Documente Academic
Documente Profesional
Documente Cultură
TIER 3
Agricultural application
F4CE9484F*J600
Produced by:
Introduction
Page
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . 7
SYMBOLS - Warnings
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
Example
Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to
! contact immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and
on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on
harmful materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes,
free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting
fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to
store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable
substances into suitable containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil
spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 16-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis
bonding) and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other
materials flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections,
which would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or
special truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of
cable side.
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
Figure 2
88039
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F
Part 1
SERIE N F4CE
Section
General specifications 1
Fuel 2
G-Drive applications 3
Tools 5
UPDATING
SECTION 1
General Specifications
Page
SCHMIERUNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 1
Figure 2
3240t
COOLING SYSTEM - heat exchanger to cool the lubrication oil: even this
component is part of the engines specific equipment.
The engine cooling system, closed circuit forced circulation type,
generally incorporates the following components: - centrifugal water pump, placed in the front part of the
- expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engines equipment. - thermostat regulating the circulation of the cooling
- radiator, which has the duty to dissipate the heat liquid.
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the - the circuit may eventually be extended to the
compressor, if this is included in the equipment.
equipment developed, both for what concerns the
placement and the dimensions.
- visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
well will be specifically equipped based on the engines
development.
Figure 3
TO RADIATOR
FROM
RADIATOR
Figure 4
EXHAUST
RADIATOR
74195
4 cylinders version
Description
Boost feeling system consists of one air filter, one The turbocharger is equipped with a transforming valve to
turbocharger and a radiator. regulate the pressure , that is located on the exhaust
The turbocharger is composed by the following main parts: collector before the turbine and connected by piping to the
one turbine, one transforming valve to regulate the boost induction collector.
feeding pressure , one main body and one compressor.
Its duty is to choke the exhaust of the emissions , releasing
During engine working process, the exhaust emission flow
part of them directly to the exhaust tube when the boost
through the body of the turbine, provoking the turbine disk
feeding pressure, over the compressor, reaches the
wheels rotation.
prescribed bar value.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates, The cooling process and the lubrication of the turbocharger
compressing the sucked air through the air filter; the above and of the bearings is made by the oil of the engine.
mentioned air is then cooled by the radiator and flown
through the piston induction collector.
SECTION 2
Fuel
Page
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General information
Fuel feed system is composed by:
- Fuel tank (placed on the machine)
- Fuel delivery and back-flow to tank
- Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
- Priming pump, assembled to the engine and driven by the camshaft
- Fuel filter (assembled to the engine in different positions according to equipment application and duty)
- Fuel feed rotary pump
- Injector feed pipeline (from fuel feed pump to injectors)
- Injectors
Figure 1
2
1
4
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
Figure 2
87401
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump
Description of working principles The fuel arrives therefore to the valve gauging the pressure
inside feed pump.
Fuel is sucked from the fuel tank by the priming pump. This The distribution plunger further increases this pressure and
last one is placed on the engine basement and is driven by delivers fuel throughout the delivery pipe fitting to the
the camshaft. injectors.
Throughout the filter, the fuel is piped to the union fitting The fuel drawing from the injectors is recovered and
vacuum chamber of the transfer pump. (For applications to delivered to the tank again.
be equipped in cold climate areas, the fuel filter is provided
with heater).
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
Example of identification
V = Distribution rotary plunger
E = Pump dimensions
4 = 4 cylinders engine (3 for three-cylinder engines, 6 for six-cylinder engines)
12 = Distribution plunger in mm
1150 = N. of pump revolutions per minute
LV = Left direction of rotation
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
Injection pump longitudinal section
1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk -
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 4
84249
1. Fuel output to the filter - 2. Drive lever - 3. Fuel inlet from the tank.
Figure 5
88209
Figure 6
88210
Figure 7
88211
SECTION 3
Industrial application
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
- Version equipped with mechanical feed pump 3
- Clearance data . . . . . . . . . . . . . . . . . . . . . . . . 4
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . 31
PART TWO -
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . 33
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Page
MAINTENANCE PLANNING . . . . . . . . . . . . . . 51
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MAINTENANCE PROCEDURES . . . . . . . . . . . . 52
GENERAL INFORMATION
Version equipped with mechanical feed pump
Figure 1
88212
Clearance data
Type F4CE9484F*J600
74
Max. output kW
(100)
(HP)
rpm
2200
Loadless engine
idling rpm
900 100
Loadless engine
peak rpm rpm
2430 50
Bore x stroke mm 104 X 132
Displacement cm3 4485
COOLING Liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
engine sump*
URANIA LD7
liters 8,5 1,5
ACEA E5/E7
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
PART ONE -
ECHANICAL COMPONENTS
NOTE For specific application exigencies, some units can - Disassemble the starter;
be assembled to the engine in different positions. Properly hold the starter (2) and loosen the fixing screws
(1);
assemble the supporting bracket using the threaded
Within General overhaul section, all the operations of ports on the basement.
engine block overhaul have been contemplated. Therefore
the above mentioned section is to be considered as following
the part hereby described.
