FICFL411S

F1C EuVI Engines
S Series
On-Road multipurpose
F1CFL411S*A302
S30ENT6K25.00
S30ENT6K26.00
S30ENT6K27.00
Technical and Repair manual

This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and special-
ised personnel.
Before performing any operation check that the part relevant
to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles, hel-
met, gloves, shoes, etc. and hoisting and transporting equip-
ment.
Operations are to be performed by following the indications
included here, using the special equipment indicated and assur-
ing proper repair, compliance with schedule and operators
safety requirements.
Each repair must aim to restore operating efficiency and safety
in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other
interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the inter-
ventions and all the instructions that are not included on this
publication.
Data included in this publication may not be up-to-date there-
fore subject to Manufacturers modifications that can be added
at any time for technical or commercial purposes and also to
meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed
on the unit, please get in touch with the FPT network before
starting any intervention.
It is forbidden to copy this text or any of its parts and all illustra-
tions included.
Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P1D32S021 E - 1st Ed. 04.2015
F1C EuV1 - ENGINES 1
F1C EuVI Engines S Series
F1C Engines EuVI 1
Print P1D32S021 E Base - April 2015

2 F1C EuV1 - ENGINES
Base - April 2015 Print P1D32S021 E

F1C EuV1 - ENGINES INTRODUCTION 1
Introduction
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7
- Grounding and screening . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

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

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND THE MOST COMMONLY
USED DERIVED SIZES . . . . . . . . . . . . . . . . . . 9
PAGE HEADER
AND FOOTER INTERPRETATION . . . . . . . . 10
UPDATE DATA . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 INTRODUCTION F1C EuV1 - ENGINES

GENERAL INFORMATION
Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections are
indicated in the general table of contents.
Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - disconnec-
tions, overhauls at the bench, troubleshooting and scheduled maintenance.
On sections or parts of the electric/electronic system there are the descriptions of the electric network and the electronic systems
assembly, wiring diagrams, electric characteristics of components.
Sections 1 and 2 describe the engine and its general features.
Section 3 describes the electrical part, concerning wiring, electrical and electronic equipment according to the specific use.
Section 4 includes scheduled maintenance.
Sections 5 and 6 concern the operations of removal/refitting of the main components and operations of general overhaul of engine
fitted on a rotating stand.
Section 7 contains the techcnical data of the motor such as installation clearances and tightening torques.
Section 8 contains the special tools list.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations
SYMBOLS
Warnings
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
Risk of serious damage to the assembly

The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify
the warranty.
General danger
! It includes the dangers of above described signals.
Environment protection
Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.
Service operations
Example
1 1 = Housing for connecting

rod small end bush.
Tighten to the specified torque + angle value

2 2 = Housing for connecting
rod bearings

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

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

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

GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur.
!
Therefore, supervisors should be contacted whenever a dangerous situation that has not been described occurs.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and mainten-
ance handbooks.
Check the working condition and suitability of tools not subject to periodic review.
The manual handling of loads must be assessed in advance since it also depends not only on weight but also 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 show clear indications regarding maximum acceptable carrying capacity.
The use of such tools is strictly permitted by authorised personnel only.
Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out
from accidentally striking workshop personnel.
Shop activities performed by two technicians must always been executed with caution; avoid operations that may be
dangerous for any collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it.
Scrupulously observe all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands
and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe
all the specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point
cards of harmful materials.
Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to pre-
vent sudden fires/explosions.
Adequately store inflammable, corrosive and polluting fluids and liquids according towhat provided by regulations in
force. Strictly avoid using containers for food to store harmful liquids.
Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suit-
able containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and
stains of liquids and oils.
Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.

Wear all required P.P.E and garments when called for by the operation at issue.
Contact with moving parts may cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing
jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes fromheating orwelding of paint, as they are harmful; operate outdoors or inwell-ventilated areas.
Wear an appropriate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns.
Avoid direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact
occurs.
Before overhauling, clean the assemblies and make sure they are integral and complete.
Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts
with nylon inserts must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions. FPTs sales and assistance net-
work is available to provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
- Disconnect all electronic control units and unplug the power cable from the batterys positive terminal (connecting
it to the chassis ground) and connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Wait approximately 15 minutes before proceeding with welding.
- Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable
materials flow when welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the
! chassis earth cable first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from
the battery terminals.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test lamp to verify circuit continuity, but proper control equipment only.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding,
grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work.
Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular
test lines, with special jacks and jack bushings.
Never use improvised equipment like metal wires, screwdrivers, pins or similar.
This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.
Do not use fast chargers to start up the engine.

Start upmust only be performed with either separate batteries or special truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries)
may lead to their destruction.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening
torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
NOTE The connectors are shown from cable side.

Connector views contained in the manual are representative of cable side.

Grounding and screening

The negative leads connected to a system grounding point must be as short as possible and connected to one another in delta
configuration; make sure that they are tightened in an orderly and adequate manner (Figure 1 ref. M).
The following precautions must be observed regarding the electronic components:
- The electronic control units must be connected to the circuits ground when they have metallic casing.
- Electronic control unit negative cablesmust be connected to a system ground point, such as the dashboard compartment ground
(do not use serial or chain connections), and to the negative terminal of the battery/ies.
- Even if not connected to the circuit ground/battery negative terminal, analog ground (sensors) should have optimal isolation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
- The metal braid of shielded circuits must be in electric contact only at the end towards the control unit where the signal enters
(Figure 2).
- In the case of junction connectors, the unshielded section d, near the connectors must be as short as possible (Figure 2).
- The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Figure 1
1. DELTA CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT EARTH M
Figure 2
88039
2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Accessory installation, additions and changes on the assembly must be carried out in compliance with the FPT assembly directives.
It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by fitters.
It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring.
In particular, the data line between the control units (CAN line) is to be considered untouchable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATION-

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

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

PAGE HEADER AND FOOTER INTERPRETATION
Type Section Page

of engine title number
Number of Language Basic edition referring to When present, a

printed copies Publication closing phase of drafting month-year update
month-year (Revi) to the basic edition

UPDATE DATA
Section Section name Modification description Page Date of revision


F1C EuV1 - ENGINES 1
F1C Engines EuVI
Section
General Specifications 1
Operating diagrams 2
Electrical equipment 3
Scheduled Maintenance 4
Removal/refitting
of the main engine components 5
General mechanical overhaul 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix

2 F1C EuV1 - ENGINES

F1C EuV1 - ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 3
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 4
ISOMETRIC VIEWS OF ENGINE . . . . . . . . . . . . 5
POWER - TORQUE CURVES . . . . . . . . . . . . . . 6
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 13

2 SECTION 1 - GENERAL SPECIFICATIONS F1C EuV1 - ENGINES

TECHNICAL CODE
F1 C F L 4 1 1 S * A 302
Progressive numbers showing engine variants
Emissions level:
A = EuVI
Performances:
A = First calibration B = Second calibration extc.
Application:
0 = Other application 5 = Genset
1 = Trucks 6 = Marine
2 = Buses eVGT 7 = Industrial / Agricultural turbo
3 = Industrial / Agricultural 8 = Cars and derivatives
Engine main characteristics:

0 = Turbocharged CNG
1 = Turbocharged diesel i.d.aftercooled
2 = Naturally Aspirated diesel i.d.
3 = Naturally Aspirated diesel i.i.
4 = Naturally Aspirated petrol
5 = Naturally Aspirated CNG
6 = Turbocharged diesel i.d.
7 = Turbocharged diesel i.i.
8 = Turbochargedpetrol
9 = Turbocharged diesel i.i. aftercooled
No. of cylinders
Cylinder configuration:
A = 4 stroke vertical E = 4 stroke vertical with post-treat
B = 4 stroke horizontal F = 4 stroke horizontal with post-treat
C = 4 stroke vertical with EGR G = 4 stroke horizontal with EGR +post treat
D = 4 stroke horizontal with EGR L = 4 stroke vertical with EGR + post treat
F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6
Engine family development
F1 = New Engine Family

COMMERCIAL CODE
S 30 E N T 6
Emission levels:
A = 2002/88 CE
C = Euro 3
D = Double omologation Europe (NRMM) and EPA-USA
E = Europe (NRMM)
F = Sprinkler
G = GAS
I = Not emissioned (without omologation)
L = Stage IV
M = Marine
R = R96 omologation
S = R96 TIER4B omologation
U = EPA - USA
X = Stage 3A - Tier 3
Y = Stage 3B - Tier 4A
Z = Tier4B
4 = Euro 4
5 = Euro 5
6 = Euro 6
Aspiration:
A = Natural
S = Supercharged
T = Supercharged with aftercooler
Crakcase:
N = Not structural (normal distribution)
S = Not structural (limited distribution)
R = Structural
Injection type:
E = Electronic
M = Mechanic
Displacement:
L *10 for displacement < 10 L
Engine:
C = Cursor
F = F5
N = NEF
S = F1
V = V Series

ISOMETRIC VIEW OF ENGINE

Figure 1
227511

POWER - TORQUE CURVES

Figure 2
227513
S30ENT6K27.00
Max. POWER 95 kW (127 HP) at 3,500 rpm
Max. TORQUE 300 Nm (30.6 kgm) at 1,300 rpm
Figure 3
227514
S30ENT6K26.00

Figure 4
227515
S30ENT6K25.00

ENGINE VIEWS
Figure 5
227507
INTAKE SIDE VIEW

1. EGR valve - 2. Hot compressed air outlet pipe - 3. Exhaust manifold protection - 4. Alternator -
5. Lubricant oil sump - 6. Engine mount - 7. Turbocharger actuator - 8. Variable geometry turbocharger -
9. Flow rate control valve - 10. Exhaust manifold - 11. EGR heat exchanger

Figure 6
227506
EXHAUST SIDE VIEW
1. Intake manifold - 2. Lubricant oil filter - 3. Engine coolant inlet pipe to heat exchanger - 4. Water/oil heat exchanger
5. Engine mount - 6. Lubricant oil level dipstick -7. Air compressor - 8. Power steering pump -
9. High pressure fuel pump - 10. Thermostat cover -11. Air inlet pipe to intake manifold

Figure 7
227508
FRONT VIEW
1. Blow-by - 2. Air compressor - 3. Fixed belt tensioner - 4. Damper pulley - 5. Alternator -
6. Automatic belt tensioner - 7. Electromagnetic pulley - 8. Lubricant oil filler cap

Figure 8
227509
REAR VIEW
1. Coolant pipe - 2. Exhaust gas pipe from EGR to intake manifold - 3. Flow rate control valve -
4. Engine flywheel - 5. Lubricant oil drain plug - 6. Air compressor -
7. Coolant inlet pipe to heat exchanger - 8. Engine flywheel rear protection

Figure 9
227510
TOP VIEW
1. Air inlet pipe to intake manifold - 2. Lubricant oil filler cap - 3. EGR valve -
4. Hot compressed air outlet pipe - 5. EGR heat exchanger - 6. Electro-injectors - 7. Cable on engine cover

GENERAL SPECIFICATIONS
Type F1CFL411S*A302
Cycle Diesel 4 strokes
Supply Turbocharged with aftercooler
Injection Direct
Number of cylinders 4 in line

Bore mm 95.8
Stroke mm 104
+ + +.. = Total displacement cm3 2998
A
TIMING SYSTEM
Start before T.D.C. A 29 5

end after B.D.C. B 30 5
B
Start before T.D.C. D 75 5
end after B.D.C. C 30 5
FUEL FEED
Injection type: common rail injection system

BOSCH EDC17 C49
Injectors BOSCH
Nozzle type
CRi2-20
Injection sequence 1-3-4-2
bar
Injection pressure bar 2000

Type F1CFL411S*A302
Maximum power kW 95 110 129

(HP) (127) (150) (173)
rpm 3500 3500 3500
Maximum torque Nm 300 370 430

(Kgm) (30.6) (37.7) (43.8)
rpm 1300 1320 1600
Slow running of engine

with no load rpm 800 25
Fast idling speed of

engine with no load rpm 4200 50
TURBOCHARGING With aftercooler
Turbocharger type GARRETT water and oil cooled variable geometry

Actuator minimum flow kg/hr 160 5.0
Actuator calibration:
Vacuum 0 bar mm Valve fully open
Vacuum 20 kPa mm 1.5 4.0
Vacuum 64.7 kPa mm 10 12.5
forced by gear pump, pressure relief valve, oil filter
LUBRICATION
with total filtering integral cartridge
Oil pressure with engine hot
bar (100C 5C):
at idling speed bar 1.5 0.3
at top speed bar 4.5 0.5
by centrifugal pump, thermostat for adjustment, coolant
COOLING
temperature, sensor, heat exchanger
Water pump control: by belt
Thermostat: brand: WAHLER
start of opening: 79 C 2 C
end of opening 94 C 2 C

Type F1CFL411S*A302
Cooling circuit (1)

Total capacity l (kg) 6.9 (6.2)
Lubrication circuit
Total capacity (2)(3) l (kg) 7.3 (6.6)
Oil sump capacity:
Oil sump at minimum level l (kg) 4.29 (3.86)
Oil sump at maximum level l (kg) 6.60 (5.94)
Power steering oil capacity (5) l (kg) -
Fuel tank capacity (4)(5) l (kg) -
Urea total capacity (6) l (kg) 25 (22.5)
(1) The amounts indicated relate to the standard configuration of the engine only.
Use a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to Paraflu HT use another
product that complies with ASTM D-6210 international standard.
(2)Only use lubricants which meet the international standards 5W-30/0W-30; ACEA C2. Recommended oil is URANIA DAILY FE
- URANIA DAILY LS. The oil used is considered to be acceptable until a quantity equalling 0.5% of fuel consumption is reached.
(3) The quantities shown refer to the first refilling and concern the refilling of engine, oil sump and filter.
(4) Use fuel compliant to the EN 590 international standard.
(5) Refer to the indications of the vehicle manufacturer.
(6) Use an AdBlue 32.5% solution in water compliant to the ISO 22241 international standard.
Warning Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection
! system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
! by FPT.
Furthermore, the equipment assembled by vehicle manufacturer shall always be in compliance with torque,
power and number of revs based on which the engine has been designed.


F1C EuV1 - ENGINES SECTION 2 - OPERATING DIAGRAMS 1
SECTION 2
Operating diagrams
Page
COMMON RAIL INJECTION SYSTEM . . . . . . . 3
- General specifications . . . . . . . . . . . . . . . . . . . 3
- Electric system . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Main sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 9
- Injection system main components . . . . . . . . . 12
- Electro-injectors CRI2-20 . . . . . . . . . . . . . . . . 15
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- General specification . . . . . . . . . . . . . . . . . . . . 17
- Lubrication system main components . . . . . . . 18
OIL VAPOUR RECIRCULATION (BLOW-BY) . 21
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 22
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Cooling system main components . . . . . . . . . 23
TURBOCHARGING SYSTEM . . . . . . . . . . . . . . 24
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Turbocharging system main components . . . . 25
EXHAUST GAS RECIRCULATION (EGR) . . . . 28
- System layout . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- E.G.R. Assembly (Exhaust Gas Recirculation) . 29
- E.G.R. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30

2 SECTION 2 - OPERATING DIAGRAMS F1C EuV1 - ENGINES
Page
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EXHAUST GAS POST-TREATMENT SYSTEM

(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- System description . . . . . . . . . . . . . . . . . . . . . 32
- ATS principle layout . . . . . . . . . . . . . . . . . . . . 32
- EMS System layout (DeNOx PC/LD 3.1) . . . . 33
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Hardware scheme . . . . . . . . . . . . . . . . . . . . . . 35
- Hydraulic scheme . . . . . . . . . . . . . . . . . . . . . . 35
- AdBlue Specifications . . . . . . . . . . . . . . . . . . . 36
- Main components of the ATS system . . . . . . 37
- ATS system main sensors . . . . . . . . . . . . . . . . 42

COMMON RAIL INJECTION SYSTEM - these pressures can be modulated between 150 bar up
to the maximum operating pressure of 2000 bar,
General specifications irrespective of the speed of rotation and engine load;
- capacity to operate at very high speeds (up to 6000
The common rail injection system is a high-pressure rpm);
electronic injection system for fast diesel engines with direct
injection. - injection control precision (injection duration and
advance);
Its main features comprise: - lower fuel consumption;
- availability of high injection pressure values (2000 bar); - lower emissions.
Electric system
Figure 1
227518
1. Air inlet from aftercooler temperature sensor - 2. Pre/heater glow plugs - 3. Air pressure and temperature sensor -
4. Oil pressure switch - 5. Fuel flow regulator on pump - 6. Coolant temperature sensor - 7. Segment speed sensor -
8. Pressure regulating valve on rail - 9. Pressure sensor on rail

Figure 2
227517
1. EGR valve - 2. Increment speed sensor - 3. Alternator - 4. VGT position sensor -

5. Flow rate control valve - 6. Electro-injectors - 7. Exhaust gas temperature sensor

Main sensors Segment speed sensor

Fuel pressure sensor It is an Hall effect type sensor positioned on the camshaft
pulley.
Assembled on a rail end, it measures the fuel pressure in the
rail in order to determine the injection pressure. It generates signals obtained from lines of magnetic flux that
close through a notch in the pulley.
The signal provided by the sensor is used by the engine
management control unit to adjust the injection pressure and The signal generated by this sensor is used by the control unit
duration. as a reduntant signal to measure the different engine speeds.
Fuel temperature sensor on fuel filter (not supplied by Oil pressure switch
FPT) It is fitted on the water/oil heat exchanger and measures the
Integrated in the fuel filter, it measures the fuel temperature engine oil pressure.
and transmits it to the electronic control unit.
The signal detected is sent to the control unit.
When the fuel temperature is too high (ambient
Air inlet from aftercooler temperature sensor.
temperature condition, engine at full load and tank in
reserve), correct lubrication of the high-pressure pump is no Air inlet from aftercooler temperature sensor
longer assured.
It is fitted on the intake manifold air inlet pipe.
On the basis of the values received, the control unit
determines the density and volume of the fuel, correcting the It measures the air temperature coming from the aftercooler.
delivery limiting engine performance.
Air pressure and temperature sensor

Positioned on the intake manifold, it measures the pressure
of the boost air introduced into the intake manifold.
This value will, together with the lambda probe and air
temperature sensor values, allow the electronic control unit
to accurately determine the amount of air fed into the
cylinders and manage the injectors by adjusting the fuel
supply accordingly, reducing noxious emissions and
improving both consumption levels and performance.
Inside the sensor there is an electronic temperature
correction circuit to optimize the measurement of the
pressure in relation to the intake air temperature.
Coolant temperature sensor

This sensor provides the control unit with an index of
thermal status of the engine in order to determine
corrections of the fuel delivery, injection pressure, EGR
injection advance when starting cold (if equipped) and
warm-up.
Increment speed sensor

It is an inductive sensor placed on the pulser ring mounted
on the crankshaft front end.
It generates signals obtained from magnetic flux lines which
close through the pulser ring teeth.
The engine management control unit uses this signal to
measure the rpm of the engine, its angular position and to
operate the electronic rev counter.

System description Checking fuel temperature

The system makes pre-injection (pilot injection) possible With the fuel temperature greater than 75C, detected by
before the TDC with the advantage of decreasing the the sensor on the fuel filter, the control unit operates the
derivative of the pressure in the combustion chamber, pressure regulator to decrease the line pressure (injection
lowering the noise level of combustion, which is typical of times are not changed).
direct injection engines.
If the temperature exceeds 90C, the power is reduced to
The control unit controls the amount of fuel injected, 60%.
adjusting the line pressure and injection times.
Checking engine coolant temperature
The information the control unit processes to regulate the
amount of fuel to be injected includes: The control unit detects the temperature of the engine
coolant fluid, of the boost air and of the fuel; if necessary, it
The information the control unit processes to regulate the controls theelectromagnetic cooling fan (Baruffaldi) and
amount of fuel to be injected includes: switches on the coolant fluid warning light.
- Engine speed;
Checking quantity of fuel injected
- Coolant temperature;
According to the signals from the sensors and the mapped
- Turbo charging pressure; values, the control unit:
- Air temperature; - operates the pressure regulator;
- Intake air quantity; - varies the pilot injection time to 2200 rpm;
- Battery voltage; - varies the main injection time.
- Diesel pressure; Checking idling adjustment
- Accelerator pedal position. The control unit processes the signals coming from the
various sensors and regulates the amount of fuel to inject,
Electronic injection control controlling the pressure regulator and altering the injector
The system calculates the injection modes by processing the injection times.
following parameters:
Within certain thresholds the rpm takes account of the
- Engine rpm. battery voltage.
- Engine coolant fluid temperature. Fuel cut-off in release phase
- Intake air capacity. In the phase of releasing the throttle pedal the control unit
- Battery voltage. actuates the following logic elements:
- Fuel pressure. - it cuts off supply to the electro-injectors;
- Accelerator pedal position. - it partially reactivates supply to the electro-injectors
before reaching idling speed;
The fuel pressure can reach a maximum of 2000 bars.
- it operates the fuel pressure regulator.
Up to 2800 rpm pre-injection is also carried out in order to
reduce the typical noise of direct injection. Checking cylinder balancing on idling
Pre-injection advance angles, the distance between According to the signals received from the sensors, the
pre-injection and main injection and advance angles of main control unit controls the regularity of the torque at idling
injection vary according to the instantaneous engine speed:
operating conditions.
- it varies the amount of fuel injected into the single
Self-diagnosis electro-injectors (injection time).
System diagnosis is performed by means of diagnostic Checking regular engine rotation (anti-sawing)
instruments (no Blink Code is used).
It ensures regular engine rotation at a constant rate while
Immobilizer recognition (if present) increasing revs.
When the control unit receives the signal of the key on The control unit processes the signals received from the
MAR it communicates with the immobilizer control unit to sensors and determines the amount of fuel to be injected via:
enable starting. - the pressure regulator;
- the electro-injector opening time.

Checking smokiness at exhaust on acceleration Checking injection pressure closed cycle

The engine control unit, using the signals from the rpm sensor Depending on the engine load, determined by processing the
and from the air flow rate meter, acting on the pressure signals from the various sensors, the control unit operates the
regulator and altering the injection time for the injectors to regulator to obtain optimum line pressure.
control the exhaust fumes during heavy acceleration.
Fuel supply
Checking exhaust gas recirculation The fuel supply is calculated in relation to:
Depending on the engine load and the signal from the
- accelerator pedal position
accelerator pedal sensor, the control unit limits the amount
of air taken in, actuating partial suction of the exhaust gases. - engine speed
Checking top speed limit - quantity of air introduced.
Depending on the number of revs, the control unit actuates The outcome may be corrected in relation to:
two action strategies: - the water temperature.
- at 4250 rpm it cuts off the fuel, decreasing the Or to avoid:
electro-injector opening time;
- noise
- over 5000 rpm it deactivates the electro-injectors.
- smoke
Checking regular rotation on acceleration - overloading
Regular progression is assured in all conditions by the control
- overheating
of the pressure regulator and the electro-injector opening
time. - turbine over-revving.
Checking pre/heating glow plug control unit The delivery can be modified in the case of:
The injection control unit times the operation of the - action of external devices (ASR, MSR, HBA)
preheating glow plug control unit depending on the engine - serious trouble decreasing the load or stopping the
temperature during start-up and post-start-up. engine.
Checking activation of air-conditioning system After determining the mass of air introduced by measuring
its volume and temperature, the control unit calculates the
The control unit operates the air-conditioning compressor:
corresponding mass of fuel to inject into the relevant cylinder
- switching it on/off when the relative switch is pressed; (mg per delivery) also taking into account the temperature
of the diesel.
- momentarily turning it off (approximately 6 sec.) if the
engine coolant reaches the set temperature. The fuel mass calculated in this way is first converted to
volume (mm3 per delivery), and then in crank degrees, i.e. in
Checking fuel pump injection duration.
Irrespective of the speed, the control unit:
Correcting flow rate according to water temperature
- supplies the auxiliary fuel pump with the key on MAR;
A cold engine meets with greater resistance during
- cuts off auxiliary pump supply if the engine is not started operation: friction is high, the oil is still very viscous, and the
up within a few seconds. various clearances are not yet optimized.
Checking fuel preheating In addition, the injected fuel tends to condense on the metal
surfaces that are still cold.
It times operation of diesel warming in relation to ambient
temperature. The fuel supply for a cold engine is therefore greater than for
a warm one.
Checking cylinder position
Correcting flow rate to avoid noise, smoke or
During each turn of the engine, the control unit recognizes overloading
which cylinder is in the power stroke and operates the
injection sequence for the appropriate cylinder. The behaviour that could lead to this kind of trouble is well
known.
Checking pilot and main injection timing The designer has therefore included special instructions in
According to the signals from the various sensors, including the control unit to avoid it.
the absolute pressure sensor built into the control unit, the
control unit determines the optimum point of injection De-rating
according to internal mapping. In the event of the engine overheating, injection is modified,
decreasing the delivery to a varying degree, in proportion to
the temperature reached by the coolant.

Turbine speed setting Warm starting

The advance (start of delivery, expressed in degrees) may be If the reference temperatures all exceed 10C, when the key
different from one injection to the next, also differentiated makes contact the indicator light comes on for
from one cylinder to another. approximately 2 sec., for a short test, and then goes out. It
is now possible to start up the engine.
It is calculated, similarly to the delivery, in relation to the
engine load (accelerator position, engine speed and air Run up
introduced).
When the key makes contact, the control unit transfers the
The advance is appropriately corrected: information stored in memory when the engine was last
- in phases of acceleration; stopped into the main memory (see After Run) and makes
a diagnosis of the system.
- according to the water temperature.
And also to obtain: After run
Whenever the engine is switched off with the key, the
- lower emissions, noise and overloading;
control unit stays powered for a few seconds by the main
- better vehicle acceleration. relay.
An extremely high advance is set on starting, depending on This makes it possible for the microprocessor to transfer
the water temperature. some data from the main memory (volatile) to a non-volatile
memory, which can be erased and written over (EEPROM),
Feedback from the start of delivery is supplied by the change
so as to make it available at the next start up (see Run Up).
in impedance of the injector solenoid valve.
These data basically consist of:
Speed governor
- various settings (engine idling adjustment, etc.);
The electronic speed regulator has the same characteristics
as traditional units (min/max, speeds) but is stable in ranges - settings of some components;
in which mechanical regulators are imprecise. - fault memory.
Engine starting The process lasts a few seconds, typically from 2 to 7
(depending on the amount of data to save), after which the
During the first few turns of the engine, the timing and
control unit sends a command to the main relay and makes
cylinder no. 1 recognition signals (flywheel sensor and
it disconnect from the battery.
camshaft sensor) are synchronized.
The accelerator pedal signal is ignored on starting. Starting
delivery is set only according to water temperature, by a
special map. NOTE It is extremely important for this procedure not to
be broken off, for example by switching off the
When the control unit detects such speed and acceleration engine with the battery cut-out, or by
of the flywheel as to be able to consider the engine started disconnecting the battery cut-out before 10
up and no longer driven by the starter motor, it re-enables seconds have passed since switching off the engine.
the accelerator pedal.
If this happens, the functioning of the system is
Cold starting ensured, but repeated interruptions may damage
the control unit.
If even just one of the three temperature sensors (water, air
or diesel) records a temperature lower than 10C, pre-post
heating is activated.
When the key makes contact the pre-heating indicator light
comes on and stays on for a length of time that varies in
relation to the temperature (while the glow plugs in the
cylinder head heat the air), then flashes. It is now possible to
start up the engine.
When the motor is running this indicator light goes out, while
the glow plugs continue to be powered for a certain length
of time (variable) for post-heating.
If, with the indicator light flashing, the engine is not started up
within 20-25 seconds (inattention time), the operation is
cancelled so as not to run down the batteries pointlessly.
The pre-heating curve is also variable in relation to the
battery voltage.

Cut-off Synchronization search

This function cuts off fuel delivery when the vehicle is If there is no signal from the camshaft sensor, the control unit
decelerating (accelerator pedal released). is anyhow able to recognize the cylinders into which the fuel
is to be injected.
Cylinder balancing
If this occurs when the engine is already running, the
The individual balance of the cylinders contributes to combustion sequence has already been acquired, so the
improving comfort and driveability. control unit continues with the sequence on which it has
This function allows an individual and personalized check on already been synchronized.
the fuel flow rate and the start of the supply for each cylinder, If this occurs when the engine is already stationary, the
in a way that is different from one cylinder to another, to control unit activates one injector; within 2 rounds of the
compensate for injector tolerances. crankshaft, in that cylinder a combustion will start.
The control unit does not directly evaluate the differences in Then the crankshaft speeds up and the control unit manages
injector flow rate: calibration takes place by entering the to synchronise the ignition order and to start the engine.
injector bar code using the diagnostic instrument (see
replacing an injector).
Hydraulic system
Figure 3
227516
A. High pressure - B. Low pressure - C. Backflow

1. Common Rail - 2. Fuel return pipe from injectors - 3. Fuel return pipe from rail -
4. Fuel pipe from pump to tank -5. Fuel pipe from filter to pump - 6. High pressure pump -
7. High pressure pipe from pump to rail - 8. Electro-injectors - 9. High pressure pipes from rail to injectors.

Operation The high-pressure circuit is made up of the following pipes:

In this injection system, the flow regulator, located above the - pipe connecting the high-pressure pump outlet to the
high-pressure pump, regulates the flow of fuel needed in the hydraulic accumulator (rail);
low pressure system. Subsequently the high-pressure pump
- hydraulic accumulator (rail);
correctly supplies the hydraulic accumulator.
- pipes feeding the electro-injectors from the hydraulic
This solution, only pressurising the necessary fuel, improves
accumulator.
the energy efficiency and limits heating the fuel in the system.
The low-pressure circuit is made up of the following pipes:
The relief valve fitted on the high-pressure pump has the
function of keeping the pressure, at the pressure regulator - fuel intake pipe from the tank to the filter;
inlet, constant at 5 bars; irrespective of the efficiency of the
fuel filter and of the system before it. - pipe assembly made up of the following:
The action of the relief valve causes an increase in the flow - feed pipe from the fuel filter to the high-pressure pump;
of fuel in the high-pressure pump cooling circuit. - fuel return pipe from the high-pressure pump to the tank;
The high-pressure pump continuously maintains the fuel at - fuel return pipe from the injectors to the pipe delivering
the working pressure, irrespective of the timing and the fuel back to the tank.
cylinder that is to receive the injection and accumulates it in
a duct common to all the electro-injectors. Due to the very high pressure that builds within this hydraulic
system, the following precautions must be observed for
At the electro-injector inlet therefore, there is always fuel at safety reasons:
the injection pressure calculated by the control unit.
- avoid connecting high-pressure pipe fittings with
When the solenoid valve of an electro-injector is energized approximate tightening;
by the control unit, fuel taken straight from the common rail
is injected into the relevant cylinder. - avoid disconnecting the high-pressure pipes when the
engine is running (DO NOT make any attempt at
The hydraulic system consists of a low-pressure fuel bleeding: this is absolutely useless and dangerous!).
recirculation circuit and a high-pressure circuit.
To ensure correct operation of the system, it is essential that
the low-pressure circuit is intact. Therefore, avoid any
attempt at modification or alteration and intervene
immediately if a leak is identified.

Fuel system layout
Figure 4
221412
1. Pressure limiter valve - 2. High-pressure delivery pipe, - 3. Common Rail return pipe - 4. Electro-injectors -
5. DRV pressure control valve - 6. Common Rail - 7. Fuel pressure sensor - 8. Electro-injector return pipe -
9. Filter with water separator - 10. Tank - 11. Electric fuel pump - 12. Electric fuel pump intake filter -
13. Electric fuel pump non-return valve - 14. High-pressure pump - 15. Mesh filter-valve
a. 4.4 bar () <p< 5.8 bar ()

b. 4.4 bar () <p< 6.0 bar ()
c. p 2 bar
d. p 10 bar
relative pressure
absolute pressure
* optional
** overpressure valve 3.3 0.1 bar

Injection system main components

Fuel filter (not supplied by FPT)
Figure 5
A B C D E F
G H
156845
1. Fuel filter support - 2. Diesel output - 3. Diesel intake - 4. Diesel filter -

5. Purge screw - 6. Electronic unit - 7. Pins - 8. 12 way connector -
H-G-B, water sensor; - H-C, clogging sensor (if applicable); - D-E, NTC temperature sensor; - F-A, heater
The fuel filter (4) comprises a filter cartridge with a water Water sensor
separator; the electronic unit is housed inside (6).
The water sensor detects water present in the filter starting
Water accumulation capacity is 140 cm3. from a volume of 110 cm3. Water sensor provides values of:
The electronic unit (6) includes the water sensor, (optional) - ow voltage with water present;
filter clogging sensor and temperature sensor.
- high voltage in absence of water.
Technical data
Rated voltage 12 V (8 to16)
Absorbed current in standby Less 15 mA
Absorbed current in alarm
(including load) Less 150 mA
Voltage on load in standby Greater 11.8 V

Voltage on load in alarm condition Less 3.9 V

CP 4.1 high pressure pump

Figure 6
230351
1. Outlet from pump to tank - 2. Inlet from filter to pump - 3 High pressure outlet to rail 4. Flow rate regulator -
5. Electrical connection
Description Flow rate regulator

Pump with one radial plunger controlled via a gear by the The fuel flow regulator is mounted on the low-pressure
timing belt; it needs no timing. circuit of the CP4.1 pump.
The pump is lubricated and cooled by the same fuel. The flow regulator modulates the amount of fuel sent to the
high-pressure circuit according to the commands received
The operating pressure is controlled as follows:
directly from the engine control unit.
- electronically by a solenoid valve located on the pump
The flow regulator is mainly composed of the
casing and controlled by the control unit;
- connector
- by a regulator valve (DRV) mounted on the hydraulic
accumulator (Rail). - casing
Fuel supply is provided by a transfer pump. - solenoid
This is built into the fuel level indicator located in the fuel tank - pre-load spring
incorporated into the fuel intake assembly (GAC) together
- shutter cylinder.
with the fuel level signalling device located in the fuel tank.
When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width
NOTE The high-pressure pump cannot be overhauled; Modulation) signal, modulates the change in fuel flow rate in
therefore, it must not be removed or tampered the high-pressure circuit by partially closing or opening the
with. sections of passage of the fuel in the low-pressure circuit.
Only the following repairs are permitted: replacing
the drive gear.

Operation Fuel manifold pipe LWR-20 (rail)
Figure 7 Figure 9
126024
190607
1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -

4. Fuel inlet - 5. Fuel outlet.
Description
The hydraulic accumulator is located on the inlet side of the
When the engine control unit governs the flow regulator (via cylinder overhead.
PWM signal), the solenoid (1) is energized that, in its turn,
generates the movement of the magnetic core (2). By its volume, it damps fuel pressure oscillations owing to:
The shift of the core causes the shutter cylinder (3) to move - High-pressure pump operation;
axially, choking the flow of fuel. - Electro-injector opening.
The hydraulic accumulator (1) is equipped with:
Figure 8 - A fuel pressure sensor (4) which measures the fuel

pressure inside the rail. The fuel pressure sensor may
affect the accuracy of the injector minimum flow rate
correction, since the minimum flow rate depends both
on the injection time and the actual pressure of the
hydraulic accumulator.
- A DRV pressure regulator valve (2) which controls the
operating pressure.
The throttle valves or control bushes (3), with 0.85 mm,
have been fitted to the fuel delivery couplings, which control
the fuel pressure waves generated by the high-pressure
pump.
Their function is to protect the electric injectors by reducing
their wear in time.
190608 The fuel pressure sensor (4) may affect the accuracy of the
1. Solenoid - 2. Magnetic core 3. Pre-load spring - injector minimum flow rate correction, since the minimum
4. Shutter cylinder. flow rate depends both on the injection time and the actual
pressure of the hydraulic accumulator.
When the solenoid (1) is not energized, the magnetic core In case of replacement, the engine management control unit
is pushed into the rest position by the pre-load spring (3). correction coefficients (ZFC) must be set to zero.
In this condition, the shutter cylinder (4) is in such a position The correction coefficients can be set to zero using the
as to offer the fuel the greatest section of passage. diagnostic tool, by reprogramming the control unit and
performing the sensor replacement procedure, following the
instructions provided by the diagnostic tool.

