Case SR130 SR200 SR150 SR220 SR175 SR250 SV185 SV250 SV300 TR270 TR320 TV380 SERVICE MANUAL

F5AE5484A / F5AE9454A / F5AE9454D / F5AE9454J / F5AE9454L / F5AE9484A / F5AE9484B / F5AE9484G / F5AE9484K / F5CE5454B*A005 / F5CE5454B / F5CE5454C*A003 / F5CE5454G*A001 / F5CE9454C / F5CE9454E / F5CE9454G / F5CE9484C / F5CE9484E Engine

SERVICE MANUAL

Printed in U.S.A.

Part number 84465357

Copyright © 2011 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

English March 2011 Replaces part number 84283922

Contents INTRODUCTION ENGINE AND PTO IN ................................................................... B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

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INTRODUCTION

84465357 28/02/2011

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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INTRODUCTION

Foreword This publication contains data, features instructions and methods for performing repair operations on the assembly and its components and is addressed to qualified, specialized personnel.

Check to make sure you have the right publication related to the component you are about to work on before you start.

Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.

Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to ensure correct repair procedures and safety of operators.

NOTE: This manual applies to multiple applications, therefore images may not all be accurate.

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INTRODUCTION

Safety rules Standard safety precautions Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for consultation.

•

Keep working areas as clean as possible.

•

Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain adequate sanitary equipment.

•

Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked on a regular basis and personnel must be trained on proper interventions and priorities.

•

Keep all emergency exits free of obstructions and clearly marked.

•

Smoking in working areas subject to fire danger must be strictly prohibited.

Prevention of injury •

Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to engines and equipment in motion.

•

Wear safety gloves and goggles when performing the following operations: •

Topping off or changing lubrication oils.

•

Using compressed air or liquids at a pressure greater than 2 bar (29 psi).

•

Wear a safety helmet when working close to hanging loads or equipment working at head level.

•

Always wear safety shoes and fitting clothes.

•

Use protection cream for hands.

•

Change wet clothes as soon as possible.

•

In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections.

Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with electricity.

•

Do not smoke or start an open flame close to batteries and any fuel material.

•

Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.

•

Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may occur.

•

If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.

During maintenance •

Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).

•

Never add coolant to an overheated engine and use only appropriate liquids.

•

Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be aware of all the risks involved with such an operation.

•

Always use adequate and safe containers for engine fluids and used oil.

•

Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.

•

Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.

Wear a safety mask if necessary.

•

Do not leave soiled rags that may contain any flammable substances close to the engine.

•

Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air in case of engine runaway.

•

Never disconnect the batteries while the engine is running.

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INTRODUCTION

•

Disconnect the batteries prior to performing any work on the equipment.

•

Disconnect the batteries to place a load on them with a load tester.

•

After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

•

Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been released. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety equipment.

•

Do not alter the lengths of any wires.

•

Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by Iveco.

•

Do not modify the fuel system or hydraulic system unless approved by Iveco, Any unauthorized modification will compromise warranty assistance and may affect engine operation and life span.

For engine equipped with an electronic control unit •

Do not weld on any part of the equipment without removing the control unit.

•

Remove the in case of work requiring heating over 80 °C (176 °F).

•

Do not paint the components and the electronic connections.

•

Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of electronic components will void engine warranty assistance and may affect the correct working order and life span of the engine.

Respect of the Environment •

Respect of the environment should be of primary importance. Take all necessary precautions to ensure personnel’s safety and health.

•

Inform the personnel of the laws regarding the dispensing of used engine fluids.

•

Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.

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INTRODUCTION

Torque F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

DESCRIPTION

SIZE

TORQUE

M8x1.25

45 - 55 N·m (33 - 41 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Oil Pan Threaded cap with O-ring Oil pan spacer

Engine Block Crankshaft caps - Pre torque - Torque - Angle torque Piston cooling nozzle Conical thread cap Conical thread cap Water drainage cap Oil turbo supply pipe fitting

45 - 55 N·m (33 - 41 lb ft) 75 - 85 N·m (55 - 63 lb ft) 85 - 95 ° 16 - 20 N·m (12 - 15 lb ft) 35 - 45 N·m (26 - 33 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

3/8" 1/8"

Timing gearcase Conical thread cap Gear cooling nozzle Cover Ignition pump screw stud Timing pin seat cap Gearcase Inspection cover

10 - 20 N·m (7 - 15 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft) 3 - 5 N·m (27 - 44 lb in) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

M8x1.25

M8x1.25

Flywheel housing Housing

M8x1.25 M12x1.75

30 - 40 N·m (22 - 30 lb ft) 115 - 125 N·m (85 - 92 lb ft)

Cylinder head Cylinder head - Stage 1 - Stage 2 - Stage 3 Cylinder head - Stage 1 - Stage 2 - Stage 3 Threaded cap

M15x1.5 120 - 140 N·m (89 - 103 lb ft) 85 - 95 ° 85 - 95 ° M12x1.5 60 - 70 N·m (44 - 52 lb ft) 85 - 95 ° 55 - 65 ° 35 - 45 N·m (26 - 33 lb ft)

Overhead Rocker arm dowel Overhead Valve adjusting nut

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 15 - 25 N·m (11 - 18 lb ft)

M8x1.25

Intake Manifold Intake manifold Throw fastening to intake manifold

M8x1.25

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Exhaust Manifold Exhaust manifold

10 - 20 N·m (7 - 15 lb ft) 84465357 28/02/2011

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INTRODUCTION

Turbocharger mounting stud

10 - 20 N·m (7 - 15 lb ft)

EGR Unit Heat exchanger fastening to valve unit Heat exchanger fastening to throw EGR fastening to intake manifold Valve Manifold fastening nuts Manifold fastening rings

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 5 - 15 N·m (4 - 11 lb ft) 20 - 30 N·m (15 - 22 lb ft) 5 - 15 N·m (4 - 11 lb ft)

Pulley Engine crankshaft pulley

335 - 365 N·m (247 - 269 lb ft)

Connecting Rod Connecting rod cap - Pre-torque - Angle torque

45 - 55 N·m (33 - 41 lb ft) 65 - 75 °

Flywheel Flywheel - Pre-torque - Angle torque

25 - 35 N·m (18 - 26 lb ft) 85 - 95 °

Timing Phonic wheel Thrust block Gear

12 - 18 N·m (9 - 13 lb ft) 20 - 30 N·m (15 - 22 lb ft) 31 - 41 N·m (23 - 30 lb ft)

Injector Injector stud screw Injector fastening nut - Pre-torque - Angle torque

21 - 29 N·m (15 - 21 lb ft) 10 - 20 N·m (7 - 15 lb ft) 25 - 35 N·m (18 - 26 lb ft)

LDA Manifold side Pump side

15 - 25 N·m (11 - 18 lb ft) 15 - 25 N·m (11 - 18 lb ft)

Sensors Crankshaft speed sensor Camshaft speed sesnor Water temperature sensor Oil temperature sensor Air pressure sensor

5 - 15 N·m (4 - 11 lb ft) 5 - 15 N·m (4 - 11 lb ft) 31 - 41 N·m (23 - 30 lb ft) 20 - 30 N·m (15 - 22 lb ft) 5 - 15 N·m (4 - 11 lb ft)

Fuel filter Union fixing to support Fuel filter

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Supply Pump Supply pump Inlet Fast clutch

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Turbocharger 84465357 28/02/2011

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INTRODUCTION

Collector fastening screw nuts Oil delivery inlet Delivery pipe fastening screw Drain pipe to heat exchanger Drain pipe to turbo

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 10 - 20 N·m (7 - 15 lb ft)

Cooling pipe Water pipe to heat exchanger Water pipe to the support Conical threaded cap

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

3/8"

Oil Oil pressure control valve Oil dipstick Oil inlet pipe Pickup tube to block Pickup tube support Oil filter cartridge union Oil filter Oil filter cartridge Oil pump - Stage 1 - Stage 2

40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 10 - 20 N·m (7 - 15 lb ft) 8 - 12 N·m (6 - 9 lb ft) 30 - 40 N·m (22 - 30 lb ft) 40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 16 - 20 N·m (12 - 15 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Heat exchanger Threaded caps Exchanger unit Heat exchanger

40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Thermostat Thermostat unit Bleed vent

20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

Fan support Water pump Bearing Fan support Pulley

20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

Alternator Alternator support Alternator

45 - 55 N·m (33 - 41 lb ft) 45 - 55 N·m (33 - 41 lb ft)

Lifting Front hook Rear hook

45 - 55 N·m (33 - 41 lb ft) 65 - 75 N·m (48 - 55 lb ft)

Injection Pump Pump gear - Pre-torque - Torque

16 - 20 N·m (12 - 15 lb ft) 85 - 95 N·m (63 - 70 lb ft)

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INTRODUCTION

Torque F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

DESCRIPTION

SIZE

TORQUE

M6 M22 M35

35 - 45 N·m (26 - 33 lb ft) 45 - 55 N·m (33 - 41 lb ft) 35 - 45 N·m (26 - 33 lb ft) 65 - 75 N·m (48 - 55 lb ft)

Oil Pan Side cap Side caps Front cap Fixing of sump

Engine Block Crankshaft caps - Pre torque - Torque - Angle torque Piston cooling nozzle Conical thread cap Conical thread cap Water drainage cap Oil turbo supply pipe fitting

45 - 55 N·m (33 - 41 lb ft) 75 - 85 N·m (55 - 63 lb ft) 85 - 95 ° 16 - 20 N·m (12 - 15 lb ft) 35 - 45 N·m (26 - 33 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

3/8" 1/8"

Timing gearcase Conical thread cap Gear cooling nozzle Cover Ignition pump screw stud Timing pin seat cap Gearcase Inspection cover

10 - 20 N·m (7 - 15 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft) 3 - 5 N·m (27 - 44 lb in) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

M8x1.25

M8x1.25

Flywheel housing Housing

M8x1.25 M12x1.75

30 - 40 N·m (22 - 30 lb ft) 115 - 125 N·m (85 - 92 lb ft)

Cylinder head Cylinder head - Stage 1 - Stage 2 - Stage 3 Cylinder head - Stage 1 - Stage 2 - Stage 3 Threaded cap

M15x1.5 120 - 140 N·m (89 - 103 lb ft) 85 - 95 ° 85 - 95 ° M12x1.5 60 - 70 N·m (44 - 52 lb ft) 85 - 95 ° 55 - 65 ° 35 - 45 N·m (26 - 33 lb ft)

Overhead Rocker arm dowel Overhead Valve adjusting nut

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 15 - 25 N·m (11 - 18 lb ft)

M8x1.25

Intake Manifold Intake manifold Throw fastening to intake manifold

M8x1.25

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 84465357 28/02/2011

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INTRODUCTION

Exhaust Manifold Exhaust manifold Turbocharger mounting stud

30 - 40 N·m (22 - 30 lb ft) 10 - 20 N·m (7 - 15 lb ft)

Pulley Engine crankshaft pulley

335 - 365 N·m (247 - 269 lb ft)

Connecting Rod Connecting rod cap - Pre-torque - Angle torque

45 - 55 N·m (33 - 41 lb ft) 65 - 75 °

Flywheel Flywheel - Pre-torque - Angle torque

25 - 35 N·m (18 - 26 lb ft) 85 - 95 °

Timing Phonic wheel Thrust block Gear

12 - 18 N·m (9 - 13 lb ft) 20 - 30 N·m (15 - 22 lb ft) 31 - 41 N·m (23 - 30 lb ft)