Engine setting operations for the assembly on Figure 3
turning stand
Figure 1
88215 88216
75675
2
Figure 7
1
87404
- Place a container under the fuel filter and screw out the - Disconnect the LDA pipe (1) from the head and from
condense drain faucet underneath said filter. Carry out the feed pump. Pipe the ends of the pipelines as well as
complete drainage of the fuel contained therein. the feed pump and the engine head.
- Screw out completely the faucet and, using equipment
99360076 disassemble fuel filter (1).
- Disconnect fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to
the feed pump.
- Remove the fuel filter bearing from the bracket fixed to
the engine head.
Base - July 2010 Print P2D32N013 E
SERIE N F4CE SECTION 3 - INDUSTRIAL APPLICATION 9
Figure 8
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate)
Figure 9 Figure 10
88218 88102
- Disconnect the pipelines (1) and (2) that provide feed - Loosen the two fixing screws (2) and disassemble
and fuel recovery between pump and injectors; screw priming pump (1).
out the nuts fixing the pipes to the pumping elements;
loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipeline;
loosen the screws holding the fixing brackets of such
pipelines (1,6, and 7, NO TAG); pipe the pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.
Figure 11 Figure 13
1 2 2
1
75683
- Disassemble rocker arm bearings; loosen the two fixing
screws (2) and remove the complete rocker arm bearing;
withdraw tappet rods. Repeat the operation for all the
remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
Figure 14
75681
Figure 15
87409
Figure 16 Figure 18
117593 88219
- Disassemble thermostat unit; loosen the three fixing - Loosen the fastening screws (4) and remove the oil filter
screws (1), disassemble the thermostat unit (2). support (5), together with the sheaths (1) and (3) and
Remove the gasket (3) and the thermostat (4). the heat exchanger (2).
- Disassemble the ignition pump (see the specific
procedure) and the power takeoff underneath (if
available).
Figure 17 Figure 19
88231 88220
- Loosen the screws (1) and withdraw the alternator - Loosen the fastening screws (3) and remove the pulley
bearing (2). controlling the fan (2).
- Proceed detaching the support (1).
Figure 20 Figure 22
1 1 2
75688
4 3
75689
Figure 23
Figure 21
00900t
123031
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
- Apply tool 99360339 (1) on the flywheel housing cover front tang (2) of the engine drive shaft. Throughout the
to block rotation of the flywheel (3) using a spanner on tool guide ports, drill the internal holding ring (1) using
the nut (2) and a pin (4). (use the stud bolts and the nuts 3,5 mm drill for a 5mm depth. Fix the tool to the ring
fixing the starter motor). tightening the screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
- Loosen the flywheel fixing screws to engine drive shaft. (3).
Figure 24 Figure 26
88214 87420
- Using the specially provided tie rod (3) for the tool - Screw out the opposite screws (1) from the ports and
99363204 and the lever (4), withdraw the external introduce the withdrawal pins (see picture following).
holding ring (1) from the front cover (2).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (2).
- Remove the flywheel block tool (2).
Figure 25 Figure 27
87419
- Loosen the screws (2) and remove the front cover (1)
and relating gasket. 87421
Figure 28 Figure 30
87423
00903t
- Turn the engine upside-down.
- Remove the flywheel cover box fixing ring using the tool - Loosen the screws (2), remove the oil pan(1) recovering
99340056 (3) to operate on the back tang (5) of the the gasket.
engine drive shaft. Throughout the tool guide ports, drill
the internal holding ring using 3,5 mm drill for a 5mm Figure 31
depth.
- Fix the tool 99340056 (3) to the ring (1) tightening the
screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Figure 29
88221
87422
87655
NOTE Take note of the screw (1) assembly position, since
the screws have different length.
- Remove the gear (1) transmitting motion to the ignition
pump and the relevant support.
