 Figure 40
88142 84065
For engine F4BE0684M In order to be able to fit bracket 380000995 to the en-
- Disconnect the pipes (1) of the LDA from the gine crankcase on the right side, it is necessary to re-
head and from the supply pump; move:
put the plugs on the pipe ends, on the supply - the starter motor (3);
pump and on the engine block. - the bracket (2) fastening the oil return pipe (1);
- Disassemble the pipes (2) that constitute the - the oil return piping (1) relative to turbine;
supply and recover fuel between the pump and
the injectors. - oil pipes (4) and (5) from heat exchanger unit (6).
- take off turbine lubrication delivery pipe (7);
Secure the engine to rotary stand 380000978.
Figure 39 Figure 41
84066
70126
Figure 45
87039
Figure 43
84070
Take off water / oil heat exchanger unit (2) with oil
pipe adapter (1).
Figure 44
78256
Figure 47 Figure 49
78257
Apply the proper tension rod (3) of tool 380000996 to 84071
outer seal ring (2) as shown in the figure, then take the Such condition is obtained when (after removing the
same off front cover (1) by means of lever (4). closing plug), by pushing pin 380002730 (1) shown by
Remove the front cover. the arrow, it is housed in its own seat obtained on dis-
tributing shaft drive gear (2).
Figure 50
Figure 48
84072
Only F4BE0684B engines
To correctly preset the injection pump prior to remov-
84237 ing it, loosen screw (2), take out the timing pin (1),
Remove screws (1) and take off gear oil pump. turn it upside down and insert it again until the pump
shaft is locked.
Fasten again screw (2).
Figure 51
IMPORTANT -- Oil pump (1) cannot be recondi-
tioned.
84073
Figure 52 Figure 54
84072
84075
Figure 53 Apply tool 380000990 (2) to unlock screws (3).
Remove tool 380000990 (2).
Remove screws (3) fastening engine flywheel (4) to
the drive shaft.
Figure 56
2 1
88148
Figure 57
84077
78258
IMPORTANT -- Take note of the mounting position
Apply tool 380000981 (3) on drive shaft rear shank of screws (2), due to the different size of the latter.
(5).
Drill inner seal ring (1), through tool 380000981 (3) Figure 60
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by screwing the
six screws (4) provided.
Take off ring (1) by fastening screw (2).
84078
Figure 58
86517
Figure 62 Figure 65
84081
86516
For each cylinder, remove rocker arm assembly (1),
Engines: F4BE0684B*401 -- F4BE0684M*D602 loosen adjusting nuts (3), unscrew registers (2) and
Remove screws (1) and (4) and dismantle oil suction remove screws (4).
strainer (5).
Remove screws (2) and dismantle stiffening plate (3).
Figure 63 Figure 66
70156 87040
Remove screws (1) and take gear (3) off distributing Remove screws (1) securing the head to the crank-
shaft (2). case.
Removing the rocker arm assembly and cylin-
der head Figure 67
Figure 64
87041
84082
Hook the wire ropes to brackets (1) and (2), then sep-
arate the cylinder head from the crankcase by means
Take out injectors (2) by means of tool (1) 380000982. of a hoist.
EW--3--47
Figure 68 Figure 71
84085 70160
Remove screws (2) and take off timing gear case (1). The penultimate bed cap (1) and its respective sup-
port have half bearing (2) provided with shoulder.
IMPORTANT -- Take note of the mounting position IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in the
Figure 69 same position they had prior to being taken off.
Figure 72
70158
Remove connecting rod cap (2) fastening screws
(1), then take off the caps.
Remove the pistons (complete with connecting 84086
rods) from the crankcase upper part.
Remove drive shaft (2) from crankcase by means of
tool 380000992 (1) and a hoist.
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be
used again, they must be mounted in the same
position they had prior to being taken off. Figure 73
Figure 70
70162
70159
Remove screws (1) and take off bed caps (2). Take off main half bearings (1).
Remove screws (2) and take off oil nozzles (3).
EW--3--48
70163
Figure 75
84087
70165
70167
Figure 79
84088
Valve gear
Distributing shaft
Figure 81
84089
70171
Bushings Figure 83
The distributing shaft bushing (2) must be force--fitted
into the respective seat.
The inner surface must show no traces of seizing or
wear.
With the borer (3) measure the diameter of the rear
bushing (2) and the seat (1) of the camshaft.
Measurements must be taken on two axes perpen-
dicular to each other.
70172
Figure 84
sec. A-A
107268
70174 70164
To disassemble and reassemble the rear bushing Rubricate the camshaft support bushing and as-
(1) when it needs to be replaces use beater semble the camshaft avoiding to damage the bushing
380000991 (2) with the handgrip 380000999 (3). and the seats of the support while operating.