Injector Injector stud screw Injector fastening nut - Pre-torque - Angle torque

21 - 29 N·m (15 - 21 lb ft) 10 - 20 N·m (7 - 15 lb ft) 25 - 35 N·m (18 - 26 lb ft)

LDA Manifold side Pump side

15 - 25 N·m (11 - 18 lb ft) 15 - 25 N·m (11 - 18 lb ft)

Sensors Crankshaft speed sensor Camshaft speed sesnor Water temperature sensor Oil temperature sensor Air pressure sensor

5 - 15 N·m (4 - 11 lb ft) 5 - 15 N·m (4 - 11 lb ft) 31 - 41 N·m (23 - 30 lb ft) 20 - 30 N·m (15 - 22 lb ft) 5 - 15 N·m (4 - 11 lb ft)

Fuel filter Union fixing to support Fuel filter

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Supply Pump Supply pump Inlet Fast clutch

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Turbocharger Collector fastening screw nuts Oil delivery inlet Delivery pipe fastening screw Drain pipe to heat exchanger Drain pipe to turbo

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 10 - 20 N·m (7 - 15 lb ft) 84465357 28/02/2011

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INTRODUCTION

Cooling pipe Water pipe to heat exchanger Water pipe to the support Conical threaded cap

20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

3/8"

Oil Oil pressure control valve Oil dipstick Oil inlet pipe Pickup tube to block Pickup tube support Oil filter cartridge union Oil filter Oil filter cartridge Oil pump - Stage 1 - Stage 2

40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 10 - 20 N·m (7 - 15 lb ft) 8 - 12 N·m (6 - 9 lb ft) 30 - 40 N·m (22 - 30 lb ft) 40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 16 - 20 N·m (12 - 15 lb ft) 10 - 20 N·m (7 - 15 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Heat exchanger Threaded caps Exchanger unit Heat exchanger

40 - 50 N·m (30 - 37 lb ft) 20 - 30 N·m (15 - 22 lb ft) 20 - 30 N·m (15 - 22 lb ft)

Thermostat Thermostat unit Bleed vent

20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

Fan support Water pump Bearing Fan support Pulley

20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft) 20 - 30 N·m (15 - 22 lb ft) 35 - 45 N·m (26 - 33 lb ft)

Alternator Alternator support Alternator

45 - 55 N·m (33 - 41 lb ft) 45 - 55 N·m (33 - 41 lb ft)

Lifting Front hook Rear hook

45 - 55 N·m (33 - 41 lb ft) 65 - 75 N·m (48 - 55 lb ft)

Injection Pump Pump gear - Pre-torque - Torque

16 - 20 N·m (12 - 15 lb ft) 85 - 95 N·m (63 - 70 lb ft)

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INTRODUCTION

Special tools F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Valve guide gasket assembly tool

380000134

380000134

1

380000150

Tool for engine T.D.C. positioning

380000150

2

380000219

Valve guide disassembly and reassembly tool

380000219

3

380000220

Piston ring compressor - 60 - 125 mm, procure locally

380000220

4

84465357 28/02/2011

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INTRODUCTION

380000221

Piston ring expander tool for removing and installing piston rings - 60 - 125 mm, procure locally

380000221

5

380000222

Valve guide reemer

380000222

6

380000228

Dial gauge - 0 - 5 mm

380000228

7

380000229

Dial gauge holding tool for rotatory injection pump phasing (use with 380000228)

380000229

8

84465357 28/02/2011

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INTRODUCTION

380000302

Tool for engine valve disassembly and reassembly, procure locally

380000302_3A

9

380000304

Measuring device for angular torque, procure locally

380000304

10

380000364

Dial gauge holding base for miscellaneous measures (use with 380000228)

380000364_3A

11

380000667

Camshaft bushing removal and installation tool

380000667

12

84465357 28/02/2011

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INTRODUCTION

380000670

Oil filter removal tool

380000670

13

380000978

Rotary stand for overhauling units, use OEM 4135 or a 2000 lb capacity engine stand

380000301

14

380000999

Handle for interchangeable bushing tools, use appropriate tool

380000999_3-2

15

Diesel engine cylinder compression tester, procure locally

380001006

380001006_3

16

84465357 28/02/2011

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INTRODUCTION

380000732

Tool for rotating the engine flywheel, barring tool

380002385_3A

17

Injection pump gear puller

380100072

380100072_3A

18

380100074

Compression test adapter

380100074_3-2

19

Front main seal installation tool

380100075

380100075_3-2

20

84465357 28/02/2011

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INTRODUCTION

Rear main seal installation tool

380100076

380100076_3-2

21

84465357 28/02/2011

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INTRODUCTION

Special tools F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Valve guide gasket assembly tool

380000134

380000134

1

380000150

Tool for engine T.D.C. positioning

380000150

2

380000219

Valve guide disassembly and reassembly tool

380000219

3

380000220

Piston ring compressor - 60 - 125 mm, procure locally

380000220

4

84465357 28/02/2011

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INTRODUCTION

380000221

Piston ring tool for disassembly and reassembly of piston rings - 60 - 125 mm, procure locally

380000221

5

380000222

Valve guide reemer

380000222

6

380000228

Dial gauge - 0 - 5 mm

380000228

7

380000229

Dial gauge holding tool for rotatory injection pump phasing (use with 380000228)

380000229

8

84465357 28/02/2011

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INTRODUCTION

380000302

Tool for engine valve disassembly and reassembly, procure locally

380000302_3A

9

380000304

Measuring device for angular torque, procure locally

380000304

10

380000364

Dial gauge holding base for miscellaneous measures (use with 380000228)

380000364_3A

11

380000667

Camshaft bushing removal and installation tool, use with suitable tool

380000667

12

84465357 28/02/2011

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INTRODUCTION

380000670

Oil filter removal tool

380000670

13

380000978

Rotary stand for overhauling units, use OEM 4135 or 2000 lb capacity engine stand

380000301

14

380000732

Rotate the engine flywheel, engine barring tool

380002385_3A

15

380000999

Handle for interchangeable bushing tools, use appropriate tool

380000999_3-2

16

84465357 28/02/2011

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INTRODUCTION

Diesel engine cylinder compression tester, procure locally

380001006

380001006_3

17

Injection pump gear puller

380100072

380100072_3A

18

380100073

Front crankshaft seal installation tool

380100073

19

380100074

Compression test adapter

380100074_3-2

20

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INTRODUCTION

Rear main seal installation tool

380100076

380100076_3-2

21

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INTRODUCTION

84465357 28/02/2011

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SERVICE MANUAL ENGINE AND PTO IN

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

84465357 28/02/2011

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ENGINE AND PTO IN - B ENGINE - 10.A

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B ENGINE - 10.A

TECHNICAL DATA ENGINE General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454C

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454G

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454E

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE9484E

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE9484C

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9484A

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9454D

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9484B

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5AE9484G

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454B*A005

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5CE5454C*A003

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5AE5484A

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5AE9454J

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5AE9454L

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5AE9484K

Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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ENGINE Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Connecting rod and piston Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Balancer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Wiring harness Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K

Electronic control Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SERVICE ENGINE Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Valve drive Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 84465357 28/02/2011

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Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing gear Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Front cover Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Rear cover Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Wiring harness Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

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ENGINE - General specification F5CE9454C

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 40 kW (54 Hp) @ 2300 RPM 220 N·m (162 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5CE9454G

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 48 kW (65 Hp) @ 2300 RPM 260 N·m (192 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5CE9454E

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 55 kW (75 Hp) @ 2500 RPM 275 N·m (203 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

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ENGINE - General specification F5CE9484E

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 57 kW (77 Hp) @ 2300 RPM 315 N·m (232 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5CE9484C

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 65 kW (88 Hp) @ 2300 RPM 340 N·m (251 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE9454A

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged with intercooler Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 44 kW (60 Hp) @ 2500 RPM 210 N·m (155 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

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ENGINE - General specification F5AE9484A

Diesel 4 strokes Turbocharged with intercooler Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 48 kW (65 Hp) @ 2300 RPM 260 N·m (192 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE9454D

Diesel 4 strokes Turbocharged with intercooler Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 55 kW (75 Hp) @ 2300 RPM 220 N·m (162 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE9484B

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged with intercooler Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 57 kW (77 Hp) @ 2300 RPM 315 N·m (232 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

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ENGINE - General specification F5AE9484G

Diesel 4 strokes Turbocharged with intercooler Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 65 kW (88 Hp) @ 2300 RPM 340 N·m (251 lb ft) @ 1400 RPM 1100 - 1200 RPM 2700 - 2800 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5CE5454G*A001

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 55 kW (74 Hp) @ 2500 RPM 275 N·m (203 lb ft) @ 1400 RPM 1150 RPM +/- 25 RPM 2750 RPM +/- 25 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5CE5454B*A005

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 61 kW (82 Hp) @ 2500 RPM 305 N·m (225 lb ft) @ 1400 RPM 1150 RPM +/- 25 RPM 2750 RPM +/- 25 RPM

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ENGINE - General specification F5CE5454C*A003

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 67 kW (90 Hp) @ 2500 RPM 340 N·m (251 lb ft) @ 1400 RPM 1150 RPM +/- 25 RPM 2750 RPM +/- 25 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE5484A

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 70 kW (95.2 Hp) @ 2300 RPM 380 N·m (280.3 lb ft) @ 1400 RPM 850 - 50 RPM 2540 - 50 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE9454J

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 41 kW (55.7 Hp) @ 2300 RPM 221 N·m (163.0 lb ft) @ 1400 RPM 850 - 50 RPM 2540 - 50 RPM

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ENGINE - General specification F5AE9454L

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 48 kW (65.3 Hp) @ 2300 RPM 260 N·m (191.8 lb ft) @ 1400 RPM 850 - 50 RPM 2540 - 50 RPM

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

ENGINE - General specification F5AE9484K

Cycle Aspiration Injection N. of cylinders Bore Stroke Total displacement Compression ratio Max. power Max. torque Loadless engine idling Loadless engine peak

Diesel 4 strokes Turbocharged Direct 4 In-line 99 mm (3.898 in) 104 mm (4.094 in) 3202 cm³ 17 : 1 55 kW (74.8 Hp) @ 2300 RPM 310 N·m (228.6 lb ft) @ 1400 RPM 850 - 50 RPM 2540 - 50 RPM

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ENGINE - Service limits F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Timing Intake - Start before T.D.C. - End after B.D.C. Exhaust - Start before B.D.C. - End after T.D.C. Valve Clearance (hot) - Intake - Exhaust Valve Clearance (cold) - Intake - Exhaust

19 ° 37 ° 61 ° 21 ° 0.25 mm (0.010 in) 0.50 mm (0.020 in) 0.20 mm (0.008 in) 0.45 mm (0.018 in)

Fuel Feed Injection Type Nozzle type Injection sequence

Bosch VE 4/12F BOSCH DSLA138PV 33 1-3-4-2

Cylinder and Crankshaft Unit Cylinder bore Pistons - Outside diameter - Pin housing Clearance between cylinder bore and piston Piston protrusion Piston pin Clearance between piston pin and housing Piston ring landings - Top - Middle - Bottom Piston rings - Top - Middle - Bottom Clearance between Rings and Landings - Top - Middle - Bottom Piston ring end gap - Top - Middle - Bottom Connecting Rod - Small end bearing housing - Big end bearing housing - Small end bearing inside diameter - Small end bearing inside diameter (installed) Connecting rod big end bearing thickness - Red - Blue