Base - July 2010 Print P2D32N013 E
SERIE N F4CE SECTION 3 - INDUSTRIAL APPLICATION 15
Figure 33 Figure 36
87652
- Orient the engine drive shaft (3) and the camshaft (4)
87656
ensuring that while assembling the conveyed gear (1)
Undo the screws (1) and extract the PTO gear (2). on the latter, the marks printed on the gears (1 and 2)
coincide.
Figure 34
Figure 37
87424
- Remove power take-off (if available). - Place the dial gauge (1) on the timing gear (2) and check
Installation of application components that the slack between the gears (2) and (3) is included
Figure 35 in the range between 0,076 0,280 mm.
Figure 38
70211
- With a pen marker, mark the tooth (1) of the driving gear
assembled to the engine drive shaft with (2) () timing
notch.
87654
NOTE Screw up two pins to facilitate operation of engine
drive shaft rotation. - Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
Figure 39
NOTE It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order to
form a kerbstone of a few mm. Diameter. It must be
uniform (no crumbs), with no air blisters, thinner or
irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
After having completed seal application, the joints
must be immediately assembled (10-20 minutes
time).
87655
Figure 42
- Spline the gear (1) transferring motion to the ignition
pump.
Figure 40
87658
Figure 41
87659
- Apply to the rear tongs hold (3) of the engine drive shaft
the part (6) of the tool 99346253, fix it with the screws
(1) and spline the new tight ring to it (2).
87657
- Place the part (5) on the part (6), tighten the nut (4)
until tight ring assembly (2) into the flywheel box is
DIAGRAM SHOWING SEALING LOCTITE 5205 completed.
APPLICATION
Base - July 2010 Print P2D32N013 E
SERIE N F4CE SECTION 3 - INDUSTRIAL APPLICATION 17
Figure 44 Figure 47
87663
87660
Tighten the engine flywheel (1) fixing screws (2) in two phases:
- Check the laying surface (1) of the clutch disk: if it is - 1st phase; tightening by means of dynamometric wrench
scratched proceed with facing. to couple 30 4 Nm;
- Check the tooth conditions of the toothed rim (2), - 2nd phase, 60 5 angle dwell.
replace it in case of broken tooth or excessive wear. Fit
the new one, previously heated at the temperature of NOTE Angle dwell shall always be performed using
150 C for 1520. 99395216 tool.
Before assembly, always check that the threads of
Figure 45 the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 48
87661
Figure 49
87662
Figure 50 Figure 53
88223 87666
- Fit part (4) of the tool 99346252 on the front tang (3)
- Introduce the pin into the port (B) of the additional mass of the engine drive shaft; fasten it with the screws (5) and
unit to temporary stop the rotation. spline the new tight ring on it (6).
- Fit part (1) on part (4), screw-tighten the nut (7) until
the assembly of the tight ring (6) into the front cover (2)
is completed.
Figure 51
Figure 54
88224
- Fit the additional masses (2) and tighten the screws (3)
88225
to the prescribed pair on the basement.
- Remove the locking pin (1) from the additional masses. - Spline the pulley (2) on the engine drive shaft and tighten
the screws to the prescribed pair and angle (1).
Figure 52
Figure 55
87665
Figure 56 Figure 59
87668 87676
- Assemble the water pump (1). - Fit the bracket (1) back to fix the alternator (2) to the
engine basement. Tighten the screws (3) fastening the
- Tighten the screws (2) and lock them to the prescribed
alternator to the support.
couple.
Figure 57 Figure 60
88219
88231
- Fit the alternator support (1) and tighten the screws (2)
fastening them to the prescribed pair.
D2 D1
75703
Figure 62
Figure 63
1
3
2
2
1 3
88226 75705
- Fit the sheath and the cylinder head on the block and - Carry out the assembly of the rocker arms after previous
insert the fastening screws as indicated in the scheme. check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms- - 4. Support.
Figure 64 Figure 67
18.975
18.963
D2 D1
75704 - Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice
SHAFT AND ROCKER ARM BASIC DATA as indicated in the picture, checking D1 and D2
Check the coupling surfaces of bearing and shaft: no evidence diameters:
of excessive wear shall be detected or damages. if D1 - D2 < 0,1 mm the screw can be utilised again;
Replace if necessary. if D1 - D2 > 0,1 mm the screw must be replaced;
Figure 65
Figure 68
19.00
16.00
75702
Figure 66
123031
122587
Find the top dead centre with the tool (99395097) - False Adjusting the rocker arm clearance
injector Figure 71
Figure 69
2 1
75806
Adjust the play between the rocker arms and valves using a
1 hex key (1), polygonal key (3) and feeler gauge (2).