Pressure regulating valve Electro-injectors CRI2-20
Figure 10 Figure 11
137787 230350
A. High pressure chamber - B. Low pressure chamber Description

The injectors are activated by a solenoid with a servo valve
Controls the pressure in the Rail in relation to the engine which allows faster and more flexible management of
load. injection events (IRS: Injection Rate Shaping).
At too high pressures, the valve opens to return some of the These injectors adapt to the most advanced injection control
fuel from the rail to the tank via the recovery circuit; at too strategies.
low pressures, the valve closes to separate the high and low Reducing the time between single injections, with these
pressure sides from each other. injectors it is possible to reach 8 fuel injections per cycle: this
The valve is a solenoid operated valve controlled by the gives advantages in terms of noise, fuel consumption,
PWM signals of the engine management control unit. particulate filter efficiency and emissions (in line with Euro 6
directive).
The control unit controls the valve after processing the
signals from the various sensors of the engine: engine speed, Injection pressure reaches 2000 bar.
load, air intake, air pressure, engine and fuel temperature. The temperature of the fuel recirculated by the
The pressure is controlled by varying the return flow to the electro-injector can reach elevated values (approximately
tank. 120 C), The head of the electro-injector has a fitting for the
electrical connector.
With the engine off, spring (2) raises piston (3) and hence rod
(1) connected to the latter, thus compensating the pressure They are mounted on the cylinder head and operated by the
between chambers (A) and (B). injection control unit.

Figure 12 Operation
The electro-injector can be divided into two parts:
- actuator/nozzle composed of pressure rod (1), pin (2)
and nozzle (3)
- driving solenoid valve made up of coil (4) and pilot valve
(5).
Electro-injector operation can be divided into three phases:
- rest position
Coil (4) is de-energised, and shutter (6) is in closing position
and prevents fuel from being introduced into the cylinder, Fc
> Fa (Fc: caused by fuel pressure acting on the control area
(7) of the rod (1); Fa: caused by line pressure acting on the
pressure chamber (8).
- beginning of injection
The coil (4) is energized and causes the shutter to rise (6).
The fuel of the control volume (9) flows towards the return
manifold (10) causing a drop in pressure in the control area
(7).
At the same time, line pressure through feed duct (12)
applies a force Fa > Fc in pressure chamber (8) lifting peg (2),
with fuel being consequently introduced into cylinders.
- end of injection
The coil (4) is de-energized and makes the shutter (6) return
50704 to its closed position. This recreates such a balance in the
forces as to make the pin (2) return to its closed position and
consequently end injection.
1. Pressure rod - 2. Pin - 3. Nozzle - 4. Coil - 5. Pilot valve
6. Ball shutter - 7. Control area - 8. Pressure chamber -
9. Control volume - 10. Low pressure fuel return -
11. Control duct - 12. Power supply pipe - 13. Electric
connection - 14. High-pressure fuel inlet fitting - 15. Spring

LUBRICATION Engine oil is drawn up from the sump by the oil pump via the
suction strainer and delivered under pressure to the heat
General specification exchanger where it is cooled.
The engine is lubricated by forced circulation performed by The oil continues through the oil filter and goes to lubricate
the following parts: the relevant parts through ducts or pipes.
- a gear oil pump with built-in depressor (GPOD); At the end of the lubrication cycle, the oil returns to the sump
- a pressure relief valve integrated in the oil pump; by gravity.
- a heat exchanger made up of five elements; The oil filter can be excluded by the safety valve built into it
if it gets clogged.
- a mono-filtering oil filter with incorporated safety valve.
In addition, the lubricating oil feeds the chain hydraulic
tightening devices for the control of the auxiliary elements
and the timing system and the hydraulic tappet.
Figure 13
227519
A. Oil under pressure - B. Oil in freefall - C. Coolant -

D. Pressure regulating valve closed - E. Pressure regulating valve open.
1. Oil pump - 2. Suction strainer - 3. Oil sump - 4. Turbocharger oil outlet pipe -
5. Turbocharger oil inlet pipe - 6. Oil introduction - 7. Water oil heat-exchanger

Lubrication system main components Figure 17

Oil and vacuum pump unit
Figure 14
88691
SECTION A-A
230349
Technical data
1. Oil pump - 2. Vacuum pump. -
3. Oil pressure adjusting valve Oil pump technical data
Transmission ratio 1
Displacement 23.52 cm3
NOTE Should the unit be faulty, not due to the oil
pressure adjusting valve, change the whole unit. Number of teeth 7
Height 18 mm.
Minimum speed 780 rpm
Section Maximum speed 3500 rpm
Figure 15 Overspeed 4200 rpm
Forced overspeed 4900 rpm
Pressure at maximum regulator valve aperture 13 bar
Speed 3500 rpm
Torque 4 Nm
Power absorbion 1047 W
Vacuum pump technical data

Transmission ratio 1
Displacement 150 cm3
88689
Volume to drain 4.5 l.
Rotor diameter 45.5 mm.
SECTIONS OF OIL PUMP/DEPRESSOR UNIT Number of blades 1
1. Oil input pipe from cylinder block - 2. Oil suction pipe - Height 23.9 mm.
3. Oil pressure adjusting valve - 4. Oil delivery pipe -
5. Vacuum pump air suction pipe - 6. Vacuum pump oil Minimum speed 780 rpm
suction pipe.. Maximum speed 3500 rpm
Overspeed 4200 rpm
Forced overspeed 4900 rpm
Figure 16 Theoric flow rate at minimum (air) 117 l/min
Actual flow rate at minimum atmosferic 76 l/min
pressure (air)
Theoric flow rate at maximum speed (air) 525 l/min
Actual flow rate at minimum atmosferic 128 l/min
pressure (air)
88690 Speed 3500 rpm
SECTION B-B Torque 1 Nm
Power absorbion 262 W

Oil pressure adjusting valve Oil filter

Figure 18 Figure 21
88626
1. Valve - 2. Spring
A. Oil intake from sump - B. Oil delivery to crankcase -
C. Oil return from crankcase - D. Oil discharge hole -
E. Oil discharge hole
Pressure at opening start: 4.4 bar
Description of oil pressure adjusting valve closed
If in pipe C the oil pressure is below 4.4 bar, the valve (1)
closes the holes D - E.
Figure 19 88061
Oil filter with built in by-pass valve differential opening

pressure 2.5 0.2 bar.
Water/oil heat exchanger
88627 Figure 22
Oil pressure adjusting valve open
If in pipe C the oil pressure is equal or above 4.4 bar, the valve
(1), as a result of the pressure itself, wins through the spring
reaction (2) and goes down, thus opening communication
between the delivery pipe A and the suction pipe B, through
draining holes D-E, and therefore the pressure drops.
When the pressure falls below 4.4 bar, the spring (2) takes
the valve (1) to the initial position of closed valve.
Figure 20
107752
HEAT EXCHANGER COMPONENT DETAILS

1. Heat exchanger made up of five elements - 2. Gasket -
3. Box - 4. Pipe union - 5. Screw - 6. Oil filter support -
7. Oil pressure switch - 8. Screw - 9. Gasket -
10. Gasket
88058
If the oil pressure regulator valve (1) malfunctions, replace

the entire vacuum pump oil pump assembly (GPOD).

Heat exchanger operation

Figure 23
227520
A. Cold oil from heat exchanger to cylinder block - B. Cold oil from heat exchanger to oil filter -
C. Hot oil from cylinder block to heat exchanger
1. Heat exchanger - 2. Heat exchanger body - 3. Oil filter support - 4. Oil filter

OIL VAPOUR RECIRCULATION

(BLOW-BY)
General specifications The device is essentially composed of a rotary filter (3) fitted to
Part of the gas produced by combustion leaks out of the piston the high pressure pump/camshaft control shaft (1) and a cover
gaskets into the sump and mixes with the oil vapour it contains. (2).
This mixture is conveyed upwards by the chain housing and is
partially separated from the oil by a device located at the top
of the timing system cover and sent into the air intake circuit.
Figure 24
221431
A. Gas with oil content above 10g/h - B. Gas with oil content of 0.2 g/h - C. Condensed oil that returns to the oil sump
1. Shaft - 2. Cover - 3. Rotary filter - 4. Chamber - 5. Pipe
Operation
The mixture passes through the rotary filter (3), where the Pipe (5), conveying the oil vapours to the turbocharger inlet,
oil is partially separated by centrifugal force, and condenses comes with an optional electrical heating element which is
on the walls of the cover, after which it returns to the actuated when the ignition key is turned.
lubrication circuit.
The purified mixture is sent via the holes in the shaft (1), into Its function is to prevent the oil vapour from solidifying and
the air conveyer upstream of the turbocharger. the steam (found in the same) from freezing when the
The part of the oil contained in the mixture exiting from the external temperature is low, thus causing the gas pressure to
rotary filter (3) condenses in the chamber (4) and drains into increase in the engine base, with resulting risk of oil leakage
the chain housing. from the crankcase seal rings.

COOLING SYSTEM
General specifications
The engine cooling system is the type with forced circulation - An engine cooling module to dissipate the heat taken
in a closed circuit. It comprises the following parts: from the engine by the coolant with a heat exchanger
for the intercooler (not supplied by FPT).
- An expansion tank whose plug has two valves
incorporated in it: an outlet and an inlet, which govern - A heat exchanger to cool the lubricating oil.
the pressure of the system (not supplied by FPT).
- A centrifugal water pump incorporated in the crankcase.
- A coolant level sensor at the base of the expansion tank
- An electric fan comprising an electromagnetic coupling
(not supplied by FPT).
on whose shaft a hub turns idle that is fitted with an
- A pressure switch notifies to the control unit when axially mobile metal plate on which is mounted the
pressure inside expansion tank exceeds 0.4 bar value; in impeller (not supplied by FPT).
this case, the central unit reduces engine performance
- A 3-way thermostat governing the circulation of the
level by modifying injection flow rate (De-rating) (not
coolant.
supplied by FPT).
Figure 25
227521
A. Cold - B. Very hot - C. Hot - D. Thermostat closed - E. Thermostat opened

1. Rear cover- 2. Thermostat - 3. Very hot water from thermostat to radiator -
4. Water inlet from radiator to heat exchanger 5. Water/oil heat exchanger - 6. Water pump -
7. Water inlet from expansion tank to pump - 8. Blow-by heater - 9. Water outlet to cylinder block -
10. Turbocharger -11. Water outlet from EGR to expansion tank- 12. EGR heat exchanger

Operation Water pump

The water pump driven by a poly-V belt by the crankshaft Figure 27
sends coolant into the crankcase and with a greater head into
the cylinder head.
When the coolant temperature reaches and exceeds the
working temperature, it causes the thermostat to open and
the fluid is channelled from here to the radiator and cooled
by the fan.
The pressure in the system due to the change in temperature
is governed by the outlet and inlet valves incorporated in the
expansion tank filler plug.
The outlet valve has a double function:
- to keep the system slightly pressurized so as to raise the
boiling point of the coolant;
- to discharge into the atmosphere the excess pressure
produced in case of high coolant temperatures.
227522
The function of the inlet valve is to permit transferring the
coolant from the expansion tank to the radiator when a
lower pressure is created in the system due to the reduction 1. Electromagnetic pulley - 2. Fixing screws -
in volume of the coolant as a result of its temperature 3. Gasket - 4. Water pump body
lowering.
The water pump cannot be overhauled. If coolant leakage or
damage to the component or seals is identified, it must be
replaced.
Cooling system main components
Thermostat
Figure 26 Testing table

Time Pressure
Description
(sec.) (Bar)
Fixture clamping pressure / 100 150
Fill time 15 /
Test time 10 /
Test pressure / 1.2
Loss accepted 10 0.002
150684
The by-pass thermostat needs no adjustment.

If there is any doubt about its operation, replace it.
The thermostat casing is fitted with the thermometric
switch/transmitter and water temperature sensor.
Start of stroke at 79 2 C = 0.1 mm.
End of stroke at 94 2C = 7 mm.

TURBOCHARGING SYSTEM
Figure 28
227523
A. Air at atmospheric temperature - B. Exhaust gas - C. Cold compressed air - D. Hot compressed air - E. Cold exhaust gas
1. EGR group - 2. Variable geometry turbocharger - 3. Exhaust manifold - 4. Intake manifold
Description The function of the turbocharger is to use the energy of the

The turbocharging system comprises an air filter, engines exhaust gas to send pressurized air to the cylinders.
turbocharger and aftercooler (air filter and aftercooler not The aftercooler consists of a radiator integrated in the engine
supplied by FPT). coolant radiator with the function of lowering the
The air filter is the dry type comprising a filtering cartridge to temperature of the air leaving the turbocharger before it is
be periodically replaced. delivered to the cylinders.

Turbocharging system main components

Variable geometry turbocharger
Figure 29
227549
A. Intake air - B. Compressed air - C. Exhaust gas

1. Oil delivery pipe - 2.Water delivery pipe - 3. Oil return pipe - 4. VGT actuator - 5. Turbocharger body -
6.Water return pipe
The variable geometry turbocharger consists of the Operation at low engine rpm
following:
- centrifugal compressor; Figure 30
- turbine;
- set of mobile blades;
- a pneumatic actuator controlling the moving vanes.
The actuator is controlled by a vacuum via a
proportional solenoid valve controlled by the engine
management control unit.
The variable geometry makes it possible to:

- increase the speed of the exhaust gases at the turbine at
low engine speeds;
126017
- slow down the speed of the exhaust gases at the turbine
at high speeds;
1. Turbine - 2. Mobile blades
In order to maximise the volumetric performance of the
engine even from low rpm speeds (with the engine under a When engine is running at low speed, the exhaust gases
load). show weak kinetic energy; under these conditions a
traditional turbine shall rotate slowly, thus providing a limited
The turbocharger will be cooled by the engine coolant and
booster pressure.
engine oil through internal ducts.
In the variable geometry turbine (1), the mobile blades (2) are
The actuator is equipped with a position sensor which
set to max. closed position and the small through-sections
communicates directly with the control unit.
between the blades increase the inlet gas speed. Higher inlet
speeds involve higher tip speeds of the turbine and therefore
of the turborcharger.
Engine speed increase results in a gradual increase of exhaust
gas kinetic energy, and also in turbine (1) speed and booster
pressure increase.

Operation at high engine rpm Proportional solenoid valve description
Figure 31 Figure 32
224836
126018
1. Output to pneumatic valve -
1. Turbine - 2. Mobile blades - 3. Pneumatic actuator 2. Vacuum system supply input - 3. Electrical connection -
4. Atmospheric pressure intake
This causes the speed of the turbine (1) to increase, this The solenoid valve modulates the low pressure controlling
building turbocharging pressure. the turbocharger actuator, taken from the air circuit of the
servo brake, according to the information exchanged
The control unit, through the actuator control solenoid valve,
between the electronic control unit and the sensors of:
modulates the vacuum acting on the diaphragm, so actuator
engine rpm, throttle pedal position and
(3) controls through the tie rod, the gradual opening of the
pressure/temperature fitted on the intake manifold.
mobile blades (2) until reaching the max. open position.
As a result, the actuator varies the aperture of the
Blade through-sections results larger thus producing a speed
turbocharger throttle that adjusts the flow of exhaust gases.
decrease in exhaust gas flow through the turbine (1) with
speeds equal to or lower than those of the low rpm
condition. Pneumatic actuator description
Turbine (1) speed is therefore adjusted to a proper value Figure 33
enabling suitable engine operation at high speed
227525
1. Electrical connection - 2. Diaphragm - 3. Control rod
The actuator consists of a diaphragm (2) connected to the

control rod (3), and it is vacuum controlled.
The proportional solenoid valve modulates the depression
that controls the turbocharger actuator, according to the
operating conditions of the engine.
The modulated depression then changes the movement of
the diaphragm (2) and therefore the control rod (3).
In VGT versions (fitted with a variable geometry turbine), the
actuator varies the opening of the blades of the turbocharger
that control the flow of exhaust gases and it is fitted with a
position sensor.
Throttle valve This possibility is exploited in order to quickly bring catalytic

converter up to standard thermal conditions (reduction of
The throttle valve is positioned at the turbocharger exhaust emissions when is cold).
gas outlet, its controlled by an electric actuator via signals
from the engine management control unit. A second function of the throttle valve is the engine brake.
The use of the engine brake with the throttle valve on the
exhaust allows use of the service brake system to be limited
The main newfeature is an electric actuatorwhich allows the
and therefore reduces brake wear.
exhaust gas outlet to be choked to increase the outlet tem-
perature. The engine brake is cooled by the engine coolant.
Figure 34
230348
1. Throttle valve - 2. Exhaust gas outlet - 3. Electric connection

EXHAUST GAS RECIRCULATION (EGR)

System layout
Figure 35
221430
1. Air charger intercooler outlet temperature sensor - 2. Air from intercooler - 3. Coolant
temperature sensor - 4. Air and temperature sensor - 5. RPM sensor - 6. EGR flow regulating valve
7. Air coming from filter - 8. Air to intercooler - 9. Engine brake - 10. Exhaust gas
11. Control unit EDC17 CP52
Operation
The control unit electronic control unit processes the air coming from the intercooler and flow to the intake
information coming from the: atmospheric pressure sensor, manifold. If the vehicle is fitted with a D.P.F. catalytic
water temperature sensor, engine rpm sensor, accelerator converter, at the same time, the control unit, adapts the flow
pedal potentiometer and, in accordance with suitably rate of the fuel to be injected into the cylinders depending on
programmed modes in its memory, operate the opening of the quantity of recirculated exhaust gases.
the plate in the E.G.R. valve by means of a PWM signal.
When the engine is running and the recirculation of the gases
In this way, some of the exhaust gases are sent towards the is not required (regeneration of the particulate filter, starting,
heat exchanger where they are cooled and directed to the engine cold, idle speed, load request, high altitude), the
chamber for the throttle valve assembly to be mixed with the control unit control signal is cancelled.

EGR group assembly (exhaust gas recirculation)
Figure 36
227524
1. Exhaust gas pipe from exhaust manifold to EGR valve - 2. Engine coolant pipe to turbocharger - 3. Collar -
4. Rear cover gasket - 5. Rear cover - 6. Exhaust gas pipe from EGR to intake manifold - 7. Gasket - 8. Engine coolant pipe -
9. EGR heat exchanger - 10. EGR valve - 11. Engine coolant outlet pipe to expansion tank

E.G.R. Assembly
Figure 37
230347
A. Engine coolant - B. Exhaust gas

1. Heat exchanger - 2. Flow regulation valve
The E.G.R. assembly (Exhaust gas recirculation) comprises a

heat exchanger (1) and a flow regulation valve (2).
The heat exchanger (1) has the task of lowering the
temperature of the exhaust gases which are partly sent to the
intake manifold.
This operation has only one aim: to lower the combustion
temperature of the mixture.
This takes place because the exhaust gases, totally inert, mix
with the mixture and slow down combustion.
Lowering this temperature produces a considerable
decrease in NOx (nitrogen oxide) emissions which are
harmful to the environment.
The body of the heat exchanger is composed of a tube
bundle cooled on the outside by the coolant fluid circulating
in the enigne. Some of the exhaust gases destined for
recirculation pass inside the tube bundle and are cooled.
The flow regulation valve (2) is fitted on the end of the heat
exchanger.
The adjustment of the amount of recirculation exhaust gases
takes place by means of an electrically operated plate valve.
The valve is cooled by the engine coolant coming out of the
heat exchanger thereby ensuring it is more efficient and lasts
longer.

TIMING SYSTEM Figure 39

Figure 38
88055
1. Rocker arm - 2. Reaction hydraulic tappet - 3. Valve

assembly - 4. Camshaft on exhaust side - 5. Camshaft on
suction side - 6. Camshaft control chain.
88342
Description TIMING SYSTEM AND AUXILIARY SYSTEM DIAGRAM

The timing system is the type with a twin camshaft in the 1. Camshaft control gears - 2. Single chain - 3. Hydraulic
overhead and four valves per cylinder with hydraulic tappets. chain tightener - 4. Mobile pads - 5. Drive gear on driving
The control is transmitted by two chains: shaft - 6. Fixed skids - 7. Oil pump/depressor control shaft
gear - Hydraulic power steering pump - 8. Double chain -
- a double chain by 3/8 is set in motion by the driving shaft 9. High pressure pump control shaft gear.
and sets the control shafts in motion: oil pump/depressor
high pressure pump; Figure 40
- a single chain is set in motion by the high pressure control
shaft gear and sets the camshafts in motion. TOP DEAD CENTER
The camshaft gears are mutually interchangeable and are

fitted with slots to make it possible for the phase sensor to
detect the phase.
The rocker arms, one for the valve, are kept in contact with
the corresponding cam by an hydraulic tappet, thus
eliminating the need for regular adjustments.
NOTE Change both chains, even if only one of them is 221427

faulty.
BOTTOM DEAD CENTER
TIMING SYSTEM DIAGRAM
A - INTAKE: start before TDC 29 5
end after BDC 30 5
B - EXHAUST: start before TDC 75 5
end after BDC 30 5

EXHAUST GAS POST-TREATMENT SYSTEM (ATS)

System description
FPT-Industrial has chosen the combination of EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst) + DPF (Diesel
Particulate Filter) and SCR (Selective Catalyst Reduction) as Euro VI emission abatement system for small industrial engines (F1C
engine, 3.0L).
The optimized combination of EGR and aftertreatment technologies is the key choice for an optimal small industrial engine
installation on vehicles, still guarantying good emission conversion efficiency and low fuel consumption.
Engine and vehicle fuel efficiency can then be lowered through the optimization of AdBlue/DEF (Diesel Exhaust Fluid) injection
on the basis of typical mission profile.
ATS principle layout

To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system
(ATS) has been adopted combining two devices:
- a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide)
and the particulate;
- the DeNOx device for the treatment of NOx (nitrogen oxide).
Figure 41
224811
ATS = After Treatment System - DPF = Diesel Particulate Filter - DOC = Diesel Oxidation Catalyst
CRT = Continuously Regenerating Trap - CUC = Clean Up Catalyst
SCR = Selective catalyst reduction
Functional requirements
- Very good low temperature performance of SCR catalyst, to comply with the cold part of emission cycles, through improved
AdBlue/DEF hydrolysis and DOC / DPF / SCR matching.
- Improved dosing system accuracy to limit NH3 slip while achieving NOx conversion ~ 90% in the whole operating speed
and load range, both in steady-state and transient conditions.
- Thermal management to heat up the aftertreatment system as quick as possible.

EMS System layout (DeNOx PC/LD 3.1)
Figure 42
221445
The ATS system is controlled electronically by the engine management control unit which on the basis of the engine rpm, torque
delivered, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the AdBlue
solution to be introduced into the system.
The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.
The ATS system consists essentially of:
1. Exhaust gas temperature sensor T1 (Toxi)
2. Oxi-catalyst
3. Exhaust gas temperature sensor T2 (Tpre)
4. Diesel Particulate Filter (DPF)
5. Delta-P Sensor (Pdiff)
6. SCR catalyst upstream temperature sensor
7. Urea Dosing unit
8. Urea Tank
9. Supply Module (splashing, measures, heating)
10. Urea Level sensor (CCLS)
11. Engine Control Unit (EDC17C49)
12. Mixer
13. SCR catalyst downstream temperature sensor
14. NOx sensor upstream SCR
15. NOx sensor downstream SCR
16. Concentration level sensor
17. NH3 sensor

Operation
Figure 43
224812
1. NOx sensor upstream DOC - 2. Delta-P Sensor (Pdiff)- 3. Dosing module - 4. NOx sensor downstream SCR -
5. NH3 sensor - 6. SCR catalyst downstream temperature sensor- 7. SCR catalytic converter - 8. SCR catalyst upstream
temperature sensor - 9. Diesel Particulate Filter (DPF) - 10. Exhaust gas temperature sensor T2 (Tpre) - 11. Oxi-catalyst -
In the first stage the exhaust gases leaving the turbine encounter the Oxi-catalist (11) in which the hydrocarbons (HC) and carbon
monoxide (CO) are transformed, through oxidation reactions, into carbon dioxide (CO2) andwater (H2O).
Subsequently the exhaust gases pass through the DPF particulate filter (9)which holds back the carbonaceous particles forming
the particulate.
In order for the systemto remain efficient, it needs to be regenerated and for this purpose there is a differential pressure sensor
(2) which, by detecting the difference in input and outlet pressure is able to provide the control unit with an index for the clogging
of the filter.
The particulate filter regeneration is performed through the Exhaust Flap device to choke the outlet section of the exhaust gas
from the turbine creating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature and
the particles of the particulate burn keeping the filter clean.
In the second phase the dosing module (3), through an injector placed in the exhaust pipe upstream of the SCR catalytic
converter (7), introduces a solution of water and urea (AdBlue) into the exhaust gas.
The first stage of the process takes place in the first part of the SCR catalytic converter: due to the effect of the exhaust gas
temperature, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2); at the
same time, the solution evaporates lowering the exhaust gas temperature to levels close to the optimum temperature required
for the process.
Exhaust gases containing ammonia at the temperature required for the reaction enter the SCR catalytic converter (7), where
the second stage of the process takes place: by reacting with the oxygen in the exhaust gas the ammonia is converted into free
nitrogen (N2) and water vapour (H2O).
The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to oxidise the excess urea produced
by the engine in the transient operating phases.
The amount of AdBlue injected is controlled through a NH3 sensor (5) fitted on the outlet pipe of the silencer, which detects
the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit thereby providing a
feedback signal.
The engine control unit, on the basis of the engine rpm, torque, exhaust gas temperature, intake air humidity, amount of nitrogen
oxide and the amount of urea present in the exhaust gas, detected by the respective sensors, regulates the flow of AdBlue to
be injected into the system.

Hardware scheme
Figure 44
SCR
224813
Adblue: Aqueous Urea Solution 32.5% according to DIN 70070

1. NH3 slip prevention coating - 2. Dosing module - 3. Heated pressure pipe - 4. Reagent tank -
5. Reagent pump (functional unit)
Hydraulic scheme
Figure 45
224814
1. Backflow throttle - 2. Reagent tank - 3. Tank heating device - 4. Pick up filter - 5. Reagent temperature sensor - 6. Reagent
level sensor - 7. Pressure sensor - 8. Reverting valve - 9. Reagent flow to dosing module - 10. Pressure pipe heating device -
11. Supply module heating device - 12. Reagent pump
CHARACTERISTICS NOMINAL
Supplier: Bosch
Supply pressure: 5 bar
Actuator control: EDC

AdBlue Specifications
ISO 22241 / AUS32 / DIN V 70070
Urea 32,5% - solution in water
Min. Max.
Urea content 31,8 33,2 % by weight
Density at 20C 1,087 1,093 g/cm3
Refracting index at 20C 1,3814 1,3843
Alcalinity as NH3 0,2 %
Biuret 0,3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0,5 mg/kg
Calcium 0,5 mg/kg
Iron 0,5 mg/kg
Copper 0,2 mg/kg
Zinc 0,2 mg/kg
Crromium 0,2 mg/kg
Nickel 0,2 mg/kg
Aluminium 0,5 mg/kg
Magnesium 0,5 mg/kg
Sodium 0,5 mg/kg
Potassium 0,5 mg/kg

Main components of the ATS system

Diesel particulate filter and diesel oxidation catalyst
Figure 46
224818
A. Inlet - B. Outlet
1. NOX sensor - 2. Exhaust gas temperature sensor T2 (Tpre) - 3. Delta-P sensor (Pdiff) - 4. Delta-P sensor (Pdiff) -
This first stage is made up of a DOC (Diesel Oxidation Catalyst) followed by a DPF (Diesel Particulate Filter) in which the exhaust
gas is cleaned of the HC (unburnt hydrocarbons), CO (carbon monoxide) and the parti culate.
Selective catalyst reduction and Clean up catalyst
Figure 47
A. Inlet - B. Outlet 224819
1. SCR catalyst downstream temperature sensor - 2. Mixing pipe - 3. Dosing module -

4. SCR catalyst upstream temperature sensor
This second stage is made up of a SCR (Selective Catalyst Reduction) and a CUC (Clean Up Catalyst), upstream of which is
the AdBlue dosing module; the reactions to reduce the NOx (nitrogen oxide) takes place in this catalytic converter.

Supply Module
Figure 48
224815
1. Pressure sensor - 2. Reverting valve - 3. Cover - 4. Cover - 5. Heating element inside - 6. Hydraulic connector to dosing
valve - 7. Outlet filter serviceable
The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the
dosing module.
It is equipped with a circuit connected to the engine cooling systemwhich, in low temperatures, stops the AdBlue fromfreezing.
Inside there is a pressure sensor.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are
dependent on the operating conditions of the engine and from the signals sent by the sensors.
To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of
any impurities.

Dosing Module
Figure 49
224820
1. Gasket - 2. V-clamp - 3. Cooling body - 4. Valve housing - 5. Hydraulic connector - 6. EIectrical connector
The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust
pipe upstream of the SCR catalytic converter.
It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected
to the engine cooling circuit by means of the pipes.
DOSING MODULE CHARACTERISTICS NOMINAL
Supplier: Bosch
Dosing quantity: Min. 15g/h Max. 3200 g/h
Spray angle: 16
Cooling concept: Passive cooling
Valve control: EDC (PWM controled)
Hydraulic connector: SAE J2044 Quick connector 1/4

Reducing agent tank
Figure 50
224816
1. Melting pot - 2. Supply module

Tank unit will be provided already assembled with melting pot and supply module, leakage test already performed.
Adblue tank material: HDPE - Volume: 25 lt
The melting pot includes:
Level sensor: 3 pin discrete level sensor
Tank heater: Electrically (PTC)
Reagent temperature: NTC
Supply module includes:
Reagent pump: membrane pump
Reverting valve: 4/2 way valve
Pressure sensor: relative pressure sensor
Supply module heater: Electrically (PTC)

Melting pot
Figure 51
224817
1. Helicoil inserts - 2. Reservoir pot - 3. Bayonet locking ring - 4. Level sensor - 5. Melting pot cover
Helicoil inserts: fixation of supply module.
Reservoir pot: contains urea suction line, tank heating, level sensor.
Bayonet locking ring: welded to tank case, twist-and-lock connection to melting pot.
Level sensor: measuring outside of pot.
Melting pot cover: fixed to tank case, interface between inside and outside of tank.
Power switch
Figure 52
224821
1. Pressure pipe heater - 2. Supply module heater - 3. Tank heater - 4. Engine control unit
The power switch is used for controlling and monitoring the electrical power supply of electric heating elements in the Reagent
system.
The controlling of the power output stage is carried out by EDC.

ATS system main sensors

NH3 sensor
Figure 53
185027
1. Heater (+) - 2. Trim resistor - 3. Trim resistor ground - 4. EMF_2 - 5. Heater (-) - 6. Temp sensing - 7. Signal ground -
8. EMF_1
The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present
in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected.
NH3 SENSOR CHARACTERISTICS NOMINAL

Supplier: Delphi
Temperature gas at the sensor: < 700 C
Installation torque: 50 10 Nm
Installation angle: 16 to 30
Bending radius for the cable coming out the sensor: > 20 mm
Bending radius for the free flexible cable: > 10 mm
Temperature range: -40 C to +900 C
(peak: 1,000 C)
Technical characteristics:
- The first resonant frequency of the NH3 sensor is above 2,500 Hz; a modal analysis at the sensors location in the exhaust
system is recommended to assure the sensor is not excited to resonance.
- The sensor is tested to sinusoidal vibration levels up to 60g peak at 2,500 Hz; random vibration levels of 35g RMS and
115g peak are performed in a bandwidth between 50 and 2,000 Hz.
- Minimum system supply voltage must be greater than 10 V. To provide sufficient heater power to ensure the sensor will
function under all operating conditions.
Positioning recommendations:
- Avoid positions in dead / shaded space (positioning not shortly after bending or sharp edges or NOx-sensor).
- No external injection of air/gas upstream or close to the sensor.
- Sheltered position (protection against splash water, stones etc.).

NH3 controller
Figure 54
185028
A. Vehicle side connector - B. Sensor side connector.

101. Power supply - 102. CAN LINE HIGH - 103. CAN LINE LOW - 104. Ground.
201. Heater (+) - 202. Trim resistor - 203. Trim resistor ground - 204. EMF_2 - 205. Heater (-) -
206. Temp sensing - 207. Signal ground - 208. EMF_1
NH3 CONTROLLER CHARACTERISTICS NOMINAL

Operating voltage 10 to 32 V
Average current 1.2 A
Peak current 4.0 A
Operating limit values -40 to 105 C
Tightening torque: 11.5 1.5 Nm
Positioning recommendations:
- Regarding vibration measurements on the controller, the best location is on the cast cover but since this might not be a
convenient location for installation on a vehicle, an accelerometer mounted on the plastic is fine.
- The controller is tested at random vibration level 6grms with 18g peak in the bandwidth between 10 Hz to 2,000 Hz.

Nitrogen oxide detecting sensor
Figure 55
102302
1. Positive - 2. Ground connection - 3. CAN LINE LOW - 4. CAN LINE HIGH - 5. Spare
The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter.
On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the
efficiency of the catalytic converters.
Tightening torque: 50 10 Nm
Temperatures
Ambient temperature: - 40 to +105 C
(+105 to +115 C allowed for up to 10 min)
Wire temperature: 230 C allowed for 100 h
Maximum exhaust gas temperature: 800C (950C allowed for up 100 h)
Maximum sensor hexagon screw temperature: 620C (650C allowed for up 100 h)
Maximum sensor grommet temperature: 200C (230C allowed for up 100 h)
Pre-heating sensor temperature: 80 to 120C
Electrical characteristics
NOx SENSOR CHARACTERISTICS NOMINAL
Minimum supply voltage (ECU): 9V
Minimum supply voltage (Sensor Heater): 12 V
Standard supply voltage: 13.5 V
Maximum supply voltage (Sensor Heater): 16.0 V
Typical supply current: < 1.5 A
Peak supply current at switch on: 16 A
Inrush current for loading of Input Caps: > 20 A
Maximum supply power: 20 W
CAN line voltage: -3 to 6 V
Max load dump protection for 12V version: 34 V

Exhaust gas temperature sensor
Figure 56
224823
1. Electrical connection - 2. Lead wire - 3. Housing - 4. Sheath pin - 5. Protection tube
Figure 57
224822
OPERATING CIRCUIT
It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting
the catalyst that is necessary for calculating the amount of urea to inject in the system.
EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS NOMINAL
Power supply 5V
Nominal resistance at a temperature -15 to 900 C 54.9 to 0.0389 k
Vibration limit 0 to 500 Hz 30 G
Vibration limit 500 to 1300 Hz 3G
Vibration limit 1300 to 4000 Hz 30 G
- Applied electric power shall not be 10 mW or more.
- Tightening torque shall be 30 6 Nm.
- Sensor is delivered with anti-seize grease applied at its threads. In case of remounting, grease shall be applied to threads,
NEVER-SEEZ, pure Nickel special grade.
- An adequate extra-length of wire harness shall be secured on sensor side in order to prevent mechanical stress applied on
internal connections of sensor.
- Max pulling force of cable shall be 100 N.
- The angle between lead wire and radial direction of sensor body shall be 30 or more (as shown on the drawing).

Differential pressure sensor

The differential pressure sensor (1), connected downstream and upstream of the DPF particulate filter, measures the
corresponding difference in pressure.
Figure 58
224824
1. Electrical connection - 2. Connections to DPF particulate filter

This difference in pressure is converted into a voltage signal sent to the engine management control unit and consists of a
clogging index of the DPF particulate filter.