99.000 - 99.020 mm (3.8976 - 3.8984 in) 98.908 - 98.918 mm (3.8940 - 3.8944 in) 36.003 - 36.009 mm (1.4174 - 1.4177 in) 0.082 - 0.112 mm (0.0032 - 0.0044 in) -0.22 - 0.07 mm (-0.0087 - 0.0028 in) 35.990 - 35.996 mm (1.4169 - 1.4172 in) 0.004 - 0.019 mm (0.0002 - 0.0007 in) 2.21 mm (0.0870 in) 2.050 - 2.070 mm (0.0807 - 0.0815 in) 2.540 - 2.560 mm (0.1000 - 0.1008 in) 2.068 - 2.097 mm (0.0814 - 0.0826 in) 1.970 - 1.990 mm (0.0776 - 0.0783 in) 2.470 - 2.490 mm (0.0972 - 0.0980 in) 0.06 - 0.100 mm (0.0024 - 0.0039 in) 0.05 - 0.09 mm (0.0020 - 0.0035 in) 0.20 - 0.35 mm (0.0079 - 0.0138 in) 0.60 - 0.80 mm (0.0236 - 0.0315 in) 0.30 - 0.60 mm (0.0118 - 0.0236 in) 39.460 - 39.490 mm (1.5535 - 1.5547 in) 67.833 - 67.841 mm (2.6706 - 2.6709 in) 39.570 - 39.595 mm (1.5579 - 1.5589 in) 36.010 - 36.020 mm (1.4177 - 1.4181 in) 1.875 - 1.884 mm (0.0738 - 0.0742 in) 1.883 - 1.892 mm (0.0741 - 0.0745 in) 84465357 28/02/2011

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ENGINE AND PTO IN - ENGINE

- Green Clearance between Piston pin and small end bearing Maximum allowable twist for connecting rod Crankshaft - Main journal diameter (1-2-3-4) - Main journal diameter (5) - Rod journals Main bearing thickness Main bore diameter (1-2-3-4) Main bore diameter (5) Clearance between main bearings and journals (1-2-3-4) Clearance between main bearings and journals (5) Clearance between rod bearing and journals Main journal width for thrust bearing on crankshaft Main journal width for thrust bearing in cylinder block Thrust bearing thickness Clearance between the crankshaft and thrust bearing

1.891 - 1.900 mm (0.0744 - 0.0748 in) 0.011 - 0.024 mm (0.0004 - 0.0009 in) 0.09 mm (0.0035 in) @ 125 mm (4.9213 in) 76.182 - 76.208 mm (2.9993 - 3.0003 in) 83.182 - 83.208 mm (3.2749 - 3.2759 in) 64.015 - 64.038 mm (2.5203 - 2.5212 in) 2.165 - 2.174 mm (0.0852 - 0.0856 in) 80.588 - 80.514 mm (3.1728 - 3.1698 in) 87.588 - 87.614 mm (3.4483 - 3.4494 in) 0.064 - 0.095 mm (0.0025 - 0.0037 in) 0.059 - 0.100 mm (0.0023 - 0.0039 in) 0.033 - 0.041 mm (0.0013 - 0.0016 in) 31.85 - 32.150 mm (1.2539 - 1.2657 in) 32.50 - 32.55 mm (1.2795 - 1.2815 in) 2.51 - 2.56 mm (0.0988 - 0.1008 in) 0.095 - 0.270 mm (0.0037 - 0.0106 in)

Cylinder Head Valve guide seats in cylinder head Valve Guides - Inside diameter - Outside diameter Valves (Intake) - Valve stem diameter - Valve face angle Valves (Exhaust) - Valve stem diameter - Valve face angle Clearance between Valve stem and Guide Valve seat in the cylinder head - Intake - Exhaust Valve seat (Intake) - Outside diameter - Seat angle Valve seat (Exhaust) - Outside diameter - Seat angle Valve recess - Intake - Exhaust Valve spring height - Free spring - Under a load of 256 - 284 N (58 - 64 lb) Under a load of 500 - 556 N (112 - 125 lb) Injector protrusion Camshaft bore inside diameter -5 - 2-3-4 -1 Camshaft Journals -5 - 2-3-4 -1

12.960 - 12.995 mm (0.5102 - 0.5116 in) 8.023 - 8.038 mm (0.3159 - 0.3165 in) 12.950 - 12.985 mm (0.5098 - 0.5112 in) 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 0.040 - 0.053 mm (0.0016 - 0.0021 in) 39.987 - 40.013 mm (1.5743 - 1.5753 in) 43.787 - 43.813 mm (1.7239 - 1.7249 in) 40.063 - 40.088 mm (1.5773 - 1.5783 in) 60 ° 43.863 - 43.880 mm (1.7269 - 1.7276 in) 60 ° 0.3 - 0.7 mm (0.0118 - 0.0276 in) 0.3 - 0.7 mm (0.0118 - 0.0276 in) 44.6 mm (1.756 in) 34 mm (1.339 in) 23.8 mm (0.937 in) 1.7 - 2.35 mm (0.0669 - 0.0925 in) 59.222 - 59.248 mm (2.3316 - 2.3326 in) 50.069 - 50.119 mm (1.9712 - 1.9732 in) 40.069 - 40.119 mm (1.5775 - 1.5795 in) 53.995 - 54.045 mm (2.1258 - 2.1278 in) 49.975 - 50.025 mm (1.9675 - 1.9695 in) 39.975 - 40.025 mm (1.5738 - 1.5758 in) 84465357 28/02/2011

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Clearance between cam bearings and journals Cam lift - Intake - Exhaust Tappets - Housing - Tappet (Upper and Lower) - Tappet (Middle) Clearance between tappets and housing Rocker Assembly - Rocker Shaft Outside diameter - Rockers Clearance between rockers and shaft

0.038 - 0.162 mm (0.0015 - 0.0064 in) 6.213 mm (0.2446 in) 5.5105 mm (0.2169 in) 15.000 - 15.018 mm (0.5906 - 0.5913 in) 15.924 - 15.954 mm (0.6269 - 0.6281 in) 15.960 - 15.975 mm (0.6283 - 0.6289 in) 0.03 - 0.068 mm (0.0012 - 0.0027 in) 18.979 - 19.000 mm (0.7472 - 0.7480 in) 19.020 - 19.033 mm (0.7488 - 0.7493 in) 0.020 - 0.054 mm (0.0008 - 0.0021 in)

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ENGINE - Service limits F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing Intake - Start before T.D.C. - End after B.D.C. Exhaust - Start before B.D.C. - End after T.D.C. Valve Clearance (hot) - Intake - Exhaust Valve Clearance (cold) - Intake - Exhaust

19 ° 37 ° 61 ° 21 ° 0.25 mm (0.010 in) 0.50 mm (0.020 in) 0.20 mm (0.008 in) 0.45 mm (0.018 in)

Fuel Feed Injection Type Nozzle type Injection sequence

Bosch VE 4/12F BOSCH DSLA138PV 33 1-3-4-2

Cylinder and Crankshaft Unit Cylinder bore Pistons - Outside diameter - Pin housing Clearance between cylinder bore and piston Piston protrusion Piston pin Clearance between piston pin and housing Piston ring landings - Top - Middle - Bottom Piston rings - Top - Middle - Bottom Clearance between Rings and Landings - Top - Middle - Bottom Piston ring end gap - Top - Middle - Bottom Connecting Rod - Small end bearing housing - Big end bearing housing - Small end bearing inside diameter - Small end bearing inside diameter (installed) Connecting rod big end bearing thickness - Red - Blue

99.000 - 99.020 mm (3.8976 - 3.8984 in) 98.908 - 98.918 mm (3.8940 - 3.8944 in) 36.003 - 36.009 mm (1.4174 - 1.4177 in) 0.082 - 0.112 mm (0.0032 - 0.0044 in) -0.22 - 0.07 mm (-0.0087 - 0.0028 in) 35.990 - 35.996 mm (1.4169 - 1.4172 in) 0.004 - 0.019 mm (0.0002 - 0.0007 in) 2.21 mm (0.0870 in) 2.050 - 2.070 mm (0.0807 - 0.0815 in) 2.540 - 2.560 mm (0.1000 - 0.1008 in) 2.068 - 2.097 mm (0.0814 - 0.0826 in) 1.970 - 1.990 mm (0.0776 - 0.0783 in) 2.470 - 2.490 mm (0.0972 - 0.0980 in) 0.06 - 0.100 mm (0.0024 - 0.0039 in) 0.05 - 0.09 mm (0.0020 - 0.0035 in) 0.20 - 0.35 mm (0.0079 - 0.0138 in) 0.60 - 0.80 mm (0.0236 - 0.0315 in) 0.30 - 0.60 mm (0.0118 - 0.0236 in) 39.460 - 39.490 mm (1.5535 - 1.5547 in) 67.833 - 67.841 mm (2.6706 - 2.6709 in) 39.570 - 39.595 mm (1.5579 - 1.5589 in) 36.010 - 36.020 mm (1.4177 - 1.4181 in) 1.875 - 1.884 mm (0.0738 - 0.0742 in) 1.883 - 1.892 mm (0.0741 - 0.0745 in) 84465357 28/02/2011

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- Green Clearance between Piston pin and small end bearing Maximum allowable twist for connecting rod Crankshaft - Main journal diameter (1-2-3-4) - Main journal diameter (5) - Rod journals Main bearing thickness Main bore diameter (1-2-3-4) Main bore diameter (5) Clearance between main bearings and journals (1-2-3-4) Clearance between main bearings and journals (5) Clearance between rod bearing and journals Main journal width for thrust bearing on crankshaft Main journal width for thrust bearing in cylinder block Thrust bearing thickness Clearance between the crankshaft and thrust bearing

1.891 - 1.900 mm (0.0744 - 0.0748 in) 0.011 - 0.024 mm (0.0004 - 0.0009 in) 0.09 mm (0.0035 in) @ 125 mm (4.9213 in) 76.182 - 76.208 mm (2.9993 - 3.0003 in) 83.182 - 83.208 mm (3.2749 - 3.2759 in) 64.015 - 64.038 mm (2.5203 - 2.5212 in) 2.165 - 2.174 mm (0.0852 - 0.0856 in) 80.588 - 80.514 mm (3.1728 - 3.1698 in) 87.588 - 87.614 mm (3.4483 - 3.4494 in) 0.064 - 0.095 mm (0.0025 - 0.0037 in) 0.059 - 0.100 mm (0.0023 - 0.0039 in) 0.033 - 0.041 mm (0.0013 - 0.0016 in) 31.85 - 32.150 mm (1.2539 - 1.2657 in) 32.50 - 32.55 mm (1.2795 - 1.2815 in) 2.51 - 2.56 mm (0.0988 - 0.1008 in) 0.095 - 0.270 mm (0.0037 - 0.0106 in)