Play is:
- intake valves: 0.25 0.05 mm
88141
- exhaust valves: 0.50 0.05 mm
To find the top dead centre position of the cylinder, end of
compression stage: Figure 72
- remove the cover of the cylinder rocker arms;
- remove the injector and position tool 99395097 (1);
- preload the dial gauge.
To obtain this condition, turn the crankshaft to the dial
gauges maximum reading; check that the cylinders intake
and exhaust valves are both closed, and not balanced.
Figure 70
1
75707
- Assemble injectors after having replaced the sealing
gasket (1).
Figure 73
130200
IFIRING ORDER: 1 3 4 - 2
Figure 74 Figure 76
1 2
87677
Figure 77
75681
Figure 75
Figure 78
117593
88220
NOTE The gasket (3) must be new.
- Assemble the fan pulley (2) to the support (1)
throughout the screws (3) tightening them to the pair.
Figure 79 Figure 81
88228
Figure 80
88229
Figure 82
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side - 7. Front bracket fixing
screw (on suction collector plate).
Figure 83
88218
Figure 84 Figure 86
70126
Figure 85
4 Figure 87
3 1
87404 75675
- Assemble the fuel filter bearing (4) to the bracket fixed Proceed assembling the turbocharger:
to the engine head. - Hold the turbocharger and place it on the exhaust
- Connect the fuel pipelines (2 and 3) respectively from manifold after having interposed the gasket.
priming pump to filter bearing and from this last one to - Screw up the fixing nuts of the turbocharger to the
feed pump. exhaust manifold tightening them to the prescribed
- Using 99360076 equipment assemble fuel filter (1). couple.
- Tighten the lubrication pipe fixing ring. Operate in the
same way on the other end of the pipe. Connect it to
NOTE The filter shall be priory filled with fuel to facilitate the upper part of the heat exchanger.
feed system bleed operations.
For the versions requiring it, connect the electrical To complete engine assembly it is necessary to remove it
connections of the sensor detecting presence of from the turning stand.
water, and of the heater.
- Using rocker arm 99360595 hold the engine and loosen
the screws fixing the brackets to the turning stand
99322205.
- Disassemble the brackets from the engine after having
properly put it on a wooden bearing.
Figure 88
88215 87712
Rotary feed pump disassembly and assembly Search for top dead center throughout tool 99360339
procedure
Figure 91
NOTE This procedure prescribes that:
- The fuel pipelines (from pumping elements to
injectors, bleeding recovery pipes from
injectors to pump, LDA pipeline and feed
provided by priming pump) shall all be
disassembled.
- Electrical connection to feed pump shall be
disconnected.
- Accelerator cable shall be disconnected.
Figure 90
Search for top dead center throughout tool 99395097 -
False injector
Figure 92
87712
Remove the first injector, fit the tool 99395097 (2) and the
relevant dial gauge 99395604 (1) and remove the tappet
cover (3).
Apply tool 99360339 (see Figure 91) in order to make the
engine shaft rotate.
The condition of 1st cylinder to TDC at end of compression
phase is obtained when the dial gauge pointer reaches
maximum value and suction and exhaust valves are both
closed and not balancing.
Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 91).
Figure 93 Figure 96
88102
Figure 97
87715
Figure 95
87718
88323 88102
- Loosen screw (1) that prevents pump shaft rotation and - Assemble the priming pump (1) to the basement (3) and
insert spacer (2). Tighten screw (1)so that it locks spacer tighten the fastening screws (2) to the prescribed pair.
(2): in this way the suppl pump shaft will be able to rotate
freely. - Connect all pipelines (from pumping elements to
injectors, bleeding recovery pipes from injectors to
- Unlock the engine flywheel. pump, LDA pipeline and feed provided by priming
- Remove the flywheel rotation locking tool 99360339; pump).
place the starter into its housing. - Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
Figure 101 NOTE The following tests shall be made after engine
assembly to the vehicle.
Preventively check that the liquid levels have been
correctly restored.
88230
PART TWO -
ELECTRICAL EQUIPMENT
88318
88314
2
75724a 75722
88319
Figure 110
88315
75723
Figure 111
It is a resistor assembled to the suction collector and is utilised
to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the engine.
Specifications:
Working tensions: 12 V
Maximum possible
Air flow: 2 cc / min
(pressure 138 kPa)
88316
Pin out
PIN Description
1 Signal
2 Signal
3 Screening
Alternator
Figure 113
75725
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Working tension: 12 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: 1mA
Sense of rotation: clockwices
Print P2D32N013 E
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your Iveco dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
SECTION 3 - INDUSTRIAL APPLICATION
43
Print P2D32N013 E
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
SERIE N F4CE
Print P2D32N013 E
Malfunctioning thermostat. Replace the thermostat.