Lambda sensor
The lambda probe detects the percentage of NOx (nitric oxide) found in the exhaust gas.
If the NOx value exceeds the specified value, the control unit will actuate the injectors by adjusting the fuel supply.
Figure 59
224825
1. Electrical connection - 2. Sensor

Installation instructions:
- Sensor must be installed at angles 10 C fron horizontal.
- With respect to the exhaust-gas flow path, positioning the sensor axis at 90 is ideal. A slope of up to -30is permissible.
- Tightening torque shall be 50 10 Nm.
Bending radius flexible cable:
- A minimum bend radius of 20 mm (long grommet) or 12 mm (short grommet) must be adhered to with respect to the
neutral filament.
- The first mounting point of the sensor cable should lie approx. 200 mm to 400 mm after the end of the grommet, depending
on the possible movements of the exhaust system.


F1C EuV1 - ENGINES SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 3
EDC 17 C49 ELECTRONIC CONTROL UNIT . 5
VEHICLE SIDE ELECTRICAL WIRING . . . . . . . . 6
- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- ECU connection to the injection cable on vehicle

side (housing B) . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE SIDE ELECTRICAL WIRING . . . . . . . . 10
- Topographic view . . . . . . . . . . . . . . . . . . . . . . 10
- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- ECU connection to the injection cable on engine

side (housing A) . . . . . . . . . . . . . . . . . . . . . . . 13
MAIN ELECTRICAL/ELECTRONIC EQUIPMENT 15
- Pressure regulator valve on HP pump . . . . . . . 15
- Electro-Injectors CRi2.20 . . . . . . . . . . . . . . . . . 15
- Rail pressure sensor . . . . . . . . . . . . . . . . . . . . 16
- Pressure regulating valve on rail . . . . . . . . . . . 16
- Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . 16
- VGT position sensor . . . . . . . . . . . . . . . . . . . . 17
- EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Driving shaft and camshaft unit . . . . . . . . . . . . 18
- Air temperature and pressure sensor . . . . . . . 20
- Engine coolant temperature sensor . . . . . . . . 21
- Exhaust gas temperature sensor . . . . . . . . . . . 22
- Air inlet from aftercooler temperature sensor 23
- Oil pressure switch . . . . . . . . . . . . . . . . . . . . . 23
- Pre/heater glow plug control unit . . . . . . . . . . 24
- Pre/heater glow plugs . . . . . . . . . . . . . . . . . . . 24
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . 26

2 SECTION 3 - ELECTRICAL EQUIPMENT F1C EuV1 - ENGINES

LOCATION OF THE MAIN ELECTRICAL COMPONENTS
Figure 1
227518
FRONT VIEW OF ENGINE, INTAKE SIDE

1. Air inlet from aftercooler temperature sensor - 2. Pre/heater glow plugs - 3. Air pressure and temperature sensor -
4. Oil pressure switch - 5. Fuel flow regulator on pump - 6. Coolant temperature sensor - 7. Segment speed sensor -
8. Pressure regulating valve on rail - 9. Pressure sensor on rail

Figure 2
227517
FRONT VIEW OF ENGINE, EXHAUST SIDE

1. EGR valve - 2. Increment speed sensor - 3. Alternator - 4. VGT position sensor - 5. Flow rate control valve -
6. Electro-injectors - 7. Exhaust gas temperature sensor

EDC 17 C49 ELECTRONIC CONTROL UNIT
Figure 3
128680
The control unit is a flash EPROM and thus can be reprogrammed remotely without modifying the hardware.
The control unit processes the signals from the sensors by applying software algorithms and controls the actuators (especially the
electroinjectors and pressure regulator).
It records, in the non-volatile memory area, the information on the engine parameters originally set or acquired during engine
operation.
The injection control unit has the absolute pressure sensor built in to further improve the control of the injection system.
The control unit is mounted on the left-hand side of the engine bay and is connected to the vehicles wiring harness by two
connectors.
- 60-pin connector (A)A for the components on the engine;
- 94-pin connector (K) for the components on the vehicle.
In addition to managing the functions of the system described in the relevant chapter, the control unit is also interfaced with the
other electronic systems on board the vehicles, such as: ABS - EBD, cruise control, speed limiting device, immobilizer, EGR,
preheating glow plugs.
On vehicles equipped with catalytic D.P.F., the control unit handles the regeneration system itself;
Consequently, after having performed any of the following operations:
- replacing one or more injectors;
- replacing all injectors;
- replace flow rate meter (flow meter);
- replacing the hydraulic accumulator (common rail) pressure sensor;
- replacing the EDC 17 C49 control unit;
- engine oil change;
- replacing D.P.F. catalytic converter;
- filter differential pressure (p) sensor replacement;
- replacing components relating to emissions;
- necessity to perform a forced regeneration.

VEHICLE SIDE ELECTRICAL WIRING

Diagram
Figure 4
224830
1. Fuel temperature sensor - 2. WIF switch - 3. Fuel heater - 4. Exhaust gas temperature sensor (inlet DPF) -
5. Particle filter differential pressure sensor -6. Exhaust gas temperature sensor (PreoxiCat) - 7. A/C request -
8. Air charger intercooler outlet temperature sensor -9. Reverse gear switch - 10. A/C compressor - 11. +50 starter -
12. Alternator D+ - 13. Pre/heater glow plugs - 14. Pre/heater glow plugs control unit - 15. FAN2 relay - 16. FAN1 relay -
17. A/C compressor relay - 18. Electric fuel pump relay - 19. Fuel filter heating relay - 20. Reduntant brake switch signal -
21. Brake main switch - 22. Clutch switch signal - 23. Hot-film air mass filter with heater - 24. Lambda sonde -
25. Accelerator pedal position sensor - 26. Key switch 15 - 27. Main relay xxA
DRAFT
ECU connection to the injection cable on vehicle side (housing B)
Figure 5
85708 224835
Pin Description
01 Main relay xxA
02 V2
03 Main relay xxA
04 V2
05 Main relay xxA
06 V2
07 Lambda sonde
08 Air charger intercooler temperature sensor
09 -
10 -
11 -
12 -
13 -
14 Particle filter, differential pressure sensor
15 -
16 Accelerator pedal position sensor
18 -
19 Hot-film air mass filter with heater
22 -
23 -
24 -
25 -
26 Glow control unit (GCU2)
27 -
28 Main relay xxA
30 WIF switch
31 -
32 -
DRAFT
Pin Description
33 -
34 -
35 Fuel temperature sensor
37 -
40 -
41 -
42 -
43 Reverse gear switch
44 Clutch switch signal
45 -
46 -
47 -
48 -
49 -
50 FAN 2 relay
51 -
52 -
53 -
54 Key switch 15
55 -
56 -
57 Fuel temperature sensor
59 -
62 -
63 Lambda sonde
64 Lambda sonde
65 -
66 Reduntant brake switch signal
67 Glow control unit (GCU2)
68 -
69 -
70 -
71 -
72 Fuel filter heating relay
73 FAN 1 relay
74 -
75 Electric fuel pump relay
DRAFT
Pin Description
76 A/C request
77 -
78 -
79 Exhaust gas temperature sensor n.1 (PreoxiCat)
80 Exhaust gas temperature sensor n.1 (PreoxiCat)
81 -
82 -
83 Exhaust gas temperature sensor n.2 (inlet DPF)
84 Exhaust gas temperature sensor n.2 (inlet DPF)
85 Lambda sonde
86 Lambda sonde
87 -
88 Brake main switch
89 Air charger intercooler temperature sensor
90 -
91 -
92 -
93 -
94 AC compressor relay
DRAFT
ENGINE SIDE ELECTRICAL WIRING

Topographic view
Figure 6
227528
1. Current sypply glow relay - 2. Vehicle side connection - 3. VGT actuator - 4. Glow plugs control unit -
5. Boost pressure with air temperature sensor - 6. Coolant temperature sensor - 7. Oil pressure switch -
8. High pressure pump fuel metering unit - 9. Air charger from aftercooler temperature sensor - 10. Pressure control valve -
11. Segment speed sensor camshaft - 12. Electro-injector cylinder 1 -13. Increment speed sensor crankshaft -
14. VGT position sensor - 15. EGR valve actuator - 16. Electro-injector cylinder 2 - 17. Electro-injector cylinder 3 -
18. Electro-injector cylinder 4 - 19. ECU connection - 20. EGR cooler outlet temperature sensor - 21. Section glow plugs -
22. Rail pressure sensor

Print P1D32S021 E
Diagram
Figure 7
F1C EuV1 - ENGINES
227526
1. ECU connection- 2. Rail pressure control valve - 3. Fuel metering unit - 4. Increment speed sensor crankshaft -
SECTION 3 - ELECTRICAL EQUIPMENT
5. Segment speed sensor camshaft -6. Coolant temperature sensor - 7. EGR cooler outlet temperature sensor -
8. VGT position sensor - 9. Electro-injector cylinder 2 - 10. Electro-injector cylinder 4 -
11. Electro-injector cylinder 3 - 12. Electro-injector cylinder 1
11
Base - April 2015

12
Base - April 2015

Figure 8
SECTION 3 - ELECTRICAL EQUIPMENT
227527
1. ECU connection- 2. Rail pressure sensor - 3. Boost pressure sensor with air temperature sensor -
4. EGR position sensor actuator- 5. Engine brake position sensor actuator -6. Reduction agent dosing valve -
7. Air charger fron aftercooler temperature sensor - 8. Pre/heater glow plugs - 9. Pre/heater glow plugs control unit -
F1C EuV1 - ENGINES
10. Oil pressure switch - 11. VGT actuator
Print P1D32S021 E
ECU connection to the injection cable on engine side (housing A)
Figure 9
85708 221442
Pin Description
01 Connection of solenoid valve 21 (injector on cylinder 3)
02 (injector on cylinder 2)
03 Rduction agent dosing valve
04 VGT actuator
05 -
06 Oil pressure switch
07 VGT position sensor
08 Engine brake position sensor actuator
09 EGR valve position sensor actuator
10 Boost pressure sensor with air temperature sensor
11 Rail pressure sensor
12 -
13 Segment speed sensor camshaft
15 Fuel metering unit
18 Reduction agent dosing valve
19 -
20 -
21 -
22 -
27 EGR cooler outlet temperature sensor
29 -
30 Rail pressure control valve
33 -

Pin Description
36 -
42 EGR cooler outlet temperature sensor
43 -
44 Increment speed sensor crankshaft
45 Rail pressure control valve
47
51 -
52 -
54 -
56 -
57 Coolant temperature sensor
58 Coolant temperature sensor
59 Increment speed sensor crankshaft
60 Fuel metering unit

MAIN ELECTRICAL/ELECTRONIC Electro-Injectors CRi2.20

EQUIPMENT
Figure 11
Pressure regulator valve on HP pump
Figure 10
224251
The new high pressure fuel pump is supplied by Bosch, model

CP4.1 (one plunger), it can pressurise the fuel circuit up to
2000 bar.
224833
A solenoid valve controlled directly by the engine control unit
regulates the fuel supply. 1. Positive - 2. Negative
It is fitted with a 2-pin connector to enable the solenoid valve
to be controlled by the engine control unit. The injectors are activated by a solenoid with a servo valve
which allows faster and more flexible management of
injection events (IRS: Injection Rate Shaping).
The head of the electro-injector has a fitting for the electrical
PIN DESCRIPTION ECU PIN connector.
1 Power supply 15 They are mounted on the cylinder overhead and are
2 Signal 60 connected individually to the control unit.
PIN DESCRIPTION ECU PIN

1 Cylinder 1 16
2 Cylinder 1 32
1 Cylinder 2 2
2 Cylinder 2 46
1 Cylinder 3 1
2 Cylinder 3 31
1 Cylinder 4 17
2 Cylinder 4 48

Rail pressure sensor Throttle valve

Fitted to a rail end, it measures fuel pressure present to the Figure 13
purpose of determining existing fuel pressure.
Pressure value is used to control pressure and determine
injection electric control duration.
Pressure regulating valve on rail

Controls the pressure in the Rail in relation to the engine load.
At too high pressures, the valve opens to return some of the
fuel from the rail to the tank via the recovery circuit; at too low
pressures, the valve closes to separate the high and low
pressure sides from each other.
The valve is a solenoid operated valve controlled by the PWM
signals of the engine management control unit.
The control unit controls the valve after processing the signals
from the various sensors of the engine: engine speed, load, air
intake, air pressure, engine and fuel temperature. 229367
1. Electrical connection - 2. Control actuator
The pressure is controlled by varying the return flow to the
tank. The throttle valve is positioned at the turbocharger exhaust
gas outlet, its controlled by an electric actuator via signals from
the engine management control unit.
The main newfeature is an electric actuator which allows the
Figure 12 exhaust gas outlet to be choked to increase the outlet
temperature.
This possibility is exploited in order to quickly bring catalytic
converter up to standard thermal conditions (reduction of
emissions when is cold).
A second function of the throttle valve is the engine brake.
The use of the engine brake with the throttle valve on the
exhaust allows use of the service brake system to be limited
and therefore reduces brake wear.
The engine brake is cooled by the engine coolant.
Figure 14
224834
A. Pressure sensor - B. Pressure regulating valve
RAIL PRESSURE SENSOR PIN OUT

1 Ground 26
2 Pressure signal 41
2 Power supply 11
224847
MOTORIZED THROTTLE VALVE PIN OUT

PRESSURE REGULATING VALVE PIN OUT
1 DC motor (+) 49
PIN DESCRIPTION ECU PIN 2 Signal 38
1 Ground 30 4 Ground 23
2 Power supply 45 5 DC motor (+) 34
6 Power supply 8

VGT position sensor EGR valve
Figure 15 Figure 17
229368
229369
1. Electrical connection - 2. EGR valve
1. Electrical connection - 2. Pneumatic actuator
The control unit processes the information coming from the
In the variable geometry turbochargers, the driving rotor is atmospheric pressure sensor, water temperature sensor,
surrounded by mobile blades, whose movement is controlled engine rpm sensor, accelerator pedal potentiometer and, in
by a pneumatic actuator that is directly controlled by the accordance with suitably programmed modes in its memory,
engine control unit via the modulating solenoid valve. operate the opening of the plate in the E.G.R. valve by means
of a PWM signal.
The movement of the mobile blades outside of the driving
turbine determines the variation in the angle of incidence of In this way, some of the exhaust gases are sent towards the
the exhaust gas with the blades of the rotor itself. heat exchanger where they are cooled and directed to the
chamber for the throttle valve assembly to bemixed with the
Based on the rotation speed, they are closed or opened to
air coming from the aftercooler and flow to the intake
influence the speed or the capacity depending on the actual
manifold.
speeds.
To make it possible for the engine control unit to be precisely
aware of the position of the mobile blades; a position sensor
is fit on the pneumatic control actuator.
Figure 18
Figure 16
224847
224848
EGR VALVE PIN OUT
VGT POSITION SENSOR PIN OUT PIN DESCRIPTION ECU PIN
1 DC motor (+) 50
PIN DESCRIPTION ECU PIN 2 Signal 39
1 Ground 37 4 Ground 24
2 Signal 53 5 DC motor (+) 35
3 Power supply 7 6 Power supply 9

Driving shaft and camshaft unit
Figure 19
3 4
162263
1. Increment speed sensor - 2. Phonic wheel on crankshaft - 3. Segment speed sensor - 4. Camshaft pulley
Increment speed sensor (crankshaft) Figure 20

The crankshaft is fitted with a pulser ring. The sensor detects the
teeth as they pass it and sends the control unit the information
required to calculate the engine speed.
The variation of the signal generated by the lack of some teeth
(synchronisation gap) occurring at each crankshaft turn is the
reference signal which enables the control unit to detect the
lead of the pair of pistons 1-4 with respect to PMS.
This signal is also used by the control unit to detect the engine
rotation speed, the duration of injection and to control the rev
counter.
221433

Figure 21 Segment speed sensor (camshaft)

A semiconductor layer, immersed in a magnetic field and
through which current flows, generates a potential difference
(called Hall voltage) at its ends.
If current intensity remains constant, the generated voltage
depends only on the magnetic field strength: periodical variation
of field strength is enough to obtain a modulated electric signal.
The smooth portion of the phonic wheel (distributing shaft
pulley) covers, while moving, the sensor, thus blocking the
magnetic field with resulting low output signal.
On the contrary, the sensor generates a high signal next to the
openings and when a magnetic field is available.
Phase sensor signals are acquired, and the engine position is
recognized according to the sequence of the phonic wheel
notches. The mounting function makes it possible to identify
signal errors and interferences (if any).
The resulting signal is supplied to the processor that controls the
injection system.
224850
Figure 22
ENGINE SPEED SENSOR PIN OUT

1 Ground 44
2 Signal 59
221434

Figure 23 Figure 24
224247

1 Ground 25
2 NTC signal 55
3 Power supply 10
4 Temp. signal 40
224849
TIMING SENSOR PIN OUT Figure 25

1 Ground 28
2 Signal 14
3 Power supply 13
Air temperature and pressure sensor

224838
This component incorporates a temperature sensor and a
pressure sensor. SIGNAL EVALUATION WITH LOAD RESISTOR TO
It is fitted on the engine intake manifold and measures the UH = 5.5 TO 16V
maximumflow rate of the intake air which is used to
accurately calculate the amount of fuel to be injected at each
cycle. Figure 26
It is connected to the central unit on connector A.
Technical data
Pressure range 20 300 kPa
Temperature range -40 130 C
224839
SIGNAL EVALUATION WITH LOAD RESISTOR TO

GROUND

Figure 28 Figure 29
150730
OPERATING GRAPH
214595
Engine coolant temperature sensor WIRING DIAGRAM

This sensor is located on the thermostat box.
It detects the temperature of the coolant fluid to give the
control unit information about the engine temperature
conditions.
Figure 27 Figure 30
214598
224837

1 Temperature signal 57
2 Ground 58

Exhaust gas temperature sensor
Figure 31
102303
Figure 32
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Ground cable (white) - 6. Sensor.
It has the function of sending information to the control unit regarding the temperature of the exhaust gas exiting the EGR heat
exchanger.
CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR VALUE
Power supply 5.00 V 0.1%
Output voltage @ Temperature -40 to 300 C 1.222 to 2.242 V
Pull up resistance 1,000 0.1%
Lead resistance 1

1 Temperature signal 42
2 Ground 27

Oil pressure switch Air inlet from aftercooler temperature sensor

It is fitted on the water/oil heat exchanger and measures the It is fitted on the intake manifold air inlet pipe.
engine oil pressure.
It measures the air temperature coming from the aftercooler.
The signal detected is sent to the engine management control
unit by the pin 6.
Contact pressure 0.5-0.7 bar
Figure 33 Figure 34
221436 221437
WIRING DIAGRA,M
Figure 35

1 Signal 6
214595
WIRING DIAGRA,M

Pre/heater glow plug control unit Figure 36

The engine control unit, in the phase of:
- starting;
- post-starting.
times the operation of the glow plug control unit according
to the engine temperature.
Glow plugs drive is through glow plugs pre-heating control
unit depending on engine temperature under direct control
of the engine control unit.
The pre-heating ECU contains an intelligent contactor that
sends feedback to the ECU communicating any faults with the
pre-heating ECU or shorting to earth of the glow plugs.
Preheat centre pin-out

31 - Mass
86 - Start switch (+15)
ST - EDC electronic centre (pin B42)
DI - EDC electronic centre (pin B37)
30 - Battery positive (+30) 003332t
G1 - Preheat plugs
PREHEAT CENTRE
G2 - Preheat plugs
G3 - Preheat plugs
Figure 37
G4 - Preheat plugs
Pre/heater glow plugs

CONTROL VALUES
With constant di 11V power supply:
- maximum current absorbed 18 A
- in 5 11 1,5 A
- in 30 6 0.9 A
- temperature after 7 850C
- torque 8-10 Nm
221439
ELECTRICAL DIAGRAM
Figure 38
75579
PRE/HEAT GLOW PLUG

Alternator
Supplier BOSCH
Technical data 14V-210A MFR OWC
Weight 7.5 kg
Voltage @ 0 rpm 1,400 A
Voltage @ 1,800 rpm 100 A
Voltage @ 6,000 rpm 210 A
Direction of rotation clockwise
Figure 39
224829
A. TERMINAL L - B. TERMINAL DFM - C. VDA connector 2 ways type A -

D. REGULATOR - E. Customer connection
Figure 40
224828
CHARACTERISTIC CURVES REGULATOR CHARACTERISTIC CURVE CABLING DIAGRAM (MFR)

(8VR-MFR)
Pin Description
DFM Digital Field Monitor
BS + 30
15 Power supply +15
L Failed recharge signal
W Battery recharge warning light
B1+ Positive 1
B2+ Positive 2

Starter motor
Supplier BOSCH
Nominal voltage 12V
Power rating R 78 - M55
Number of poles 6
Gear ratio 5 5
Direction of rotation Right
Figure 41
227562
1. Collector bearing - 2. Plate - 3. Pole housing - 4. Drive end shield - 5. Relais - 6. Closure caps
Figure 42
227563
ELECTRIC DIAGRAM

F1C EuV1 - ENGINES SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled Maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Extraordinary interventions - daily checks . . . . 3
MAINTENANCE PROCEDURES . . . . . . . . . . . . 5
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Periodic maintenance . . . . . . . . . . . . . . . . . . . 7
- Extraordinary maintenance . . . . . . . . . . . . . . . 11

2 SECTION 4 - SCHEDULED MAINTENANCE F1C EuV1 - ENGINES

SCHEDULED MAINTENANCE
Introduction
To ensure best operating conditions, on the following pages are indicated the checks, tests and adjustments which shall be carried
out on the different parts at the established time.
The frequency of the maintenance operations are indicative since the engine use and its characteristics are essential in evaluating
replacements and checks.
Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking
andmaintenance operations which do not fall among those listed below, but are recommended by good-practices and particular
conditions of use of the engine.
Furthermore, in case of clearmalfunctioning of the engine, for example excessive grade of smoke of exhaust gases, high temperature
of the coolant or low oil pressure, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with
accident-prevention laws for the safety of the staff in charge of maintenance.
Extraordinary interventions - daily checks

Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series
nature, while the engine is operating.
These checks are usually performed by the vehicle operators and drivers.
- Checking the levels and checking for any leaks from the fuel, cooling and lubrication circuits.
- Informing maintenance personnel if any problems are found; top up if necessary.
After starting the engine and with the engine operating, perform the following checks and controls:
- Checking for any leaks from the fuel, cooling and lubrication circuits.
- Making sure there is no unusual noise or knocking during operation.
- Using the vehicle instruments to check the specified pressure, temperature values, etc.
- Visually checking the smoke (colour of the exhaust gas).
- Visually checking the level of the coolant in the expansion tank.
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 Manufacturer
fully complies with all the installation prescriptions provided by FPT.
Furthermore, the equipment assembled by the Manufacturer shall always be in conformance to couple, power and
number of turns based on which the engine has been designed.

Checks Frequency (***)

Engine lubricant oil level check Daily
Engine coolant level check Daily
Engine visual inspection 15 days
Air filter & housing cleanness check(**) 1 month
Electrolyte level in batteries check/top up and terminals cleaning (**) 6 months
Tension and condition check of auxiliary members belt 6 months
Exhaust duct(s) condition check 6 months
Periodic maintenance Frequency (***)
Water drainage from the fuel pre filter(**) Weekly
Condensed water drainage from fuel tank Weekly
Engine lubricant oil replacement 24,000 km / 600 hours / 1 year(3)
Lubricant oil filter replacement 24,000 km / 600 hours / 1 year(3)(4)
Fuel pre-filter replacement (**) 24,000 km / 600 hours / 1 year(1)
Fuel filter replacement (*) (**) 24,000 km / 600 hours / 1 year(1)(4)
Power steering oil replacement 24,000 km / 600 hours / 1 year
Air filter cleaning (**) 1 year
Air filter replacement (**) 3 years(2)
Auxiliary members belt replacement 96,000 km / 2,400 hours / 4 years(5)
Heat exchanger (radiator) cleaning (**) 96,000 km / 2,400 hours / 4 years
Extraordinary maintenance Frequency (***)
Turbocharger visual inspection 2 years
Engine coolant replacement 2 years
Pre-heating glow plug replacement 160,000 km / 4,000 hours / 5 years
Auxiliary members belt tensioning device replacement 160,000 km / 4,000 hours / 5 years
Timing system chain and tensioning device replacement 240,000 km / 6,000 hours / 5 years
Particulate filter replacement 120,000 km / 3,000 hours / 5 years
(1) Maximum period for using good quality fuel (EN 590 standard). It is reduced based on the dependency on fuel contamination
and on the alarm signals for pre-filter/filter clogging and/or water in the filter. The filter clogging warning requires its replacement.
If the water alarm is not disabled after draining, the filter needs to be replaced.
(2) Early filter cloggingis usually due to enviromental conditions. For this reason, the filter should be changed if clogging is signalled
by the related sensor, regardless of the prescriptions, that shall be observed if no specific indications have been provided.
(3) Frequency applicable to lubricants which meet the international standards 5W-30/0W-30; ACEA C2; recommended oil is
URANIA DAILY FE - URANIA DAILY LS.
(4) Use only filters with the following features:
- filtering degree < 12 m,
- filtering efficiency > 200.
(5) Replace every 60.000 km under harsh conditions of use (dust and/or heat).
(*) If the clogged filter warning lamp lights up on the instrument panel, the filter must be replaced before the programmed
replacement interval.
(**) Frequencies valid only if the components are supplied by FPT.
(***) Action needed @ km/hour/temporal (whichever occurs first).
Checks, inspections and changes are indicative and must integrate specifications for vehicles equippedwith the F1C EuVI
! engine.
The data are only valid if the fitter observes all the installation regulations provided by FPT.

MAINTENANCE PROCEDURES Engine coolant level check

Proceed only with engine not running and at low temperature
Checks to avoid any risk of burns.
Engine lubricant oil level check With the engine at low temperature, make sure that the fluid
level in the expansion tank is above the minimum level.
Figure 1 Visually check that the fluid level is not more than 2/3 of the
height of the tank in order to enable any increase in volume
of the fluid caused by the temperature increase.
Top up the tank if necessary, using a 50% mixture of water and
Paraflu HT even during the summer months. As an alternative
to Paraflu HT use another product which complies with ASTM
D-6210 international standard.
NOTE In the event that only the heat exchanger without

the expansion tank is available on the vehicle, refill
it if necessary, paying attention that the fluid does
not saturate the internal volume of the exchanger
in order to enable any increase in volume of the
229366 fluid caused by the temperature increase.
The check must be performed when the engine is stopped and
possibly cold.
The check is carried out with the flexible dipstick (2). When the engine is warm, a pressure liable to cause
! hot liquid to be expelled with extreme violence is
Remove the dipstick (2) from its housing and check that the created within the cooling circuits. This results in a
level is between the minimum and maximum ends etched on danger of burning.
it.
If the reading is unclear, clean the dipstick (2) with a cloth with
no looses threads and put it back in its seat. Take it off again Engine visual inspection
and check the level. Before starting, it is recommended to carry out a series of
If the level is insufficient, it is necessary to top up with lubricant simple checks that can significantly help avoid problems, also
oil which meets the international standards 5W-30/0W-30; of a series nature, while the engine is operating. These checks
ACEA C2; recommended oil is URANIA DAILY FE - URANIA are usually performed by the vehicle operators and drivers.
DAILY LS. Check the levels and check for any leaks from the fuel, cooling
Remove the lubricant oil cap (1) and pour engine lubricant oil and lubrication circuits.
through the hole. Inform maintenance personnel if any problems are found; top
Always make sure to add oil with the same characteristics as up if necessary.
the one contained in the sump. Mixtures which do not ensure After starting the engine and with the engine operating,
the proper lubrication of the internal parts of the engine are perform the following checks and controls:
not permitted.
Check for any leaks from the fuel, cooling and lubrication
circuits.
The engine oil is highly pollutant and toxic. Make sure there is no unusual noise or beating during
! In case of contact with skin, wash thoroughly with operation.
water and detergent.
Use the vehicle instruments to check the foreseen pressure,
Suitably protect skin and eyes; proceed in temperature values, etc.
accordance with accident prevention standards.
Visually check the smoke (colour of the exhaust gas).
Suitably dispose of the residuals and in accordance
with regulations. Visually check the level of the coolant in the expansion tank.

Air filter & housing cleanness check Electrolyte level in batteries check/top up and
(supplied on demand) terminals cleaning (supplied on demand).
Only proceed with the engine stopped. Place the batteries on a level surface, then proceed as follows.
Visually check that the fluid level is between the Min and
Figure 2 Max limits; in the absence of references, check that the fluid
covers the Lead plates inside the elements.
Top up with distilled water only those elements in which the
level is below the minimum.
Contact specialised technical staff if the battery needs
recharging.
On this occasion, make sure that the terminals and clamps are
clean, properly locked and protected by vaseline.
If all the elements of the battery need refilling with a

! considerable quantity of distilled water, contact
specialised technical personnel in order to perform
a diagnostic check on the efficiency state of the
229365 recharge system and battery.
Remove the cover (1) of the filter housing and extract the
cartridge paying attention that the dust does not get into the
sleeve.
The batteries contain sulphuric acid, which is
Blow the filtering element by means of dry and compressed air, extremely caustic and corrosive; always wear
acting from the inside outwards (max. pressure: 200 kPa).
!
protective gloves and goggles when topping them up.
Avoid using detergents; do not use diesel oil. Whenever possible it is recommended that this
Never hit the filtering element by means of tools, and check control be carried out by specialised personnel.
its condition before reinstalling it. Do not smoke or use live flames near the batteries
In the event that breakages or tears take place, or it is not during the control, and make sure that the room you
possible to remove the impurities, replace it. are working in is adequately ventilated.
Check that the gasket base is in good condition.

Reassembly the filtering element and close the housing. Figure 3
Take care to ensure that the parts are reassembled

! correctly.
Imperfect assembly might result in unfiltered air being
sucked into the engine, causing serious damage.
225112
Some types of battery have a single cover for all the inspection
plugs to access the elements, use a lever as shown in the figure.

Tension and conditions check of auxiliary member Periodic maintenance

belts
Water drainage from the fuel pre-filter (supplied on
Only proceed with the engine stopped and at a low demand)
temperature, so as to avoid the risk of burning.
Depending on its use, some vehicles adopt a fuel pre-filter as
well.
Figure 4
The high risk of refuelling with fuel that is polluted by foreign
bodies and water makes it advisable to carry out this control
every time you refuel.
Proceed with the engine stopped.
Figure 5
229364
Check that the belt (1) is not torn or worn, and that there are
no lubricants or fuel on it. If this is not the case, replace them.
At the same time, make sure that the tensioning device is
working properly.
229363
Exhaust duct(s) condition check
Visually check that the exhaust gas system is not blocked, Place a container under pre-filter to collect the fluid.
corroded or damaged. Unscrew the tap plug (1) in the bottom part of the filter; in
In the event of any problems, perform the operations some lay-outs the plug includes a sensor to detect the
necessary to restore the exhaust duct. presence of water in the diesel.
Drain off liquid until only diesel can be seen.
Close the plug again, tightening it completely by hand.
Dispose of the drained fluids according to current
requirements.
Condensed water drainage from fuel tank

Perform the drainage/suction of water, condensation and
impurities from the fuel tank/s by following the instructions
contained in the manual supplied by the tank manufacturer.
Proceed as necessary based on the structure or location of the
tank: engines that operate in adverse environments and
conditions and/or that are refuelled using drums or jerry cans,
require more attention when cleaning the tank.
Engine lubricant oil replacement
The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
Place a suitable container to collect the oil as it drains out.

Figure 6
Only use filters with a filtration level equivalent to the
ones you are replacing (see the table at the beginning
of section 4).
Place a container under the filter support, to collect the used

oil.
Figure 8
229361
Pull out the oil dipstick (1).
Figure 7
227800
Unscrew the filter (1) and remove it.
Ref. No. Description

(1) 1 M22x1.5
Carefully clean the surfaces of the support that are in contact
with the seal.
Moisten the new filter seal with a thin layer of oil.
229362
Manually tighten the new filter (1) on the support until it comes
into contact with the seal. Additionally tighten it using a specific
Unscrew the filler cap (2) at the top of the engine. tool to the torque indicated in the table.
Unscrew the drain plug (1) and drain the oil into a container
Tightening
Ref. No. Description torques
(1) 1 M22x1.5x10 (1) 1 M22x1.5 25 2,5 Nm
Wait until the oil sump has completely emptied, then retighten Operate the engine for a few minutes and then check the level
the lubricant oil drain plug (1) under the sump at the torque using the dipstick. If necessary, top up to compensate for the
indicated in the table. quantity of oil used to fill up the filtering cartridge.
Tightening
torques
(1) 1 M22x1.5x10 50 5 Nm
Proceed with the refilling operation:
Add the specified quantity of lubricant oil that meets the
international standards 5W-30/0W-30; ACEA C2;
recommended oil is URANIA DAILY FE - URANIA DAILY LS.
Lubricant oil filter replacement

Only proceed with the engine stopped and at a low

Fuel pre-filter replacement (supplied on demand) Fuel filter replacement (supplied on demand)
Only proceed with the engine stopped. Only proceed with the engine stopped and at a low
Figure 9 Only use filters with a filtration level equivalent to the ones you
are replacing (see the table at the beginning of section 4).
Disconnect the electrical connection and the fuel pipes.
Loosen the screws and remove the support including the filter.
Remove the connector from the filter housing.
Remove the filter housing from the support and remove the
filtering element.
Moisten the new filter seal with diesel or engine oil.

Hand screw the new filter into place until the seal gasket
touches the support, then lock by a further 3/4 of a turn.
Insert the connector into its seat and refit the fuel filter in the
229360
engine compartment, reversing the operation described
previously.
Remove the prefilter by unscrewing it.
Check that the new filter has performance levels that satisfy the
needs of the engine (e.g. by comparing them with the old one). Do not fill up the new filter before it is fitted to the
support, to avoid inserting harmful impurities into the
Moisten the new filter seal with diesel or engine oil. injection system and circuit.
Hand screw the new filter into place until the seal gasket
touches the support, then lock by a further 3/4 of a turn.
Place the water presence sensor in its seat, taking care to In the event that fuel pipings have to be disconnected,
couple the threads correctly. clean with the utmost care the fittings before
Loosen the bleeder screw (2) on the pre-filter support and connecting them again. Make sure that the seal is
activate the hand pump (1) until the supply circuit is full. appropriate by starting the engine. If leakages occur
take adequate countermeasures against this
Ensure that any fuel coming out is not dispersed into the immediately.
environment.
Lock the bleeder screw tightly.
Start the engine and run it at idle for a few minutes to eliminate Never loosen the high pressure common rail
any residual air. ! injection circuit fitting in any way. Do not carry out
un necessary and dangerous bleeding attempt.
NOTE Should it be necessary to accelerate the bleeding
phase, the hand pump can be used during start-up.
Do not smoke or use open flames during this
! operation.
Do not inhale the vapours that exit the filter.

Power steering oil replacement Heat exchanger (radiator) cleaning (supplied on

Only proceed with the engine stopped. demand)
Open the cap of the storage tank and proceed depending on Figure 11
the necessity related to the vehicle building.
Air filter cleaning (supplied on demand)

Refer to the instructions provided for Air filter & housing
cleaness check.
Air filter replacement (supplied on demand)

Refer to the instructions provided for Air filter & housing
cleaness check.
Auxiliary members belt replacement
Figure 10
229359
Check that the air intake surfaces of the radiators are free of
impurities (dust, mud, straw etc.). Clean them if necessary
using compressed air or steam.
When using compressed air, it is required to use

suitable personal protections for hands, face and
eyes.
229364
Using a suitable tool remove the A/C compressor belt (2).