Cylinder Head Valve guide seats in cylinder head Valve Guides - Inside diameter - Outside diameter Valves (Intake) - Valve stem diameter - Valve face angle Valves (Exhaust) - Valve stem diameter - Valve face angle Clearance between Valve stem and Guide Valve seat in the cylinder head - Intake - Exhaust Valve seat (Intake) - Outside diameter - Seat angle Valve seat (Exhaust) - Outside diameter - Seat angle Valve recess - Intake - Exhaust Valve spring height - Free spring - Under a load of 256 - 284 N (58 - 64 lb) Under a load of 500 - 556 N (112 - 125 lb) Injector protrusion Camshaft bore inside diameter -5 - 2-3-4 -1 Camshaft Journals -5 - 2-3-4 -1

12.960 - 12.995 mm (0.5102 - 0.5116 in) 8.023 - 8.038 mm (0.3159 - 0.3165 in) 12.950 - 12.985 mm (0.5098 - 0.5112 in) 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 0.040 - 0.053 mm (0.0016 - 0.0021 in) 39.987 - 40.013 mm (1.5743 - 1.5753 in) 43.787 - 43.813 mm (1.7239 - 1.7249 in) 40.063 - 40.088 mm (1.5773 - 1.5783 in) 60 ° 43.863 - 43.880 mm (1.7269 - 1.7276 in) 60 ° 0.3 - 0.7 mm (0.0118 - 0.0276 in) 0.3 - 0.7 mm (0.0118 - 0.0276 in) 44.6 mm (1.756 in) 34 mm (1.339 in) 23.8 mm (0.937 in) 1.7 - 2.35 mm (0.0669 - 0.0925 in) 59.222 - 59.248 mm (2.3316 - 2.3326 in) 50.069 - 50.119 mm (1.9712 - 1.9732 in) 40.069 - 40.119 mm (1.5775 - 1.5795 in) 53.995 - 54.045 mm (2.1258 - 2.1278 in) 49.975 - 50.025 mm (1.9675 - 1.9695 in) 39.975 - 40.025 mm (1.5738 - 1.5758 in) 84465357 28/02/2011

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Clearance between cam bearings and journals Cam lift - Intake - Exhaust Tappets - Housing - Tappet (Upper and Lower) - Tappet (Middle) Clearance between tappets and housing Rocker Assembly - Rocker Shaft Outside diameter - Rockers Clearance between rockers and shaft

0.038 - 0.162 mm (0.0015 - 0.0064 in) 6.213 mm (0.2446 in) 5.5105 mm (0.2169 in) 15.000 - 15.018 mm (0.5906 - 0.5913 in) 15.924 - 15.954 mm (0.6269 - 0.6281 in) 15.960 - 15.975 mm (0.6283 - 0.6289 in) 0.03 - 0.068 mm (0.0012 - 0.0027 in) 18.979 - 19.000 mm (0.7472 - 0.7480 in) 19.020 - 19.033 mm (0.7488 - 0.7493 in) 0.020 - 0.054 mm (0.0008 - 0.0021 in)

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ENGINE - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

73092733

1

ENGINE FRONT VIEW

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73092734

2

ENGINE RIGHT SIDE VIEW

73092735

3

ENGINE LEFT SIDE VIEW

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73092736

4

ENGINE REAR VIEW

73092737

5

ENGINE TOP VIEW

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ENGINE - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

73092883

1

ENGINE FRONT VIEW

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73092885

2

ENGINE RIGHT SIDE VIEW

73092884

3

ENGINE LEFT SIDE VIEW

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73092886

4

ENGINE REAR VIEW

73092887

5

ENGINE TOP VIEW

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ENGINE - Overview F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

93111631

1

ENGINE FRONT VIEW

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93111630

2

ENGINE RIGHT SIDE VIEW

93111629

3

ENGINE LEFT SIDE VIEW

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93111632

4

ENGINE REAR VIEW

93111628A

5

ENGINE TOP VIEW

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Connecting rod and piston - Exploded view

73092848A

1

CONNECTING ROD AND PISTON UNIT COMPONENTS (1) (2) (3) (4)

Snap ring Pin Piston Piston rings

(5) (6) (7) (8)

Screws Half bearings Connecting rod Bushing

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Balancer - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

73092889

1

Dynamic Balancer (1) Reference notches for alignment and timing (2) Thrust washers (3) Bushings

(4) Balancing masses (5) Shaft (6) Case

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Wiring harness - Overview EGR System F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

73092804

(1) Water temperature sensor (2) Air temperature pressure sensor (3) EGR Valve

1

(4) Crankshaft speed sensor (5) Sectioning

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Wiring harness - Overview KSB F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K

73092807

1

ELECTRIC CABLE TO CONNECT KSB WITH CERA (1) Interface (2) KSB signal

(3) Air sensor (4) STOP

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Electronic control Control module - Electrical schema EGR System F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

73092805

1

Electrical Layout 20000 - Starter battery 25201 - Remote control for pre-heating switch 48035 - Engine rev. no. sensor 52502 - Key commutator for services with start 61121 - Resistor for engine pre-heating 58101 - Pre--heating (on) warning light

58105 - Engine high water temperature warning light 58484 - Diagnosis warning light 47034 - Engine water temperature sensor for EGR 78029 - EGR solenoid valve 86020 - EGR E.C.U. 85156 - Air pressure temperature sensor

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Electronic control Control module - Overview EGR System F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

73092806

1

Technical specifications Bitron 13.5 V 10 - 16 V -30 - 100 °C (-22 - 212 °F) Less than 5 A PWM 133 - 147 Hz

Manufacturer Rated Voltage Actual Voltage Working temperature Maximum current input EGR valve control signal 84465357 28/02/2011

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Ref.

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PWM output signal for EGR solenoid valve ECU Mass Mass for pre--heating (on) warning light ECU supply (+ 15) K line signal Intake manifold temperature and pressure sensor supply EGR solenoid valve feed (potentiometer) K line mass EGR solenoid valve mass (potentiometer) Cooling liquid temperature sensor mass, on thermostat unit Air pressure and temperature sensor mass Engine RPM Signal E.C.U. supply (+30) Pre--heating remote control switch Engine high temperature warning light Diagnosis warning light Start EGR solenoid valve position signal Cooling liquid temperature sensor, on thermostat unit Air temperature sensor signal Pressure sensor signal, on intake manifold Negative from engine drive shaft impulse transmitter Engine drive shaft transmitter mass Positive from engine drive shaft impulse transmitter

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Sensing system Crankshaft sensor - Overview It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic flow lines closing up through the openings of a tone wheel splined on the engine crankshaft. The same signal is used to pilot the tachometer fitted on the vehicle instrument panel. It is connected to the Electronic Control Unit pins 25C (signal) and 24C (signal). The third pin is for shielding. The Sensor’s resistance value is nearly 900 Ω.

73092812

1

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ENGINE - Service instruction - Finding Top Dead Center (TDC) F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit the tool 380000150 (1) through the case and into the port on the flywheel, as shown.

2.

Using the tool 380000150 (1) rotate the flywheel until the notch (2) is visible in the inspection hole and cylinder one is at T.D.C..

73092764

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ENGINE - Service instruction - Finding Top Dead Center (TDC) F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

2.

Fit the tool 380000150 through the case and into the port (1) on the flywheel.

93111650

1

93111626

2

Using the tool 380000150 rotate the flywheel until the notch is visible in the inspection hole (2) and cylinder one is at T.D.C..

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Rocker assembly Housing - Remove Prior operation: Valve cover - Remove (B.10.A) 1.

Loosen the fastening screws (1), remove the overhead holding the whole rocker arm unit (2) and recover the two gaskets (3).

73092771

Next operation: Rocker assembly Housing - Install (B.10.A)

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Camshaft Push rod - Remove Prior operation: Rocker assembly Housing - Remove (B.10.A) 1.

Remove the push rods (1).

73092775

Next operation: Camshaft Push rod - Inspect (B.10.A)

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Rocker assembly Rocker arm - Remove Prior operation: Rocker assembly Housing - Remove (B.10.A) 1.

2.

Loosen the rocker arm fastening screw (1) from the disassembled rocker arm (2) holding unit and then remove the rocker arm.

73092779

1

73092780

2

Withdraw the rocker arm (1) from one side recovering the equalizers (2) from the other.

Next operation: Rocker assembly Rocker arm - Install (B.10.A)

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Camshaft Push rod - Inspect Prior operation: Camshaft Push rod - Remove (B.10.A) 1.

Check that the rocker arm rods are not deformed; there must be no trace of wear or seizure on the spherical housings of the rocker arm adjusting screws as well as on the tappets (pointers); otherwise these parts must be replaced. The suction valve rods are identical and therefore interchangeable.

73092794

Next operation: Camshaft Push rod - Install (B.10.A)

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Camshaft Push rod - Install Prior operation: Camshaft Push rod - Inspect (B.10.A) 1.

Fit the push rods (1) in their housing.

73092775

Next operation: Rocker assembly Housing - Install (B.10.A)

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Rocker assembly Rocker arm - Install Prior operation: Rocker assembly Rocker arm - Remove (B.10.A) 1.

Fit the rocker arms onto the shaft.

2.

The intake arms (short) (2) goes on first, and then the exhaust arms (long) (1).

73092780

Next operation: Rocker assembly Housing - Install (B.10.A)

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Rocker assembly Housing - Install Prior operation: Rocker assembly Housing - Remove (B.10.A) 1.

Replace the gaskets (3), reassemble the rocker arm holding case (2) and tighten the fastening screws (1) to the prescribed torque setting.

2.

After having completed the assembly, check that the rocker arms are correctly positioned on the valves and the tappet push rods.

73092771

Next operation: Valve cover - Install (B.10.A)

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Valve drive Camshaft - Remove Prior operation: Timing gear housing - Remove (B.10.A) 1.

2.

Loosen the fastening screws (1) and disassemble the camshaft (3) holding plate (2).

73092822A

1

73092823A

2

Carefully withdraw the camshaft (1) from the engine bock.

Next operation: Valve drive Camshaft - Install (B.10.A)

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Camshaft Tappet - Remove Prior operation: Valve drive Camshaft - Remove (B.10.A) 1.

Withdraw the tappets (1) from the engine block.

73092824A

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Valve drive Camshaft - Measure Prior operation: Valve drive Camshaft - Remove (B.10.A) 1.

Place the camshaft on footstocks and, using a dial gauge placed on the central support, check that the radial oscillation does not exceed 0.015 mm (0.0006 in) otherwise, replace the shaft.

NOTICE: The surface of the camshaft pins and of cams must be extremely smooth. In case any trace of meshing or scratches are detected, replace the shaft and the relevant bushings.

2.

73092828

1

73092829

2

Using a micrometer (1), check the diameter of the camshaft (2) supporting pins on the two perpendicular axles.

Next operation: Valve drive Camshaft - Install (B.10.A)

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Camshaft Bushing - Measure 1.

The front camshaft bushing (2) must be driven into the respective seat.

2.

There must be no trace of meshing or wear in the inner surface.

3.

Using a bore meter (1) measure the front diameter of the camshaft bushing (2).

4.

Measurements must be made on two perpendicular axles.

73092830

73092831

2

MAIN DATA OF THE CAMSHAFT BUSHING AND RELEVANT SEAT

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Camshaft Bushing - Replace 1.

Use the beater 380000667 (2) and hand grip 380000999 (3) to disassemble and replace the bushings (1).