The engine overheats Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your Iveco dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Incorrect timing of injection pump. Check timing and correctly set pump.
Engine operation is irregular and lacks Automatic timing variator defective Check operation of the injection pump See your Iveco dealer.
power on a test bench; if the values found do not
tally with the prescribed ones, replace the
variators spring.
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your Iveco dealer.
tor.
SECTION 3 - INDUSTRIAL APPLICATION
45
Print P2D32N013 E
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
SERIE N F4CE
Print P2D32N013 E
or excessive play on shoulders. half-rings.
Engine running with abnormal knocking Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
Excessive maximum pump output. Disconnect the pump and adjust delivery See your Iveco dealer.
in accordance with the data given in the
calibration table.
The engine smokes abnormally. Black or K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust See your Iveco dealer.
dark grey smoke. tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.
SECTION 3 - INDUSTRIAL APPLICATION
47
Print P2D32N013 E
SERIE N F4CE SECTION 3 - INDUSTRIAL APPLICATION 49
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
Figure 114
87757
Cooling system check Check of water presence within fuel filter or pre-filter
The check must be executed both when the engine
disconnected and when it is running.
NOTE The components of the system can be damaged
Check the pipelines from the engine to the radiator, from the very quickly in presence of water or impurity within
expansion tank and vice-versa. Find out any blow-by, verify the the fuel.
status of the pipes specially close to the holding strips.
Timely proceed operating on the pre-filter (not
Verify that the radiator is clean, the correct working of the fan available on the engine block) to carry out the
flywheels, the presence of any leakage from the connectors, drainage of the water within the feed circuit.
from the manifold and from the radiating unit.
Fuel filter is equipped with pump screw-valve to drain the
water eventually mixed with fuel (some applications of 6
Due to the high temperatures achieved by the cylinders engines will be equipped with two fuel filters, both
system, do not operate immediately after the engines provided with drainage.
disconnection, but wait for the time deemed
necessary for the cooling. Place a container underneath the filter and slightly loosen the
Protect the eyes and the skin from any eventual high screw. Drain the water eventually contained in the filters
pressure jet of cooling liquid. bottom.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
Figure 116
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.
123031
Figure 119
Figure 118
70520
130201
Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
- Also check that the unperforated part (1) of the phonic Clearance shall be as follows:
wheel is positioned uppermost (cylinder n. 1 at TDC) and - intake valves 0.25 0.05 mm
the valves of cylinder n. 4 are balanced. If cylinder n.1 is - exhaust valves 0.50 0.05 mm.
balanced, rotate the engine through one revolution to
obtain the specified condition.
- Adjust the clearance of cylinder n. 1s valves as indicated
in the relevant paragraph.
- Now rotate the crankshaft as shown in the table to adjust
the clearance of the rocker arms of the other cylinders.
Oil motor and filter replacement Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ-
Warning: We recommend to wear proper protec- ent positions: the following procedure is a valid guide for all ap-
tions because of high motor service temperature. plications.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering
must always wear protection gloves. cartridge. For the cartridge replacement use the
9936076-tool.
Due to the several applications, the pan shape and the oil
Warning: the oil filter contains inside a quantity of oil
quantity can change slightly. However, the following oper-
of about 1 kg.
ations are valid for all applications.
Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor
is hot. Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the
pan connected with the drain plug. The motor oil is very pollutant: it must be disposed
of according to the rules.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the
lubrication oil.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the
dipsick.
Figure 120
During this operation dont smoke and dont use free
flames.
Avoid to breathe the vapors coming from filter.
- Clean the gasket seat on the support and oil slightly the - Assemble the drive belt (6) ensuring that the relevant ribs
gasket on the new filtering cartridge. are correctly placed in the respective races of the pulleys.
- Screw manually the new filtering cartdrige until when the - Approximately ad just the belt tight working on the screw
gasket is completely on its seat. (4).
- Tigthen through the 99360076-tool at 10-15 Nm torque. - Using the tool to control belt tightening, check in point A
that frequency detected is 164 6 Hz corresponding to
an assembly tension of 1200 10 N, in case it is not, duly
work on the screw (4).
Once adjustment has been completed, fasten the nut (5)
and the screws (1 and 2) to the prescribed pair.
- Let the engine run for a few hours and check that the belt
tight is correct.