Using the specific wrench on the automatic belt tensioner (3),
reduce the tension of the belt (1) and remove it from
alternator, water pump, crankshaft pulley, compressor and
fixed guide roller.
Using a specific wrench on the automatic belt tensioner (3), fit
the belt (1) on the pulleys and fixed guide roller, making sure
that the ribs on the belt fit properly into the grooves on the
pulley.
Additional adjustments are not required. The belt (1) tension
is adjusted automatically by the calibrated spring in the
automatic belt tensioner (3).
Using a suitable tool fit the A/C compressor belt (2).
Operate the engine for a few hours and check that the auxiliary
members belt (1) is properly fitted.

Extraordinary maintenance Pre-heating glow plug replacement

Turbocharger visual inspection To perform this operation correctly, proceed as described in
section 5 PRE/HEATER GLOW PLUGS
Only proceed when the engine is not turning over. Visually REMOVAL/REFITTING chapter.
check that the turbine and compressor impellers and the
relative inlet and outlet ducts are not obstructed or damaged, Auxiliary members belt tensioning device
otherwise replace them. replacement
Engine coolant replacement. Figure 12
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
In the event that a mixture of PARAFLU HT and water is used,
the density value is equal to 1.0675 g/cm3 (at a temperature
of 15C ).
For replacing the coolant, observe the following procedure:
Use suitable containers to ensure that the coolant is not
dispersed in the environment.
Loosen the retaining elements and remove the sleeves that
couple the engine circuit with the heat exchanger and wait for
them to empty completely. Once emptied, restore the
condition of the circuit, ensuring the perfect seal of the sleeves.
Refill the circuit according to the requirements specified: 227797
Use a 50% mixture of water and Paraflu HT even during the Using a suitable tool remove the air compressor belt (2).
summer months. As an alternative to PARAFLU HT use
Using the specific wrench on the automatic belt tensioner (4),
another product which complies with ASTM D-6210
reduce the tension of the belt (1) and remove it.
international standard.
Undo the screw (3) and remove the automatic belt tensioner
Refill the engine and the exchanger until the exchanger is
(4).
completely filled.
With the filler plug open, start the engine and idle it for approx. Ref. No. Description
1 minute. This phase helps to completely bleed the air (3) 1 M10x1.5x45
contained in the cooling circuit.
Fit the automatic belt tensioner (4) and tighten the screw (3)
Stop the engine and then top up the incomplete quantity.
to the torque indicated in the table.
When the engine is cold, make sure that the coolant level is
a few centimetres below the filling hole. Tightening
In the event of an externally located level indicator as regards torques
the heat exchangers, proceed with the top up operation by (3) 1 M10x1.5x45 45 5 Nm
making sure that the coolant does not overfill the internal
volume of the exchanger in order to allow the expansion of Using a specific wrench on the automatic belt tensioner (4), fit
coolant volume during increases in temperature. the belt (1), making sure that the ribs on the belt fit properly
into the grooves on the pulley.
Using a suitable tool fit the air compressor belt (2).
The failure to observe the aforesaid procedure does
not guarantee the presence of the correct quantity Timing system chain and tensioning device
of coolant in the engine. replacement
To perform this operation correctly, proceed as described in
section 5 CYLINDER HEAD REMOVAL/REFITTING
chapter.
When the engine is hot, pressure builds up in the

! cooling circuits which may eject hot liquid violently,
resulting in a risk of burns.
Open the filler cap of the coolant tank only if
necessary and only when the engine is cold.

Particulate filter replacement

The particulate filter is designed to filter particulate particles
that are deposited between the ceramic structure pores.
When necessary (time intervals or loss in pressure along the
filter), the filter is cleaned bringing the temperature of the
exhaust gases to 630C; to do this, an exothermic reaction
must be created in the catalytic converter by injecting a small
quantity of fuel after the top dead centre with a delay that
allows vaporization in the combustion chamber without
burning.
When the vaporised fuel reaches the catalytic converter, if the
temperature is at least 230C, the catalysts allows the start of
the combustion bringing the DPF to a temperature of 630C.
The control unit, acting at the time of the post-injection and
on the quantity of oxygen (closure of the throttle valve),
maintains the optimum regeneration temperature.
During the regeneration stage, the E.G.R. is closed to prevent
the intake of the vapours produced into the cylinder.
The filter regeneration is not possible when it presents signs
of damaging: in this case proceed to the particulate filter
replacement.
The filter regeneration requires that all the parameter counters
are reset, as: the quantity of particulate/ashes accumulated in
the new filter is zero; in the case of simultaneous replacement
of the particulate filter and the engine oil is necessary to reset
the amount of post-injected fuel.
All the regeneration parameters must be reset because, to all
intents and purposes, this is a new life cycle. If you do not zero:
the ash counter, the frequency of the regenerations will be
greater than required with an unnecessary increase in
consumption, the thermal fatigue of the particulate filter and,
in extreme cases, an unfounded request to change the engine
oil; the Oxicat ageing function with a risk of unjustified
post-injection quantities; the post-injection fuel counter, may
make an early request to change the engine oil.

F1C EuV1 - ENGINES SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS 1
SECTION 5
Removal/Refitting of the main engine

components
Page
ENGINEWIRING REMOVAL/REFITTING ............ 5
- Removal ................................................................................ 5
- Refitting .................................................................................. 6
LOW PRESSURE FUEL PIPE GROUP AND

FUEL RECOVERY PIPE REMOVAL/REFITTING 7
- Removal ................................................................................ 7
- Refitting .................................................................................. 8
HIGH PRESSURE FUEL PIPE FROM PUMP TO

RAIL REMOVAL/REFITTING .................................. 10
- Removal ................................................................................ 10
- Refitting .................................................................................. 11
ELECTRO-INJECTORS REMOVAL/REFITTING . 12
- Removal ................................................................................ 12
- Refitting .................................................................................. 13
FUEL MANIFOLD PIPE

REMOVAL/REFITTING .............................................. 15
- Removal ................................................................................ 15
- Refitting .................................................................................. 16
OIL FILTER REMOVAL/REFITTING .......................... 18
- Removal ................................................................................ 18
- Refitting .................................................................................. 18
WATER/OIL HEAT EXCHANGER

REMOVAL/REFITTING .............................................. 19
- Removal ................................................................................ 19
- Refitting .................................................................................. 20
HIGH PRESSURE PUMP REMOVAL/REFITTING 21
- Removal ................................................................................ 21
- Refitting .................................................................................. 23

2 SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS F1C EuV1 - ENGINES
Page Page
ELECTRIC EXHAUST GAS FLAP AUXILIARY DRIVE BELT AND AUTOMATIC BELT
REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 26 TENSIONER REMOVAL/REFITTING . . . . . . . 49
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TURBOCHARGER OIL DELIVERY PIPE GASKET CRANKSHAFT FRONT SEAL RING

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 27 REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 50
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TURBOCHARGER/EXHAUST MANIFOLD TIMING SYSTEM LOWER COVER

GROUP REMOVAL/REFITTING . . . . . . . . . . . 28 REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 52
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
- Checking and adjusting the actuator . . . . . . . . 31 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 DEPRESSOR/OIL PUMP

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 56
EGR GROUP REMOVAL/REFITTING . . . . . . . . . 34
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WATER PUMP REMOVAL/REFITTING . . . . . . . . 61
PRE HEATING GLOW PLUGS
REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 37 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 CRANKSHAFT REAR SEAL RING

THERMOSTAT REMOVAL/REFITTING . . . . . . . 41
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SIDE/UPPER CHAIN GUIDE
INTAKE MANIFOLD REMOVAL/REFITTING . . . 42 REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 63
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BLOW-BY REMOVAL/REFITTING . . . . . . . . . . . 48 ALTERNATOR REMOVAL/REFITTING . . . . . . . 65
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Page
POWER STEERING PUMP
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CYLINDER HEAD REMOVAL/REFITTING . . . . . 69
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
OIL SUMP REMOVAL/REFITTING . . . . . . . . . . . 80
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80


ENGINE WIRING REMOVAL/REFITTING

Removal
Disengage the engine wiring cover from the cylinder overhead, disengage the pins from the relative brackets and remove the
engine wiring.
Disconnect the following electrical connections
Figure 13
227787
REAR VIEW OF ENGINE, INTAKE SIDE

1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor - 4. Engine brake
actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump - 8. Air charger
intercooler outlet temperature sensor - 9. Coolant temperature sensor -10. Air pressure and temperature sensor -
11. Pressure regulating valve on rail - 12. Segment speed sensor

Figure 14
227788

1. Air charger intercooler outlet temperature sensor - 2. Coolant temperature sensor - 3. Segment speed sensor -
4. EGR valve - 5. Increment speed sensor - 6. VGT position sensor - 7. Engine brake actuator
Refitting
Fit the engine wiring, engage the pins in the relative brackets and engage the engine wiring cover in its housing on the cylinder
overhead.
Connect the following electrical connections:
- FRONT VIEW OF ENGINE, EXHAUST SIDE
- REAR VIEW OF ENGINE, INTAKE SIDE
1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor - 4. Engine brake
actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump - 8. Air charger
intercooler outlet temperature sensor - 9. Coolant temperature sensor -10. Air pressure and temperature sensor -
11. Pressure regulating valve on rail - 12. Segment speed sensor

LOW PRESSURE FUEL PIPE GROUP AND Figure 17

FUEL RECOVERY PIPE
REMOVAL/REFITTING
Removal
Place a suitable container, to collect any fuel which may leak
out.
In order to facilitate the operations, remove the engine wiring
as described in the relative procedure.
Figure 15
229303
Undo the screw (2) fixing the oil level dipstick upper bracket
to the intake manifold and extract the oil level dipstick (1)
from the oil sump.

(2) 1 M8x1.25
Figure 18
229299
Lift the retaining clips (1) in the direction shown by the arrow
and disconnect the fuel recovery pipe (2) from the
electro-injectors.
Open the retaining clip (3).
Figure 16
229310
Using tool 99360076 remove the oil filter (1) from the
water/oil heat exchanger (2).

(1) 1 M22x1.5
229300
Loosen the clamp and disconnect the fuel return pipe (1)
from the fuel manifold pipe (2).

Figure 19 Refitting
Figure 21
229311
Release the intermediate retaining clip securing the low 227802

pressure pipes group to the cranckcase.
Fit the low pressure pipes group together with the fuel
Adjust the quick connector (2) and disconnect the fuel return recovery pipe from electro-injectors and engage the group in
pipe from the high pressure pump. the intermediate retaining clips.
Loosen the clamp (1) and disconnect the fuel supply pipe Fit the bracket fixing the low pressure pipes duplex anchorage
from the high pressure pump. and tighten the screws (2) to the torque indicated in the table.
Figure 20 Fit the bracket fixing the low pressure pipes group to the
intake manifold and tighten the screw (1) to the torque
indicated in the table.
Tightening
(1) 1 M6x1 25 2.5
(2) 2 M6x1X10 10 1
Figure 22
227802
Release the intermediate retaining clip securing the low

Undo the bracket screw (1), fixing the low pressure pipes
group to the intake manifold.
Undo the screws (2) fixing the duplex pipe anchorage
bracket, and remove the low pressure pipes group together
with the fuel recovery pipe.
229311
Ref. No. Description Connect the fuel supply pipe to the high pressure pump and
(1) 1 M6x1 close the clamp (1).
(2) 2 M6x1x10 Connect the fuel return pipe to the high pressure pump and
engage the quick connector (2).
Tie the intermediate retaining clip securing the low pressure
pipes group to the cranckcase.

Figure 23 Figure 25
229310 229300
Place the oil filter (1) on the water/oil heat exchanger (2) and Connect the fuel return pipe (1) to the fuel manifold pipe (2)
tighten to the torque indicated in the table. and close the relative clamp.
Tightening Figure 26
(1) 1 M22x1.5 25 2.5
Figure 24
229302
Fit and connect the fuel recovery pipe (2) to the

elctro-injectors and close the retaining clips (1) in the way
shown by the arrow.
229303
Close the intermediate retaining clip (3).
Insert the oil level dipstick (1) into the oil sump and tighten
the screw (2) fixing the oil level dipstick upper bracket to the Fit the engine wiring as described in the relative procedure.
intake manifold to the torque indicated in the table.
Tightening
(2) 1 M8x1.25 25 2.5

HIGH PRESSURE FUEL PIPE FROM PUMP Figure 29

TO RAIL REMOVAL/REFITTING
Removal
out.
Figure 27
229304
Undo the fitting (2) and disconnect the high pressure fuel pipe
from the high pressure pump.
Undo the bracket nut (1) and remove the high pressure fuel
pipe.

(1) 1 M8x1.25
229303 (2) 1 M16x1
from the oil sump. Because of the high pressure in the pipelines running
from the fuel feed pump to the electro-injectors, it
Ref. No. Description is absolutely required NOT to:
(2) 1 M8x1.25 - disconnect the pipelines when the engine is
working;
Figure 28
218891
from the fuel manifold pipe.

(1) 1 M15x1

Refitting Figure 31
Figure 30
218891
Connect the high pressure fuel pipe to the fuel manifold pipe
229304 and tighten the fitting (1) with specific series wrench
99317915 and specific torque wrench 99389829 to the
Fit the new high pressure fuel pipe and tighten the bracket
torque indicated in the table. Use tool 99395216 for angle
nut (1) to the torque indicated in the table.
tightening.
Connect the high pressure fuel pipe to the high pressure
pump and tighten the fitting (2) with specific series wrench Tightening
99317915 and specific torque wrench 99389829 to the Ref. No. Description torques
M15x1
tightening.
(1) 1 1st phase 242
Tightening 2nd phase 90
(1) 1 M8x1.25 252.5
Because of the high pressure in the pipelines running
M16x1 from the fuel feed pump to the electro-injectors, it
(2) 1 1st phase 252 is absolutely required NOT to:
2nd phase 90 - re-use the disassembled pipelines.
Figure 32
229303
the screw (2) fixing the oil level dipstick upper bracket to the
Tightening
(2) 1 M8x1.25 252.5
Fit the engine wiring as described in the relative procedure.

ELECTRO-INJECTORS
REMOVAL/REFITTING Because of the high pressure in the pipelines running
Removal is absolutely required NOT to:
out. - disconnect the pipelines when the engine is
working;
Disconnect the electro-injectors electrical connections.
as described in the relative procedure. Figure 35
Figure 33
229306
Undo the screws (1) and remove the brackets (2) securing
229299 the electro-injectors (3) to the cylinder overhead.
and disconnect the fuel recovery pipe (2) from the Ref. No. Description
electro-injectors. Open the retaining clip (3). (1) 4 M8x1.25x80
Using tool 99342153 to extract the electro-injectors from
Figure 34 the cylinder overhead.
NOTE This procedure has to be done to avoid damage

of the electro-injectors s electrical connector.
Figure 36
229305
Using tool 99317915 (rail side) and tool 99352115

(electroinjectors side), undo the fittings on the fuel manifold
pipe (1), and on the electro-injectors (2), then remove the
high pressure fuel pipes.
Ref. No. Description 227791
(1) 4 M15x1 Remove the bracket (1).

(2) 4 M14x1.5 Using an hammer and 3,5 max punch, remove the pins (2).
When the bracket (1) is reassembled, rotate it about 3 4
in this direction from the original position.

Figure 37 Refitting
NOTE Thoroughly clean the seat of the electro

injectors, taking care that no foreign bodies enter
the cylinder liners.
Figure 38
88244
Apply tool 99342153 (1), using the screw holes of securing

electro-injectors brackets and extract the electroinjectors
(2) from the cylinder overhead (3).
NOTE After removal, mark the injector with the cylinder

number of belonging, for a proper calibration of
217915
the codes IMA; or in case of replacement, we
want to make laboratory analysis. Also make sure Fit a new seal (3) on the electro-injectors (1) and mount them
that the seal is not left in the injector seat engine in the overhead (2) in the same position as they has been
head. removed.
Figure 39
229306
Fit the brackets (2), securing the electro-injectors (3) to the

overhead and screw down the screws (1) without tightening
them completely.

Figure 40
is absolutely required NOT to:
- disconnect the pipelines when the engine is
working;
Figure 42
229307
Connect the new high pressure fuel pipes to the fuel manifold
pipe (1) and to the electro injectors (2), then tighten the
electro-injectors bracket screws (3) to the torque indicated
in the table.
Tightening
Ref. No. Description torques 229302
(3) 4 M8x1.25x80 291.45 Fit and connect the fuel recovery pipe (2) to the
Figure 41 shown by the arrow. Close the intermediate retaining clip (3).
Connect the electroinjectors electrical connections.
229305
Using the 99317915 (rail side) and 99352115

(electro-injectors side) wrenches, the torque wrenches
99389829 (rail side) and 99389831 (electro-injectors side),
tighten the high pressure fuel pipe fittings (1) and (2) to the
torque indicated in the table.
Use tool 99395216 for angle tightening.
Tightening
M15x1
(1) 4 1st phase 242
2nd phase 90
M14x1.5
(2) 4 1st phase 252
2nd phase 50

FUEL MANIFOLD PIPE Figure 45

REMOVAL/REFITTING
Removal
out.
Disconnect the rail pressur sensor and the pressure regulating
valve electrical connections from the fuel manifold pipe.
Figure 43
229305


(1) 4 M15x1
(2) 4 M14x1.5
229299
Figure 46
electro-injectors. Open the retaining clip (3).
Figure 44
229303
from the oil sump.

229300
(2) 1 M8x1.25

Figure 47 Figure 49
217924
229308
from the fuel manifold pipe. Undo the screws (1) and remove the fuel manifold pipe (2).
Ref. No. Description Ref. No. Description

(1) 1 M15x1 (1) 2 M8x1.25
Figure 48 Refitting
Figure 50
229304
Undo the fitting (2) and disconnect the high pressure fuel pipe 229308
Fit the fuel manifold pipe (2) in its housing on the overhead
Undo the bracket nut (1) and remove the high pressure fuel and tighten the screws (1) to the torque indicated in the table.
pipe.
Tightening
Ref. No. Description Ref. No. Description torques
(1) 1 M8x1.25 (1) 2 M8x1.25 291.45
(2) 1 M16x1

working;

Figure 51 Figure 53
229304 229303
Fit the new high pressure fuel pipe and tighten the bracket nut Insert the oil level dipstick (1) into the oil sump and tighten
(1) to the torque indicated in the table. the screw (2) fixing the oil level dipstick upper bracket to the
pump and tighten the fitting (2) with specific series wrench
99317915 and specific torque wrench 99389829 to the Tightening
torque indicated in the table. torques
(2) 1 M8x1.25 25 2.5
(1) 1 M8x1.25 252.5
M16x1
(2) 1 1st phase 252
2nd phase 90
Figure 52
229305
Using the 99317915 (rail side) and 99352115

(electro-injectors side) wrenches, the torque wrenches
99389829 (rail side) and 99389831 (electro-injectors side),
217924
Tightening
Connect the high pressure fuel pipe to the fuel manifold pipe Ref. No. Description torques
and tighten the fitting (1) with specific series wrench
99317915 and specific torque wrench 99389829 to the M15x1
torque indicated in the table. Use tool 99395216 for angle (1) 4 1st phase 242
tightening. 2nd phase 90
Tightening M14x1.5
Ref. No. Description (2) 4 1st phase 252
torques
M15x1 2nd phase 50
(1) 1 1st phase 242
2nd phase 90

OIL FILTER REMOVAL/REFITTING

from the fuel feed pump to the electro-injectors, it Removal
is absolutely required NOT to: Place a suitable container, to collect any fuel which may leak
- re-use the disassembled pipelines. out.
Figure 57
Figure 55
229309
229300 Using tool 99360076 remove the oil filter (1) from the
Connect the fuel return pipe (1) to the fuel manifold pipe (2) water/oil heat exchanger (2).
and close the relative clamp.
Figure 56 (1) 1 M22x1.5
Refitting
Figure 58
229302

shown by the arrow.
229309
Place the oil filter (1) on the water/oil heat exchanger (2) and
Connect the rail pressure sensor and the pressure regulating tighten to the torque indicated in the table.
valve electrical connections on the fuel manifold pipe.
Fit the engine wiring as described in the relative procedure. Tightening
(1) 1 M22x1.5 252.5

WATER/OIL HEAT EXCHANGER Figure 61

REMOVAL/REFITTING
Removal
Place a suitable container, to collect any engine oil which may
leak out.
Disconnect the oil pressure sensor electrical connection
from the water/oil heat exchanger.
Figure 59
229311

Adjust the quick connector (1) and disconnect the fuel return
pipe from the high pressure pump.
Loosen the clamp (2) and disconnect the fuel supply pipe
Figure 62
229303
from the oil sump.

(2) 1 M8x1.25
Figure 60
227802

bracket, and move aside the low pressure pipes group
together with the fuel recovery pipe from electro-injectors.

229310
(1) 1 M6x1
Using tool 99360076 remove the oil filter (1) from the (2) 2 M6x1x10
water/oil heat exchanger (2).

(1) 1 M22x1.5

Figure 63 Figure 65
229312 227802
Undo the screw (3) fixing the engine cooling water pipe Fit the low pressure pipes group together with the fuel
bracket to the feeding pump holder. recovery pipe from electro-injectors and engage the group in
the intermediate retaining clips.
Undo the screws (1) and remove the water/oil heat
exchanger (2) with the relative gasket and the engine cooling Fit the bracket fixing the low pressure pipes duplex anchorage
water pipe. and tighten the screws (2) to the torque indicated in the table.
Fit the bracket fixing the low pressure pipes group to the
Ref. No. Description intake manifold and tighten the screw (1) to the torque
(1) 8 M8x1.25x30 indicated in the table.
(3) 1 M8x1.25
Tightening
Refitting torques
(1) 1 M6x1 25 2.5
Figure 64 (2) 2 M6x1X10 10 1
Figure 66
229312
Fit the water/oil heat exchanger (2), with a new gasket and
tighten the screws (1) to the torque indicated in the table. 229311
Tighten the screw (3) fixing the engine cooling water pipe Connect the fuel supply pipe to the high pressure pump and
bracket to the feeding pump holder to the torque indicated close the clamp (1).
in the table.
Connect the fuel return pipe to the high pressure pump and
Tightening engage the quick connector (2).
Tightening
(1) 8 M8x1.25x30 252.5 Ref. No. Description torques
(3) 1 M8x1.25 252.5
(2) 1 M8x1.25 25 2.5

Figure 67 HIGH PRESSURE PUMP

REMOVAL/REFITTING
Removal
Place a suitable container, to collect any engine oil and fuel
which may leak out.
Disconnect the fuel flow regulator from the high pressure
pump
Figure 69
229310
Place the oil filter (1) on the water/oil heat exchanger (2) and
tighten to the torque indicated in the table.
Tightening
(1) 1 M22x1.5 252.5
Figure 68
229303
from the oil sump.

(2) 1 M8x1.25
Figure 70
229303
Tightening
(2) 1 M8x1.25 25 2.5
Connect the oil pressure sensor electrical connection on the
water/oil heat exchanger.
218891
Fit the engine wiring as described in the relative procedure. Undo the fitting (1) and disconnect the fuel high pressure pipe
from the fuel manifold pipe

(1) 1 M15x1

Figure 71 Figure 73
229304 227801
Undo the fitting (2) and disconnect the high pressure fuel pipe Loosen clamp (1), disconnect the quick- connector (2) to
from the high pressure pump. remove both the low pressure pipes from the high pressure
pump and take them out from the clips.
pipe.
Figure 74
(1) 1 M8x1.25
(2) 1 M16x1

working;
Figure 72
227803
Undo the screw (3) fixing the engine cooling water pipe
bracket to the feeding pump holder.
Undo the screws (1) and remove the water/oil heat
exchanger (2) with the relative gasket and the engine cooling
water pipe.

(1) 8 M8x1.25x30
(3) 1 M8x1.25
Unscrew and remove the screw (5), unscrew and remove
screws (1) with their washers (3).
227800 Remove the high pressure pump (2) from its support (4).
water/oil heat exchanger. Ref. No. Description
(1) 2 M8x1.25x90
Ref. No. Description (5) 1 M6x1x20
(1) 1 M22x1.5

Figure 75 Refitting
If a new high pressure pump is fitted, it is delivered by Bosch
in its stable position (BDC) with flange fitted.
If the high pressure pump is not replaced, it must be
positioned in its stable position (BDC) by turning the control
shaft as appropriate.
The relative position between control shaft and pump axis is
determined by the flange fitted on the pump.
Figure 76
229313
Unscrew and remove the screw (5), unscrew and remove

Remove the high pressure pump (2) from its support (4).

(1) 2 M8x1.25x90
(5) 1 M6x1x20
220106
Remove the inspection caps from the overhead and turn the
crankshaft with a suitable wrench until you can see the
camshaft timing hole, and fit specific tools 99360614 (1).

(-) 2 M14x1.5x10
NOTE To reinstall the high pressure pump, the

camshafts and crankshaft must be in phase.
NOTE Two revolutions of the crankshaft correspond to

one revolution of the camshafts.

Figure 77 Figure 79
229313
220130 Fit the high pressure pump (2) vertically as shown in the
Lubricate a new seal ring (3) and fit it to the high pressure previous figure onto the support (4) and rotate it in an
pump. anticlockwise direction until the mounting bolt holes are
aligned.
Make sure the flange (4) is fitted to the high pressure pump.
Tighten screw (5) and screws (1) with their washers (3) to
Make sure the high pressure pump is in stable equilibrium, the torque indicated in the table.
with the one of the two recesses (1) on the flange (4) in line
with the reference on the pump itself (2). Remove specific tools 99360614 and reinstall the camshaft
timing inspection caps on the cylinder overhead.
Fit the pump (2) in such a way that the teeth of the control
shaft engage in the cross housings (1). Tightening
Figure 78 (1) 2 M8x1.25x90 252.5
(5) 1 M6x1x20 252.5
(-) 2 M14x1.5x10 252.5
Figure 80
227803
tighten the screws (1) to the torque indicated in the table.
Tighten the screw (3) fixing the engine cooling water pipe
bracket to the feeding pump holder to the torque indicated
in the table.
135043
Make sure you are in vertical mounting position. Tightening

(1) 8 M8x1.25x30 25 2.5
(3) 1 M8x1.25 25 2.5

Figure 81 Figure 83
227801 229304
Connect both low pressure pipes supported by the clips to Fit the new high pressure fuel pipe and tighten the bracket nut
the high pressure pump and fit a new clamp (1) and engage (1) to the torque indicated in the table.
quick-connector (2).
Figure 82 99317915 and specific torque wrench 99389829 to the
tightening.
Tightening
(1) 1 M8x1.25 252.5
M16x1
(2) 1 1st phase 252
2nd phase 90
Figure 84
227800
Place the oil filter (1) on the water/oil heat exchanger and
tighten to the torque indicated in the table.
Tightening

(1) 1 M22x1.5 25 2.5
218898
tightening.
Tightening
M15x1
(1) 1 1st phase 242
2nd phase 90

ELECTRIC EXHAUST GAS FLAP

Because of the high pressure in the pipelines running REMOVAL/REFITTING
is absolutely required NOT to: Removal
- re-use the disassembled pipelines. Figure 86
Figure 85
229314
Disconnect the exhaust gas flap electrical connection (1).

229303 Unlock the V-clamp (2), disconnect and remove the electric
Insert the oil level dipstick (1) into the oil sump and tighten exhaust gas flap (3) from the turbocharger.
intake manifold to the torque indicated in the table. Ref. No. Description
(2) 1 M8x70
Tightening
Ref. No. Description torques Refitting
(2) 1 M8x1.25 25 2.5
Figure 87
Connect the fuel flow regulator to the high pressure pum p.
Fit the engine wiring as described in the relative proce dure.
229314
Fit the electric exhaust gas flap (3) onto the turbocharger and
tighten the V-clamp (2) to the torque indicated in the table.
Connect the exhaust gas flap electrical connection (1).
Tightening
(2) 1 M8x70 121

TURBOCHARGER OIL Refitting

DELIVERY PIPE GASKET
REMOVAL/REFITTING Figure 90
Removal
Figure 88
230346
Replace the gasket with a new one and reassemble the

interface connector (1) to the torque indicated in the table.
230345
Tightening
If necessary, drain the cooling water from engine. Ref. No. Description torques
Undo the union (4) and disconnect the turbocharger water (1) 1 M14x1.5 27 3 Nm
return pipe (5) from the turbocharger.
Undo the bracket screws (6) and move the turbocharger
water return pipe (5) aside.

(4) 1 M14x1.5
(6) 2 M8x1.25x16
Undo the fittings (1 and 3) and remove the turbocharger oil
delivery pipe (2).

(1)
(3) 1 M14x1.5
Figure 89
230346
Remove the interface connector to turbocharger oil delivery

pipe (1) with the relative gasket.

(1) 1 M14x1.5

Figure 91 TURBOCHARGER/EXHAUST MANIFOLD

GROUP REMOVAL/REFITTING
Removal
Place a suitable container, to collect any coolant or oil which
may leak out.
Figure 92
230345
Fit the turbocharger oil delivery pipe (2) then tighten the
fittings (1) and (3) to the torque indicated in the table.
Tightening
(1) 220107
(3) 2 M14x1.5 40 4 Nm
Disconnect the VGT position sensor electrical connection
Tighten the bracket screws (2) to the torque indicated in the (1) from the turbocharger actuator.
table. Undo the bracket screw (2), securing the turbocharger
Connect the turbocharger water return pipe to the actuator to the engine mount.
turbocharger and tighten the union (1) to the torque
indicated in the table. Ref. No. Description
(2) 1 M8x1.25x20
Tightening
Ref. No. Description torques Figure 93
(1) 1 M14x1.5 404
(2) 2 M8x1.25x16 252.5
NOTE Before closing the oil inlet pipe at the prescribed

torque, block the rotation of interface connector,
to avoid gasket deformation due to excessive
torque on the gasket with consequent oil leakage.
217929
Undo the screws (1), the fitting (2) and remove the oil return
pipe from the turbocharger and from the crankcase with the
relative gasket.

(1) 2 M6x1x16
(2) 1 M22x1.5

Figure 94 Figure 96
229314
Disconnect the exhaust gas flap electrical connection (1).

Unlock the V-clamp (2), disconnect and remove the electric
exhaust gas flap (3) from the turbocharger.

(2) 1 M8x70
Undo the union (1) and disconnect the turbocharger water
return pipe from the turbocharger.
Figure 95
Undo the bracket screws (2) and move the turbocharger
water return pipe aside.

(1) 1 M14x1.5
(2) 2 M8x1.25x16
Figure 97
214647
Undo the screws (2) and remove the union bracket (3).
Undo the screws (1) and disconnect the union bracket (5)
from the EGR heat exchanger.
Disconnect and remove the turbocharger air outlet pipe (4).

229315
(1) 2 M8x1.25x20
Undo the fittings (1) and (5), then remove the turbocharger
(2) 2 M6x1x18 oil delivery pipe (6).
Undo the screws (2) and remove the exhaust manifold guard
(3) taking care to retrieve all the spacers.
Undo the union (4) and disconnect the turbochargerwater
delivery pipe from the cranckase.

Ref. No. Description Figure 100

(1)
(5) 2 M14x1,5
(2) 4 M6x1.25x14
(4) 1 M14x1.5
Figure 98
229316
Undo the screws (1), disconnect and remove the exhaust gas
delivery pipe from the EGR valve and from the exhaust
manifold.
Remove the relative gaskets.
(1) 4 M8x1.25x20 Undo the nuts (3) and separate the turbocharger (2) from the
exhaust manifold (1), remove the gasket.
Figure 99
(3) 4 M8x1.25
If necessary undo the union and disconnect the water

delivery pipe from the turbocharger.

(-) 1 M14x1.5
NOTE Make sure all turbocharger pipes are whole, clean

and free from foreign bodies.
Furthermore, check that the sealing gaskets
229317
operate correctly and that the connection
sleeves are fastened.
Undo the nuts (1) securing the exhaust manifold to the
cylinder head.
Remove the exhaust manifold-turbocharger group (2) and
the relative gasket, taking care to retrieve all the spacers.

(1) 10 M8x1.25

Checking and adjusting the actuator Refitting

Figure 101 Figure 102
221447
Cover air, exhaust gas and lubricant inlets and outlets.

Clean the turbocharger outside accurately using
anticorrosive and antioxidant fluid and check the actuator (4).
Clamp the turbocharger in a vice.
Apply vacuometer 99367121 (1) pipe to actuator (4) hose.
Apply themagnetic base gauge (2) to exhaust gas inlet flange
in the turbine.
Set gauge (2) feeler pin on tie rod (3) end and set gauge (2)
to zero.
Operate the vacuum pump and check whether the tie rod (3)
stroke values correspond to the vacuum values shown in the 218885
following table: If previously removed, connect the water delivery pipe to the
turbocharger and tighten the union to the torque indicated
- vacuum 0 Kpa Fully open valve
in the table.
- vacuum 20 Kpa Valve stroke 1.5 - 4.0 mm
Tightening
- vacuum 60 Kpa Valve stroke 10 - 12.5 mm torques
(-) 1 M14x1.5 353.5
NOTE The turbocharger shall be replaced if a different Approach the turbocharger with a new gasket, to the exhaust
value is found and/or if the vacuum value falls manifold and tigheten the nuts (3)to the torque indicated in
during the check. the table.
Tightening
NOTE NOT ALLOWED ARE: Ref. No. Description torques
- any replacement or regulation of the (3) 4 M8x1.25 252.5
actuator, since the calibration of such
component is made in an optimal way for
each turbocharger and is guaranteed for the
turbocharger;
- any operation on nut and ring nut, since
such operation does not change engine
supply characteristics but may impair engine
reliability and duration.
Ring nut is sealed with antitempering yellow
paint.
In case of engines under guarantee, each above
specified intervention and/or alteration to paint
applied on ring nut causes the lapse of the
guarantee.

229317 229315
Place a new metallic gasket and fit the exhaust gas - Fit the exhaust manifold guard (3) with the spacers and
turbocharger group (2) on the cylinder head with the spacers. tighten the screws (2) to the torque indicated in the table.
Tighten the nuts (1) to the torque indicated in the table. Fit the turbocharger oil delivery pipe (6) then tighten the
Tightening Connect the turbocharger water delivery pipe to the
Ref. No. Description torques cranckase and tighten the union (4) to the torque indicated
(1) 10 M8x1.25 252.5 in the table.
Figure 104 Tightening

(1)
(5) 2 M14x1,5 404
(2) 4 M6x1.25x14 18
(4) 1 M14x1.5 404
229316
Place new gaskets and connect the exhaust gas delivery pipe
(2) to the exhaust manifold and to the EGR valve and tighten
the screws (1) to the torque indicated in the table.
Tightening
(1) 4 M8x1.25x20 252.5

229314
Fit the electric exhaust gas flap (3) onto the turbocharger and
tighten the V-clamp (2) to the torque indicated in the table.
Tightening
214665
(2) 1 M8x70 121
Tighten the bracket screws (2) to the torque indicated in the
table. Connect the exhaust gas flap electrical connection (1).
Connect the turbocharger water return pipe to the
turbocharger and tighten the union (1) to the torque Figure 109
Tightening
(1) 1 M14x1.5 404
(2) 2 M8x1.25x16 252.5
Figure 107
217929
Fit the turbocharger oil outlet pipe, and tighten the fitting to
the cranckase (2) and the bracket screws (1) to the torque
Tightening
(1) 2 M6x1x16 101
214647
(2) 1 M22x1.5 454.5
Connect the turbocharger air outlet pipe (4) to the
turbocharger, place the union bracket (3) and tighten the
screws (2) to the torque indicated in the table.
Connect the union bracket (5) to the EGR heat exchanger
and tighten the screws (1) to the torque indicated in the table.
Tightening
(1) 2 M8x1.25x20 282.8
(2) 2 M6x1x18 101

Figure 110 EGR GROUP REMOVAL/REFITTING

Removal
Place a suitable container, to collect any coolant or oil which
may leak out.
Disconnect the EGR valve electrical connection
Figure 111
220107
Tighten the bracket screw (2), securing the turbocharger

actuator to the engine mount, to the torque indicated in the
table.
Tightening
217933
(2) 1 M8x1.25x20 252.5
Undo the screw (1) to open the fixing collar and disconnect
Connect the VGT position sensor electrical connection (1) the exhaust gas delivery pipe from the EGR heat exchanger.
to the turbocharger actuator.
(1) 1 M6x1
Figure 112
217934
Open the clamp and disconnect the enginecoolant delivery

pipe from the EGR heat exchanger.