Tappets
Figure 86
84053
MAIN FEATURES OF TAPPETS AND THEIR RE-
SPECTIVE SEATS ON THE CRANKCASE Figure 89
Mounting the tappets – Distributing shaft
Figure 87
70238
Figure 92
70179
70182
70180
IMPORTANT -- Journals and crankpins must al-
Mount nozzles (2) and tighten fastening screws (1) to ways be ground to the same reduction class.
the specified torque. The reduction carried out on journals and crank-
pins must be marked with a special stamping made
on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
EW--3--54
Figure 93
84090
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--3--55
Figure 94
84091
Figure 95
84275
EW--3--56
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 96 Figure 98
70184 84092
Verify that the teeth of gear (1) are not damaged or Mount drive shaft (1).
worn; otherwise, proceed with removal by means of Check the play between the drive shaft journals and
a suitable extractor (3) foce--fitted on drive shaft (2). their respective bearings by following the procedure
When fitting the new gear, the latter must be heated below:
for 10 minutes in a small furnace at a temperature of
180 °C and force--fitted onto the drive shaft by putting
the key in between.
Figure 99
70185
70187 70189
Fasten pre--lubricated screws (1) by tightening them - take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
Figure 101
70190
Figure 104
70191
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000221 (3). moved by means of a mark scraper (3).
EW--3--59
Figure 107
84095
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
84097 84100
Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 111
Figure 114
84098
Piston rings
Figure 112
84101
70194
CONNECT- WEIGHT
Connecting rods
Figure 116
70196
Figure 118
61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ~ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.
61696
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--3--63
Figure 121
72705
Figure 122
84093
70200 84040
Mount half bearings (1) both on the connecting rod SCHEME FOR MOUNTING THE CONNECTING
and the cap. ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
IMPORTANT -- If connecting rod bearings do not by 120°;
need replacing, they must be fitted in the same - all the connecting rod/piston assemblies weigh
order and positions they had prior to being taken the same;
off. - the writing stamped on the piston crown faces the
No matching operation must be carried out on half crankcase front side, or the notch obtained on the
bearings. piston skirt corresponds to the position of oil nozz-
les.
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 128
Figure 126
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4).
EW--3--65
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a 70207
torque wrench (2); If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
Figure 130 screws as described.
IMPORTANT -- Prior to mounting the connecting
α rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.
70205
70206 70208
- take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane. Said protrusion
must be 0.28 to 0.52 mm.
EW--3--66
70211
Figure 138
84106
2 1
88148
Figure 142
84112
84110
70216
84111 84075
Replacing the engine flywheel ring gear Apply tool 380000990 (2) to the flywheel cover case
(1) to stop engine flywheel (3) rotation.
Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear Tighten screws (4) fastening engine flywheel (3) to
from the engine flywheel (1, Figure 146) by using a the drive shaft.
normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.
Figure 149
Figure 147
84114
Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 153
Figure 150
84115 70220
Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 151
Figure 154
84116
Apply sealant (1) as shown in the figure, then put on
small cover (2), then tighten screws to the specified 70221
torque.
Apply a new seal ring (2) onto water pump (1).
Figure 152
Figure 155
84072
IMPORTANT -- Always check the direction of in- Mount water pump (1). Fasten screws (2) and tighten
sertion of the timing pin. them to the specified torque.
EW--3--71
70223
70225
Take seal ring (2) off front cover (1), clean thoroughly Apply part (5) of tool 380000983 on drive shaft front
the attaching surface and apply sealant LOCTITE shank (6), secure it by means of screws (4) and force--
5205 onto the same. fit the new seal ring (3) onto the same. Position part
(1) on part (5), then screw nut (2) to fully mount seal
ring (3) in front cover (7).
Mounting the oil sump
Figure 159
Figure 157
86517
70224
86516
Clean thoroughly the surface of front cover (2) attach- Engines: F4BE0684B*D401 -- F4BE0684M*D602
ing base, then mount front cover.
Mount plate (3) and strainer (5), then screw down
Fasten screws (1) and tighten them to the specified fastening screws (2) and (4) and tighten them to the
torque. specified torque.
EW--3--72
84117 84174
Place gasket (1) on oil sump (2). Force--fit pulley (3) with damper flywheel (4) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (1) and (5) to the front cover by
means of screws (2) and (6) and tighten them to the
specified torque.
Figure 162
84118
Mount oil sump (1) and apply plate (3) on the same.
Fasten screws (2) and tighten them to the specified
torque.