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 10
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 14
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Page
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 22
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 27
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . 33
GENERAL SPECIFICATIONS
Type F4CE9484F*J600
Number of cylinders 4
Bore mm 104
Stroke mm 132
TIMING
Checking timing
mm 0.25 0.05
X X
mm 0.50 0.05
Injection
Type: Bosch
VE 4/12 F ....
bar
NOTE The EN 590 standard distinguishes different grades of diesel identifying the characteristics of the most suitable ones
for use at low environmental temperatures.
It is entirely up to the Oil companies to comply with these regulations, which require that fuels suited to the climatic
and geographic conditions of the various Countries be distributed.
CLEARANCE DATA
Type F4CE9484F*J600
1 0.4
Spare pistons
1 type:
X Size X 55.9
Outside diameter 1 103.730 to 103.748
2 Pin housing 2 38.010 to 38.016
Piston cylinder barrels 0.252 to 0.294
X
Piston protrusion X 0.28 to 0.52
Type F4CE9484F*J600
S 1 S1 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening
X2 in cylinder barrel:
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
Type F4CE9484F*J600
Main bearings
3 No. 1 5 3 87.982 to 88.008
No. 2 3 4 3 87.977 to 88.013
X 1
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Type F4CE9484F*J600
Valve seats -
4 Valves:
4
7.960 to 7.980
60o
4 7.960 to 7.980
45o
Valve stem and guide 0.039 to 0.079
Housing on head for
valve seat:
1 46.987 to 47.013
1 1 43.637 to 43.663
Valve seat outside diameter;
2 valve seat angle on cylinder
head:
2 47.063 to 47.089
60o
2 43.713 to 43.739
45o
X X 0.336 to 1.072
X Sinking X
0.104 to 0.840
0.050 to 0.102
Between valve seat
and head
0.050 to 0.102
Valve seats -
Type F4CE9484F*J600
injector protrusion X
X
Camshaft journals:
1 2 53.995 to 54.035
3 53.995 to 54.045
1 3
Bush inside
diameter 54.083 to 54.147
H H 11.02
H 10.74
Type F4CE9484F*J600
2
3 Tappet cap outside
diameter: 2 15.929 to 15.959
3 15.965 to 15.980
2
Between tappets and housings 0.020 to 0.065
Tappets -
1
Rocker shaft 1 18.963 to 18.975
2
Between rockers and shaft 0.025 to 0.063
70160
The second last main bearing cap (1) and the relevant support
Figure 1 are fitted with shoulder half-bearing (2).
Figure 4
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
Figure 5
Figure 2
70159
70162
Remove the screws (1) and the main bearing caps (2). Disassemble the bench half-bearings (1).
For the supercharged engines, withdraw the screws (2) and
disassemble the oil sprayers (3).
70163
70164
Figure 10
Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
D2 D1
75703
87753
Checking head supporting surface on cylinder
unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them in
case of uncertain seal or if rusted.
TIMING SYSTEM
Camshaft
Figure 12
88367
Figure 13
70172
The collet (2) for distribution shaft must result forced in its
respective seat.
The internal surface must result without a trace of seizure or
deterioration.
Measure with the bore machine (3) the diameter of the collet
70171
(2) and of the intermediate seats (1) for the distribution shaft.
The measurements must be made on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two
perpendicular axes.
Figure 15
107399
MAIN DATA OF THE COLLET FOR DISTRIBUTION SHAFT AND RELATIVE SEAT (3 cylinders)
* Quota to be obtained after the planting of the collet (dimensions in mm).
Bush replacement Tappets
Figure 16 Figure 17
70174 84053
To replace the collet (1) use for its disassembly and assembly MAIN DATA CONCERNING THE TAPPETS AND THE
the 99360362 beater (2) and 99370006 handle (3). RELEVANT HOUSINGS ON THE ENGINE BLOCK
(dimensions in mm).
70176 70179
Lubricate the tappets (1) and fit them into the relevant Check camshaft end float (1).
housings on the engine block. It shall be 0.23 0.13 mm.
Figure 19 Figure 22
70164 137363
Lubricate the camshaft bushes and fit the camshaft (1) taking Fit nozzles (2) and tighten the fastening screws (1) to the
care not to damage the bushes or the housings. specified torque.
Figure 20
70238
Set camshaft (3) retaining plate (1) with the slot facing the top
of the engine block and the marking facing the operator, then
tighten the screws (2) to the specified torque.
70182
Figure 24
82.99
83.01
68.98
69.01
70181
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value (dimensions in mm)
Figure 25
70183
Figure 26
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING
SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
Figure 27 Figure 29
87722
128169
NOTE Refit the main bearings that have not been replaced,
in the same position found at removal.