214647 229316
Undo the screws (2) and remove the union bracket (3). Undo the screws (1), disconnect and remove the exhaust gas
delivery pipe (2) from the EGR valve and from the exhaust
Undo the screws (1) and disconnect the union bracket (5)
manifold. Remove the relative gaskets.
from the EGR heat exchanger.
Disconnect and remove the turbocharger air outlet pipe (4). Ref. No. Description
(1) 4 M8x1.25x20
(1) 2 M8x1.25x20 Figure 116
(2) 2 M6x1x18
Figure 114
229319
Undo the screws (1) and remove the EGR group (2).
229318
Undo the fitting (1) and (4) and remove the turbocharger oil (1) 3 M8x1.25x80
delivery pipe (5).
(1) 1 M8x1.25x95
(1)
(4) 2 M14x1,5
Undo the screws (2) and remove the exhaust manifold guard
(3) taking care to retrieve all the spacers.

(2) 4 M6x1.25x14

Refitting Figure 119

Figure 117
229318
229319
Fit the exhaust manifold guard (3) with the spacers and
Fit the EGR group (2) on the overhead and tighten the screws
(1) to the torque indicated in the table. Fit the turbocharger oil delivery pipe (5) then tighten the
Tightening
Ref. No. Description Tightening
torques Ref. No. Description torques
(1) 3 M8x1.25x80 252.5
(1
(1) 1 M8x1.25x95 252.5 (4) 1 M14x1,5 404
(2) 4 M6x1.25x14 18
Figure 118
Figure 120
229316
Place new gaskets and connect the exhaust gas delivery pipe 214647
(2) to the exhaust manifold and to the EGR valve. Tighten the
screws (1) to the torque indicated in the table. Connect the turbocharger air outlet pipe (4) to the
Tightening screws (2) to the torque indicated in the table.
Ref. No. Description torques Connect the union bracket (5) to the EGR and tighten the
(1) 4 M8x1.25x20 252.5 screws (1) to the torque indicated in the table.
Tightening
(1) 4 M8x1.25x20 282.8
(2) 2 M6x1x18 101

Figure 121 PRE HEATING GLOW PLUGS

REMOVAL/REFITTING
Removal
Place a suitable container, to collect any engine oil and fuel
which may leak out.
Disconnect the glow plugs electrical connections and the air
temperature sensor electrical connection from the air inlet
ppe.
Figure 123
217934
Connect the engine coolant delivery pipe to the EGR heat

exchanger and close the relative clamp (1).
Figure 122
229303
from the oil sump.

(2) 1 M8x1.25
217933
Connect the exhaust gas delivery pipe to the EGR heat Figure 124
exchanger, close the collar and tighten the screw (1) to the
Tightening
(1) 1 M6x1 50.5
Connect the EGR valve electrical connection
218891

(1) 1 M15x1

229304 227801
Undo the fitting (2) and disconnect the high pressure fuel pipe Loosen clamp (1), disconnect the quick- connector (2) to
from the high pressure pump. remove both the low pressure pipes from the high pressure
pump and take them out from the clips.
pipe..
Figure 128
(1) 1 M8x1.25
(2) 1 M16x1

working;
Figure 126
227802

bracket, and move aside the low pressure pipes group
together with the fuel recovery pipe.

(1) 1 M6x1
(2) 2 M6x1x10
227800
water/oil heat exchanger.

(1) 1 M22x1.5

Figure 129 Refitting

Figure 131
229320
Undo the screws (1), remove the air inlet pipe (2) from the 229321
intake manifold with the gasket and the air temperature Fit the glow plugs (1) in their housing on the cylinder head and
sensor. using the torque wrench 99389819 with the bush SP. 2275,
tighten them to the torque indicated in the table.
(1) 4 M8x1.25x25 Tightening
Figure 130 (1) 4 M8x1 91
Figure 132
229321
Unsing a suitable tool, undo and remove the glow plugs (1)
from the cylinder head. 229320
Ref. No. Description Fit the air inlet pipe (2) on the intake manifold, together with
the new gasket and the air temperatur sensor, then tighten
(1) 4 M8x1 the screws (1) to the torque indicated in the table.
Tightening
(1) 4 M8x1.25x25 252.5

227802 227800
Fit the low pressure pipes group together with the fuel Place the oil filter (1) on the water/oil heat exchanger and
recovery pipe from electro-injectors and engage the group in tighten to the torque indicated in the table.
Fit the bracket fixing the low pressure pipes duplex anchorage Tightening
and tighten the screws (2) to the torque indicated in the table.
(1) 1 M22x1.5 25 2.5
indicated in the table. Figure 136
Tightening
(1) 1 M6x1 25 2.5
(2) 2 M6x1X10 10 1
Figure 134
229304
Fit the new high pressure fuel pipe and tighten the bracket nut
(1) to the torque indicated in the table.
227801
tightening.
Connect both low pressure pipes supported by the clips to Tightening

the high pressure pump and fit a new clamp (1) and engage Ref. No. Description torques
quick-connector (2).
(1) 1 M8x1.25 252.5
M16x1
(2) 1 1st phase 252
2nd phase 90

Figure 137 THERMOSTAT REMOVAL/REFITTING

Removal
Figure 139
218891
tightening.
Tightening
torques
Disconnect the engine coolant temperature sensor electrical
M15x1
connection (1).
(1) 1 1st phase 242
Undo the screws (2) and remove the thermostat cover, the
2nd phase 90 thermostat and the relative gasket.
Because of the high pressure in the pipelines running Ref. No. Description
from the fuel feed pump to the electro-injectors, it (2) 4 M8x1.25x20
- re-use the disassembled pipelines.
Figure 138
229303
Tightening
(2) 1 M8x1.25 25 2.5
Connect the glow plugs electrical connections and the air
temperature sensor to the air inlet pipe.
Refitting INTAKE MANIFOLD REMOVAL/REFITTING

Figure 140 Removal
out.
Disconnect the air temperature sensor and the air
temperature/pressure sensor electrical connections from the
air inlet pipe and from the intake manifold.
Figure 141
220128
Fit the thermostat cover, together with the thermostat and

the relative gasket on the cylinder head and tighten the
Connect the engine coolant temperature sensor electrical
connection (1).
229299
Tightening Lift the retaining clips (1) in the direction shown by the arrow
Ref. No. Description torques and disconnect the fuel recovery pipe (2) from the
(1) 4 M8x1.25x20 252.5 electro-injectors. Open the retaining clip (3).
Figure 142
229300

229303 229304
Undo the screw (2) fixing the oil level dipstick upper bracket Undo the fitting (4) and disconnect the high pressure fuel pipe
to the intake manifold and extract the oil level dipstick (1) from the pump.
from the oil sump.
pipe.
(2) 1 M8x1.25 Ref. No. Description
(1) 1 M8x1.25
Figure 144
(2) 1 M16x1

working;
Figure 146
218891
Undo the fitting (1) and disconnect the fuel high pressure pipe

(1) 1 M15x1
227800
Using tool 99360076 remove the oil filter (1) from the water/
oil heat exchanger.

(1) 1 M22x1.5

227801 229320
Release the intermediate retaining clip securing the low Undo the screws (1), remove the air inlet pipe (2) from the
pressure pipes group to the cranckcase. intake manifold with the gasket and the air temperature
sensor..
Loosen the clamp (1) and disconnect the fuel supply pipe
Adjust the quick connector (2) and disconnect the fuel return (1) 4 M8x1.25x25
pipe from the high pressure pump.
Figure 150
Figure 148
229322
227802
Undo the screws (1) and disconnect the exhaust gas delivery
pipe (2) from the intake manifold. Remove the relative gasket.
Undo the bracket screw (1), fixing the low pressure pipes Ref. No. Description
group to the intake manifold. (1) 2 M8x1.25x30
bracket, and remove the low pressure pipes group together
with the fuel recovery pipe.

(1) 1 M6x1
(1) 2 M6x1x10


Figure 152
229323
If necessary to facilitate the operation undo the nut (1) and 229323
remove the air temperature/pressure sensor with the relative
o-ring. Fit the intake manifold (6) with a new gasket on the cylinder
head and tighten the screws (2), (4) and (5) to the torque
Ref. No. Description indicated in the table.
(1) 1 M6 Fit the two threaded plugs (3) on the intake manifold and
Undo the two plugs (3) on the intake manifold, in order to
reach the screws below. Tightening
Undo the screws (2), (4) and (5) securing the intake manifold torques
to the cylinder head. (2) 2 M8x1.25x60 252.5
Remove the intake manifold (6) and the relative gasket. (4) 6 M8x1.25x40 303
(5) 1 M8x1.25x140 303
Ref. No. Description (3) 2 M24x1.5 303
(2) 2 M8x1.25x60
If previously removed, fit the air temperature/pressure sensor
(4) 6 M8x1.25x40 on the intake manifold and tighten the nut (1) to the torque
(5) 1 M8x1.25x140 indixcated in the table.
(3) 2 M24x1.5
Tightening
(1) 1 M6 101

229322 227802
Place a new gasket and connect the exhaust gas delivery pipe Fit the low pressure pipes group together with the fuel
(2) to the intake manifold, tighten the screws (1) to the recovery pipe from electro-injectors and engage the group in
torque indicated in the table. the intermediate retaining clips.
Fit the bracket fixing the low pressure pipes duplex anchorage
Tightening and tighten the screws (2) to the torque indicated in the table.
(1) 2 M8x1.25x30 252.5
Figure 154
Tightening
(1) 1 M6x1 252.5
(2) 2 M6x1x10 252.5
Figure 156
229320
Fit the air inlet pipe (2) on the intake manifold, together with
the new gasket and the air temperature sensor, then tighten
the screws (1) to the torque indicated in the table.
Tightening
227801
(1) 4 M8x1.25x25 252.5
Connect the fuel supply pipe to the high pressure pump and
close the clamp (1).
engage the quick connector (2).
Tie the intermediate retaining clip securing the low pressure
pipes group to the cranckcase.

218891
227800
Place the oil filter (1) on the water/oil heat exchanger and and tighten the fitting (1) with specific series wrench
tighten to the torque indicated in the table. 99317915 and specific torque wrench 99389829 to the
Tightening tightening.
(1) 1 M22x1.5 252.5 Tightening
Figure 158 M15x1
(1) 1 1st phase 242
2nd phase 90

Figure 160
229304
Fit the the fuel high pressure pipe and tie the intermediate
retaining clip (5).
Tighten the bracket nut (1) to the torque indicated in the
table.
Connect the fuel high pressure pipe to the pump and tighten
the fitting (4) with specific series wrench 99317915 and
specific torque wrench 99389829 to the torque indicated in
the table. Use tool 99395216 for angle tightening.
229303
Tightening
Ref. No. Description Insert the oil level dipstick (1) into the oil sump and tighten
torques
(1) 1 M8x1.25 252.5 intake manifold to the torque indicated in the table.
M16x1
(4) 1 1st phase 252 Tightening
2nd phase 90
(2) 1 M8x1.25 252.5

Figure 161 BLOW-BY REMOVAL/REFITTING

Removal
Figure 163
229300
Connect the fuel return pipe (1) to the fuel manifold pipe (2)
and close the relative clamp.
229324
Figure 162 Undo the nut (1) fixing the blow-by pipe bracket to the
cylinder head.
Undo the screws (2) and remove the cover (3) complete
with blow-by pipe.
Remove the piston ring and the centrifugal filter.

(1) 1 M8x1.25
(2) 3 M6x1x18
NOTE The centrifugal filter and the seal ring of the cover
must be changed at every removal.
229302

shown by the arrow.
Connect the air temperature sensor and the air temperature/
pressure sensor electrical connections to the air inlet pipe and
to the intake manifold.

Refitting AUXILIARY DRIVE BELT AND AUTOMATIC

BELT TENSIONER REMOVAL/REFITTING
Figure 164
Removal
Figure 165
229324
Fit a new centrifugal filter and a new piston ring.

Fit the cover (3), tighten the screws (2) to the torque 227797
indicated in the table. Using a suitable tool remove the A/C compressor belt (2).
Fit the blow-by pipe bracket on the cylinder head and tighten Using the specific wrench on the automatic belt tensioner,
the nut (1) to te torque indicated in the table. reduce the tension of the belt (1) and remove it.
Tightening Undo the screw (3) and remove the automatic belt tensioner
Ref. No. Description torques (4).
(2) 3 M6x1x18 101
(1) 1 M8x1.25 252.5
(3) 1 M10x1.5x45
Refitting
Figure 166
227797
Fit the automatic belt tensioner (4) and tighten the screw (3)
Tightening
(3) 1 M10x1.5x45 45 5
Using a specific wrench on the automatic belt tensioner (4),
fit the belt (1), making sure that the ribs on the belt fit properly

CRANKSHAFT FRONT SEAL RING Figure 169

REMOVAL/REFITTING
Removal
Figure 167
229327
Undo the screw (1) and detach the damper pulley (2).

229325
(1) 1 M20x1.5x58
Stop the rotation of the engine flywheel (2) by means of tool
99360306 (1). Figure 170
Figure 168
229326
221408
Using a suitable tool remove the A/C compressor belt (2). Mount the extractor 99340062 (1) on the crankshaft, close
Using the specific wrench on the automatic belt tensioner, the screw (2) on the crankshaft hole by hand, then with a key
reduce the tension of the belt (1) and remove it. close for another 4515.
NOTE The extractor doesent need an angular position

(can rotate 360).

221409 221411
Block the extractor closing the nut (1) by hand, then with a Unscrew the nut (1), then the screw (2) until the extractor
key close for another 4515. come out with the gasket.

Figure 175
221421
Pierce the gasket with the punch (1), using a hammer, stroke 229328
until it arrive at the shoulder of the extractor.
Thoroughly clean the seat of the cover seal ring (5), screw
Figure 173 part (3) of the specific tool 99346258 into the crankshaft
shank.
Lubricate the shank of the crankshaft and the outer surface
of part (3) and fit the new seal ring (4).
Position part (1) on part (3); screw down the nut (2) to fit the
seal (4) fully inside the cover (5).
Remove the tool 99346258 (1).
221410
Tighten the screw (1) by hand.
NOTE Three screws at 120 are sufficient.

Figure 176 TIMING SYSTEM LOWER COVER

REMOVAL/REFITTING
Removal
Figure 178
229327
Fit the damper pulley (2) and tighten the screw (1) to the
229325
Tightening
Ref. No. Description torques Stop the rotation of the engine flywheel (2) by means of tool
(1) 1 M20x1.5x58 35017.5 99360306 (1).
229326 229324
Using a specific wrench on the automatic belt tensioner, fit Undo the nut (1) fixing the blow-by pipe bracket to the
the belt (1), making sure that the ribs on the belt fit properly cylinder head.
into the grooves on the pulley. Undo the screws (2) and remove the cover (3) complete
Using a suitable tool fit the A/C compressor belt (2). with blow-by pipe.
Remove the tool 99360306 used to stop the rotation of the Remove the piston ring and the centrifugal filter.
engine flywheel.
(1) 1 M8x1.25
(2) 3 M6x1x18

229329

221408
Using the specific wrench on the automatic belt tensioner,
reduce the tension of the belt (1) and remove it. Mount the extractor 99340062 (1) on the crankshaft, close
the screw (2) on the crankshaft hole by hand, then with a key
Figure 181 close for another 4515.

(can rotate 360).
Figure 183
229330

(3) 1 M20x1.5x58
Undo the screw (1) and remove the A/C compressor belt
221409
tensioner (2).
Block the extractor closing the nut (1) by hand, then with a
Ref. No. Description key close for another 4515.
(1) 1 M8x1.25x45

221421 229331
Pierce the gasket with the punch (1), using a hammer, stroke Undo the screws (1) and remove the timing system lower
until it arrive at the shoulder of the extractor. cover (2) and the gasket.
Figure 185 Ref. No. Description

(1) 9 M8x1,25x30
(1) 7 M8x1,25x16
Refitting
Figure 188
221410
229331
Figure 186
Fit the cover (2) with a new gasket and screw the screws (1)
without tighten them completely.
221411
Unscrew the nut (1), then the screw (2) until the extractor
come out with the gasket.

229328 229330
Thoroughly clean the seat of the cover seal ring (5), screw Fit the damper pulley (4) and tighten the screw (3) to the
part (3) of the specific tool 99346258 into the crankshaft torque indicated in the table.
shank.
Lubricate the shank of the crankshaft and the outer surface Tightening
(3) 1 M20x1.5x58 35017.5
seal (4) fully inside the cover (5). Fit the A/C compressor belt tensioner (2) and tighten the
screw (1) to the torque indicated in the table.
Figure 190
Tightening
(1) 1 M8x1.25x45 252.5
Figure 192
229332
Mount tool 99396039 (1), for centering cover (4), into

centrifugal filter seat and tighten screws (3) at the torque
Tightening 229329
Using a specific wrench on the automatic belt tensioner, fit
(3) 9 M8x1.25x30 252.5 the belt (1), making sure that the ribs on the belt fit properly
(3) 7 M8x1.25x16 252.5 into the grooves on the pulley.
Remove the 99346258 (2) and 99396039 (1) tools. Using a suitable tool fit the A/C compressor belt (2).

Figure 193 DEPRESSOR/OIL PUMP

REMOVAL/REFITTING
Removal
Place a suitable container to collectany engine oil which may
leak out.
Figure 194
229324

Fit the cover (3), tighten the screws (2) to the torque
Fit the blow-by pipe bracket on the cylinder head and tighten
the nut (1) to te torque indicated in the table.
229325
Tightening Stop the rotation of the engine flywheel (2) by means of tool
Ref. No. Description torques 99360306 (1).
(2) 3 M6x1x18 101
(1) 1 M8x1.25 252.5 Figure 195
Remove the tool 99360306 used to stop the rotation of the

engine flywheel.
229324
Undo the nut (1) fixing the blow-by pipe bracket to the
cylinder head.
with blow-by pipe.
Remove the piston ring and the centrifugal filter.

(1) 1 M8x1.25
(2) 3 M6x1x18

229329

221408
reduce the tension of the belt (1) and remove it. Mount the extractor 99340062 (1) on the crankshaft, close
the screw (2) on the crankshaft hole by hand, then with a key
Figure 197 close for another 4515.

(can rotate 360).
Figure 199
229330

(3) 1 M20x1.5x58
Undo the screw (1) and remove the A/C compressor belt
221409
tensioner (2).
Ref. No. Description key close for another 4515.
(1) 1 M8x1.25x45

221421 221411
Pierce the gasket with the punch (1), using a hammer, stroke Unscrew the nut (1), then the screw (2) until the extractor
until it arrive at the shoulder of the extractor. come out with the gasket.
221410
229331
Undo the screws (1) and remove the timing system lower
cover (2) and the gasket.
(1) 9 M8x1,25x30
(1) 7 M8x1,25x16

229333 229331
Undo the screws (3) and disassemble the depressor/oil pump Fit the cover (2) with a new gasket and screw the screws (1)
unit (2). without tighten them completely.
Remove the coupling drive (1).
Figure 207
(3) 5 M8x1.25x60
Refitting
Figure 205
229328
Thoroughly clean the seat of the cover seal ring (5), screw
part (3) of the specific tool 99346258 into the crankshaft
shank.
Lubricate the shank of the crankshaft and the outer surface
229333
Position the coupling drive (1) in the gear. seal (4) fully inside the cover (5).
Fit the oil pump/depressor unit (2) by inserting a new gasket.
Tighten the screws (3) to the torque indicated in the table.
Tightening
(3) 5 M8x1.25x60 252.5

229332 229329
Mount tool 99396039 (1), for centering cover (4), into Using a specific wrench on the automatic belt tensioner, fit
centrifugal filter seat and tighten screws (3) at the torque the belt (1), making sure that the ribs on the belt fit properly
indicated in the table. into the grooves on the pulley.
Tightening
Figure 211
(3) 9 M8x1.25x30 252.5
(3) 7 M8x1.25x16 252.5
Remove the 99346258 (2) and 99396039 (1) tools.
Figure 209
229324

229330
Fit the blow-by pipe bracket on the cylinder head and tighten
torque indicated in the table. Tightening
Tightening
Ref. No. Description torques (2) 3 M6x1x18 101
(1) 1 M8x1.25 252.5
(3) 1 M20x1.5x58 35017.5
Remove the tool 99360306 used to stop the rotation of the
Fit the A/C compressor belt tensioner (2) and tighten the engine flywheel.
Tightening
(1) 1 M8x1.25x45 252.5

WATER PUMP REMOVAL/REFITTING Refitting

Removal Figure 214
Place a suitable container, to collect any coolant which may
leak out.
Figure 212
229335
Fit the water pump (5) with a new gasket and tighten the
229326
Fit the electromagnetic pulley (3) on the water pump, tighten
the nuts (1) and the ring nut (2) to the torque indicated in
Using a suitable tool remove the A/C compressor belt (2). the table.
reduce the tension of the belt (1) and remove it. Tightening
Figure 213 2 M8x1.25x45 252.5
(4)
3 M10x1.5x55 505
(2) 1 M30x1 15015
(1) 4 M6x1 101
Figure 215
229335
Undo the ring nut (2), the nuts (1) and remove the
electromagnetic pulley (3).
Undo the screws (4) and remove the water pump (5) with
the relative gasket.
229326
Ref. No. Description Using a specific wrench on the automatic belt tensioner, fit
(1) 4 M6x1 the belt (1), making sure that the ribs on the belt fit properly
(2) 1 M30x1.5 into the grooves on the pulley.
2 M8x1.25x45 Using a suitable tool fit the A/C compressor belt (2).
(4)
3 M10x1.5x55

CRANKSHAFT REAR SEAL RING Figure 218

REMOVAL/REFITTING
Removal
Figure 216
225110
To mount the tool 99340060 it is necessary to perform the

following operations:
- unscrew the extractor central screw (2) almost
229336
completely.
Block rotation of the flywheel (2) with the specific tool
- loosen the three screws (1) to enlarge the three flanges
99360306 (1).
(3) in order to hold them over the ring (4) of the seal.
Undo the screws (3) and remove the flywheel (2).
- tighten the screws (1) until the flanges hold over the seal
ring.
(3) 8 M12x1.25x51 - finally tighten the central screw (2) and extract the seal
ring.
NOTE Ensure that the flanges are driven into the entire
Figure 217 circumference of the seal ring: an improper
positioning of the tool could make necessary a
complete dismantling of the crankshaft to extract
the seal ring.
Refitting
Figure 219
229337
Apply specific tool 99340060 (2) to the rear seal ring (1) and
extract it from the cranckase.
229338
Thoroughly clean the seal ring seat.

Lubricate the rear end of the crankshaft with engine oil.
Apply specific tool part 99346259 (4) to the rear crankshaft
tang, secure it by screws (3) and fit the new sealing ring (5).
seal (5) fully inside the crankcase.
Figure 220 SIDE/UPPER CHAIN GUIDE

REMOVAL/REFITTING
Removal
Figure 221
229336
Mount the flywheel (2) and screw down the screws (3)
without tighten them completely.
Fit specific tool 99360306 (1) onto the crankcase to lock
229339
rotation of the flywheel (2).
Disconnect the phase sensor electrical connection (4).
Using tool 99395216 for angle tightening, tighten the screws
(3) retaining the flywheel (2) to the torque indicated in the In order to facilitate the operation, disengage the engine
table. wiring cover from the cylinder overhead and move aside.
Undo the nuts (1), the screws (2) and remove the timing
Tightening system upper cover (3).
M12x1.25x51 Ref. No. Description
(3) 8 1st phase 301.5 Nm (1) 2 M6x1
2nd phase 90 (2) 7 M6x1x30
Figure 222
229340
Remove the inspection caps (1) from the overhead.

(1) 2 M14x1.5x10
Turn the crankshaft clockwise so that specific pins 99360614
can be inserted through the cap holes.

NOTE Replace with new ones: the seal rings, gaskets,

safety circlips.
Before assembly, lubricate the seal rings with
engine oil.
Figure 225
229341
Undo the screws (1) retaining the gear wheel intake side.

(1) 1 M12x1.75x40
Figure 224
229342
Fit the upper chain guide (6), drive in the nuts (5) and tighten
them to the torque indicated in the table.
Fit the side chain guide (1), drive in the screws (2 and 3) and
Fit the plug (4) with a new gasket and tighten it to the torque
Tightening
(2)
(3) 2 M6x1x20 101
(4) 1 M26x1.5x16 505
229342 (5) 2 M6x1 101
Support the timing chain so that it remains tense with one
clamp. Figure 226
Remove the plug (4) and undo the screw (3).
Undo the retaining screw (2) and remove the side chain guide
(1).
Undo the retaining nuts (5) and remove the upper chain
guide (6).

(5) 2 M6x1
(2)
(3) 2 M6x1x20
(4) 1 M26x1.5x16
229341
NOTE Pay close attention that the lower screw retaining Fit the the gear wheel intake side and tighten the screws (1)
the side chain guide does not fall within the timing to the torque indicated in the table.
compartment.
If necessary, use a magnetized bushing or apply Tightening
mastic to the bush body itself.
(1) 1 M12x1.75x40 1105.5

Figure 227 ALTERNATOR REMOVAL/REFITTING

Removal
Figure 229
229340
Remove the specific pins 99360614.

Place the two inspection plugs (1) in their housing on the
229326
overhead, tightening them to the torque indicated in the
table. Using a suitable tool remove the A/C compressor belt (2).
Tightening reduce the tension of the belt (1) and remove it.
(1) 2 M14x1.5x10 252.5 Figure 230
Figure 228
229343
Undo the screw (3) and bolt (1), then remove the alternator
229339
(2) from its support.
Fit a new gasket on the cover (3).
Fit the cover (3), on the cylinder overhead and tighten the Ref. No. Description
screws (2) and the nuts (1) to the torque indicated in the (3) 1 M10x1.25x30
table. (1) 1 M10x1.25x130
Engage the engine wiring cover in its housing on the cylinder
overhead.
Connect the phase sensor electrical connection (4).
Tightening
(1) 2 M6x1 101
(2) 7 M6x1x30 101

225111 229343
If necessary, replace the alternator freewheel (2) as follows: Fit the alternator (2) in its support, tighten the screw (3) and
bolt (1) to the torque indicated in the table.
- Remove the freewheel cap (5).
- Fit specific tool 99358026 (3, 4) as shown in the figure. Tightening
- Block the rotation of the alternator freewheel (2) with
part (4) and unscrew the shaft (1) of the alternator (6) (3) 1 M10x1.25x30 50 5
with part (3). (1) 1 M10x1.25x130 50 5

Figure 234
(1) 1 M16x1.5
Refitting
Figure 232
229326
Using a specific wrench on the automatic belt tensioner, fit

the belt (1), making sure that the ribs on the belt fit properly
225111 Using a suitable tool fit the A/C compressor belt (2).
If previously removed, fit the new alternator freewheel (2) in
the reverse order.
The freewheel (2) must be secured to the shaft (1), applying
to the shaft a maximum specified torque indicated in the
table.
Tightening
(1) 1 M16x1.5 80 5

POWER STEERING PUMP Figure 237

REMOVAL/REFITTING
Removal
Figure 235
229345
Remove the coupling (1) from the drive shaft (2).
Refitting
229303
Figure 238
from the oil sump.

(2) 1 M8x1.25
Figure 236
229345
Fit the coupling (1) in its housing on the drive shaft (2).
229344
Undo and remove the screw (1) and the screws (2) with their
washer.
Remove the power steering pump (3) from its support.

(1) 1 M10x1.25x30
(2) 1 M10x1.25x110

229344 229303
Fit the power steering pump (3) with a new gasket, tighten Insert the oil level dipstick (1) into the oil sump and tighten
the screw (1) and the screw (2) with their washer to the the screw (2) fixing the oil level dipstick upper bracket to the
torque indicated in the table. intake manifold to the torque indicated in the table.
Tightening Tightening
torques torques
(1) 1 M10x1.25x30 40 4 (2) 1 M8x1.25 25 2.5
(2) 1 M10x1.25x110 40 4
NOTE Replace with new ones: the seal rings, gaskets.

Before assembly, lubricate the seal rings with
engine oil.
NOTE After refitting, top up the power steering circuit

and bleed air.

CYLINDER HEAD REMOVAL/REFITTING

Removal
Figure 241
229346
Remove the engine wiring (1) as described in the relative Remove the electric exhaust gas flap (5) as described in the
procedure. relative procedure.
Remove the timing system upper cover (2) as described in the Remove the turbocharger/exhaust manifold group (4) as
SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING described in the relative procedure.
procedure.
Remove the EGR group (6) as described in the relative
Remove the timing system lower cover (3) as described in the procedure.
relative procedure.

Figure 242
229347
Remove the low pressure fuel pipe group (3), together with Remove the electro-injectors (1) as described in the relative
the fuel return pipe as described in the relative procedure. procedure.
Remove the high pressure fuel pipe from pump to rail (4) as Remove the thermostat (5) as described in the relative
described in the relative procedure. procedure.
Remove the fuel manifold pipe (2) as described in the relative Remove the intake manifold (6) as described in the relative
procedure. procedure.

229348 229350
Undo the bracket screw (1) securing the coolant delivery Undo the two plugs (1) on the tappet cover in order to fit
pipes group (2) to the cylinder overhead. the timing tools 99360614.
Open the clip (6) securing the EGR exhaust gas temperature
sensor. Ref. No. Description
(1) 2 M14x1.5x10
Undo the screws (5) and remove the rear cover (3) and the
relative gasket, together with the exhaust gas pipe (4) and the Rotate the crankshaft and fit the timing tools 99360614 on
coolant delivery pipes group (2). the overhead and 99360615 onto the crankshaft.

(1) 1 M8x1.25
(5) 3 M8x1.25x35
(5) 4 M8x1.25x45
Figure 244
229349
Undo and remove the chain anti-return hydraulic tensioner

(1).

227805 (1) 1 M22x1.5x22
Undo and remove the glow plugs (1) from the cylinder head.
NOTE The chain hydraulic tensioners are equipped with
Ref. No. Description an anti-return device; it is therefore necessary to
(1) 4 M8x1 replace the chain tensioners each time they are
removed.

227815 229275
Undo the screw (5), keep the washer (6) and remove the Undo the screws (1) and remove the bracket (2).
exhaust camshat gear (7).
Undo the screw (3), keep the washer (4), remove the intake Ref. No. Description
camshaft gear (2) and the single link timing chain (1). (1) 2 M8x1.25x16

(3)
(5) 2 M12x1.75x40
Figure 248
230341
Undo the fixing screws (1) and take off the over-head (2)
from the cylinder head (3).
227816 Ref. No. Description

Remove the plug (4) and undo the screw (3). (1) 10 M8x1.25x40
Undo the retaining screw (2) and remove the side chain guide (1) 20 M8x1.25x77
(1).
Undo the retaining screw (5) and remove the upper chain
guide (6).

(5) 2 M6x1
(2)
(3) 2 M6x1x20
(4) 1 M26x1.5x16

Figure 251
NOTE Check the protrusion of the pistons (2) as
described under the relevant heading to check
the possibility of facing the crankcase if it has
deformed.
Refitting
Figure 254
88281
Remove the hydraulic tappets (1) with the rocker arms.

Remove the gasket (2).
Figure 252
224215
Check that contact surfaces of the cylinder head and

crankcase are clean.
Place the cylinder head dowels on the crankcase (if they were
removed previously).
Place a new cylinder head gasket (1) with the tickness
indicated in the Section 6 Checking piston protrusion
paragraph with the writing TOP facing the cylinder head.
88282 It is absolutely necessary to keep the cylinder head

Undo the screws (1) and remove the cylinder head (2). ! gasket sealed in its packaging and remove it just
before fitting to avoid getting it dirty.
(1) 6 M15x1.5x193
(1) 4 M12x1.5x165 Figure 255
(1) 4 M8x1.25x117
(1) 1 M8x1.25x58
Figure 253
88354
Mount the cylinder head (2) on the crankcase.

Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
224215 the following figure, using tool 99395216 for the angle closing.
Remove the cylinder head gasket (1).
88355
230341
Tightening Mount the overhead (2) on the cylinder head (3) together
with the tools 99360614 for the timing and tighten the fixing
M15x1.5x193 screws (1) to the torque indicated in the table.
1st phase 1306.5 Nm Remove the tools SP. 2264 previously mounted.
(1)(6) 6
2nd phase 90
3rd phase 90 Ref. No. Description
Tightening
torques
M12x1.5x165
1st phase 65 3.25 Nm (1) 10 M8x1.25x40 252.5
(7)(10) 4 (1) 20 M8x1.25x77 252.5
2nd phase 90
3rd phase 60
Figure 259
4 M8x1.25x117 25 2.5 Nm
A
1 M8x1.25x58 25 2.5 Nm
Figure 257
229275
Fit the bracket (2) on the overhead and tighten the screws
88356
Tightening
Position the cylinder head extension dowels on the cylinder torques
head (if they were removed previously). (1) 2 M8x1.25x16 252.5
Thoroughly clean the hydraulic tappets (2), lubricate them
and place them in the cylinder head (3), positioning the rocker
arms (1) on the valves correctly.
Place a new cylinder head extension gasket (5) in its seat.
Insert the two tools SP. 2264 (4) into the electro-injector
seats for subsequent centring of the overhead on the cylinder
head.

227816 229288
Fit the upper chain guide (6), drive in the screws (5) and Position the single link chain (4) on the gear (3) and fit the
tighten them to the torque indicated in the table. latter on the camshaft of the exhaust valves.
Fit the side chain guide (1), drive in the screws (2 and 3) and Drive in the fastening screw (1) with the washer (2) without
tighten them to the torque indicated in the table. tightening it completely.
NOTE The gear (3) must be mounted with the markings
inwards.
Tightening
Ref. No. Description torques In the gear (3) there is a larger hole for
adjustment, which fits onto the pin on the
(2) exhaust camshaft shank.
(3) 2 M6x1x20 101
(4) 1 M26x1.5x16 505
(5) 2 M6x1 101
NOTE The chain arm (4) between the two gears must
be tensioned.
Figure 261
88358
Position the single link chain (1) on the drive gear (5) and on
the intake camshaft gear (2).
Mount the gear in such a way that fitting on intake valve timing
system shaft dowel makes slots A to result to be positioned
as in figure.
Drive in the fastening screw (4) with the washer (3) without
tightening it completely.
be tensioned.