NOTICE: In phase of assembly, the bushing (1) must be oriented making the lubrication ports coincide with those on the crankcase.

73092832

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Camshaft Tappet - Install Prior operation: Camshaft Tappet - Remove (B.10.A) 1.

Lubricate the tappets (1) and fit them into the relevant seats within the crankcase.

73092834

Next operation: Valve drive Camshaft - Install (B.10.A)

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Valve drive Camshaft - Install Prior operation: Valve drive Camshaft - Remove (B.10.A) 1.

2.

Lubricate the camshaft supporting bushing and assemble the camshaft (1) paying attention not to damage the bushing or the shaft’s seats.

73092823A

1

73092835

2

Position the camshaft (3) holding plate (2) with the slot towards the upper side of the crankcase and the marking towards the operator; tighten the fastening screws (1) to the prescribed torque setting.

Next operation: Valve drive Camshaft - End play (B.10.A)

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Valve drive Camshaft - End play Prior operation: Valve drive Camshaft - Install (B.10.A) 1.

Check the end play of the camshaft. The measurement should be 0.10 - 0.36 mm (0.004 - 0.014 in).

73092836

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Valve assembly Valve - Cleaning Prior operation: Cylinder head - Disassemble (B.10.A) 1.

Remove carbon deposits from the valves using a wire wheel.

2.

Check that the valves show no signs of seizure or cracking. Replace if any defects are found.

73092876

Next operation: Valve assembly Valve - Measure (B.10.A)

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Valve assembly Valve - Measure Prior operation: Valve assembly Valve - Cleaning (B.10.A) 1.

Using a micrometer (2) measure the valve stem (1).

The prescribed value is 7.985 - 8.000 mm (0.314 0.315 in).

73092877

Next operation: Cylinder head - Assemble (B.10.A)

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Valve assembly Spring - Measure Prior operation: Cylinder head - Disassemble (B.10.A) 1.

Before assembly, test the valve spring flexibility using specific tool. Compare the load and elastic strain test results with the technical specifications of the new springs, reported in the table below.

73092880

Height

Load

(H) 44.6 mm (1.756 in) (H1) 34 mm (1.339 in) (H2) 23.8 mm (0.937 in)

0 N (0 lb) 256 - 284 N (58 - 64 lb) 502 - 554 N (113 - 125 lb)

Next operation: Cylinder head - Assemble (B.10.A)

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Crankshaft Rear seal - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Fit the specific tool 380100076 (5) to the rear shank (6) of the engine drive shaft, fix it with the screws (4) and install the new seal (3).

2.

Position part (1) on part (5), tighten the screw nut (2) until the seal has been fitted (3) into the flywheel casing (7).

73092782

Next operation: Flywheel - Install (B.10.A)

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Crankshaft Front seal - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Fit the inner part of tool to the front crankshaft. Make sure that the engine crankshaft pin is correctly fitted into the tool spline in order to avoid damaging it. Fix it with the screw and install the new seal.

2.

Place the outer section of the tool on the previously fitted one, tighten the screw nut until completely fitting the seal into the casing.

73092788A

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Crankshaft Main bearing - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

2.

Loosen the screws (1) and disassemble the crankshaft bearing caps . (2).

73092818

1

73092819

2

73092821

3

The third (central) main bearing cap (1) and associated support have a bearing-half equipped with thrust bearing.

NOTE: Note down the assembly position of the upper and lower half bearings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

3.

Remove the crankshaft. Refer to Crankshaft - Remove (B.10.A) for the proper procedure.

4.

Remove the crankshaft upper half bearings (1).

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Oil pan - Remove (B.60.A) 1.

Using tool 380000362 (1) and a hoist, remove the engine crankshaft (2) from the crankcase.

73092820

Next operation: Crankshaft - Install (B.10.A)

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Crankshaft - Measure Prior operation: Crankshaft - Remove (B.10.A) 1.

In case meshing, scratches or excessive oval shaping is detected on the main journals and crankshaft bearing pins, it is necessary to grind the pins. Before proceeding with pin (2) grinding, measure the shaft pins by means of a micrometer (1) in order to establish to which diameter the pins must be reduced.

73092838

73092839

2

PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND CRANKSHAFT BEARING PINS

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73092840

3

ENGINE DRIVE SHAFT MAIN TOLERANCES

73092841

4

Next operation: Crankshaft - Install (B.10.A)

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Crankshaft Main bearing - Install 1.

Carefully clean the crankshaft half bearings (1) having lubrication port and fit them in their respective seats.

NOTICE: If using the old bearings, be sure to place them back into their original position.

2.

Install the bearing with the thrust shoulders in the correct position.

73092842

Next operation: Crankshaft - Install (B.10.A)

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Crankshaft - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Crankshaft Main bearing - Install (B.10.A) 1.

Install the engine crankshaft (2) using a suitable hoist (1).

73092820

Next operation: Crankshaft - End play (B.10.A)

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Crankshaft Journal - Measure Prior operation: Crankshaft - Remove (B.10.A) 1.

Check the clearance between the engine crankshaft main journals and the respective crankshaft bearings proceeding as follows: •

Carefully clean the parts and eliminate any oil residue.

•

Place a calibrated wire (3) onto the journal (4), lengthwise, as shown in the figure.

•

Fit the caps (1) and the half bearings (2) on the relevant supports.

NOTE: Always use new screws in the assembly phase.

2.

3.

73092843

1

73092844A

2

73092845A

3

Tighten the pre-lubricated screws (1) and tighten them in three subsequent phases: •

Stage 1 - 45 - 55 N·m (33 - 41 lb ft).

•

Stage 2 - 74 - 86 N·m (55 - 63 lb ft).

•

Stage 3 - Using tool 380000304 (1) fitted as shown in the figure and further tighten the screws (2) by 85 - 95 °.

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4.

Remove the caps from their support. The clearance between the crankshaft bearings and the relevant pins should be detected comparing the width measured by the gauge wire (2) at the point of maximum width with the scale graduation reported on the package (1) of the gauge wire.

5.

The numbers reported on the scale indicate the clearance in millimeters. If the clearance detected differs from the prescribed value, replace the half bearings and repeat the measurement; once achieving the slack prescribed, lubricate the crankshaft bearings and finally assemble the supports tightening the fastening screws as described previously.

73092846A

Next operation: Crankshaft - Install (B.10.A)

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Crankshaft - End play Prior operation: Crankshaft - Install (B.10.A) 1.

The check of the shoulder clearance is performed with a magnetic based dial gauge (2) placed on the engine shaft (3) as indicated in the figure.

2.

If the clearance is out of spec, remove the cap (1) and replace the thrust bearing.

73092847A

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Crankshaft Rear seal - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit the specific tool (5) to the rear shank (6) of the engine drive shaft, fix it with the screws (4) and install the new seal (3).

2.

Position part (1) on part (5), tighten the screw nut (2) until the seal has been fitted (3) into the flywheel casing (7).

73092904

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Crankshaft Front seal - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit the inner part of tool to the front crankshaft. Make sure that the engine crankshaft pin is correctly fitted into the tool spline in order to avoid damaging it. Fix it with the screw and install the new seal.

2.

Place the outer section of the tool on the previously fitted one, tighten the screw nut until completely fitting the seal into the casing.

73092909

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Crankshaft - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Using tool 380000362 (1) and a hoist, remove the engine crankshaft (2) from the crankcase.

73092920

Next operation: Crankshaft - Install (B.10.A)

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Crankshaft - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Crankshaft - Remove (B.10.A) 1.

Install the engine crankshaft (2) using a suitable hoist (1).

73092920

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Timing gear - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Align the tooth on the crankshaft gear (1) that has the 45 ° bevel, with the timing gear (2) that has two reference marks as shown in the figure.

2.

Rotate the camshaft keeping the timing gear in place until the camshaft’s pin fits into the relevant housing within the timing gear.

3.

Install the screws of the transmission gear without fully tightening them.

4.

With a magnetic base dial gauge, check the clearance among the engine crankshaft gear and the camshaft gear: it must be 0.068 - 0.168 mm (0.003 - 0.007 in).

5.

Tighten the fastening screws of the transmission gear.

73092907

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Timing gear - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Align the tooth on the crankshaft gear (1) that has the 45 ° bevel, with the timing gear (2) that has two reference marks as shown in the figure.

2.

Rotate the camshaft keeping the timing gear in place until the camshaft’s pin fits into the relevant housing within the timing gear.

3.

Install the screws of the transmission gear without fully tightening them.

4.

With a magnetic base dial gauge, check the clearance among the engine crankshaft gear and the camshaft gear: it must be 0.068 - 0.168 mm (0.003 - 0.007 in).

5.

Tighten the fastening screws of the transmission gear.

73092907

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Timing gear housing - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the rear part (1), of the timing gearcase cover.

73092774

Next operation: Timing gear housing - Install (B.10.A)

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Timing gear housing - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Timing gear housing - Remove (B.10.A) 1.

Assemble the front case (1) and tighten the fastening screws to the prescribed torque.

NOTE: It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply LOCTITE® 5970 sealer on the gearcase in order to form a sealing bead of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must be homogeneous (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoid the excess of sealer: too much sealing material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

73092785

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Timing gear housing - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Remove the rear part (1), of the timing gearcase cover.

73092900

Next operation: Timing gear housing - Install (B.10.A)

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Timing gear housing - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Timing gear housing - Remove (B.10.A) 1.

Assemble the front case (1) and tighten the fastening screws to the prescribed torque.

NOTE: It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply LOCTITE® 5970 sealer on the gearcase in order to form a sealing bead of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must be homogeneous (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoid the excess of sealer: too much sealing material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

73092906

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Connecting rod and piston - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

Loosen the screws (1) fastening the connecting rod caps (2) and remove the connecting rod caps.

2.

Withdraw the pistons with the connecting rods from the upper part of the crankcase.

NOTE: Keep the half bearings in their respective housings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

73092817

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston - Disassemble Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Make sure that the piston does not show any signs of seizing, scoring or cracking. Replace if necessary.

2.

Remove the piston rings (2) using the tool 380000324 (1).

3.

4.

73092849

1

73092863

2

73092862

3

Remove the snap rings (1) that hold the piston pin in place using round tipped pliers.

Remove the piston pin (1). It may be necessary to use hammer and wooden dowel to remove the pin.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston Piston - Measure Prior operation: Connecting rod and piston - Disassemble (B.10.A) 1.

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.

NOTE: The diameter of the piston must be measured at the point shown in the figure for accurate measurement.

73092850

73092852

2

MAIN DATA OF THE PISTON, PINS AND SNAP RINGS Next operation: Connecting rod and piston - Assemble (B.10.A)

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Piston Pin - Measure Prior operation: Connecting rod and piston - Disassemble (B.10.A) 1.

Measure the diameter of the piston pin (1) with a micrometer (2).

2.

Lubricate the pin (1) and the pin housing in the piston with engine oil.

3.

Insert the pin into the piston. It must be inserted with slight finger pressure and it should not come out by gravity.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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73092853

1

73092854

2

ENGINE AND PTO IN - ENGINE

Piston Ring - Measure Prior operation: Connecting rod and piston - Disassemble (B.10.A) 1.

2.

3.

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

73092855

1

73092856

2

73092857

3

Check the clearance between the rings (3) and their landings on the piston (2) with a feeler gauge (1).