Screws:
- M10 x 1.50 x 90 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 190 70 ± 5 Nm
- M10 x 1.50 x 125 70 ± 5 Nm
84175
NOTE – On engines:, F4BE0684B*D402 -- Mount the following items on the crankcase: a new
F4BE0684M*D600 the oil sump is to be assembled gasket (1), heat exchanger (2), a new gasket (3), and
on a rotated position of 180° in relation to the one oil filter support (4). Fasten screws (5) and tighten
shown on the figure. them to the specified torque.
EW--3--73
Figure 168
84176
Place a new seal ring (3) in the crankcase housing. Valves can be removed by means of tool 380000987
(1) by pressing slightly on collar (3) so that lock cones
Figure 166 (2) can be removed by compressing springs (4). Then
remove collar (3) and springs (4).
Repeat the operation on all valves.
84177
Position alternator support (1) in such a way that pins
(3 and 4) are placed against the engine crankcase. Figure 169
Fasten screws (2) and tighten them to the specified
torque.
Figure 167
87042
INTAKE EXHAUST If leaks are detected from the cylinder head, the latter
84181
must be replaced.
In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are Figure 173
equipped with a supplementary notch (1) obtained on
the stem for intake valves.
Figure 171
87044
84183
84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns. INTAKE EXHAUST
Reface, if necessary, the valve seats by means of
grinder, by removing as less material as possible. 84046
84187
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). If slight burns or scoring are
parator (1) placed as shown. Assembling play must found, proceed with reconditioning by means of the
be equal to 0.039 to 0.079 mm. proper tool (1) according to the inclination values
Check, by making valve (2) rotate, that the centring shown in Figure 180.
error is not greater than 0.03 mm.
EW--3--76
Figure 180
EXHAUST INTAKE
87009
Figure 181
EXHAUST INTAKE
87010
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool (1, Figure 179) and taking care not to indent the cylinder head, remove as much material
as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of the proper tool, according to the values shown in Figure 180.
EW--3--77
84192
of base 380001000 (2) and comparator 380001004 Apply sealant LOCTITE 5205 between cover (3) and
(1), that valve hollow (3) corresponds to the specified cylinder head, mounting the cover, then tighten the
value. screws to the specified torque.
Mounting the thermostat unit (2) and brackets (1) and
(4), then tighten the screws to the specified torque.
Valve springs
87042
87040
84179
Position spring (4) and upper collar (3) on the cylinder Mount the cylinder head on the crankcase by fasten-
head: use tool 380000987 (1) to compress spring (4) ing screws (1) without torque--tightening them.
and link the parts to the valve by means of lock cones
(2). Figure 189
84209
84113
84196
84199
MAIN DATA OF ARBOUR--ROCKER ARM
Scheme of cylinder head fastening screw tightening
Verify that the arbour/rocker arm matching surfaces sequence:
do not show excessive wear or damages.
- 1st phase: pre--fastening by means of a torque
wrench:
Figure 192 screw M12 x 1.75 x 70 [ ] 50 Nm ± 5 Nm;
s
Figure 195
84197
Figure 193
87037
Ad just the play between the rocker arms and the
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
The operation play is:
-- intake valves: 0,25 ± 0,05 mm
-- exhaust valves: 0,50 ± 0,05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--6, 2--5 and 3--4.
FIRING ORDER 1--5--3--6--2--4
Adjuting cylinder
1 5 3 6 2 4
87036 valve no.
Fasten the head screws (1) according to the instruc- Adjusting clearance
6 2 4 1 5 3
tions given Figure 194. of cylinder valve no.
EW--3--80
87046
87047
- Mount exhaust manifold (3).
- Mount turbine (1) by means of screws (2).
- Mounting water temperature sensor (4).
87045
The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5205 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
EW--3--81
Figure 200
87048
EW--3--82
84065
- Mount starter motor (3).
88142
- Mount turbine lubricating oil (1) return pipe with its
respective fastening bracket (2).
For engine F4BE0684M
- Mount turbine lubricating oil (7) delivery pipe and
- Connect pipes (1) for the LDA from the head and engine oil pipes (4) and (5) to water/oil heat ex-
from the feed pump. changer (6).
- Assemble the pipes (2) that constituted feed and
recovery of fuel between the pump and the injec- Figure 204
tors.
87049
Figure 205
70126
84204
Act on fork (1) as shown in the figure (detail A), then Mount fan pulley (2) with spacer (5) on support (1) by
remove the adapter. To avoid deformations, bring fork torque--tightening screws (3).
(1) back to the locking position (detail B) after the Mount fan (4) on spacer and torque--tighten the
adapter has been removed. screws.