230342 229294
Screw on the chain anti-return hydraulic tensioner (2) and Make sure that the chain (1) in the tract between the gear (2)
tighten to the torque indicated in the table. and gear (3) is tensioned.
Tightening Tighten the fastening screw of the gear (3) on the exhaust
Ref. No. Description torques valve camshaft to the torque indicated in the table.
(2) 1 M22x1.5x22 502.5 Tightening
From the opening in the overhead, press on the tab (3) of the
secondary tensioner arm (4) with a screwdriver and push the (3) 1 M12x1.75x40 1105.5
piston (1) of the chain anti-return hydraulic tensioner (2) fully
down.
Figure 266
Release the secondary tensioner arm (4) and check that the
piston (1) protrudes from its seat, thus tensioning the chain
(5).
The hydraulic chain tensioners (with anti-return

! device) can absolutely never be re-used.
Whenever the piston has inadvertently been made
to come out of the new chain tensioner, it must be
replaced; it cannot be reset.
Figure 264
230343
Remove tools 99360614 (1) and fit the two inspection caps
in their housing tightening to the torque indicated in the table.
Tightening
(-) 2 M14x1.5x10 252.5
229293
Tighten the fastening screw of the gear (1) on the intake valve
camshaft to the torque indicated in the table.
Tightening
(1) 1 M12x1.75x40 1105.5
229348 227805
Fit the exhaust gas pipe (4), on the cylinder head, together Fit the pre/heater glow plugs (1) in their housing on the
with the rear cover (3) and a new gasket and tighten the cylinder head using the SP.2275 tool and torque wrench
screws (5) to the torque indicated in the table. 99389819, then tighten them to the torque indicated in the
Engage the EGR exhaust gas temperature sensor electrical table.
connection (6) to the bracket and to the intermediate clips.
Tightening
Fit the bracket securing the coolant delivery pipes group (2) Ref. No. Description torques
to the cylinder overhead and tighten the screw (1) to the
torque indicated in the table. (1) 4 M8x1 91
Tightening
(1) 1 M8 x1.25 252.5
(5) 3 M8x1.25x35 252.5
(5) 4 M8x1.25x45 252.5

Figure 269
229347
Remove the intake manifold (6) as described in the relative Remove the fuel manifold pipe (2) as described in the relative
procedure. procedure.
Remove the thermostat (5) as described in the relative Remove the high pressure fuel pipe from pump to rail (4) as
procedure. described in the relative procedure.
Remove the electro-injectors (1) as described in the relative Remove the low pressure fuel pipe group (3), together with
procedure. the fuel return pipe as described in the relative procedure.

Figure 270
229346
Remove the EGR group (6) as described in the relative Remove the timing system lower cover (3) as described in the
procedure. relative procedure.
Remove the turbocharger/exhaust manifold group (4) as Remove the timing system upper cover (2) as described in the
described in the relative procedure. SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING
procedure.
Remove the electric exhaust gas flap (5) as described in the
relative procedure. Remove the engine wiring (1) as described in the relative
procedure.

OIL SUMP REMOVAL/REFITTING Refitting

Removal Figure 273
Place an appropriate container for the oil collection under the
sump in correspondence with the drain plug.
Open the oil filler inlet on the cylinder overhead and take out
the oil level dipstick to allow the oil to flow more freely.
Figure 271
230419
Fit the oil sump (2) with a new gasket and the oil pan frame
(3), than tighteen the screws (1) to the torque indicated in
the table.
Tightening
230418 torques
Unscrew the drain plug (1) and let the oil in the sump drain (1) 13 M8x1.25x35 252.5
out completely.
Place the oil drain plug (4) and tighteen it to the torque
(1) 1 M22x1.5x10 Tightening
NOTE It is recommended that the oil drained while hot. (4) 1 M22x1.5x10 505
Rotate the engine through 180 on the overhaul stand.
Proceed to refill with the specified oil.
Figure 272 Operate the engine for a few minutes and then check the
level using the dipstick: the level must come close to the MAX
notch which can be seen on the dipstick.
If this is not the case, top-up as necessary the engine lubricant
oil with the specified quantity and quality of lubricant oil.
NOTE Only use recommended oils or oils with the

properties required for proper engine operation.
Failure to observe these standards will invalidate
the service warranties.
230344
Undo the screws (1) and remove the oil sump (2) with the
gasket and its oil pan frame (3).

(1) 13 M8x1.25x35


F1C EuV1 - ENGINES SECTION 6 - GENERAL MECHANICAL OVERHAUL 1
SECTION 6
General mechanical overhaul
Page
ENGINE DISASSEMBLING ON BENCH . . . . . . 3
- Removal of components hindering

bracket assembly . . . . . . . . . . . . . . . . . . . . . . . 3
- Fitting the engine on the rotating stand . . . . . 7
- Engine disassembling
(components on top side part 1) . . . . . . . . . . 7
(components on exhaust side) . . . . . . . . . . . . 9
(components on intake side side) . . . . . . . . . . 11
(components on front side) . . . . . . . . . . . . . . 13
(components on rear side) . . . . . . . . . . . . . . . 19
(components on top side part 2) . . . . . . . . . . 20
(components on bottom side) . . . . . . . . . . . . 21
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Checking head mating surface on cylinder block 25
- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Main bearing shells selection . . . . . . . . . . . . . . 29
- Main bearings shell position . . . . . . . . . . . . . . . 31
- Standard main journals (STD) . . . . . . . . . . . . . 33
- Undersized main journals (-0.127 mm) . . . . . 36
- Big end bearing shell selection . . . . . . . . . . . . 39
- Big end bearing shells position . . . . . . . . . . . . . 40
- Standard cranckpins (STD) . . . . . . . . . . . . . . 41
- Undersized cranckpins (-0.127) . . . . . . . . . . . 42

2 SECTION 6 - GENERAL MECHANICAL OVERHAUL F1C EuV1 - ENGINES
Page Page
- Undersized cranckpins (-0.254) . . . . . . . . . . . 43 - Checking crankshaft end float . . . . . . . . . . . . . 61
- Undersized cranckpins (-0.508) . . . . . . . . . . . 43 - Engine assembling

(components on bottom side) . . . . . . . . . . . . 64
- Connecting rod - piston assembly . . . . . . . . . 44
- Engine assembling
- Cylinder head components . . . . . . . . . . . . . . . 49 (components on top side part 1) . . . . . . . . . . 65
- Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - Engine assembling

(components on rear side) . . . . . . . . . . . . . . . 66
- Valves guide . . . . . . . . . . . . . . . . . . . . . . . . . . 52
- Engine assembling
(components on front side part 1) . . . . . . . . . 67
- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Engine assembling
- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . 55 (components on intake side ) . . . . . . . . . . . . . 76
- Rocker arms - tappets . . . . . . . . . . . . . . . . . . . 55 - Engine assembling
(components on exhaust side ) . . . . . . . . . . . 78
- Assembling valves . . . . . . . . . . . . . . . . . . . . . . 56
- Engine assembling (components
- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 on top side part 2) . . . . . . . . . . . . . . . . . . . . . 80
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - Removing the engine from the rotating

stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Assembling overhead components . . . . . . . . . 59
- Refitting of components hindering
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 60 bracket assembly . . . . . . . . . . . . . . . . . . . . . . 83
- Crankcase components assembly . . . . . . . . . . 60 CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 88
- Cranckshaft assembly . . . . . . . . . . . . . . . . . . . 60 - Low pressure supply circuit diagnostics . . . . . 89

ENGINE DISASSEMBLING ON BENCH

In order to apply the brackets 99361041 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary
to perform the following operations.
Removal of components hindering bracket assembly

Engine wire removal
Disengage the engine wiring cover from the cylinder overhead, disengage the pins from the relative brackets and remove the
engine wiring.
Disconnect the following electrical connections:
Figure 1
227787

1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor -
4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch 7. Fuel flow regulator on high pressure pump -
8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor -
10. Air pressure and temperature sensor - 11. Pressure regulating valve on rail - 12. Segment speed sensor

Figure 2
227788


Disengage the engine wiring cover from the cylinder

Exhaust side enginemount and turbocharger oil outlet pipe
overhead, disengage the pins from the relative brackets and
removal
remove the engine wiring.
Intake side engine mount Figure 4
Figure 3
227789
Undo the screws (1), and remove the Intake side engine
mount (2),
214660
(1) 1 M10x1.25x95 Undo the screws (1), the fitting (2) and remove the oil return
pipe from the turbocharger and from the crankcase with the
(1) 2 M10x1.25x50
relative gasket. Undo the screws (3),(4) and the bracket
Place a suitable container, remove the plug from the oil sump screw (6) then remove the exhaust side engine mount (5).
and drain the engine oil.
Ref. No. Description (1) 2 M6x1x16
- 1 M22x1.5x10 (2) 1 M22x1.5
(3) 2 M10x1.25x85
(4) 1 M10x1.25x50
Warning: avoid contact of engine oil with the skin: (6) 1 M8x1.25x20
in case of skin contamination, rinse in running water.
Electric exhaust gas flap removal
Figure 5
Engine oil is highly pollutant: provide for disposal in

compliance with the law and regulations in force.
214646
Unlock the V-clamp (1) and remove the electric exhaust gas
flap (2) from the turbocharger.

(1) 1 M8x70
Turbocharger air outlet pipe removal Turbocharger - Exhaust manifold group removal
Figure 6 Figure 8
214647 229316
Undo the screws (2) and remove the union bracket (3). Undo the screws (1), disconnect and remove the exhaust gas
Undo the screws (1) and disconnect the union bracket (5) delivery pipe.
from the EGR heat exchanger. Remove the relative gaskets.
Disconnect and remove the turbocharger air outlet pipe (4)
with the bracket. Ref. No. Description
(1) 4 M8x1.25x20
(1) 2 M8x1.25x20 Figure 9
(2) 2 M6x1x18
Turbocharger oil delivery pipe and exhaust manifold guard

removal
Figure 7
229315 220125
Undo the fittings (1) and (5), then remove the turbocharger Undo the fitting (1) and disconnect the turbocharger water
oil delivery pipe (6). return pipe from the turbocharger.
Undo the screws (2) and remove the exhaust manifold guard Undo the bracket screws (2), and move the turbocharger
(3) taking care to retrieve all the spacers. water return pipe (1) aside.
Undo the union (4) and disconnect the turbocharger water
delivery pipe from the cranckase. Ref. No. Description
(1) 1 M14x1.5
(2) 2 M8x1.25x16
(1)
2 M14x1,5
(5)
(2) 4 M6x1.25x14
(4) 1 M14x1.5
Figure 10 Electro-Injectors and fuel manifold pipe (rail) removal
NOTE Place a suitable container to collect the fuel as it

drains out of the pipes.
Figure 12
229317
Undo the nuts (1) securing the exhaust manifold to the

cylinder head.
Remove the exhaust manifold-turbocharger group (2) and
the relative gasket, taking care to retrieve all the spacers.
(1) 10 M8x1.25 Lift the retaining clips (1) in the direction shown by the arrow
electro-injectors, open the retaining clip (3) and move the
NOTE Block the turbocharger air/exhaust gas inlets and fuel recovery pipe aside.
outlets to prevent foreign bodies getting inside.
Figure 13
Fitting the engine on the rotating stand.

Fit the brackets 99361041 to the crankcase and use these to
secure the engine to the rotary stand 99322205.
Engine disassembling
(components on top side part 1).
Air inlet pipe removal
Figure 11
229305


(1) 4 M15x1
(2) 4 M14x1.5
227790
Undo the screws (2), remove the air inlet pipe (1) and the Because of the high pressure in the pipelines running
flange (3) from the intake manifold, together with the gasket from the fuel feed pump to the electro-injectors, it
and the air charger intercooler outlet temperature sensor. is absolutely required NOT to:
Ref. No. Description working;
(2) 4 M8x1.25x25

Figure 14 Figure 16
88244
229306
Apply tool 99342153 (1), using the screw holes of securing
Undo the screws (1) and remove the brackets (2) securing electro-injectors brackets and extract the electro injectors
the electro-injectors (3) to the cylinder overhead. (2) from the cylinder overhead (3).

(1) 4 M8x1.25x80 NOTE After removal, mark the injector with the cylinder
number of belonging, for a proper calibration of
Using tool 99342153 to extract the electro-injectors from the codes IMA; or in case of replacement, we
the cylinder overhead. want to make laboratory analysis. Also make sure
that the seal is not left in the injector seat engine
head.
NOTE This procedure has to be done to avoid damage
of the electro-injectorss electrical connector.
Figure 17
Figure 15
227792
227791
Remove the bracket (1). from the oil sump.
Using an hammer and 3,5 max punch, remove the pins (2).
When the bracket (1) is reassembled, rotate it about 3 4 (2) 1 M8x1.25
in this direction from the original position.

Figure 18 Engine disassembling

(components on exhaust side)
EGR group removal
Figure 19
227793
Undo the fittings (1) and (4), the bracket nut (2), and remove
the high pressure fuel delivery pipe.
Loosen the clamp (5) and disconnect the fuel return pipe
227794
Undo the screws (7), open the relative band and remove the Undo the screw (1) to open the fixing collar for the exhaust
fuel manifold pipe (6) from the cylinder overhead. gas pipe.
Losen the clamp (2) and disconnect the EGR heat exchanger
Ref. No. Description engine coolant delivery pipe.
(1) 1 M16x1 Undo the screws (5) fixing the exhaust gas pipe to the intake
(2) 1 M8x1.25 manifold; open the clip (6) securing the EGR exhaust gas
(4) 1 M15x1 temperature sensor.
(7) 2 M8x1.25x35 Undo the rear cover screws (4) and remove the exhaust gas
pipe group (3), together with the rear cover and the relative
gasket.
from the fuel feed pump to the electro-injectors, it Ref. No. Description
is absolutely required NOT to: (1) 1 M6x1
- disconnect the pipelines when the engine is (4) 3 M8x1.25x35
working; (4) 4 M8x1.25x45
(5) 2 M8x1.25x30

Figure 20 Auxiliary drive belt - automatic belt tensioner removal
Figure 22
227795
Losen the clip-sleeve (1) and disconnect the EGR heat

227797
exchanger engine coolant delivery pipe (2) from EGR.
Undo the bracket screw (4) securing the coolant delivery
pipes to the cylinder overhead. Using the specific wrench on the automatic belt tensioner,
reduce the tension of the belt (1) and remove it.
Remove the coolant delivery pipes group (3).
Undo the screw (3) and remove the automatic belt tensioner
Ref. No. Description (4).
(4) 1 M8x1.25
Figure 21 (3) 1 M10x1.5x45
Alternator removal
Figure 23
227796
Undo the screws (1) and remove the EGR group (2).

(1) 3 M8x1.25x80
Undo the screw (3) and bolt (1), then remove the alternator
(1) 1 M8x1.25x95 (2) from its support.

(3) 1 M10x1.25x30
(1) 1 M10x1.25x130

Figure 24 Low pressure pipes group removal
Figure 26
227799
Undo the fixing screws (1) then remove the alternator

227801
support (2).
Loosen the clamp (1) and disconnect the fuel pipe fromfilter
Ref. No. Description to high pressure pump.
(1) 1 M8x1.25x70 Adjust the quick connector (2) and disconnect the fuel pipe
(1) 1 M8x1.25x35 from the high pressure pump to tank.
(1) 2 M8x1.25x30
Figure 27
(components on intake side)
Oil filter removal
Figure 25
227802

227800 Undo the screws (2) fixing the duplex pipe anchorage
Using tool 99360076 remove the oil filter (1) from the bracket, and remove the low pressure pipes group together
water/oil heat exchanger. with the fuel recovery pipe from electroinjectors.

(1) 1 M22x1.5 (2) 2 M6x1x10
(1) 1 M6x1

Water/oil heat exchanger removal Thermostat removal
Figure 28 Figure 30
227803 214644
Undo the screw (3) fixing the engine cooling water pipe Undo the screws (1) and remove the thermostat cover (2),
bracket to the feeding pump holder. with the thermostat and the relative gasket.
Undo the screws (1) and remove the water/oil heat Ref. No. Description
exchanger (2) with the relative gasket and the engine cooling
water pipe. (1) 4 M8x1.25x20
Intake manifold removal

(1) 8 M8x1.25x30
Figure 31
(3) 1 M8x1.25
High pressure pump removal
Figure 29
227804
If necessary to facilitate the operation undo the nut (1) and

remove the air temperature/pressure sensor with the relative
o-ring.
229313 Ref. No. Description
Unscrew and remove the screw (5), unscrew and remove (1) 1 M6
Undo the two threaded plugs (3) on the intake manifold, in
Remove the high pressure pump (2) from its support (4). order to reach the screws below.
Undo the screws (2), (4) and (5) securing the intake manifold
Ref. No. Description to the cylinder head.
(1) 2 M8x1.25x90
Remove the intake manifold (6) and the relative gasket.
(5) 1 M6x1x20
(2) 2 M8x1.25x60
(4) 6 M8x1.25x40
(5) 1 M8x1.25x140
(3) 2 M24x1.5

Pre/heater glow plugs removal Water pump and 3 speed electromagnetic pulley removal
Figure 32 Figure 34
227805 227807
Undo and remove the glow plugs (1) fromthe cylinder head. Undo the ring nut (2), the nuts (1) and remove the
electromagnetic pulley (3).
Ref. No. Description Undo the screws (4) and remove the water pump (5) with
(1) 4 M8x1 the relative gasket.
Engine disassembling Ref. No. Description

(components on front side) (1) 4 M6x1
Blow-by removal (2) 1 M30x1.5
2 M8x1.25x45
(4)
Figure 33 3 M10x1.5x55
Timing sensor and timing system upper cover removal
Figure 35
227806
Undo the nut (1) fixing the complete blow-by pipe bracket
to the cylinder head.
217902
with blow-by pipe.
Remove the piston ring and the centrifugal filter. Undo the screw (3), and remove the phase sensor (4).
Undo the nuts (1), the screws (2) and remove timing system
Ref. No. Description upper cover (5).
(1) 1 M8x1.25
(2) 3 M6x1x18 Ref. No. Description
(1) 2 M6x1
(2) 7 M6x1x30
NOTE The centrifugal filter and the seal ring of the cover (3) 1 M6x1x16

Dumper pulley and crankshaft front gasket removal Figure 38
Figure 36
227808
221408
Stop the rotation of the engine flywheel (2) by means of tool Mount the extractor 99340062 (1) on the crankshaft, tighten
99360306 (1). the screw (2) on the crankshaft hole by hand, then with a key
close for another 30 60.
Figure 37

(can rotate 360).
Figure 39
227809

(3) 1 M20x1.5x58
Undo the screw (1) and remove the A/C compressor belt 221409
tensioner (2).
key close for another 30 60.
(1) 1 M8x1.25x45

Figure 40 Timing system lower cover removal
Figure 43
221421
Pierce the gasket with the punch (1), using a hammer, stroke
until it arrive at the shoulder of the extractor. 227810
Undo the screws (1) and remove the timing system lower
Figure 41 cover (2) and the gasket.
Undo the screw and remove the engine increment speed
sensor (3).

(1) 9 M8x1.25x30
(1) 7 M8x1.25x16
(3) 1 M6x1x12
Depressor/oil pump unit removal
Figure 44
221410
Figure 42
227811
Undo the screws (3) and disassemble the depressor/oil pump

unit (2).
Remove the coupling drive (1).

(3) 5 M8x1.25x60
221411
Unscrew the nut (1), then the screw (2) until the extractor
come out with the gasket.

Camshaft gears and upper timing chain removal Figure 47
Figure 45
227812
Undo and remove the chain anti-return hydraulic tensioner

227813
(1) and chain standard hydraulic tensioner (5).
Undo the two plugs (1) on the tappet cover in order to fit
Undo the bolt shoulder (3), disassemble and remove the
the timing tools 99360614.
secondary tensioner arm (2).
Ref. No. Description Disassemble and remove the primary tensioner arm (4).
(1) 2 M14x1.5x10
Figure 46 (1) 1 M22x1.5x22
(5) 1 M22x1.5x22
(3) 1 M10x1.5
NOTE The chain hydraulic tensioners are equipped with

an anti-return device; it is therefore necessary to
replace the chain tensioners each time they are
removed.
Figure 48
227814
Rotate the crankshaft and fit the timing tools 99360614 (1)
on the overhead.
227815
Undo the screw (5), keep the washer (6) and remove the
exhaust camshat gear (7).
Undo the screw (3), keep the washer (4), remove the intake
camshaft gear (2) and the single link timing chain (1).

(3)
2 M12x1.75x40
(5)

Side/upper chain guide removal High pressure drive gear and lower chain removal
Figure 49 Figure 51
227816 227819
Remove the plug (4) and undo the screw (3). Stop the rotation of the high pressure pump control shaft (1)
by inserting the suitable wrench inside it.
Undo the retaining screw (5) and remove the upper chain
guide (6). Figure 52

(5) 2 M6x1
(2)
2 M6x1x20
(3)
(4) 1 M26x1.5x16
Side/lower fixed pads removal
Figure 50
227820
Undo the screw (3) and remove the shaft with the drive gear
(2) from the high pressure pump control shaft (1).

(3) 1 M12x1.5x42.5
Figure 53
227818
Undo the screws (2) and remove the side fixed pad (1).
Undo the screws (4) and remove the lower fixed pad (3).

(2)
4 M8x1.25x35
(4)
227821
Remove the gear (1) and the double link chain (2) from the
high pressure pump control shaft.
Figure 54 Figure 56
227822 227825
Remove the high pressure pump control shaft (3). Undo the screws (1 and 2) and remove the A/C compressor
support (3).
Undo the nuts (2) and remove the support (1).
(1) 2 M8x1.25x20
(2) 3 M8x1.25
(2) 2 M8x1.25x130
Power steering pump, A/C compressor and A/C
compressor support removal Power steering control shaft removal
Figure 55 Figure 57
227529
227823
Undo and remove the screw (1) and the screw (2) with their Stop the rotation of the hydraulic power steering pump
washer. control shaft (1) by inserting tool 99360187 (3) in the shaft
and fastening the tool on the support (4) by means of the
Remove the power steering pump (3) from its support. screws (2).

(1) 1 M10x1.25x30 (2) 2 M10x1.25
(2) 1 M10x1.25x110
Undo the screws (4) and remove the A/C compressor (5).

(4) 4 M8x1.25x90


(components on rear side)
Engine flywheel removal
Figure 60
227530
Undo the screw(3) and remove the gear (2) for the hydraulic
power steering control shaft (1).
(3) 1 M12x1.25x42.5 Block rotation of the flywheel (2) with tool 99360306 (1).
Undo the fixing screws and remove the tool 99360187 for Undo the screws (3) and remove the engine flywheel (2).
locking the rotation of the power steering pump shaft..
Figure 59 (3) 8 M12x1.25x51
Figure 61
227531
Remove the hydraulic power steering control shaft (3).

Undo the nuts (2) and remove the power steering support 227533
(1).
Undo the stud (2), the threaded bushes (1) and remove the
rear protection (3) from crankcase.
(2) 3 M8x1.25 Ref. No. Description
(1) 2 M12x1.5x22.5
(2) 1 M6x1.25


(components on top side part 2)
Over head removal
Figure 64
227534
Apply specific tool 99340060 (2) to the rear seal ring (1) and
extract it from the cranckase.
Figure 63 229275
Undo the screws (1) and remove the bracket (2).

(1) 2 M8x1.25x16
Figure 65
225110
To mount the tool 99340060 it is necessary to perform the

following operations:
- unscrew the extractor central screw (2) almost
completely.
- loosen the three screws (1) to enlarge the three flanges
(3) in order to hold them over the ring (4) of the seal. 229298
- tighten the screws (1) until the flanges hold over the seal Undo the fixing screws (1) and take off the over-head (2)
ring. from the cylinder head (3).
- finally tighten the central screw (2) and extract the seal
ring.
(1) 10 M8x1.25x40
(1) 20 M8x1.25x77
NOTE ensure that the flanges are driven into the entire
circumference of the seal ring: an improper
positioning of the tool could make necessary a
complete dismantling of the crankshaft to extract
the seal ring.

Hydraulic tappets removal Figure 68
Figure 66
224215
Remove the cylinder head gasket (1).

88281
Remove the hydraulic tappets (1) with the rocker arms.

NOTE Check the protrusion of the pistons (2) as
Remove the gasket (2).
described under the relevant heading to check
the possibility of facing the crankcase if it has
Cylinder head removal
deformed.
Figure 67
(components on bottom side)
Oil sump removal
NOTE Place a suitable container below the sump to

collect the oil as it drains out of the drain plug.
Figure 69
Undo the screws (1) and remove the cylinder head (2).

(1) 6 M15x1.5x193
(1) 4 M12x1.5x165
(1) 4 M8x1.25x117
(1) 1 M8x1.25x58
229276
Undo the screws (2) and remove the oil sump (1) with the
gasket and its oil pan frame (3).

(2) 13 M8x1.25x35

Engine oil suction pipe removal

NOTE Mark the connecting rods and caps with the
Figure 70 cylinder number to which they belong and the
respective fitting positions; keep the half-bearings
in their respective housings. If some components
are re-used they must be fitted in the same
positions they were in before being dismantled.
Lower cylinder block removal
Figure 72
229277
Undo the screws (2) and remove the engine oil suction pipe
(1) with the relative gasket.

(2) 3 M6x1x12
Pistons and caps removal

214653
Figure 71 Using a suitable tool undo the screws (1), (3), (4) and remove
the lower cylinder block (2).

(1) 17 M8x1.25x77.5
(3) 2 M8x1.25x40
(4) 10 M12x1.5x125
Figure 73
214652
Bring pistons 1 and 4 close to BDC.

Take out the screws (2) and remove the connecting rod caps
(3) for cylinders 1 and 4.
Slide out pistons 1 and 4 complete with connecting rods.
Remove the pistons, caps, connecting rods from cylinders 2
and 3, following the same procedure. 88289

(2) 8 M11x1.25x51 NOTE Note the assembly position of the top main
bearing shells (2) on the lower cylinder block (1)
since, if they are reused, they will need to be fitted
in the position found during removal.

Cranckshaft removal Replacing timing control gear

On finding the timing control gear teeth (1) damaged or
Figure 74 worn, remove them from the crankshaft (2) using a suitable
extractor.
The new gear is fitted onto the crankshaft by heating it to a
temperature of 180C for no longer than 15 minutes.
On completing assembly and after the gear has cooled, it
must withstand a torque of 150 Nm without slipping.
Cooling piston nozzles removal
Figure 76
87793
With the aid of a hoist and a rope, remove the crankshaft (1).
NOTE Note the assembly position of the top main

bearing shells (2) since, if they are reused, they will
need to be fitted in the position found during
removal.
The central half-bearing (3) is fitted with shoulder half-rings.
Replacing phonic wheel 75290
Take out the couplings (1) and remove the oil jets (2).
Figure 75
(1) 4 M10x1
NOTE On completing engine removal, it is necessary to

clean the removed parts thoroughly and check
their integrity.
The following pages give the instructions for the
main checks and measurements to make in order
to determine whether the parts can be reused.
87792
Undo the screw (1) and remove the phonic wheel (2) from
the cranckshaft (3).
Fit a new phonic wheel (2) on the cranckshaft (3) and
tighteen the screws (1) to the torque indicated in the table.
Tightening
(1) 3 M6x1x15 15 Nm

Figure 78
CHECKS
Cylinder block
Checking cylinder liners
Figure 77
186835
The measurements must be made for each single cylinder at

three different heights up the liner and on two planes at right
angles to each other: one parallel to the longitudinal axis of
the engine (B) and the perpendicular (A); the greatest wear
is generally found on this last plane with the first
18837
measurement.
After disassembling the engine, thoroughly clean the cylinder On finding ovalization, taper or wear, go ahead and
crankcase assembly. bore/grind and finish the face of the cylinder liners.
Use the rings provided to carry the cylinder block. The refacing of the cylinder liners should be done in relation
to the diameter of the pistons supplied as spare parts
Check thoroughly that no cracks are to be noticed on the oversized by 0.4 mm of the nominal value and to the
crankcase. Check the condition of casting hole plugs. prescribed assembly clearance.
If the caps are rusted, or if there is any doubt about the Figure 79
efficiency of the seal, replace them.
When assembling plugs, apply sealant Loctite 270 on them.
Inspect the surfaces of the cylinder liners; they should not be
scored, seized, ovalized, conical or worn to excess.
Check the inner diameter of the cylinder liners to ascertain
the extent of ovalization, taper and wear, using the bore
meter (1) fitted with a dial gauge previously reset on the ring
gauge of the diameter of the cylinder liner or on a
micrometer.
87782

Figure 80 Checking head mating surface on cylinder

block
Figure 81
88290
See that the head mating surface, on the cylinder block, has
no deformation.
This check can be made, after taking out the grub screws (3),
with a surface plate spread with carbon black or with a
calibrated rule (1) and a feeler gauge (2).
After ascertaining the areas of deformation, level the bearing
surface with a grinding machine.
NOTE The crankcase can only be surfaced after making

sure that, on completing the work, the piston
protrudes from the cylinder liner by no more than
224203
the prescribed value.
* Surface roughness parameters:
R1 = 4 10 m Crankshaft
Rz = 3 8 m
Ra = 0,25 0,6 m Measuring main journals and crankpins
W1 < 1.5 m
Figure 82
Permissible surface porosity for machined cylinder
(see figure above)
ZONE B1 = Area of greatest mechanical stress,

segment/liner contact: No.2 non-continuous C
porosities are permissible max. 0.5x0.5.
100%
ZONE B2 = Surface involved in segment rubbing:

No.2 non-contiguous porosities are permissible C 75298
max. 1x0.8. 100% On finding signs of seizure, scoring or excessive ovalization
on main journals and crankpins, it is necessary to regrind the
pins.
Before grinding the pins (2), measure the shaft pins with a
micrometer (1) to establish to what diameter it is necessary
to decrease the pins.
NOTE It is advisable to enter the measurements in a table.

See the following figure.

Figure 83 NOMINAL VALUE NOMINAL VALUE
MINIMUM
MAXIMUM
NOMINAL VALUE
MINIMUM
MAXIMUM
87784
TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS
NOTE The main journals and crankpins must always be For undersized crankpins, letter M.
ground to the same undersize class. For undersized main journals, letter B.
The undersizing performed, on the main journals or For undersized crankpins and main journals, letter MB.
crankpins, must be marked by punching on the side
of crank arm no. 1. The undersize classes are:
0.127 - 0.254 - 0.508 mm.

Checking crankshaft
Figure 84
87785
MAIN CRANKSHAFT TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Circularity
SHAPE
Cylindricality
Parallelism
ORIENTATION
Perpendicularity
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY
Figure 85
NOTE The checks on the tolerances indicated in the
figures must be made after grinding the crankshaft
pins.
SYMMETRY BETWEEN MAIN JOURNALS AND

CRANKPINS
1. Crankpins
2. Main journals
3. Normal position
After grinding, keep to the following: round off and deburr
the edges of the holes for lubrication of the main journals and
crankpins.
Follow the measurements of corner rounding deburring
holes shown in the following figures, (main journal on timing
side).
229278

Main journal on timing system side Journal on flywheel side

Figure 86 Figure 89
honed
honed
max. 0.1 on 360
Before rolling
87787 waviness in
circumferential direction
Intermediate journals no. 2 - 4 waviness in axial
direction
Figure 87 RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING) 87790
Crankpins
max. 0.1 on 3605
Before rolling
Figure 90
honed
honed
max. 0.13 on 360
Before rolling
87791
* As far as both values are concerned, for the whole 360.

87788
NOTE Since, during the 0.127 - 0.254 and 0.508 mm

undersizing on the diameter of the crankpins and
main journals, the rolled portion of the side races
Intermediate journal no. 3 of the pins may get involved, it is necessary to turn
Figure 88 the races keeping to the data given in the figure and
to do the rolling keeping to the following
instructions.
Rolling force:
- 1st main journal 925 25 daN.
- 2nd - 3rd - 4th - 5th main journal 1850 50 daN.
smooth
- crankpin 1850 50 daN.
max. 0.1 on 360
- Rolling turns: 3 approach, 12 effective, 3 out.

- Rolling speed: 56 rpm.
Before rolling
- Reduction of the connecting rod pin slot diameter after

rolling: 0.15 0.30 mm*.
217913
- Reduction of the journal slots after rolling: 0.15 0.30
mm.
MAIN DATA OF MAIN JOURNALS AND CRANKPINS
* Measured with calibrated rollers 2.5 mm.

Main bearing shells selection

Selection of main bearing shells No. 1-2-3-4-5
During the preliminary stages (points 1 and 2) identify the main bearing shell class in relation to the crankshaft and crankcase
selected; this operation is essential for cases in which the exact positions of the bearing shells were not marked during removal.
The operation consists in identifying the classes from the codes on the components (measuring thickness, as a solution to
possible fading of colour of identification), and then using these in the corresponding charts to select the main bearing shells:
- Identification of crankshaft codes
Figure 91
227251
A. Crankpin (1=standard, 2=undersized) - B. Crankpin classes (indicates class from 1 to 3 for pins no. 1-2-3-4 - see Table
for selection of big end bearing shells) - C. Main journals (1=standard, 2=undersized) - D. Main bearing shell classes
(indicates class from 1 to 9 for pins no. 1-2-3-4-5 - see Table for selection of main bearing shells No. 1-2-3-4-5, row X)

Figure 92
227252
D. Main bearing shell classes (indicates class from 1 to 9 for pins no. 1-2-3-4-5 - see Table for selection of main bearing
shells No. 1-2-3-4-5, row Y)

Main bearings shell position

Lower main bearing shells
Figure 93
227284
1. Coupling between bearing shell notch and lower crankcase seat spotface - 2. Coupling of the lower bearing shells and
lower crankcase - 3. Lower crankcase
NOTE Always couple the bearing shell with the spotface on the lower crankcase (1); failure to do so will cause bearing
shell rotation and seizure of the crankshaft.

Upper bearing shells

Figure 94
227290
1. Upper bearing shells - 2. Upper thrust bearing shells
NOTE Always couple the bearing shell with the spotface on the crankcase; failure to do so will cause bearing shell rotation
and seizure of the crankshaft.

Standard main journals (STD)
NOTE Before removing the bearings from their seats make sure that they have been numbered. The following images
show two possible numbering methods as way of example.
The main bearing shells can be used again during engine re-assembly if they have no visible surface cracks or damage and
if each of their thickness falls into the specified ranges.
Figure 95
227289

Table for selection of main bearing shells No. 1-2-3-4-5
Figure 96
227253
X. Crankshaft no. 1-4, d = 76 [mm]; no. 5, d = 83 [mm]. - Y. Crankcase no. 1-4, D = 80 [mm]; no. 5, D = 83 [mm].
d+: Diameter of pin on crankshaft D+: Diameter of main journal on crankcase

A: Class A - Red C Class C - Green
B: Class B - Blue D Class D - Brown

Diameter of seats - main journals

Location Diameter
d+ 14 76 mm
d+ 5 83 mm
D+ 14 80 mm
D+ 5 87 mm
Technical data
Clearance of main journals - half bearings STD 0.044 0.075 mm
NOTE If the bearings on the same pin have different thickness, always fit the thickest bearings towards the lower crankcase
side.
Main bearing shell selection class (STD)

Class Thickness Colour Standard Standard Standard Standard No. 5
No. 1-2-4 No. 3 No.
Top (axial) 1-2-3-4 Top Top
Top Lower
A 2.155 2.164 Red P P P P P
B 2.165 2.174 Blue R R R R R
C 2.175 2.184 Green P P P P P
D 2.185 2.194 Brown np np P np P
key
P Pre-installed during production
R Pre-installed during production / spares
np Not received

Undersized main journals (-0.127 mm)

Figure 97
227254
W. Crankshaft no. 1-4, d = 76 [mm]; no. 5, d = 83 [mm]. - Z. Crankcase no. 1-4, D = 80 [mm]; no. 5, d = 83 [mm].
d+: Diameter of pin on crankshaft D+: Diameter of main journal on crankcase

G: Class G - Red/Black L Class L - Green/Black
N Class N - Yellow/Black M Class M - Brown/Black


Location Diameter
d+ 14 76 mm
d+ 5 83 mm
D+ 14 80 mm
D+ 5 87 mm
Technical data
Clearance of main journals - half-bearings -0.127 mm 0.044 0.075 mm
NOTE If the bearings on the same pin have different thickness, always fit the thickest bearings towards the lower crankcase
side.
Main bearing shell selection class (-0.127 mm)
Class Thickness Colour Standard Standard Standar Standard No. 5

No. No. 3 d No.
1-2-4 (axial) 1-2-3-4 Top Top
Top Top Lower
G 2.218 2.227 Red/Black P P P P P
N 2.228 2.237 Yellow/Black P P P P P
L 2.238 2.247 Green/Black P P P P P
M 2.248 2.257 Black/Brown np np P np P
key
np Not received

Location Diameter
Crankshaft 14 d = 75.928 75.954 mm
5 d = 82.928 82.954 mm
Crankcase 14 D = 80.588 80.614 mm
5 D = 87.588 87.614 mm
Technical data


No. No. 3 d No.
1-2-4 (axial) 1-2-3-4 Top Top
Top Top Lower
- 2.292 2.301 - R R R R R
key
np Not received
NOTE For the axial bearing (in position 3), use two pre-assembled split-rings with mobile clearance.