The ring (2) of the first landing has a "V" shape. The clearance (X) between the ring and landing is measured by setting the piston (1) with the ring in the cylinder liner (3) so that the ring is exposed half way out of the cylinder liner.

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4.

Using a feeler gauge (1), check the opening between the ends of the rings (2).

5.

The ring must be inserted in the cylinder liner for an accurate measurement. If the gap is less than or greater than as required, replace the rings.

73092858

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston - Assemble Prior operation: Connecting rod and piston - Disassemble (B.10.A) 1.

2.

Throughout the pin (3), connect the piston (2) to the connecting rod (4) following the indication of the reference arrow (1) to correctly fix the piston (2) into the cylinder barrel, also taking into consideration the numbers printed on the connecting rod (4).

73092862

1

73092863

2

73092849

3

Install the snap rings (1) using the round tipped pliers to hold to the assembly together.

3.

Install the piston rings (1) on the piston (2) by using the pliers 380000221 (3).

4.

Direct the ring openings so they are staggered 120 ° apart.

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston - Install Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Fit the half bearings (1) on the connecting rod and cap.

2.

Lubricate the pistons, the snap pins and the cylinder barrel interior.

3.

73092864

1

73092865

2

Using the band 380000220 (2), fit the connecting rod and piston unit (1) into the cylinder barrel, checking that: •

The number of each connecting rod corresponds to the coupling cap number.

•

The snap rings’ openings must be misaligned by 120 °.

•

All the connecting rod/piston units must have the same weight.

•

The notch on the piston shield must match the oil nozzles’ position.

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73092866

3

Journal Clearance 4.

Carefully clean the parts eliminating any oil residuals.

5.

Place a piece of calibrated wire (2) on the engine crankshaft pins (1).

6.

Fit the connecting rod caps (3) and the relevant half bearings (4).

NOTICE: Always use new screws in phase of assembly.

7.

73092867

4

73092868

5

Lubricate the fastening screws (1) with engine oil and tighten them to 45 - 55 N·m (33 - 41 lb ft) using a torque wrench (2).

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8.

Fit the tool 380000304 (1) to the socket wrench and then further tighten the screws (2) by 65 - 75 °.

9.

Remove the cap and measure the clearance by comparing the width measured by the calibrated wire (1) with the scale graduation reported on the calibrated wire package (2).

10.

In case the clearance measured differs from the prescribed value, replace the half bearings and measure the clearance again.

Next operation: Oil pan - Install (B.60.A)

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73092869

6

73092870

7

ENGINE AND PTO IN - ENGINE

Flywheel - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Fit tool (1) 380002385 to the flywheel housing and, using a wrench, lock the flywheel rotation.

2.

Loosen the screws fastening the flywheel to the engine drive shaft.

3.

Screw two medium length screws in the ports (4), in order to secure the flywheel (1) with a sling.

4.

By means of two guide pins (2) previously screwed in the engine drive shaft ports (3), guide the flywheel withdrawal throughout a hoist.

5.

Withdraw the flywheel casing grommet.

6.

Withdraw the grommet of the timing gearcase.

Next operation: Flywheel - Install (B.10.A)

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73092772

1

73092773

2

ENGINE AND PTO IN - ENGINE

Flywheel - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Prior operation: Flywheel - Remove (B.10.A) 1.

Screw two hooks or eyebolts on the flywheel (1) through the ports (4).

2.

By means of a hoister, draw the flywheel up to its housing inside the casing.

NOTE: The flywheel has a reference dowel that couples with the relevant seat on the box.

3.

Screw two pins (2) of appropriate length into the shaft’s ports (3) and, using them as a guide, duly fit the engine flywheel (1) into its casing.

4.

Fit the tool 380002385 to the flywheel casing in order to lock the engine flywheel rotation.

5.

73092773

1

73092783

2

Tighten the engine flywheel (3) fastening screws (2) in the following sequence.

•

25 - 35 N·m (18 - 26 lb ft)

•

85 - 95 °

NOTE: Angular fastening must be executed using tool 380000304. Before assembly, always check that the port threads and the screws show no trace of wear and dirt.

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Flywheel - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit tool (1) 380002385 to the flywheel housing and, using a wrench, lock the flywheel rotation.

2.

Loosen the screws fastening the flywheel to the engine drive shaft.

3.

Screw two medium length screws in the ports (4), in order to secure the flywheel (1) with a sling.

4.

By means of two guide pins (2) previously screwed in the engine drive shaft ports (3), guide the flywheel withdrawal throughout a hoist.

5.

Withdraw the flywheel casing grommet.

6.

Withdraw the grommet of the timing gearcase.

Next operation: Flywheel - Install (B.10.A)

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73092772

1

73092899

2

ENGINE AND PTO IN - ENGINE

Flywheel - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Flywheel - Remove (B.10.A) 1.

Screw two hooks or eyebolts on the flywheel (1) through the ports .

2.

By means of a hoister, draw the flywheel up to its housing inside the casing.

NOTE: The flywheel has a reference dowel that couples with the relevant seat on the box.

3.

Screw two pins (2) of appropriate length into the shaft’s ports (3) and, using them as a guide, duly fit the engine flywheel (1) into its casing.

4.

Fit the tool 380002385 to the flywheel casing in order to lock the engine flywheel rotation.

5.

73092899

1

73092905

2

Tighten the engine flywheel (2) fastening screws (1) in the following sequence.

•

25 - 35 N·m (18 - 26 lb ft)

•

85 - 95 °

NOTE: Angular fastening must be executed using tool 380000304. Before assembly, always check that the port threads and the screws show no trace of wear and dirt.

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Flywheel - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Fit tool (1) 380002385 to the flywheel housing and, using a wrench, lock the flywheel rotation.

2.

Loosen the screws fastening the flywheel to the engine drive shaft.

3.

Screw two medium length screws in the ports (4), in order to secure the flywheel (1) with a sling.

4.

By means of two guide pins (2) previously screwed in the engine drive shaft ports (3), guide the flywheel withdrawal throughout a hoist.

5.

Withdraw the flywheel casing grommet.

6.

Withdraw the grommet of the timing gearcase.

Next operation: Flywheel - Install (B.10.A)

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73092772

1

93111650

2

ENGINE AND PTO IN - ENGINE

Flywheel - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Flywheel - Remove (B.10.A) 1.

Screw two hooks or eyebolts on the flywheel (1) through the ports (4).

2.

By means of a hoister, draw the flywheel up to its housing inside the casing.

NOTE: The flywheel has a reference dowel that couples with the relevant seat on the box.

3.

Screw two pins (2) of appropriate length into the shaft’s ports (3) and, using them as a guide, duly fit the engine flywheel (1) into its casing.

4.

Fit the tool 380002385 to the flywheel casing in order to lock the engine flywheel rotation.

5.

93111650

1

93111650

2

Tighten the engine flywheel (3) fastening screws (2) in the following sequence.

•

25 - 35 N·m (18 - 26 lb ft)

•

85 - 95 °

NOTE: Angular fastening must be executed using tool 380000304. Before assembly, always check that the port threads and the screws show no trace of wear and dirt.

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Balancer - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Oil pan - Remove (B.60.A) 1.

Unscrew the screws (2) which fasten the dynamic balancer (1) and remove it.

73092902

Next operation: Balancer - Install (B.10.A)

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Balancer - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Balancer - Remove (B.10.A) 1.

Mount the dynamic balancer (1) taking care that the reference notches (2) coincide as shown in figure.

76092914

Next operation: Oil pan - Install (B.60.A)

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Cylinder block Bore - Check Prior operation: Connecting rod and piston - Remove (B.10.A) Once engine is disassembled, clean accurately the cylinder block assembly.

Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

Inspect cylinder bore surfaces; they shall be free from seizing, scores, ovalization, taper, or excessive wear.

Inspection of cylinder bore to check ovalization, taper, and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder bore diameter.

NOTE: Should a ring gauge not be available, use a micrometer for zero-setting.

73092825A

1

73092826A

2

Measurements shall be performed on each cylinder at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B).

Maximum wear is usually found on plane (B) in correspondence with the first measurement.

Should ovalization, taper, or wear be found, bore and grind the cylinder bores. Cylinder bore regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm (0.016 in) and to the specified assembling clearance.

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NOTE: In case of regrinding, all bores shall have the same oversize 0.4 mm (0.016 in).

73092827

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Cylinder head - Remove Prior operation: Rocker assembly Housing - Remove (B.10.A) 1.

Disassemble the cylinder head; loosen the cylinder head (1) fastening screws (2); hook the brackets with metal ropes and, throughout a hoister, detach the cylinder head with valves from the basement.

2.

Remove the cylinder head gasket.

73092775

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head - Install Prior operation: Cylinder head - Remove (B.10.A) 1.

Measure the piston projection and refer to the table to select the appropriate thickness of the gasket.

Piston protrusion (A)

Gasket thickness (B)

0.07 - -0.07 mm (0.0028 - -0.0028 in) -0.08 - -0.22 mm (-0.0031 - -0.0087 in)

0.80 mm (0.031 in) 0.70 mm (0.028 in)

2.

73092790

1

73092791

2

Fit the gasket (1) on the block centering it on the pins (2) as a reference.

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3.

Place the head (1) on the block while aligning the centering pins.

NOTE: Always use new screws for assembly.

4.

Lubricate the head fastening screws (2) and tighten them to the prescribed torque.

73092775

Next operation: Rocker assembly Housing - Install (B.10.A)

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Cylinder head - Disassemble Prior operation: Cylinder head - Remove (B.10.A) 1.

The intake valves (1) and exhaust valves (2) have different head diameter.

2.

Number the valves before removing them from the cylinder head in order to be able to reassemble them in the same order in case replacement is not necessary.

3.

Valve disassembly must be executed using tool 380000302 (1) to slightly press the plate (3) so that, compressing the spring (4), it is possible to remove the keepers (2). Then remove the plate (3) and the spring (4).

4.

Repeat the operation in correspondence of each valve.

5.

Turn the cylinder head upside down and withdraw the valves (5).

6.

73092871

1

73092872

2

73092873

3

Remove the seals (1) and (2) from their valve guides.

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head - Check Prior operation: Cylinder head - Disassemble (B.10.A) 1.

Any deformation detected on the whole length of the cylinder head must not exceed 0.20 mm (0.008 in).

In case higher value is detected, grind the cylinder head in order to obtain the prescribed value.

73092874

Next operation: Cylinder head - Assemble (B.10.A)

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Cylinder head Valve guide - Measure Prior operation: Cylinder head - Disassemble (B.10.A) 1.

Using a bore meter, measure the valve guide inner diameter.

73092878

Next operation: Cylinder head - Assemble (B.10.A)

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Cylinder head Valve seat - Replace Prior operation: Cylinder head - Disassemble (B.10.A) 1.

If the valve seat are damaged replace them.

2.

With the tools and being careful not to indent the cylinder heads, remove as much material as possible from the valve seats until removal from cylinder head is possible by means of a punch.

3.

Heat cylinder head up to 80 - 100 °C (176 - 212 °F) and with the beater assemble the new valve seats previously cooled into the cylinder head.

Next operation: Cylinder head - Assemble (B.10.A)

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73092879

1

ENGINE AND PTO IN - ENGINE

Cylinder head - Assemble Prior operation: Cylinder head - Disassemble (B.10.A) 1.