Figure 31
75703
NOTE Do not try to adapt the bearings.
- At final assembly, before re-using the bench support
fastening screws, measure them twice as indicated in the
picture, checking D1 and D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
Clean accurately the main half bearings (1) having the if D1 - D2 > 0,1 mm the screw must be replaced;
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder half
rings.
Figure 34
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1st stage, with dynamometric wrench to 50 6 Nm.
- 2nd stage, with dynamometric wrench to 80 6 Nm. 70190
Figure 35
70188
- 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90 6 angle.
70191
126311 126312
Remove split rings (1) from piston (2) using pliers 99360183 Piston pin (1) split rings (2) are removed using a scriber (3).
(3).
Figure 38
87730
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS - SUPERCHARGED ENGINES
(dimensions in mm)
18857
16552
128140
32619
Lubricate the pin (1) and its seat on piston hubs with engine Check the clearance between the sealing rings (3) of the 1st
oil; the pin shall be fitted into the piston with a slight finger slot (only for pistons of supercharged engines), of the 2nd and
pressure and shall not be withdrawn by gravity. 3rd slot and the relevant housings on the piston (2), using a
feeler gauge (1).
41104
70194
Figure 46
YEAR DAY
CONN.
WEIHGT
ROD No.
87742
126311
87731
The piston crown is marked as follows: Use pliers 99360183 (3) to fit the split rings (1) on the piston
1. Part number and design modification number; (2).
2. Arrow showing piston assembling direction into cylinder Split rings shall be fitted with the marking TOP facing
barrel, this arrow shall face the front key of the engine upwards and their openings shall be displaced with each
block; other by 120.
3. Date of production (only for pistons of supercharged
engines).
4. Marking showing 1st slot insert testing; NOTE The split rings are supplied with spare parts in the
following sizes:
Figure 48 - standard;
- increased by 0,4 mm.
Figure 51
87732
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 49
70200
126312
128170
70201
To measure the clearance proceed as follows:
Lubricate accurately the pistons, including the split rings and - clean the parts accurately and remove any trace of oil;
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston - fit the connecting rod caps (1) with the relevant half
assembly (1) into the cylinder barrels and check the following: bearings (2).
- the number of each connecting rod shall correspond to
the cap coupling number.
NOTE Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
Figure 53 if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
75703
Figure 55
87733
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2).
Figure 58
70205
70207
2 6
A 75751
Figure 61
NOTE Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
2
A = intake side
75752
Figure 62
A
B
87735
VALVES Figure 66
Figure 64
18882
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 65 Figure 67
18625
Remove carbon deposits from valves using the proper metal 87738
brush.
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 0.092 mm.
Regrind the valve seats, if required, using tool 99305018 and Turn the valve (2) and check that the centering error is not
removing as less material as possible. exceeding 0.03 mm.
Figure 69
75754
Figure 70
137358
Figure 71
88369
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 to 100C and, using a suitable
them with the spare ones. Use tool 99305019 (Figure 69) to drift, fit the head with the new valve seats (previously cooled).
remove as much material as possible from the valve seats
Then, using a suitable tool, regrind the valve seats according
(take care not to damage the cylinder head) until they can
to the values given in Figure 71
be extracted from the cylinder head using a punch.
VALVE SPRINGS
Figure 73
Figure 72
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before assembly, check the flexibility of the valve springs with
a specific tool. Compare the elastic deformation and load
data with those of the new springs shown in the following
table.