Location Diameter
Crankshaft 14 d = 75.674 75.700 mm
5 d = 82.674 82.700 mm
Crankcase 14 D = 80.588 80.614 mm
5 D = 87.588 87.614 mm
Technical data

No. No. 3 d No.
1-2-4 (axial) 1-2-3-4 Top Top
Top Top Lower
- 2.419 2.428 - R R R R R
key
np Not received
NOTE For the axial bearing (in position 3), use two slackened pre-assembled split-rings.

Big end bearing shell selection

During the preliminary stages (points 1 and 2) identify the big end bearing shells class in relation to the crankshaft and
connecting rods selected; this operation is essential for cases in which the exact positions of the bearing shells were not
marked during removal.
The codes on the components (shaft and connecting rods) are required to this end.
- Identifying the connecting rod codes
Figure 98
227285
A. Blank vendor (1 digit) - B. Weight class (2 digits) - C. Diameter class (1 digit) -

D. Progressive serial number (4 digits 0000 - 9999) - E. Day of production (3 digits 001 - 365).

See previous paragraph

Big end bearing shells position

Figure 99
227288
1. Connecting rod - 2. Coupling between bearing shell notch and connecting rod spotface - 3. Coupling between big end
bearing shell and connecting rod (piston side) - 4. Coupling between bearing shell notch and lower rod cap - 5. Coupling
between big end bearing shell and lower rod cap
NOTE Always couple the bearing shell with the connecting rod (2, 4); failure to do so will cause bearing shell rotation
and seizure of the crankshaft.

Standard crankpins (STD)

Table for selection of big end bearing shells (STD)
210309 210312
X O
STD CLASS
67.833 67.840 67.841 67.848
1
2A A+B
64.038 64.031
2
A+B 2B
64.030 64.023
3
2B B+C
64.022 64.015
210310
Technical data
Clearance of half-bearings - crankpins (STD) 0.027 0.059 mm
NOTE If the bearings on the same pin are of a different thickness always fit the thickest ones on the side of the stem.

Big end bearing shell selection class (STD)
Upper bearing shell (no. 1-4) Lower bearing shell (no. -4)
Class Thickness Colour Type Class Thickness Colour Type
A 1.882 1.886 Red P A 1.878 1.882 Red P
B 1.887 1.891 Blue R B 1.883 1.887 Blue R
C 1.892 1.897 Green P C 1.888 1.893 np np
key
np Not received
Undersized crankpins (-0.127 mm)
210309 210312
X O
-0.127 CLASS
67.833 67.840 67.841 67.848
1
2D D+E
63.911 63.904
2
D+E 2E
63.903 63.896
3
2E E+F
63.895 63.888
210310
key
D, E, F Big end bearing shell class
Technical data
Clearance of crankpins - half-bearings -0.127 mm 0.027 0.059 mm
NOTE If the bearings on the same pin are of a different thickness always fit the thickest ones on the side of the stem.

Big end bearing shell selection data (-0.127 mm)
Upper bearing shell (no. 1-4) Lower bearing shell (no. 1-4)
Class Thickness Class Thickness Class Thickness Class Thickness
D 1.946 1.950 Red/Black P D 1.942 1.946 Red/Black P
E 1.951 1.955 Yellow/Black P E 1.947 1.951 Yellow/Black P
F 1.956 1.961 Green/Black P F 1.952 1.957 Green/Black np
key
np Not received

Diameter of crankpin (crankshaft) Diameter of connecting rod (diameter class)
d = 63.784 63.761 D = 67.833 67.848
Technical data
Class Thickness Colour Type Class Thickness Colour Type
- 2.005 2.014 - R D 2.001 2.010 - R
key
np Not received

Diameter of crankpin (crankshaft) Diameter of connecting rod (diameter class)
d = 63.530 63.507 D = 67.833 67.848
Technical data
Class Thickness Class Thickness Class Thickness Class Thickness
- 2.132 2.141 - R D 2.128 2.137 - R
key
np Not received

Connecting rod piston assembly Disassembly of connecting rod and piston
75393
Remove the piston rings (1) from the piston (2) using pliers
99360183 (3).
75392
Figure 102
PISTON CONNECTING ROD ASSEMBLY

1. Piston 2. Piston ring 3. Pin 4. Trapezoidal ring
5. Oil scraper ring 6. Slotted oil scraper ring with spiral
spring 7. Connecting rod body 8. Bearing shells
9. Connecting rod cap 10. Cap fixing screws.
Check the pistons. They must show no signs of seizure,
scoring, cracking or excessive wear; replace them if they do.
NOTE The pistons are supplied as spare parts with the

standard, normal and 0.4mm oversize diameters
together with rings, pin and retaining rings.
75394
Remove the piston (1) from the connecting rod, taking out
the piston ring (2) and extracting the pin (3).
Figure 103
229279
MAIN DATA FOR MAHLE, PINS AND PISTON RINGS

* The value is measured at 1.5 mm from the outer diameter
** The value of the diameter measured is 92.5 mm

Checking piston diameter Conditions for correct pin-piston coupling
87794
Using a micrometer (2), measure the diameter of the piston

(1) to determine the assembly clearance.
The diameter has to be measured at the value shown. 75397
Lubricate the pin (1) and its seat on the hubs of the piston
(2) with engine oil.
NOTE The pistons are supplied as spare parts with the
standard, normal and 0.4mm oversize diameters The pin must go into the piston by lightly pressing with the
together with rings, pin and retaining rings. fingers and must not drop out by gravity.
Checking piston rings

Figure 105
Figure 108
74947
88300
The clearance between the piston and cylinder liner can also The trapezoidal split rings (1st slot) and the oil scraper rings
be checked using a feeler gauge (1) as illustrated in the figure. (2nd slot) have the word TOP etched in them; when fitting
them on the piston, the word TOP must be facing upwards.
Checking piston pins
214626 214633
Measuring the diameter of the piston pin (1) with a Check the thickness of the piston rings (2) with a micrometer
micrometer (2). (1).

88301 75398
Check the clearance between the trapezoidal ring (2) (1st Check the clearance between the piston rings (2) of the 2nd
slot) and the associated slot on the piston with a feeler gauge and 3rd slot and the associated seats on the piston (3) with
(1), proceeding as follows: insert the piston into the cylinder a feeler gauge (1).
liner so that the ring (2) comes approximately half way out
of it.
214628
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
1. Piston slot - 2. Trapezoidal piston ring - 3. Cylinder liner
75399
Using a feeler gauge (Previous figure), check the clearance Check the opening between the ends of the piston rings (2)
(X) between the ring (2) and the slot (1); this clearance must inserted in the cylinder liner using a feeler gauge (1).
have the prescribed value.

Checking connecting rods Figure 115
Figure 114
217909
A. One character number showing the supplier raw

B. Two characters number showing weight class
C. One character O or X showing diameter class
D. Four characters serial number (from 0000 to 9999)
224205 E. Three characters number showing production day
(from 001 to 365)
MAIN DATA OF THE CONNECTING ROD, BUSHING,
PISTON PIN AND BEARING SHELLS
* Internal diameter to obtain after driving into the Checking Bushing
small end and grinding with a reamer. Check that the bush in the small end has not come loose and
** Dimension cannot be measured in the free state. shows no sign of seizure or scoring.
*** Thickness of the bearing shell supplied as a spare
part. If it does, replace the complete connecting rod.
Check rod quotas, bushing, piston pin and half bearing shown Checking connecting rod alignment
in the figure.
The cap of each connecting rod is marked with an Figure 116
alphanumeric code, as indicated in the following figure.
NOTE The connecting rods are supplied as spare parts

with the diameter of the big end
67.833 - 67.848 mm marked with the letter O and
the weight class marked with the number
22-23-32-33.
In addition, it could be stamped with the number
of the cylinder in which it is fitted.
In the event of replacement it is therefore
necessary to number the new connecting rod with
the same number as the one replaced.
The numbering must be done on the opposite side
to the bearing shell retaining slots.
It is not permissible to remove material.
61696
Check the alignment of the connecting rod axes (1) using the
tool (5) as follows:
- fit the connecting rod (1) on the tool (5) spindle and se-
cure it with the screw (4);
- set the spindle (3) on the V-prisms, resting the connect-
ing rod on the stop bar (2).

Checking connecting rod torsion Checking connecting rod deflection
61694 61695
Check the torsion of the connecting rod (5) by comparing Check the deflection of the connecting rod (5) comparing
two points (A and B) of the pin (3) on the horizontal plane two points (C and D) of pin (3) on the vertical plane of the
of the connecting axis. connecting axis.
Position the dial gauge (2) support (1) to obtain a preload of Position the vertical mount (1) of the dial gauge (2) so that
0.5 mm on the pin (3) in point A and then set the dial gauge this rests on the pin (3) at point (C).
(2) to zero.
Swing the connecting rod backwards and forwards seeking
Shift the spindle (4) with the connecting rod (5) and compare the highest position of the pin and zero the dial gauge (2).
any deviation on the opposite side (B) of the pin (3): the
Shift the spindle with the connecting rod (5) and repeat the
difference between (A) and (B) must not exceed 0.08 mm.
check on the highest point on the opposite side (D) of the
pin (3). The difference between points (C) and (D) must not
exceed 0.08 mm.
Assembling connecting rod-piston assembly
Figure 119
87797
The roof of the piston is stamped with the engine type (1),
class selection (2) and supplier (3); the direction of
installation of the piston in the lining (4). Mark (5) signifies that
it has passed the 1st slot insert adhesion test.

Figure 120 Assembling piston rings

Figure 122
41097
Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).
NOTE The 1st and 2nd slot rings need to be mounted with
the word TOP facing upwards.
87798
Connect the piston (1) to the connecting rod (2) together

with its cap so that the piston assembly reference, position NOTE Check that the piston rings opening are offset by
of the connecting rod and of the cap are observed as shown 120.
in the figure.
Figure 121
Cylinder head components
Cylinder head components disassembly
Figure 123
75394
Position the piston (1) on the connecting rod, insert the pin
(3) and secure it with the split rings (2). 229280
Apply the support SP. 2271 (2) on the cylinder head and
tighten the support in a vice.
Undo the screws and remove the lifting brackets (1).

(1) 4 M8x1.25x20
(1) 2 M8x1.25x25

Disassembling valves Figure 126
Figure 124
88426
223212 The intake (1) and exhaust (2) valves have the same diameter
mushroom.
NOTE Previously disassemble the valves using tool The central cavity () of the mushroom of the intake valve
SP.2271. (1) is distinguished from that of the exhaust valve (2).
Fit part (1) of tool 99360260 onto the cylinder head (2) and NOTE Before removing the valves from the cylinder
secure it with the screws (3). heads, number the valves in order to refit them
correctly if they are not changed.
A = intake side S = exhaust side
Figure 125 Remove the intake (1) and exhaust (2) valves.
Checking cylinder head seal

Check the hydraulic seal using a suitable tool.
Pump in water heated to approx. 90C at a pressure of 2
3 bars.
Replace the cup plugs if they are found to leak at oil, using
a suitable drift for their removal assembly.
NOTE Before mounting the plugs, apply LOCTITE 270

water-reacting sealant on their sealing surfaces.
223213
If there is any leakage from the cylinder head, it must be
Fit part (3) of tool 99360260 onto part (5), screw down the replaced.
nut (1) so that on compressing the springs (8) it is possible
to remove the cotters (6). Then take out the plates (7) and
the springs (8).
Using suitable pliers, remove the oil seal (9).
Repeat these operations on the remaining valves.
Turn the cylinder head over and remove tool SP.2271.

Checking cylinder head mating surface Valves

Figure 127
Cleaning, checking and grinding valves
Figure 128
88331 0,6
The mating surface of the head (1) with the cylinder block
is checked using a rule (2) and a feeler gauge (3).

The deformation found on the entire length of the cylinder
head must be no greater than 0.20 mm. 224207
For greater values, regrind the cylinder head according to the MAIN DATA OF INTAKE AND EXHAUST VALVES
values and instructions given in the following figure.
The nominal thickness A of the cylinder head is 112 0.1 mm;
the maximum permissible removal of metal must not exceed Removing deposits, refacing and checking valves
a thickness of 0.2 mm.
Figure 129
NOTE After regrinding, check the valve recessing and if

necessary regrind the valve seats.
The prescribed value is 0.375 - 0.625 for both
intake and exhaust valves.
204301
Remove the carbon deposits on the valves with a wire brush.

Check that the valves show no signs of seizure, cracking or
burning.

Figure 130 Valve guides

Replacing valve guide
Figure 132
18882
Use a micrometer (2) to measure the valve stem (1): it must

have the value indicated in the Figure 128.
If necessary, grind the valve seats by means of the grinding
machine, and remove as little material as possible.
87800
Check that measures made after driving in the valve guides

are as specified in the figure.
Checking clearance between valve stem and valve MAIN DATA OF VALVE GUIDES SEATS
guide and centring valves Valve guide seat inside 9.980 10.000 mm
Valve guide outside 10.028 10.039 mm
Figure 131
Figure 133
88332
The checks are made using a dial gauge (2) with a magnetic
base, positioned as illustrated. 88333
The assembly clearance is 0.033 0.063 mm for exhaust Remove the valve guides (2) with the SP.2312 tools.
valves and 0.023 - 0.053 for intake valves.
Making the valve (1) turn, check that the centring error is no
greater than 0.03 mm.

Figure 134 Boring valve guides
Figure 135
88334
Warm up the cylinder head to 80 100C and, by means

of beater SP.2312 (1) fitted with element SP.2311 (2), fit the
new valve guides (3) previously lubricated with engine oil. 88335
Driving force 4.2 12 KN (430 1250 kg) After driving in the valve guides (2), regrind them with the
SP.2310 sleeker.
If the above mentioned tools are not available, fit the valve
guides by positioning them in the cylinder head according to
the value shown in the previous Figure 132.

Valve seats
Regrinding - replacing valve seats
Figure 136
87801
Check the valve seats. On finding any slight scoring or burns, Mount the valves, block the seat of the electro-injectors and
regrind them with an appropriate tool according to the glow plugs; using a suitable tool, check the seal of the
angles given the figure. valves/seats.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material Figure 138
from the valve seats as possible until, with a punch, it is
possible to extract them from the cylinder head.
Heat the cylinder head to 80 100C and, using a suitable
drift, fit in it the new valve seats, previously chilled in liquid
nitrogen.
Using a specific tool, regrind the valve seats according to the
angles given in the figure.
Figure 137
88337
Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:
88336
- Valve recessing: 0.375 0.625 mm.
Using the milling cutter (1), clean the injector seat of any - Injector protrusion: -0.10 0.40 mm.
deposits. - Glow plug protrusion: 3.47 4.07 mm.

Valve springs Rocker arms tappets

50676
Prior to assembling, check the valve spring flexibility using a

suitable tool.
Compare the load and elastic deformation data with those
of the new springs indicated in the table.
To make the control of the springs for the intake valves and 75461
exhaust check the main data shown in the table. COMPLETE ROCKER ARM ASSEMBLY
The rocker arm assembly is composed of the rocker arm (1),
hydraulic tappet (3), made integral with each other by the clip
MAIN DATA TO CHECK INTAKE AND EXHAUST
(2).
VALVE SPRINGS
Height Under a load of Figure 141

mm N
H 55.05 Free
H1 45 P 320 16
H2 35 P1 657 30
214658
CROSS-SECTION OF THE HYDRAULIC TAPPET

A = 30.65 0.2, end of stroke
B = 33.79 0.45, working position
C = 5,7 mm.

Figure 142
87802
MAIN DATA HYDRAULIC TAPPETS SEATS
Checks Figure 144

The sliding surface of the tappets must have no scoring/dents;
replace them if they do.
Using a micrometer, measure the diameter of the tappets
and, using a bore meter, measure the diameter of the seats
in the cylinder head; the difference in the measurements will
give the assembly clearance.
Assembling valves
Figure 143
223214
Fit the springs (3) and the plates (2) on the cylinder head (4).
Figure 145
87803
NOTE Before valves mounting, use the sp.2271 tool for

cylinder head support.
Lubricate the stem of the valves (1) and insert them into the
associated valve guides (4) according to the position marked
during removal. Using tool SP.2264 (2), mount the oil seals
(3) on the valve guides (4).
223215
Fit part (7) of tool 99360260 onto part (4), screw down the
NOTE The suction valves (5) are different from the nut (1) so that on compressing the springs (3) it is possible
exhaust ones for a slot () in the centre of the to install the cotters (2). Unscrew the nut (1) and check that
valve head. the the cotters are installed correctly.
Repeat these operations on the remaining valves.
Figure 146 Ref. No. Description

(1) 3 M6x1x20
Figure 149
229280
Fit the lifting brackets (1) on the cylinder head and tighten
the screws to the torque indicated in the table.
Remove the support SP. 2271 (2) from the cylinder head.
Ref. No. Description Tightening torques
(1) 4 M8x1.25x20 252.5 Nm
(1) 2 M8x1.25x25 252.5 Nm
88341
Overhead
Tilt the over-head (1) and take care not to damage the seats,
Overhead components removal then take off the camshafts (2 and 3) from the overhead.
Figure 147
Camshaft
Checks
The surfaces of the shaft supporting pins and of the cams
must be finely honed; if there is any sign of meshing or
scoring, replace the shaft.
Figure 150
217911
Using a suitable tool, remove the lock plugs (1) with the seal
rings from the overhead.
Figure 148
75474
Using a micrometer (1), measure the diameter of the pins (2)

of the camshaft and, using a bore meter, measure the
diameter of the supporting seats in the overhead.
The difference between these two measurements gives the
existing clearance.
The nominal assembly clearance is 0.032 0.087 mm.
229281
Undo the screws (1) and remove the shoulder plate (2).

Checking cam lift and pin alignment
Figure 151
87806
Place the shaft (1) on the parallels and use a centesimal dial
gauge fitted on the central support to check that the
alignment error does not exceed 0.04 mm; otherwise,
change the shaft.
Check also the cam lift: it must correspond to the prescribed
value; if different values are detected, change the shaft.
Figure 152
224208
MAIN DATA, CAMSHAFT PINS AND SEATS

1. Intake valve camshaft seats 2. Exhaust valve camshaft seats 3. Intake valve camshaft 4. Exhaust valve camshaft.

Assembling overhead components Figure 155

Figure 153
217911 229281
Fit the lock plugs (1) with the seal rings on the overhead, Fit the shoulder plate (2) and drive in the screws (1), then
tighten them to torque indicated in the table.
Figure 154 Ref. No. Description Tightening torques

(1) 3 M6x1x20 10 1 Nm
Figure 156
88344
Lubricate the support pins of the suction camshafts (2) and

exhaust camshafts (4) and fit them on the overhead (1).
229282
NOTE During this operation do not exchange the Position the camshafts (1 and 2) so that the pins 99360614
assembly position of the shafts. (3) can be inserted in the camshaft slots through the
over-head threaded holes.
The suction camshaft can be recognised (2)
through the dowel (3) on the front side and the
retainer on the rear side.
In addition, take care not to damage the support
seats of the over-head shafts.

ENGINE ASSEMBLY Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
Crankcase components assembly
The following parts must be replaced with new ones at the
time of assembly: retaining rings, seals and gaskets, screws NOTE The middle half ring (2) is fitted with thrust washers.
whose thread is coated with sealant.
Figure 157 Cranckshaft assembly

Main journal fitting and clearance check
Figure 159
75306
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to torque indicated in the table.
Ref. No. Description Tightening torques 90064
(1) 4 M10x1 27.52.5 Nm Mount the crankshaft (1).

Assembling main bearings Check the clearance between the crankshaft main journals
and their respective bearings, working as follow:
Figure 158
Clean accurately the parts and remove any trace of oil;
Lay down pieces of calibrated wire on the journals, parallel
to the longitudinal axis.
Figure 160
88345
NOTE Not having found it necessary to replace the main

bearings, they need to be fitted back on in the same
sequence and position found upon disassembly.
88289
The main bearings (1) are supplied as spare parts undersized Thoroughly clean the bottom main bearing shells (2) and
on the inside diameter by 0.127, 0.254, 0.508 mm. mount them in the crankcase base (1).
NOTE Do not do any accommodating on the bearings.

Figure 161 Checking crankshaft end float
Figure 163
88293
The end float is checked by setting a dial gauge (2) with a

magnetic base on the crankshaft (1) as shown in the figure.
88292 The normal assembly clearance is 0.040 - 0.240 mm.
Mount the crankcase base (12) and using the tool 99395216 If you find the clearance to be greater than as required,
(11) for the angle closing, tighten the fixing screws to the replace the rear main bearing shells carrying the thrust
torque indicated in the table, following the sequence shown bearings and repeat the clearance check between the
in the figure: crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
M12x1.5x125 accordingly change the main bearing shells.
1st phase 505 Nm
(1)(10) 10 2nd phase 60
3rd phase 60
- 17 M8x1.25x77.5 252.5 Nm NOTE The middle main bearing has half thrust washers
- 2 M8x1.25x40 252.5 Nm integrated in it, so it performs the function of a
thrust bearing.
Figure 162 It is supplied as a spare part only with the normal
shoulder thickness.
75310
Undo the screws and remove the lower cylinder block.

The clearance between the main bearings and the related
pins can be found by comparing the width of the calibrated
wire (1) at the greatest squeezing point, with the graduation
of the scale shown on the casing which holds the calibrated
wire.
The numbers shown on the scale indicate the clearance in
millimetres of the coupling; it must be 0.012 0.122. If the
clearance is not as prescribed, change the bearing shells and
repeat the check.

Crankcase base assembly Figure 166
Figure 164
88294
217912
Thoroughly clean the crankcase / crankcase base mating
surface. Tighten the outer screws (1) and (2) to the torque indicated
in the table.
Apply, on base, sealant LOCTITE 510, as indicated in the
scheme. The sealant must result to be even, not patchy.
1 17 M8x1.25x77.5 252.5 Nm
2 2 M8x1.25x40 252.5 Nm
NOTE Mount the crankcase base within 10 minutes of
applying the sealant.
Assembling rear seal
220287
Carefully clean the seal seat.

Apply sealant LOCTITE 5205 on the sealing ring (1), in the
two zones at the opposite sides, covering a section of about
30 as indicated in the figure.
88292 Lubricate the rear shank of the crankshaft with engine oil.
Fit part (2) of tool 99346259 onto the rear shank of the
Mount the crankcase base (12) and using tool 99395216 (11) crankshaft; secure it with the screws (3) and key the fresh seal
for the angle closing, tighten the screws to the torque (1) onto it.
indicated in the table, following the sequence shown in the Position part (4) on part (2); screw down the nut (5) to fit
figure: the seal (1) fully inside the crankcase.

M12x1.5x125
1st phase 505 Nm
(1)(10) 10 2nd phase 60
3rd phase 60

Assembling connecting rod - piston assembly in Measuring crankpin assembly clearance

cylinder barrels
88302 88303
Lubricate the pistons well, including the piston rings and the Remove the connecting rod cap involved and carefully clean
inside of the cylinder liners. the crankpin (4) and the connecting rod half-bearing (1),
eliminating all traces of oil.
Rotate the crankshaft and bring the crankpins of pistons 1 and
4 close to BDC. Position a length of calibrated wire (3) with a graduated scale
(2) on the crankpin (4).
With the aid of the clamp 99360605 (2), fit the connecting
rod - piston assembly (1) in the cylinder liners, checking that:
Figure 170
- The number of each connecting rod corresponds to the
cap mating number.
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same weight.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil spray nozzles.
Fit the connecting rod caps of pistons 1 and 4, respecting the

order they were in before dismantling and screw in the
retaining bolts without tightening.
Fit the pistons, caps, connecting rods and half-bearings for
cylinders 2 and 3 by following the same procedure.
88326
Fit the connecting rod caps (3) with the associated bearing
shells.
Using tool 99395216 (1) for the angle closing, tighten the
NOTE If it was not necessary to replace the connecting
rod bearings, they must be fitted in exactly the Ref. No. Description Tightening torques
same order and position they were found in before
dismantling. M11x1.25x51
(2) 8 1st phase 502.5 Nm
2nd phase 70

Undo the screws and remove the connecting rod caps. Engine assembling
The clearance between the connecting rod bearings and the
(components on bottom side)
connecting rod is measured by comparing the width assumed Engine oil suction pipe refitting
by the calibrated wire, at the point of greatest crush, with the
gradation of the scale printed on the calibrated wire casing.
Figure 171
The numbers shown on the scale indicate the coupling
clearance (in millimetres).
If the measured clearance differs from the recommended
one, replace the bearings and repeat the check.
On obtaining the prescribed clearance, lubricate the
connecting rod bearing shells and fit them permanently by
tightening the connecting rod cap fixing new screws as
described prevously.
The connecting rod cap fixing screws must always be

! replaced for permanent assembly.
Manually check that the connecting rods slide axially
on the pins of the crankshaft.
229277
Fit the engine oil suction pipe (1) and tighten the screws (2)
Checking piston protrusion to the torque indicated in the table.
Figure 172 (2) 3 M6x1x12 10 1
Oil sump refitting

Figure 173
88327
At the end of the connecting rod-piston assembly refitting,

check the piston protrusion (2) at the T.D.C. compared to
the top level of the cylinder block by means of a dial gauge
(1) and relevant base 99370415 (use with 99395603).
These values depend on the type of cylinder head gasket
used; below the summary table: 229283
Fit a new gasket on the oil sump (1) and place them on the
Piston Gasket thickness Piston protrusion cranckcase; suddenly place the oil pan frame (3) on the
protrusion [mm] max. difference cranckcase and tighteen the screws (2) to the torque
[mm]* [mm]** indicated in the table.
0.3 0.4 1.1 0.04 Ref. No. Description Tightening torques
0.4 0.5 1.2 0.04 0.15 (2) 13 M8x1.25x35 25 2.5
0.5 0.6 1.3 0.04 Place the oil sump drain plug (4) and tighten it to the torque
* 4 pistons max. protrusion
** The difference between the minimum and maximum
protrusions of the four pistons must be 0.15 mm. (4) 1 M22x1.5x10 50 10
Engine assembling Figure 176

(components on top side part 1)
Cylinder head refitting
Figure 174
88355

M15x1.5x193
224215 1st phase 1306.5 Nm
Check that contact surfaces of the cylinder head and (1)(6) 6 2nd phase 90
crankcase are clean. 3rd phase 90
Place the cylinder head dowels on the crankcase (if they were M12x1,5x165
removed previously). 1st phase 65 3.25 Nm
(7)(10) 4 2nd phase 90
Place a new cylinder head gasket (1) with the tickness 3rd phase 60
indicated in the Checking piston protrusion paragraph with 4 M8x1.25x117 25 2.5 Nm
the writing TOP facing the cylinder head. A
1 M8x1.25x58 25 2.5 Nm
Hydraulic tappets refitting
It is absolutely necessary to keep the cylinder head Figure 177

! gasket sealed in its packaging and remove it just
before fitting to avoid getting it dirty.
Figure 175
88356
Position the cylinder head extension dowels on the cylinder

head (if they were removed previously).
Thoroughly clean the hydraulic tappets (2), lubricate them
and place them in the cylinder head (3), positioning the
88354
rocker arms (1) on the valves correctly.
Mount the cylinder head (2).
Place a new cylinder head extension gasket (5) in its seat.
Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown Insert the two tools SP. 2264 (4) into the electro-injector
in the following figure, using tool 99395216 for the angle seats for subsequent centring of the overhead on the cylinder
tightening. head.

Overhead refitting Engine assembling

(components on rear side)
Figure 178
Engine flywheel refitting
Figure 180
229298
Mount the overhead (2) on the cylinder head (3) together

with the tools 99360614 for the timing and tighten the fixing 227533
Fit the rear protection (3) on the crankcase and tighten the
Remove the tools SP. 2264. stud (2) and the threaded bushes (1) to the torque indicated
in the table.
Tightening
Ref. No. Description torques Tightening
(1) 10 M8x1.25x40 252.5
(1) 2 M12x1.5x22.5 5 0.5
(1) 20 M8x1.25x77 252.5
(2) 1 M6x1.25 10 1
Figure 179
Figure 181
229275
227532
Fit the bracket (2) on the overhead and tighten the screw (1)
to the torque indicated in the table. Mount the engine flywheel (2) and screw down the screws
(3), without tightening.
Tightening Place tool 99360306 (1) onto the crankcase to block rotation
Ref. No. Description torques of the engine flywheel (2).
(1) 2 M8x1.25x16 - Tighteen the screws (3) fixing the engine flywheel (2) to the
torque indicated in the table, using tool 99395216 for the
angle tightening.
Tightening
M12x1.25x51
(3) 8 1st phase 30 1.5
2nd phase 90
Engine assembling Figure 184

(components on front side part 1)
Power steering control shaft refitting
Figure 182
227529
Stop rotation of the hydraulic power steering pump control

shaft (1) inserting in the latter the tool 99360187 (3) and
fastening the tool on the support (4) by means of the screws
229284
(2).
Rotate the driving shaft so that the tool 99360615 (1) can be
Figure 185
inserted in the shaft crank hole through the cylinder block
hole, in order to stop the engine in the timing system setting
condition.
Figure 183
227530
Fit the gear (2) on the hydraulic power steering pump control
shaft (1).
Drive in the screw (3) without locking it.
227531
Lubricate new power steering support seal rings with engine

oil and fit them on the support.
Place the power steering support (1) in its housing and
tighten the nuts (2) to the torque indicated in the table.
Fit the hydraulic power steering pump control shaft (3).
Tightening
(2) 3 M8x1.25 252.5

Power steering pump, A/C compressor and A/C High pressure drive gear and lower chain refitting
compressor support refitting
Lubricate new high pressure pump support seal rings with
engine oil and fit them on the support.
Figure 186
Figure 188
227825
Fit the A/C compressor support (3), drive the screws (1 and 128158
2) and tighten them to the torque indicated in the table.
The drive wheel (1) has a hole (2) for a reference pin on its
rear face.
Tightening
Ref. No. Description torques The front face of the drive wheel (1) has a reference notch
which must be held vertical when adjusting the timing of the
(1) 2 M8x1.25x20 25 2.5
pump.
(2) 2 M8x1.25x130 25 2.5
The driving shaft (3) has a seat (4) for a reference pin (5).
Figure 187 The position of the seat (4) of the pin on the spindle (3) has
been set sop as to ensure synchronisation of the pump and
crankshaft.
Figure 189
227823
Fit the A/C compressor (5) on its support and tighten the
227822
Tightening
Ref. No. Description torques Fit the support (1), drive in the nuts (2) and tighten them to
(4) 4 M8x1.25x90 25 2.5 the torque indicated in the table.
Fit the power steering pump (3) with a new gasket, tighten Fit the high pressure pump control shaft (3) of the high
the screw (1) and the screw (2) with their washer to the pressure pump.
Tightening
Tightening
Ref. No. Description (2) 3 M8x1.25 252.5
torques
(1) 1 M10x1.25x30 40 4
(2) 1 M10x1.25x110 40 4

229285 227820
Check that the drive shaft (2) is positioned with the pin (1) Fit the shaft with the drive gear (2) on the high pressure pump
at the top (as indicated by the arrow). control shaft (1).
Drive in the fastening screw (3) without tightening.
Figure 191
Side/lower fixed pads refitting
Figure 193
229286
Using tool 99360615 (4), rotate the crankshaft until the

crankshaft timing adjustment tool can be positioned
correctly. 229287
Position a new double link chain (6) on the gears (2, 3 and Check the condition of the fixed pads, replace them if they
5) and fit the gear (2) on the shaft (1) so that branches A and are worn.
B of the chain (6) are under tension.
Fit the side fixed pad (1) and drive in the fastening screws (2),
then tighten them to the torque indicated in the table.
Fit the lower fixed pad (3) and drive in the fastening screws
(4), then tighten them to the torque indicated in the table.
Tightening
(2) 2 M8x1.25x35 252.5
(4) 2 M8x1.25x35 252.5

Side/upper chain guide refitting

Figure 194 be tensioned.
Figure 196
227816
Fit the upper chain guide (6), drive in the screws (5) and
229288
Fit the side chain guide (1), drive in the screws (2 and 3) and
tighten them to the torque indicated in the table. Position the single link chain (4) on the gear (3) and fit the
latter on the camshaft of the exhaust valves.
indicated in the table. Drive in the fastening screw (1) with the washer (2) without
Tightening
(2) NOTE The gear (3) must be mounted with the markings
(3) 2 M6x1x20 101 inwards.
(4) 1 M26x1.5x16 505 In the gear (3) there is a larger hole for
adjustment, which fits onto the pin on the
(5) 2 M6x1 101 exhaust camshaft shank.
Upper timing chai n and camshaft gear refitting
Figure 195 NOTE The chain arm (4) between the two gears must
be tensioned.
88358
Position the single link chain (1) on the gear (5) and gear (2).
Mount the gear in such a way that fitting on intake valve timing
system shaft dowel makes slots A to result to be positioned
as in figure.
Drive in the fastening screw (4) with the washer (3) without

229289 229290
Check the conditions of the primary and secondary tensioner Tighten the fastening screw of the gear (1) on the hydraulic
arm (3 and 1), if worn out change them. power steering control shaft to the torque indicated in the
table.
Position the primary and secondary tensioner arm (3 and 1)
and clamp them on the cylinder block by the bolt shoulder
(2) and tighten it to the torque indicated in the table. Tightening
Tightening (1) 1 M12x1.25x42.5 13013
(2) 1 M10x1.5 402 Figure 199
Drive in the chain standard hydraulic tensioner (4) and
tighten it to the torque indicated in the table.
Tightening
(4) 1 M22x1.5x22 502.5
The chain standard hydraulic tensioner can

! absolutely never be re-used.
229291
Stop the rotation of the high pressure pump control shaft (1)
by inserting a suitable wrench inside it.

229292 229293
Screw on the chain anti-return hydraulic tensioner (2) and Tighten the fastening screw of the gear (1) on the intake valve
tighten to the torque indicated in the table. camshaft to the torque indicated in the table.
Ref. No. Description torques Ref. No. Description torques
(2) 1 M22x1.5x22 502.5 (1) 1 M12x1.75x40 1105.5
From the opening in the overhead, press on the tab (3) of the
secondary tensioner arm (4) with a screwdriver and push the Figure 202
piston (1) of the chain anti-return hydraulic tensioner (2) fully
down.
Release the secondary tensioner arm (4) and check that the
piston (1) protrudes from its seat, thus tensioning the chain
(5).
The hydraulic chain tensioners (with anti-return

! device) can absolutely never be re-used.
229294
Make sure that the chain (1) in the tract between the gear (2)
and gear (3) is tensioned.
Tighten the fastening screw of the gear (3) on the exhaust
valve camshaft to the torque indicated in the table.
Tightening
(3) 1 M12x1.75x40 1105.5

Figure 203 Timing sensor and timing system upper cover refitting
Figure 205
227814
Remove tools 99360614 (1) and fit the two inspection caps
217916
in their housing tightening to the torque indicated in the table.
Fit a new gasket (6) on the cover (5).
Tightening Fit the cover (7), on the cylinder overhead tighten the screws
Ref. No. Description torques (2) and the nuts (1) to the torque indicated in the table.
(-) 2 M14x1.5x10 252.5
Place the phase sensor (4) and tighten the screw (3) to the
Figure 204
Tightening
(1) 2 M6x1 101
(2) 7 M6x1x30 101
(3) 1 M6x1x16 101
NOTE Insert the gasket into the seat in the cover with
the blade part facing towards the engine.
Align the three references (A, B, C) on the gasket
with the respective seats in the cover.
229334
Make sure that the chain (1) in the tract (A) is tensioned.
Tighten the fastening screw of the stem with the drive gear
(2) on the high pressure pump control stem to the torque
Tightening
(2) 1 M12x1.5x42.5 11011
Remove the suitable wrench used to stop of the high
pressure pump control shaft.