Lubricate the valve stems (1) and fit them in the relevant valve guides in the same position they were before disassembly.

2.

Fit the grommets (2)and (3) to the valve guide using tool 380000134.

3.

Place the spring (4) and the upper plate (3) on the cylinder head.

4.

Using tool 380000302 (1), compress the spring (4) and constrain the parts to the valve (5) using the keepers (2).

Next operation: Cylinder head - Install (B.10.A)

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73092881

1

73092872

2

ENGINE AND PTO IN - ENGINE

Valve cover - Remove 1.

Loosen the screws (1) and remove the tappet covers (2).

73092766

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Valve cover - Install 1.

Replace the gaskets (2) and install the valve covers (1).

73092797

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Front cover - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Fit the new gasket using the centring pins (1) on the casing for its correct positioning.

2.

Fit the casing’s cover using the centring pins (1) to correctly position it and then tighten the fastening screws to the prescribed torque.

73092787A

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Front cover - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit the new gasket using the centring pins (1) on the casing for its correct positioning.

2.

Fit the casing’s cover using the centring pins (1) to correctly position it and then tighten the fastening screws to the prescribed torque.

73092908

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Rear cover - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Accurately clean the timing gearcase and the engine block.

NOTICE: It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply LOCTITE® 5970 sealer on the gearcase in order to form a sealing bead of 1.5 mm (0.059 in). The sealing bead must be homogeneous (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoid the excess of sealer: too much sealing material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

73092781

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Rear cover - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Accurately clean the timing gearcase and the engine block.

NOTICE: It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply LOCTITE® 5970 sealer on the gearcase in order to form a sealing bead of 1.5 mm (0.059 in). The sealing bead must be homogeneous (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoid the excess of sealer: too much sealing material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

73092903

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Rear cover - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Accurately clean the timing gearcase and the engine block.

NOTICE: It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply LOCTITE® 5970 sealer on the gearcase in order to form a sealing bead of 1.5 mm (0.059 in). The sealing bead must be homogeneous (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoid the excess of sealer: too much sealing material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

93111626

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Wiring harness - Remove F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

1.

Remove the wiring harness from all electrical equipment.

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Index ENGINE AND PTO IN - B ENGINE - 10.A Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Balancer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Crankshaft Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Cylinder head Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Cylinder head Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Electronic control Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Electronic control Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454C

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454G

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE9454E

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE9484E

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE9484C

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9484A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9454D

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9484B

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5AE9484G

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454B*A005

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5CE5454C*A003

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5AE5484A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5AE9454J

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5AE9454L

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5AE9484K

ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003 84465357 28/02/2011

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Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wiring harness - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Wiring harness - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K

Wiring harness - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

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ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

FUNCTIONAL DATA FUEL AND INJECTION SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel injection pump Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel filter system Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Priming pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

SERVICE FUEL AND INJECTION SYSTEM Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fuel injection pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuel filter system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

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Fuel injector Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Priming pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

FUEL AND INJECTION SYSTEM - Overview

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1

SUPPLY SYSTEM DIAGRAM (1) Injectors

(2) Fuel filter

(3) Tank

(4) Supply pump

(5) Ignition pump

The engine supply system consists of the following components: •

Fuel tank (aboard the vehicle)

•

Fuel delivery and return pipes

•

Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)

•

Priming pump, fitted on the engine and driver by the engine camshaft

•

Fuel filter (its position on the engine may vary depending on the outfit and use)

•

Supply rotary pump

•

Injector feed pipe (from the fuel supply pump to the fuel injectors)

•

Injectors

NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift pump, description will not be accurate.

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2

PIPE LAYOUT (1) Injector feed pipe (2) Fuel exhaust pipe from injectors (3) Supply rotary pump (4) Union for pressure gauge pipe within LDA intake manifold

(5) KSB thermal bulb (6) Solenoid valve (7) Injector

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Working system description The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the fuel pressure based on the increase of engine revolutions’ number. Then, the fuel reaches the valve controlling fuel pressure within the supply pump. The distributor piston further increases such pressure and delivers the fuel to the injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the fuel tank.

NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift pump, description will not be accurate.

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3

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Fuel injection pump - Dynamic description Supply phase The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).

73092753

(1) Fuel supply pipe (2) Solenoid valve (3) Axial groove

1

(4) Compression chamber (5) Fuel delivery pipe from pump to injectors (6) Distributor piston

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(7) End of delivery port (8) Cursor (9) Injector

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Delivery phase The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The combination of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).

73092754

(1) Fuel feed pipe (2) Compression chamber

2

(3) Distributor piston inner pipe (4) Fuel delivery pipe from pump to injector

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(5) Distributor piston (6) Injector

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

End of delivery phase The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby establishing pressure balance between the distributor piston inner chamber, the injectors? delivery pipe and the pump interior. Since such pressure is lower than the one required to start the injector, end of delivery will be determined.

73092755

(1) Fuel feed pipe (2) Compression chamber

3

(3) Fuel delivery pipe (4) End of delivery pipe

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(5) Cursor (6) Distributor piston

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Engine stop Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs the fuel feed pipe (1).

73092756

(1) Fuel feed pipe (2) Mobile cap

4

(3) Spring (4) Solenoid valve

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(5) Compression chamber

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Load Delivery Adjustment (LDA) device The duty of the LDA device is to adjust the fuel delivery depending on the air pressure within the intake manifold. Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a conical housing (5) in which the feeling pin runs (6). The setting pin (4) axial motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates on its own axle (8) and acts on the control plate in order to adjust the fuel delivery depending on the air quantity within the cylinders.

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5

Section of the LDA device

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Fuel injection pump - Sectional view Identification coding example rotary distributor piston pump pump dimensions four cylinder engines distributor piston size in mm no. of pump rev/min. right direction rotation

V E 4 12 1150 RV

73092752

Ref. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

1

Description Membrane Setting ring Feeler pin Drive lever Speed regulator Transfer pump Drive shaft Cam disk Spark lead adjuster Distributor piston Supply pipe fitting Hydraulic head Control plate Adjusting pin Counter spring

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system Fuel filter - Overview The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge filter.

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(1) Fuel filter support

1

(2) Cartridge filter

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(3) Water drainage device (not available on all versions)

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Priming pump - Overview The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the engine block and driven by the engine camshaft.

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(1) Pump

1

(2) Control lever

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(3) Camshaft

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Air temperature-pressure sensor - Overview F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device.

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1

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

FUEL AND INJECTION SYSTEM - Bleed 1.

Disconnect the fuel filter pipe (1) and act on the priming pump (2) drainage lever.

2.

Continue drainage until fuel discharge is completed.

3.

Connect the pipe (1) to the filter.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injection pump - Remove 1.

Unscrew the pump fastening screws on the rear part of the gear cover. To disassemble the pump, fit tool to the pump wheel and fix it with the three screws (1).

Using the specially provided wrench, slowly tighten the screw (2) holding the rear part of the pump removing the pump completely.

NOTE: Before pump disassembly, check whether a drive shaft locking system is available for that model. In such case, using the specially provided tool 380000150, lock the engine into the position corresponding to T.D.C. for cylinder 1. Then, throughout the specific locking system available, lock the pump drive shaft. At this point, the pump should be in phase and therefore no timing will be requested in phase of reassembly (unless any maintenance operation is necessary).

Next operation: Fuel injection pump - Install (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injection pump - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Fuel injection pump - Remove (B.20.A) 1.

Fit the ignition pump gear (1) into its housing.

2.

Fit the pre-set ignition pump into its housing on the engine, inserting the shaft into the gear hole.

3.

Tighten the three screw nuts on the rear part of the timing gearcase and the front cover fixing the shaft to the gear.

4.

With magnetic base dial gauge, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 - 0.168 mm (0.003 - 0.007 in).

73092787A

Next operation: Fuel injection pump - Timing adjust (B.20.A)

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injection pump - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Fuel injection pump - Remove (B.20.A) 1.

Fit the ignition pump gear (1) into its housing.

2.

Fit the pre-set ignition pump into its housing on the engine, inserting the shaft into the gear hole.

3.

Tighten the three screw nuts on the rear part of the timing gearcase and the front cover fixing the shaft to the gear.

4.

With magnetic base dial gauge, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 - 0.168 mm (0.003 - 0.007 in).

73092908

Next operation: Fuel injection pump - Timing adjust (B.20.A)

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injection pump - Timing adjust Prior operation: Fuel injection pump - Remove (B.20.A)

Cold KSB timing 1.

Place the pump in vice.

2.

Remove the plug on the backside of the pump.

3.

Install the dial gauge 380000228 (1) and dial gauge holder into the pump.

4.

Turn the pump shaft (2) until tension is relieved and the pump cam plate is not loading the plunger.

NOTE: Double nut the end of the pump shaft, this will aid in rotating the pump shaft.

5.

Pre load the dial gauge by 3 mm (0.118 in) and zero the gauge.

6.

Turn the pump shaft so that the key way is aligned closely to the 11 O’clock position while watching the dial gauge and stop when the correct specification (below) is reached.

7.

•

Specification is 1.60 mm (0.063 in)

•

Timing between 1.55 - 1.65 mm (0.061 - 0.065 in)

Lock pump in position by removing the spacer plate (3) and snugging the bolt (4).

NOTE: Do not loosen the locking bolt until the pump is installed and torqued on the engine.

8.

Set the engine to Cylinder 1 top dead center. Refer to ENGINE - Service instruction (B.10.A) for the proper procedure.

9.

Install the pump and gear on the engine. Refer to Fuel injection pump - Install (B.20.A) for the proper procedure.

10.

Remove the lock screw.

NOTE: Leave the dial gauge in the back of the pump.

11.

Rotate the engine one full rotation to #1 TDC while monitoring the pump pre-travel.

12.

Pin the flywheel at #1 TDC and make note of the reading on the dial gauge. If the reading is within 10 mm (0.394 in), timing is correct.

13.

Remove the dial gauge.

14.

Install the plug.

15.

Install the spacer plate and tighten the lock bolt.

Hot KSB timing 16.

Set the engine to T.D.C. refer to ENGINE - Service instruction (B.10.A).

17.

Remove the spin-on fuel filter. Do not discard.

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93101557

1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

18.

Apply 12 volts to the KSB for a minimum of 5 minutes.

12 volts is required to remove the cold-start advance on the pump in order to check the static (hot) timing.

19.

Use a mirror to ensure that the KSB timing is retarded with the KSB lever (arm) moved forward (toward the front of the pump) almost against the angle stop (1).

20.

Use a 12 mm socket or wrench to remove the plunger access plug. The access plug is in the center of the rear end cap of the injection pump.

21.

Install the timing adaptor (2) and the dial indicator (3) into the hole where you removed the plunger access plug.

22.

If needed, loosen and reposition the bottom two injector lines to allow room for the dial indicator.

23.

Tighten the timing adapter.

24.

Preload the dial indicator needle to 2.5 mm (0.10 in).

25.

Pull outward on the end of the dial indicator stem and release it to ensure the stem moves freely and does not bind. If the stem does not move freely, reposition the dial indicator until the stem moves freely.

26.

Slide out the TDC timing pin from the flywheel to unlock the flywheel.

27.

Rotate the engine counter-clockwise until the dial indicator needle drops to a minimum reading and stops moving. You are now positioned between cam lobes of the injection pump.