3 1
75759 87670
75703
TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 3 1.5 0.3
Main bearing cap 1st stage 50 6 5.0 0.6
2nd stage 80 6 8.0 0.6
3rd stage 90 5
Rear gear housing assembly
(M8x1.25x40) 24 4 2.4 0.4
(M8x1.25x25) 24 4 2.4 0.4
(M10x1.5) 49 5 4.9 0.5
Front cover assembly - Oil pump
(M8x1.25x45) 24 4 2.4 0.4
(M8x1.25x30) 24 4 2.4 0.4
Connecting rod bolts(M11x1.25) 1st stage 30 3 3.0 0.3
2nd stage 60 5 6.0 0.5
3rd stage 60 5
Ladder frame assembly (M10x1.25x25) 43 5 4.3 0.5
Oil rifle plugs
(M10x1) 61 0.6 0.1
(M14x1.5) 11 2 1.1 0.2
Assemble oil suction tube (M8x1.25x20) 24 4 2.4 0.4
Oil pan assembly
(M8x1.25x25) 24 4 2.4 0.4
(M18x1.50) 60 9 6.0 0.9
Set timing pin 51 0.5 0.1
Fuel pump assembly
M8 screw 24 4 2.4 0.4
M6 screw 10 1 1.0 0.1
M6 nut 10 1 1.0 0.1
M10x1.5 flange head nuts pre-torque 10 - 15 1.0 - 1.5
Final torque 50 - 55 5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque 15 - 20 1.5 - 2.0
Final torque 85 - 90 8.5 - 9.0
Timing pin cap of fuel pump 30 - 35
Equalizer fastening to cylinder head (M8) 24 4 2.4 0.4
Cylinder head bolts
(M12x70) 50 + 90 5.0 + 90
(M12x140) 40 + 180 4.0 + 180
(M12x180) 70 + 180 7.0 + 180
Assy rocker covers (M8x1.25x25) 24 4 2.4 0.4
Intake manifold (M8x1.25) 24 4 2.4 0.4
Assy air intake connection (M8x1.25) 24 4 2.4 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 8 8.0 0.8
Plug (M12x1.5x12) 10 1 1.0 0.1
Exhaust manifold (M10x1.5x65) 43 6 4.3 0.6
Water pump (M8x1.25x25) 24 4 2.4 0.4
Water outlet connection
(M8x1.25x35) 24 4 2.4 0.4
(M8x1.25x70) 24 4 2.4 0.4
Fan support (M10x1.5x20) 33 5 3.3 0.5
Fan pulley
(M6) 10 2 1.0 0.2
(M10) 43 6 4.3 0.6
TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 12 7.7 1.2
Crankshaft pulley (M12x1.75x10.9) 110 5 11 0.5
Flywheel housing
(M12x120) 85 10 8.5 1.0
(M12x80) 85 10 8.5 1.0
(M10x80) 49 5 4.9 0.5
(M10x40) 49 5 4.9 0.5
Flywheel housing (M12x1.25) 1st stage 30 4 3.0 0.4
2nd stage 60 5
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 4 2.4 0.4
Fuel injectors 60 5 60 0.5
Fuel lift pump 24 4 24 0.4
Turbocharger to exhaust manifold (M10) 43 6 4.3 0.6
Oil feed to oil filter head 24 4 2.4 0.4
Oil feed to turbocharger (M12x1.5) 35 5 3.5 0.5
Oil drain (M8x1.25x16) 24 4 2.4 0.4
Alternator to alternator support (M8x1.25x30) 24 4 2.4 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 4 2.4 0.4
Lower alternator mounting (M10x1.25x25) 24 4 2.4 0.4
Alternator upper pivot to support (M10) 49 5 4.9 0.5
Alternator mounting hardware (M12x1.75x120) 43 6 4.3 0.6
Alternator wiring (M6x1.0 nut) 10 2 1.0 0.2
Starter motor to gear case (M10) 49 5 4.9 0.5
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 5
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 to 125 mm)
Bracket to fasten the engine to the rotating stand 99322205 (use with
99361039 99361037)
TOOLS
TOOL NO. DESCRIPTION
Spacers (3) to fasten the engine to the rotating stand 99322205 (use
99361040 with 99361037)
99370415 Gauge base for different measurements (to be used with 99395603)
Dial gauge holding tool for rotating ignition pump timing (use with
99395100 99395603)
TOOLS
TOOL NO. DESCRIPTION
99395216 Pair of gauges with and square head for angle tightening
Appendix
Pagina
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Wear safety gloves and goggles when performing the - Upon engine start after maintenance, undertake proper
following operations: preventing actions to stop air suction in case of runaway
- filling inhibitors or anti-frost speed rate.
- lubrication oil topping or replacement - Do not utilize fast screw-tightening tools.
- utilization of compressed air or liquids under pressure
(pressure allowed: 2 bar) - Never disconnect batteries when the engine is running.
- Wear safety helmet when working close to hanging - Disconnect batteries before any intervention on the
loads or equipment working at head height level. electrical system.
- Always wear safety shoes when and cloths adhering to - Disconnect batteries from system aboard to load them
the body, better if provided with elastics at the ends. with the battery loader.
- Use protection cream for hands. - After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
- Change wet cloths as soon as possible from accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry - Before proceeding with pipelines disassembly
out working operations if not trained for. (pneumatic, hydraulic, fuel pipes) verify presence of liquid
or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
- Put the dirty rags with oil, diesel fuel or solvents in Non fulfillment of these prescriptions may cause serious
anti-fire specially provided containers. injury and poisoning.