Depressor/oil pump unit refitting Figure 208
Figure 206
229297
Clean accurately the seat of the cover seal ring (1).

229295
Drive in the element (3) of tool 99346258 in the driving shaft
Position the coupling drive (1) in the gear (5).
tang.
Fit the oil pump/depressor unit (2) with a new gasket and
Lubricate the tang of the driving shaft and the element outside
(3) and fit flush the new seal ring on this element (2).
Remove crankshaft timing adjustment tool 99360615 (4).
Position the element (5) on element (3), lock the nut (4) until
fitting the seal ring (2) completely in the cover (1).
Tightening
Figure 209
(3) 5 M8x1.25x60 252.5
Timing system lower cover refitting
Figure 207
229296
Mount tool 99396039 (1), for centering cover (4), into

centrifugal filter seat and tighten screws (3) at the torque
227810
Tightening
Fit the cover (2) with a new gasket. torques
Drive in the screws (1) without tightening them completely. (3) 9 M8x1.25x30 252.5
(3) 7 M8x1.25x16 252.5
Fit the engine increment speed sensor and tighten the screw
(3) to the torque indicated in the table. Remove the 99346258 (2) and 99396039 (1) tools.
Tightening
(3) 1 M6x1x12 101

Water pump and 3 speed electromagnetic pulley refitting Figure 212
Figure 210
227809
227807
Fit the water pump (5) with a new gasket and tighten the
screws (4) to the torque indicated in the table. Tightening
Fit the electromagnetic pulley (3) on the water pump, torques
(3) 1 M20x1.5x58 35017.5
tighten the nuts (1) and the ring nut (2) to the torque
indicated in the table Fit the A/C compressor belt tensioner (2) and tighten the
Tightening
Ref. No. Description torques Tightening
2 M8x1.25x45 252.5 torques
(4) (1) 1 M8x1.25x45 252.5
3 M10x1.5x55 505
(2) 1 M30x1 15015
Blow-by refitting
(1) 4 M6x1 101
Dumper pulley refitting Figure 213
Figure 211
227806

227808
Stop the rotation of the engine flywheel (1) by means of tool indicated in the table.
99360306 (2). Fit the blow-by pipe bracket on the cylinder head and tighten
Tightening
(2) 3 M6x1x18 101
(1) 1 M8x1.25 252.5

Engine assembling If previously removed, fit the air temperature/pressure sensor

(components on intake side ) on the intake manifold and tighten the nut (1) to the torque
Pre/heater glow plugs refitting
Tightening
Figure 214 Ref. No. Description torques
(1) 1 M6x1 101
Thermostat refitting
Figure 216
227805
Fit the pre/heater glow plugs (1) in their housing on the

cylinder head using the SP.2275 tool and torque wrench
99389819, then tighten them to the torque indicated in the
table.
214644
Tightening
Ref. No. Description torques Fit the thermostat in its housing on the cylinder head.
(1) 4 M8x1 91 Fit the thermostat cover (2), together with the relative gasket
and the coolant temperatur sensor and tighten the screws (1)
Intake manifold refitting to the torque indicated in the table.
Figure 215 Tightening

(1) 4 M8x1.25x20 252.5
227804
Fit the intake manifold (6) with a new gasket on the cylinder
head and tighten the screws (2), (4) and (5) to the torque
Fit the two threaded plugs (3) on the intake manifold and
Tightening
(2) 2 M8x1.25x60 252.5
(4) 6 M8x1.25x40 303
(5) 1 M8x1.25x140 303
(3) 2 M24x1.5 303

High pressure pump refitting Figure 219
Figure 217
229313
Fit the high pressure pump (2) vertically as shown in the

previous figure onto the support (4) and rotate it in an
227804 anticlockwise direction until the mounting bolt holes are
Lubricate a new seal ring (3) and fit it to the high pressure aligned.
pump. Tighten screw (5) and screws (1) with their washers (3) to
Make sure the flange (4) is fitted to the high pressure pump. the torque indicated in the table.
Make sure the high pressure pump is in stable equilibrium, Tightening
with the one of the two recesses (1) on the flange (4) in line Ref. No. Description torques
with the reference on the pump itself (2).
(1) 2 M8x1.25x90 252.5
Figure 218 (5) 1 M6x1x20 252.5
Water/oil heat exchanger refitting
Figure 220
227803
Tighten the screw (3) fixing the engine cooling water pipe
bracket to the feeding pump holder to the torque indicated
in the table.
Tightening
135043 torques
The figure shows the vertical position of high pressure pump (1) 8 M8x1.25x30 252.5
assembly. (3) 1 M8x1.25 252.5
The high pressure pump can rotate through 45.

Low pressure pipes group refitting Oil filter refitting
227802 227800
Fit the low pressure pipes group together with the fuel Place the oil filter (1) on the water/oil heat exchanger and
recovery pipe from electro-injectors and engage the group in tighten it to the torque indicated in the table.
Fit the bracket fixing the low pressure pipes duplex anchorage Tightening
and tighten the screws (2) to the torque indicated in the table. torques
(1) 1 M22x1.5 252.5
indicated in the table. Engine assembling
(components on exhaust side )
Tightening Alternator support refitting
(1) 1 M6x1 252.5 Figure 224
(2) 2 M6x1x10 101
Figure 222
227799
Fit the alternator support (2) on the crankcase and tighten the
fixing screws (1) to the torque indicated in the table.
227801
Connect the fuel supply pipe to the high pressure pump and Tightening
close the clamp (1).
(1) 1 M8x1.25x70 303
engage the qick connector (2). (1) 2 M8x1.25x30 303
(1) 1 M10x1.25x35 505

Alternator refitting EGR group refitting
227798 227796
Fit the alternator (2) in its support, tighten the screw (3) and Place the EGR group (2) on the overhead and tighten the
bolt (1) to the torque indicated in the table. screws (1) to the torque indicated in the table.
torques torques
(3) 1 M10x1.25x30 50 5 (1) 3 M8x1.25x80 252.5
(1) 1 M10x1.25x130 50 5 (1) 1 M8x1.25x95 252.5
Auxiliary drive belt - automatic belt tensioner refitting Figure 228
Figure 226
227795
Fit the engine coolant delivery pipes group (3) by connecting

227797
the pipes (2) to the EGR heat exchanger and close the
Fit the automatic belt tensioner (4) and tighten the screw (3) clip-sleeve (1).
Fit the bracket securing the coolant delivery pipes group (3)
to the cylinder overhead and tighten the screw (4) to the
Tightening torque indicated in the table.
(3) 1 M10x1.5x45 45 5 Tightening
Using a specific wrench on the automatic belt tensioner (4), torques
fit the belt (1), making sure that the ribs on the belt fit properly (4) 1 M8x1.25 252.5

Figure 229 Engine assembling (components

on top side part 2)
Fuel manifold pipe and electro-injectors refitting
Figure 230
227794
Fit the exhaust gas pipe (3), on the cylinder head, together
with the rear cover and a new gasket and tighten the screws
Place a newgasket connect the exhaust gas pipe to the intake 227793
manifold and tighten the screws (5) to the torque indicated Fit the fuel manifold pipe (6) in its housing on the overhead,
in the table. close the relative band and tighten the screws (7) to the
Connect the exhaust gas pipe to the EGR heat exchanger, torque indicated in the table.
close the collar and tighten the screw (1) to the torque Connect the high pressure pipe (3) to the fuel manifold and
indicated in the table. to the high pressure pump, tighten the fitting (1 and 4) with
Connect the engine coolant delivery pipe and close the specific series wrench 99317915 and specific torque wrench
clamps (2). 99389829 to the torque indicated in the table.
Engage the EGR exhaust gas temperature sensor electrical Tighten the bracket nut (2) to the torque indicated in the
connection (6) to the bracket and to the intermediate clips. table.
Tightening
Ref. No. Description Connect the fuel return pipe (5) to the fuel manifold pipe and
torques
close the clamp.
(1) 1 M6x1 50.5
(4) 3 M8x1.25x35 50.5 Tightening
(4) 4 M8x1.25x45 50.5 Ref. No. Description torques
(5) 2 M8x1.25x30 50.5 M16x1
(1) 1 1st phase 252
2nd phase 90
(2) 1 M8x1.25 252.5
M15x1
(4) 1 1st phase 242
2nd phase 90
(7) 2 M8x1.25x35 291.45

! from the fuel feed pump to the injectors, it is
absolutely required NOT to:

227792 229306
Insert the oil level dipstick (1) into the oil sump and tighten Fit the brackets (2), securing the electro-injectors to the
the screw (2) fixing the oil level dipstick upper bracket to the overhead and screw down the screws (1) without tightening
intake manifold to the torque indicated in the table. them completely.

(2) 1 M8x1.25 25 2.5
Figure 232
229307
Connect the newhigh pressure fuel pipes to the fuelmanifold

pipe (1) and to the electro injectors (2), then tighten the
electro-injectors bracket screws (3) to the torque indicated
217915
in the table.
Fit a new seal (3) on the electro-injectors (1) and mount them
in the overhead (2). Tightening
(3) 4 M8x1.25x80 291.45

229305 230353
Using the 99317915 (rail side) and 99352115 Fit and connect the fuel recovery pipe (2) to the
(electroinjectors side) wrenches, the torque wrenches elctro-injectors and close the retaining clips (1) in the
99389829 (rail side) and 99389831 (electro-injectors side), direction shown by the arrow.
torque indicated in the table. Close the intermediate retaining clip (3).
Use tool 99395216 for angle tightening. Air inlet pipe refitting

M15x1
(1) 4 1st phase 242
2nd phase 90
M14x1
(2) 4 1st phase 252
2nd phase 50

! from the fuel feed pump to the injectors, it is
absolutely required NOT to:
227790
Fit the air inlet pipe (1) on the intake manifold, together with
the flange (3) and a new gasket, then tighten the screws (2)
Tightening
(2) 4 M8x1.25x25 252.5

Removing the engine from the rotating stand Figure 239

Remove the engine from the rotary stand 99322205 and
remove the the brackets 99361041 from the crankcase.
Refitting of components hindering bracket

assembly
Turbocharger - Exhaust manifold group refitting
Figure 238
220125
Tighten the bracket screws (2), securing the turbocharger

229317 water return pipe group to the cylinder head to the torque
Place a new metallic gasket and fit the exhaust gas -
turbocharger group (2) on the cylinder head. Connect the turbocharger water return pipes group to the
turbocharger and tighten the union (1) to the torque
Then tighten the nuts (1) to the torque indicated in the table. indicated in the table.
torques torques
(1) 10 M8x1.25 252.5 (1) 1 M14x1.5 404
(2) 2 M8x1.25x16 252.5

Figure 240 Turbocharger air outlet pipe refitting
Figure 242
229316
Fit the exhaust gas delivery pipe (2) with new gaskets,
2144647
connect it to the exhaust manifold and to the EGR valve and
tighten the screws (1) to the torque indicated in the table. Connect the turbocharger air outlet pipe (4) to the
Tightening screws (2) to the torque indicated in the table.
Ref. No. Description torques Connect the union bracket (5) and tighten the screws (1) to
(1) 4 M8x1.25x20 252.5 the torque indicated in the table.
Turbocharger oil delivery pipe and exhaust manifold guard Tightening

refitting Ref. No. Description torques
(1) 4 M8x1.25x20 282.8
Figure 241 (2) 2 M6x1x18 101
Electric exhaust gas flap refitting
Figure 243
229315
Fit the turbocharger oil delivery pipe (6) and tighten the
Connect the turbocharger water delivery pipe to the
cranckase and tighten the union (4) to the torque indicated 214646
in the table. Fit the electric exhaust gas flap (2) onto the turbocharger and
Fit the exhaust manifold guard (3) with the spacers and tighten the V-clamp (1) to the torque indicated in the table.
Tightening
Tightening torques
Ref. No. Description torques (1) 1 M8x70 121
(1)
(5) 2 M14x1,5 404
(2) 4 M6x1.25x14 18
(4) 1 M14x1.5 404

Exhaust side engine mount and turbocharger oil outlet pipe Intake side engine mount refitting
refitting
Figure 245
Figure 244
227789
Fit the intake side engine mount (2) and tighten the screws
Tightening
(1) 1 M10x1.25x95 505
214646
(1) 2 M10x1.25x50 505
Fit the turbocharger oil return pipe, and tighten the fitting to
the cranckase (2) and the bracket screws (1) to the torque
Fit the exhaust side engine mount and tighten the the screws
(3) and (4) to the torque indicated in the table.
Tighten the union bracket screw (6) to the torque indicated
in the table.
Tightening
(1) 2 M6x1x16 101
(2) 1 M22x1.5 454.5
(3) 2 M10x1.25x85 505
(4) 1 M10x1.25x50 505
(6) 1 M8x1.25x20 252.5

Engine wire refitting

Fit the engine wiring, engage the pins in the relative brackets and engage the engine wiring cover in its housing on the cylinder
overhead.
Connect the following electrical connections:
Figure 246
227787

1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor -
4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump -
8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor -
10. Air pressure and temperature sensor - 11. Pressure regulating valve on rail - 12. Segment speed sensor

Figure 247
227788

When fitting is completed, top-up the engine lubricant oil with the specified quantity and quality.
Only use recommended oils or oils with the properties required for proper engine operation.Failure to observe these
! standards will invalidate the service warranties.
Check the oil level with the oil level dipstick: the level must come close to the MAX notch which can be seen on the
dipstick.

CHECKS AND INSPECTIONS

The following tests shall be made after engine assembly to the
vehicle.
Preventively check that the liquid levels have been correctly
restored.
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- There is no water bleeding from the
manifolds connecting engine cooling circuit
pipelines and cabin internal heating,
eventually providing to further tighten the
locking rings.
- Carefully check the fuel connection pipes to
the respective unions.
- There is no oil leakage from the lubrication
circuit of the various pipelines connecting
covers.
- Cylinder head, oil pan and bearing, oil filter
and heat exchanger as well as relating
housings.
- There is no fuel leakage from fuel pipelines.
- There is no blow-by from pneumatic pipes (if
provided).
- Verify correct working of the lighting leds of
the dashboard containing the tools as well as
of the equipment that was disconnected
during engine disconnection.
- Check and blow by with care the engine
cooling system, carrying out frequent
drainage.

Low pressure supply circuit diagnostics

Figure 248
Diagnosis methodology: complete the vehicle acceptance

card.
Connect the diagnosis instrument 99305454 to the vehicle
diagnosis socket and carry out the engine test analysis: If the
result of the Run-up Test gives a high negative deviation
(DEV%) on one cylinder and a correct compression value, go 146611
straight to the electro-injectors removal/refitting Turn off the engine, disconnect pressure gaugeD and restore
procedure described in section 5; otherwise proceed with the the connection of the pipe (4) to the fuel filter (2).
analyses described below, where the advice for correct
diagnosis will be listed. Connect pressure gauge D between fuel inlet F of the filter
(2) and the fuel pipe (3) from the tank. Start the engine, keep
the speed at 1500 rpm. and compare the pressure values read
NOTE Low pressure, in either the feed circuit or the with those given in the tables A1 - A3.
return circuit, has a direct affect on the high
pressure system. Table A1 Low pressure at filter inlet
The electronic diagnosis instruments are unable Pressure value readings (P)
Pressure gauge
to identify faults in the low pressure (except bar
D
control of the electric pump supply relay). 4.4 p 5.8
Connect pressure gauge D (using specific tool) between Table A1 Low pressure at filter inlet
outlet E of the fuel filter (2) and the fuel delivery pipe (4) to Pressure value readings (P)
the high pressure pump (1). Pressure gauge
bar
D
Connect pressure gauge B (using specific tool) between 4.4 p 6.0
outlet G of the high pressure pump (1) and the fuel
recirculation pipe. Table A1 Low pressure at filter inlet
Start the engine, keep the speed at 1500 rpm. and compare Pressure value readings (P)
Pressure gauge
the pressure values read with those given in the tables A2 and bar
B
A3. 2


F1C EuV1 - ENGINES SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
ASSEMBLY DATA CLEARANCES . . . . . . . . . 3
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 8

2 SECTION 7 - TECHNICAL SPECIFICATIONS F1C EuV1 - ENGINES

ASSEMBLY DATA CLEARANCES
Type F1CFL411S*A302
CYLINDER ASSEMBLY AND CRANK MEMBERS

1 Cylinder liners:
1 95.802 95.812
Pistons:
1 supplied as spares type MAHLE
X measurement X 58
outside diameter 1 95.543 95.557
2 seat for pin 2 36.003 36.009
Piston cylinder liners 0.245 0.269
Piston diameter 1 0.4
X
Piston protrusion
from crankcase X 0.3 0.6
3 Piston gudgeon pin 3 35.990 35.996
Piston gudgeon pin pin seat 0.007 0.019

Type F1CFL411S*A302
CYLINDER ASSEMBLY AND CRANK MEMBERS mm

X1* 2.200 2.230
X1
Piston ring slots X2 2.050 2.070
X2
X3 X3 2.540 2.560
* measured on of 92.8 mm
Piston rings: S1* 2.068 2.097
S1 S2 1.970 1.990
S2
S3 2.470 2.495
S3
* measured at 1.5 mm from
the external .
Piston rings slots 1 0.103 0.162
2 0.060 0.100
3 0.545 0.590
Piston rings 0.4
X1 Piston ring end opening in

cylinder liner:
X2
X1 0.20 0.35
X3
X2 0.60 0.80
X3 0.30 0.60
1 Small end bushing seat
1 39.460 39.490
2 Connecting rod bearing seat*

2 67.833 67.848
* connecting rod supplied as
spare part
Small end bushing diameter
4
outside 4 39.570 39.595
3 inside 3 36.010 36.020
S Big end bearing shells

supplied as spare part -
- top S 1.882 1.887*/1.887 1.892**/1.892 1.897***
- bottom S 1.878 1.883*/1.883 1.888**/1.888 1.893***
Small end bushing seat
(interference) 0.08 0.135
Piston gudgeon pin bushing 0.007 0.019
Big end bearing shells 0.127 - 0.254 - 0.508
* RED - ** BLUE - *** GREEN

Type F1CFL411S*A302
CYLINDER ASSEMBLY AND CRANK MEMBERS mm

X
Measurement X 125
Maximum error
on alignment of
connecting rod axes = 0.09
Main journals 1
No. 1-2-3-4 76.182 76.208
No. 5 83.182 83.208
1 2 Crankpins 2 64.015 64.038
Main bearing shells
S1^
Red 2.155 2.164
Blue 2.165 2.174
Green 2.175 2.184
S1 S 2 Brown 2.185 2.194
Big end bearing shells
- top S2^ 1.882 1.887*/1.887 1.892**/1.892 1.897***
- bottom S2^ 1.878 1.883*/1.883 1.888**/1.888 1.893***
^ supplied as spare parts
Main bearing housings 3
3 No. 1-2-3-4 80.588 80.614
No. 5 87.588 87.614
Bearing shells -
main journals 0.012 0.122
Bearing shells
crankpins 0.009 0.077
Main bearing shells 0.127 0.254 0.508
Big end bearing shells 0.127 0.254 0.508
Main journal
for shoulder X1 32.500 32.550
X 1
Main bearing housing

for shoulder X2 30.650 31350
X 2
X3
Half thrust washers X3
32.310 32.460
Crankshaft shoulder 0.040 0.240
* RED - ** BLUE - *** GREEN

Type F1CFL411S*A302
CYLINDER HEAD TIMING SYSTEM mm

1
Guide valve seats

on cylinder head 1 9.980 10.000
2 6.023 6.038
Valve guides
3 10.028 10.039
3
Valve guides and seats on head

(interference) 0.028 0.059
Valve guides 0.05 - 0.10 - 0.25

4 Valves:
4 5.985 6.000
60 7.5
4 5.975 5.990
60 7.5
Valve stem and relevant guide
0.023 0.053
0.033 0.063
Seat on head for valve seat:
1 34.490 34.515
1 34.490 34.515
1
Outside diameter of valve

2 seats; angle of valve seats on
cylinder head:
2 34.595 34.610
60 1
2 34.595 34.610
60 1
X 0.375 0.625
X Recessing X 0.375 0.625
0.08 0.12
Between valve
seat and head
0.08 0.12
Valve seats -
Type F1CFL411S*A302
CYLINDER HEAD TIMING SYSTEM mm

Valve spring height:
free spring H 55.05
H under a load of:
H1
H 2 N320 16 H1 45
N657 30 H2 35
Injector protrusion X -0.10 0.40

X
Seats for tappets on

cylinder head normal 12.016 12.034
Normal diameter tappets 11.988 12.000

Between tappets and seats 0.016 0.046

Camshaft pin seats in
cylinder overhead
17
1 48.988 49.012
2 46.988 47.012
3 35.988 36.012
2
Camshaft supporting pins:
1 48.925 48.950
2 46.925 46.950
1 2 3
3 35.925 35.950
Supporting pins and seats 0.032 0.087
Useful cam height
H H
3.622
H
4.328

TIGTHENING TORQUES
TORQUE
PART
Nm kgm
Camshaft shoulder plate
(3 screws M6x1x20) 10 1 1 0.1
Engine hook
(4 screws M8x1.25x20) 25 2.5 2.5 0.25
(2 screws M8x1.25x25) 25 2.5 2.5 0.25
Piston cooling nozze
(4 screws M10x1) 27.5 2.5 2.75 0.25
Phonic wheel
(3 screws M6x1x15) 15 1.5
Lower cylinder block
(17 screws M8x1.25x77.5) 25 2.5 2.5 0.25
(2 screws M8x1.25x40) 25 2.5 2.5 0.25
(10 screws M12x1.5x125)
1st phase 50 5 5.0 0.5
2nd phase 60
3rd phase 60
Engine oil suction pipe
(3 screws M6x1x12) 10 1 1 0.1
Oil sump
(13 screws M8x1.25x35) 25 2.5 2.5 0.25
Oil sump drain plug
(M22x1.5x10) 50 10 5.0 0.1
Connecting rod caps
(8 screws M11x1.25x51)
1st phase 50 2.5 5.0 0.25
2nd phase 70
Cylinder head
(6 internal screws M15x1.5x193)
1st phase 130 6.5 13.0 0.65
2nd phase 90
3rd phase 90
(4 internal screws M12x1.5x165)
1st phase 65 3.25 6.5 0.325
2nd phase 90
3rd phase 60
(4 external screws M8x1.25x117) 25 1.25 2.5 0.125
(1 external screw M8x1.25x58) 25 1.25 2.5 0.125
Cylinder overhead
(10 screws M8x1.25x40) 25 2.5 2.5 0.25
(20 screws M8x1.25x77) 25 2.5 2.5 0.25
Flywheel rear protection
(1 stud M6x1.25) 10 1 1.0 0.1
(2 threaded bush M12x1.5x22.5) 5 0.5 0.5 0.05
Engine flywheel assembly
(8 screws M8x1.25x51)
1st phase 30 3 3.0 0.3
2nd phase 90
Hydraulic power steering support
(3 nuts M8x1.25) 25 2.5 2.5 0.25
Hydraulic power steering pump control shaft
(1 screw M12x1.25x42.5) 130 13 13.0 1.3
High pressure pump support
(3 nuts M8x1.25) 25 2.5 2.5 0.25

TORQUE
PART
Nm kgm
High pressure pump control shaft
(1 screw M12x1.5x42.5) 110 11 11.0 1.1
Side/lower fixed pad
(4 screws M8x1.25x35) 25 2.5 2.5 0.25
Cylinder head plug
(1 plug M26x1.5x16) 50 5 5.0 0.5
Upper/side chain guide
(2 nuts M6x1) 10 1 1.0 0.1
(2 screws M6x1x20) 10 1 1.0 0.1
Camshaft gears
(2 screw M12x1.75x40) 110 5.5 11.0 0.55
Primary and secondary tensioner arms
(1 pin M10x1.5) 40 2 4.0 0.2
Intermediate controls assembly
(Chain anti-return hydraulic tensioner M22x1.5x2) 50 5 5.0 0.5
(Chain standard hydraulic tensioner M22x1.5x2) 50 5 5.0 0.5
Inspection caps on overhead
(2 caps M14x1.5x10) 25 2.5 2.5 0.25
Depressor/oil pump unit
(5 screws M8x1.25x60) 25 2.5 2.5 0.25
Timing system lower cover
(7 screws M8x1.25x16) 25 2.5 2.5 0.25
(9 screws M8x1.25x30) 25 2.5 2.5 0.25
A/C compressor belt tensioner
(1 screw M8x1.25x45) 25 2.5 2.5 0.25
Damper pulley
(1 screw M20x1.5x58) 350 17.5 35.0 1.75
Segment speed sensor
(1 screw M6x1) 8 0.5 0.8 0.05
Timing system upper cover
(2 nuts M6x1) 10 1 1.0 0.1
(7 screws M6x1x30) 10 1 1.0 0.1
Water pump
(2 screws M8x1.25x45) 25 2.5 2.5 0.25
(3 screws M10x1.5x55) 50 5 5.0 0.5
Electromagnetic pulley
(4 nuts M6x1) 10 1 1.0 0.1
(1 ring nut M30x1.5) 150 15 15 1.5
Blow-by cover
(3 nuts M6x1x18) 10 1 1.0 0.1
Blow-by complete pipe
(1 nut M8x1.25) 25 2.5 2.5 0.25
Oil level dipstick pipe bracket
(1 screw M8x1.25) 25 2.5 2.5 0.25
A/C compressor support
(2 screws M8x1.25x130) 25 2.5 2.5 0.25
(2 screws M8x1.25x20) 25 2.5 2.5 0.25
A/C compressor
(4 screws M8x1.25x90) 25 2.5 2.5 0.25
Power steering pump
(1 screw M10x1.25x30) 40 4 4.0 0. 4
(1 screw M10x1.25x110) 40 4 4.0 0. 4

TORQUE
PART
Nm kgm
Pre/heater glow plugs (M8x1) 9 0.9 0.9 0.09
Intake manifold
(2 screws M8x1.25x60) 25 2.5 2.5 0.25
(6 screws M8x1.25x40) 30 3 3.0 0.3
(1 screw M8x1.25x140) 30 3 3.0 0.3
(2 plugs M24x1.5) 30 3 3.0 0.3
Air temperature and pressure sensor on intake manifold
(1 nut M6x1) 10 1 1.0 0.1
Thermostat cover
(4 screws M8x1.25x20) 25 2.5 2.5 0.25
(M12x1.5) 20 5 2.0 0.5
High pressure pump
(2 screws M8x1.25x90) 25 2.5 2.5 0.25
(1 screw M6x1x20) 25 2.5 2.5 0.25
Water/oil heat exchanger
(8 screws M8x1.25x30) 25 2.5 2.5 0.25
Low pressure pipes group bracket
(1 screw M6x1) 25 2.5 2.5 0.25
Duplex pipe support bracket
(2 screws M6x1x14) 10 1 1.0 0.1
Alternator support
(2 screws M8x1.25x30 30 3 3.0 0.3
(1 screw M8x1.25x70 30 3 3.0 0.3
(1 screw M8x1.25x35) 50 5 5.0 0.5
Alternator
(1 screw M10x1.25x30) 50 5 5.0 0.5
(1 bolt M10x1.25x130) 50 5 5.0 0.5
Alternator shaft freewheel
(M16x1.5) 80 5 8.0 0.5
Increment speed sensor
(1 screw M6x1x12) 82 0.8 0.2
Automatic belt tensioner
(1 screw M8x1.25x45) 45 5 4.5 0.5
Exhaust manifold
(10 nut M8x1.25) 25 2.5 2.5 0.25
Exhaust manifold guard
(4 screws M6x1.25x14) 18 1.8
Turbocharger
(4 nuts M8x1.25) 25 2.5 2.5 0.25
Turbocharger water delivery pipe
(2 unions M14x1.5) 40 4 4.0 0.4
Turbocharger oil delivery pipe
(2 fittings M14x1.5) 40 4 4.0 0.4
Turbocharger water return pipe
(1 union M14x1.5) 40 4 4.0 0.4
(2 bracket screws M8x1.25x16) 25 2.5 2.5 0.25
Turbocharger oil return pipe
(2 screws M6x1x16) 10 1 1.0 0.1
(1 fitting M22x1.5) 45 4.5 4.5 0.45

TORQUE
PART
Nm kgm
Turbocharger oil delivery pipe connector
(1 fitting M14x1.5) 27 3 2.7 0.3
Turbocharger - air duct pipe union bracket
(2 screws M6x1x10) 10 1 1.0 0.1
Turbocharger air duct - EGR union bracket
(4 screws M8x1.25x20) 28 2.8 2.8 0.28
Turbocharger - engine mount union bracket
(1 screw M8x1.25x20) 25 2.5 2.5 0.25
EGR group
(3 screws M8x1.25x80) 25 2.5 2.5 0.25
(1 screw M8x1.25x95) 25 2.5 2.5 0.25
Exhaust gas delivery pipe (EGR/exhaust manifold)
(4 screws M8x1.25x20) 25 2.5 2.5 0.25
Engine coolant delivery pipe group
(1 screw M8x1.25) 25 2.5 2.5 0.25
EGR exhaust gas pipe group
(2 screws M8x1.25x30) 25 2.5 2.5 0.25
Rear cover
(3 screws M8x1.25x35) 25 2.5 2.5 0.25
(4 screws M8x1.25x45) 25 2.5 2.5 0.25
EGR exhaust gas pipe group collar
(1 screw M6x1) 5 0.5 0.5 0.05
Fuel manifold pipe (rail)
(2 screws M8x1.25x35) 29 1.45 2.9 0.145
High pressure fuel delivery pipe bracket
(1 nut M8x1.25) 25 2.5 2.5 0.25
High pressure fuel delivery pipe (pump/rail)
(1 fitting M16x1 - pump side)
1st phase 25 2 2.5 0.2
2nd phase 90
(1 fitting M15x1 - rail side)
1st phase 24 2 2.4 0.2
2nd phase 90
Electro-injector securing bracket
(4 screws M8x1.25x80) 29 1.45 2.9 0.145
High pressure fuel pipes
(4 fittings M14x1.5 - electro-injector side)
1st phase 25 2 2.5 0.2
2nd phase 50
(4 fittings M15x1 - rail side)
1st phase 24 2 2.4 0.2
2nd phase 90
Air inlet pipe
(4 screws M8x1.25x25) 25 2.5 2.5 0.25
Exhaust side engine mount
(1 screw M8x1.25x50) 50 5 5.0 0.5
(2 screws M10x1.25x85) 50 5 5.0 0.5
Intake side engine mount
(2 screws M10x1.25x50) 50 5 5.0 0.5
(1 screw M10x1.25x95) 50 5 5.0 0.5

TORQUE
PART
Nm kgm
Oil filter
(M22x1,5) 25 2.5 2.5 0.25
Pressure sensor on rail
(M18x1.5) 140 14
Oil pressure switch
(M8x1.25x20) 35 3.5 3.5 0.35
(M12x1.5) 20 5 2.0 0.5
Air temperature sensor
(M12x1.5) 15 1.5 1.5 0.15
Air temperature/pressure sensor
(M6) 5 0.5
High pressure pump flow regulator
(2 screws M6) 6.5 0.5 0.65 0.05

F1C EuV1 - ENGINES SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 8

2 SECTION 8 - TOOLS F1C EuV1 - ENGINES

TOOLS
TOOL NO. NAME
99305454 Tool to check the diesel supply circuit and the common-rail
injection system
99317915 Set of 5 insert box wrenches 9x12 (14-15 17-18 19 mm)
Assemblies overhaul revolving stand (bearing capacity 1000 daN,

99322205 torque 120 daN/m)
99340060 Tool to remove crankshaft rear gasket
99340062 Tool to remove crankshaft front gasket
99342153 Tool to remove injectors

TOOLS
TOOL NO. NAME
99346258 Key for crankshaft front gasket installation and timing cover
centering
Crankshaft rear seal installer

99346259
99360076 Remover cartridge filter
99352115 Wrench (17 mm) for injector pipes torque closure
99358026 Wrench for removing and refitting the alternator pulley
99360183 Piston ring removal and refitting pliers (65-110 mm)

TOOLS
TOOL NO. NAME
99360187 Oil pump drive shaft retaining tool
99360260 Engine valves remover/installer
99360306 Flywheel restrainer
99360605 Compression tool for fitting engine piston (65-125 mm)
99360614 Tool for camshaft timing
99360615 Tool for crankshaft timing

TOOLS
TOOL NO. NAME
99361041 Brackets fixing engine to revolving stand 99322205
99367121 Manual pump for measuring pressure and vacuum
Comparator holder base for different surveys (use with 99395603)

99370415
Torque meter spanner (20-120 Nm) with 1/2 square attachment

99389813
99389817 Torque meter spanner (60-320 Nm) with 1/2 square attachment
99389818 Torque meter spanner (150-800 Nm) with square attachment

TOOLS
TOOL NO. NAME
99389819 Torque meter spanner (0-10 Nm) with 1/4 square attachment
99389829 9x12 snap coupling torque wrench (5-60 Nm)
Torque meter spanner (10-60 Nm) with 3/8 square attachment

99389831
Snap coupling torque wrench 14x18 plus 1/2 square attachment

99389832 (60-320 Nm)
Pair of gauges for angular tightening with 1/2 and 3/4 square
99395216 connections
99395603 Dial gauge (0-5 mm)

TOOLS
TOOL NO. NAME
Centering ring for timing gear cover (use with 99346258)

99396039
EXPERIMENTAL TOOLS
This section shows the working drawings for the experimental tools (S.P.) used in overhauling the engine described in this
section, which may be made by the repair shops.







F1C EuV1 - ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . . 4

2 APPENDIX F1C EuV1 - ENGINES

F1C EuV1 - ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX F1C EuV1 - ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

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F1C EuVI Engines

Technical and Repair manual

Publication edited by:

F1C EuVI Engines S Series

F1C Engines EuVI 1

Print P1D32S021 E Base - April 2015

Base - April 2015 Print P1D32S021 E

- Grounding and screening . . . . . . . . . . . . . . . . . 8

OPTIONAL ELECTRICAL AND MECHANICAL

CONVERSIONS BETWEEN THE MAIN UNITS

Print P1D32S021 E Base - April 2015

Base - April 2015 Print P1D32S021 E

Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

1 1 = Housing for connecting

Print P1D32S021 E Base - April 2015

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - April 2015 Print P1D32S021 E

Print P1D32S021 E Base - April 2015

Base - April 2015 Print P1D32S021 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Do not use fast chargers to start up the engine.

NOTE The connectors are shown from cable side.

Print P1D32S021 E Base - April 2015

Grounding and screening

The following precautions must be observed regarding the electronic components:

1. DELTA CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT EARTH M

2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

Base - April 2015 Print P1D32S021 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATION-

NOTE Where accuracy is not particularly needed:

Print P1D32S021 E Base - April 2015

PAGE HEADER AND FOOTER INTERPRETATION

Type Section Page

Number of Language Basic edition referring to When present, a

Base - April 2015 Print P1D32S021 E

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Base - April 2015 Print P1D32S021 E

F1C Engines EuVI

General mechanical overhaul 6

Safety prescriptions Appendix

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Base - April 2015 Print P1D32S021 E

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

POWER - TORQUE CURVES . . . . . . . . . . . . . . 6

Print P1D32S021 E Base - April 2015

Base - April 2015 Print P1D32S021 E

Progressive numbers showing engine variants

Engine main characteristics:

F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6

Engine family development

F1 = New Engine Family

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ISOMETRIC VIEW OF ENGINE

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POWER - TORQUE CURVES

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INTAKE SIDE VIEW