EW--3--83
84205 84082
Mount Poli--V belt (1) on fan pulley, drive shaft pulley, Remove injectors (2) by means of tool 380000982 (1)
guide pulleys, water pump and on alternator; then, and take them off the cylinder head.
stretch the belt by acting on automatic belt stretcher
(2).
Reassembling
Replacing the injectors Figure 209
Removal
Figure 207
84206 84201
Place the vehicle in safe conditions. Mount a new seal ring (2) lubricated with petrolatum
Lift the engine compartment cover, disconnect the and a new seal washer (3) on injector (1).
battery cables and proceed as follows: Mount the injectors on their seats on the cylinder
- disconnect engine oil vapour recovery pipe (2) head, then tighten them by means of a torque wrench.
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
EW--3--84
Mount new seal rings (1) on fuel manifolds (2). Reassemble the tappet cover.
Connect the manifolds to the injectors, by tightening Re--connect the engine oil vapour recovery pipe to the
the fastening nuts to a torque of 50 Nm. blow--by.
Figure 210
84208
EW--3--85
84200
84081
Ad just the play between the rocker arms and the Loosen tappet adjuster fastening nuts (3), then un-
valves by means of an Allen wrench (2), box wrench screw adjusters (2).
(3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem-
The operation play is: bly (1) made up of the rocker arm support and ar-
-- ± 0,05 mm bours, then take off valves.
– intake valves: 0,25 ± 0,05 mm Reassembling
-- exhaust valves: 0,50 ± 0,05 mm. Verify that the tappet adjusters are unscrewed to pre-
Take the cylinder where clearance must be adjusted vent the latter from crawling on the rods when the
to the bursting phase; its valves are closed while bal- rocker arm assembly is mounted.
ancing the symmetric cylinder valves. Mount the rocker arm assemblies made up of rocker
Symmetric cylinders are 1--6, 2--5 and 3--4. arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
FIRING ORDER 1--5--3--6--2--4 torque of 36 Nm.
Adjuting cylinder Ad just the tappets as described above.
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
of cylinder valve no.
Valve timing
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 213
84210
EW--3--86
Check priming of the injection pump Check priming of the injection pump
(F4BE0684M engine only) (F4BE0684B engine only)
Figure 214 Figure 216
88141 88141
Turn the engine shaft unit the piston of the 1st cylinder Turn the engine shaft unit the piston of the 1st cylinder
near the P.M.S. and close the relevant valves (com- near the P.M.S. and close the relevant valves (com-
pression stage). pression stage).
Assemble tool 380000977 (1) and with the compara- Assemble tool 380000977 (1) and with the compara-
tor 380001005 in the seat of the injector of the 1str cyl- tor 380001005 in the seat of the injector of the 1str cyl-
inder, preload the comparator (2). inder, preload the comparator (2).
Figure 215 Figure 217
87720 90636
With the injection pump inserted in the relevant seat Once the injection pump is correctly positioned and
and the fixing screws loosened, assemble the the locking screws are loose, remove the side cover.
comparator holding tool 380001003 (1), supplied with Mount the gauge 380001005 (2) on the No. 6 pumping
comparator 380001005 (2), preloading the rod of 2.5 element and the No. 380000997 gauge tool (1) and
mm. pre--load the 2.5--mm rod.
Turn the engine shaft properly in order to determine Turn the engine shaft properly in order to determine
the exact PMS of the piston of the 1st cylinder and of the exact PMS of the piston of the 6th cylinder and of
the injection pump pumping element, zero the the injection pump pumping element, zero the
comparators (2, Figure 214 e 2, Figure 215). comparators (2, Figure 216 e 2, Figure 217).
Turn the engine shaft counter clockwise of a few de- Turn the engine shaft counter clockwise of a few de-
grees and then turn again in the opposite direction un- grees and then turn again in the opposite direction un-
til the P.M.S. is determined. In this position, on the til the P.M.S. is determined. In this position, on the
comparator (2) you will read the pumping element comparator (2) you will read the pumping element
pre--lift value prescribed. Turn the pump counter pre--lift value prescribed. Turn the pump counter
clockwise if the stroke is lower, or clockwise if the clockwise if the stroke is lower, or clockwise if the
stroke is higher until the stroke prescribed is stroke is higher until the stroke prescribed is
achieved. achieved.
Then lock the pump with the fixing nuts to the couple Then lock the pump with the fixing nuts to the couple
prescribed. prescribed.
SECTION 4
INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--4--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--4--5
STARTER MOTOR
BOSCH -- 24 V -- 4 kW
Quick diagnosis
Bosch 24 V -- 4 kW
6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
84262 84267
84268 84269
ALTERNATOR
Quick diagnosis
84270 84271
84272 84274