28.

Position the dial indicator needle at the zero position.

29.

Rotate the engine clockwise until the TDC timing pin reengages the flywheel and locks it at TDC.

30.

Check the injection pump timing.

31.

•

Specification is 0.75 mm (0.030 in)

•

Timing between 0.65 - 0.85 mm (0.026 - 0.033 in)

20111651A

2

20111652

3

If only a slight timing adjustment is required, loosen the pump mounting bolts and rotate the injection pump.

NOTE: The holes for the mounting bolts are not elongated. Only a slight adjustment can be made by rotating the injection pump.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Place a container under the diesel fuel filter and unscrew the water drainage valve (3)under the filter; completely drain the diesel fuel container.

2.

Disassemble the diesel fuel filter (1), the filter support (2).

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Install the fuel filter support (1) and the fuel filter (2).

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Place a container under the diesel fuel filter and unscrew the water drainage valve (3)under the filter; completely drain the diesel fuel container.

2.

Disassemble the diesel fuel filter (1), the filter support (2).

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Install the fuel filter support (1) and the fuel filter (2).

73092894

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Refer to your product service manual.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Refer to your product service manual.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector - Remove 1.

Unscrew the injector support fastening screws (1), disassemble the injector supports and remove the injectors (2).

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector - Install 1.

Install new seals on the injectors.

2.

Make the holes (1) for fuel return all face the same direction.

3.

73092796

1

73092795

2

Install the injectors (1) and tighten the fastening screws (2) to the prescribed torque setting.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Priming pump - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the priming pump (1).

73092765

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Priming pump - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Install the priming pump (1).

73092765

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Priming pump - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Remove the priming pump (1).

73092894

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Priming pump - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Install the priming pump (1).

73092894

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the Load Delivery Adjustment (LDA) pipe.

Remove the fuel pipes from the priming pump (1) to the filter and from the filter to the ignition pump (2), then fit the specially provided caps to the pipes, the pumps and the filter. Unscrew the screws (3), fastening the fuel ignition pipes and remove them.

73092762

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Reassemble the pipe from the pump to the injector and tighten the bracket’s fastening screws (3).

2.

Reassemble the pipe from the pump to the fuel filter (2) and from the fuel filter to the priming pump (1).

3.

Reassemble the Load Delivery Adjustment (LDA) pipe.

73092762

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Remove the Load Delivery Adjustment (LDA) pipe.

Remove the fuel pipes from the priming pump (1) to the filter and from the filter to the ignition pump (2), then fit the specially provided caps to the pipes, the pumps and the filter. Unscrew the screws (3), fastening the fuel ignition pipes and remove them.

73092893A

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Reassemble the pipe from the pump to the injector and tighten the bracket’s fastening screws (3).

2.

Reassemble the pipe from the pump to the fuel filter (2) and from the fuel filter to the priming pump (1).

3.

Reassemble the Load Delivery Adjustment (LDA) pipe.

73092762

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1

Index ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A FUEL AND INJECTION SYSTEM - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FUEL AND INJECTION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fuel filter system Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fuel injection pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fuel injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fuel injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

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F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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FUNCTIONAL DATA AIR INTAKE SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

SERVICE Turbocharger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Air intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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AIR INTAKE SYSTEM - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

The boosting system is composed of the following parts: •

Air filter

•

Turbocharger

73092748

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BOOSTING

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AIR INTAKE SYSTEM - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

The boosting system is composed of the following parts: •

Air filter

•

Turbocharger

73092891

1

BOOSTING

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Turbocharger - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Disconnect the oil delivery pipe (2) from the turbocharger.

2.

Disconnect the oil drain pipe (3).

3.

Remove the turbocharger to intake hose (4).

4.

Remove the turbocharger unit (1).

73092760

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Turbocharger - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Reassemble the turbocharger (1) unit.

2.

Connect the oil delivery pipe (2) to the turbocharger.

3.

Connect the oil drain pipe (3).

4.

Install the turbocharger to intake hose (4).

73092760

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Turbocharger - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Disconnect the oil delivery pipe (2) from the turbocharger.

2.

Disconnect the oil drain pipe (3).

3.

Remove the turbocharger to intake hose (4).

4.

Remove the turbocharger unit (1).

73092892

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Turbocharger - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Reassemble the turbocharger (1) unit.

2.

Connect the oil delivery pipe (2) to the turbocharger.

3.

Connect the oil drain pipe (3).

4.

Install the turbocharger to intake hose (4).

73092892

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Turbocharger - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Disconnect the oil delivery pipe (2) from the turbocharger.

2.

Disconnect the oil drain pipe (3).

3.

Remove the turbocharger to intake hose (4).

4.

Remove the turbocharger unit (1).

93111630

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Turbocharger - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Reassemble the turbocharger (1) unit.

2.

Connect the oil delivery pipe (2) to the turbocharger.

3.

Connect the oil drain pipe (3).

4.

Install the turbocharger to intake hose (4).

93111630

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Air intake manifold - Remove 1.

Remove the intake manifold (1).

73092766

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Air intake manifold - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Reassemble the whole intake manifold (1) replacing the gasket (2) and (3).

73092799

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Air intake manifold - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Reassemble the whole intake manifold (1) replacing the gasket (2) and (3).

73092912

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Index ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

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F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B EXHAUST SYSTEM - 40.A

FUNCTIONAL DATA EXHAUST SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Sensing system Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

SERVICE EXHAUST SYSTEM Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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EXHAUST SYSTEM - Overview EGR (EXHAUST GAS RECIRCULATION) The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and therefore is an efficient NOx emission control system.

INTERNAL EGR The specific design of intake cams of the internal EGR system allows part of exhaust gas to be recycled to engine cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always active. Its configuration requires no additional parts such as control valves, pipelines or heat exchangers therefore engine profile remains unchanged. Besides main lobe, intake cam has an additional lobe as to configuration without EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled to cylinder inlet for combustion phase.

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Aspiration cam profile (X) Cam rotation angle

(Y) Cam lift

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EXHAUST SYSTEM - Overview EGR (EXHAUST GAS RECIRCULATION) The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and therefore is an efficient NOx emission control system.

EXTERNAL E.G.R. The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial exhaust gas recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the combustion temperature maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced.

Hence, reducing the aforesaid temperatures by decreasing the concentration of oxygen in the combustion chamber, the EGR system efficiently controls NOx emissions. The exhaust gases through the conduit (4) and only after receiving the consent by the electronic control unit EGR, cross the valve (1) and reach the heat exchanger (2) where, thanks to the engine coolant recycle, are cooled to be then entered into the intake manifold (5).

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EXTERNAL E.G.R. (1) (2) (3) (4)

Valve unit Heat exchanger Water delivery pipe Exhaust gas pipe

(5) Intake manifold (6) Exhaust manifold (7) Engine head

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Sensing system - Overview EGR valve F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

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(A) Exhaust gas input - (B) Exhaust gas output

Potentiometer characteristic

Coil characteristic Resistance Frequency Voltage

7.5 - 8.5 Ω 100 - 150 Hz 12 - 16 V

Total resistance Maximum voltage Supply current Circuit configuration

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4000 Ω 15 V 10 mA Voltage divider

ENGINE AND PTO IN - EXHAUST SYSTEM

EXHAUST SYSTEM - Remove EGR System F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

1.

Using pliers, remove the clips (1) and the water delivery pipe connected to the valve support and the exchanger (2). Loosen the clip (3) and detach the pipe (4), from the EGR valve housing. Unscrew the EGR fastening screws on the front side (5), and those on the valve support side (6), then remove the EGR unit.

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EXHAUST SYSTEM - Install EGR System F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

1.

Place the whole E.G.R. on the intake manifold, tighten the front side (5) and valve support (6) fastening screws to the prescribed torque.

2.

Connect the pipe (4) to the E.G.R. valve housing and then tighten the clip (3).

3.

Reassemble the pipe (2) and, using pliers, fit the relevant clip (1).

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Exhaust manifold - Remove 1.

Remove the exhaust manifold (1).

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Exhaust manifold - Install 1.

Fit the exhaust manifold (3) with new seal (2) and tighten the nuts (1) with studs tightening them to the required torque.

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Index ENGINE AND PTO IN - B EXHAUST SYSTEM - 40.A Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EXHAUST SYSTEM - Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EXHAUST SYSTEM - Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

Sensing system - Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A

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F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A

FUNCTIONAL DATA ENGINE COOLANT SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Water pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Coolant line Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003 84465357 28/02/2011

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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ENGINE COOLANT SYSTEM - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

The closed circuit forced circulation engine cooling system is composed of the following parts: •

expansion tank: position, form and dimensions may vary depending on the engine fitting

•

radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions may vary depending on the application

•

fan increasing the radiator’s cooling power. This component may vary depending on the application

•

heat exchanger cooling the lubricant oil. This component may vary depending on the application

•

centrifugal water pump positioned in the front part of the engine block

•

thermostat controlling cooling liquid circulation

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ENGINE COOLING SYSTEM DIAGRAM

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ENGINE COOLANT SYSTEM - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

The closed circuit forced circulation engine cooling system is composed of the following parts: •

expansion tank: position, form and dimensions may vary depending on the engine fitting

•

radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions may vary depending on the application

•

fan increasing the radiator’s cooling power. This component may vary depending on the application

•

heat exchanger cooling the lubricant oil. This component may vary depending on the application

•

centrifugal water pump positioned in the front part of the engine block

•

thermostat controlling cooling liquid circulation

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ENGINE COOLING SYSTEM DIAGRAM

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Thermostat - Overview When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine circuit, allowing engine heat up quickly. The thermostat valve starts opening at nearly 80 °C (176 °F), allowing water circulation into the radiator and also obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning.

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THERMOSTAT DIAGRAM (1) Stroke starts at 77 - 81 °C (171 - 178 °F).

(2) 7 mm (0.28 in) stroke at 92 - 96 °C (198 - 205 °F).

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Water pump - Overview The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft as a whole. Water tight between the pump unit (3) and the shaft (2) is ensured by the sheath (4).

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WATER PUMP SECTION (1) Hub (2) Shaft with bearing (3) Pump unit

(4) Sheath (5) Impeller

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Sensing system Coolant temperature - Overview The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores.

73092808

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Characteristics Working temperature range - Connector’s side - Bulb’s side on engine Voltage

-40 - 130 °C (-40 - 266 °F) ; 150 °C (302 °F) for less than 10 min.

-40 - 140 °C (-40 - 284 °F) 6 - 28 V

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Sensing system Coolant temperature - Overview KSB

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Characteristics Contact closing temperature Maximum load on contacts

60 - 70 °C (140 - 158 °F) 15 A

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Thermostat - Remove 1.

Remove the thermostat unit (1).

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Water pump - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the water pump (1).

73092770

Next operation: Water pump - Install (B.50.A)

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Water pump - Install Prior operation: Water pump - Remove (B.50.A) 1.

Fit a new seal (2) on the water pump (1).

2.

Assemble the water pump (1).

3.

Tighten the fastening screws to the prescribed torque.

73092789

Next operation: Fan and drive - Install (B.50.A)

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Water pump - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the water pump (1).

73092898A

Next operation: Water pump - Install (B.50.A)

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Coolant line - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the water delivery pipe (1) from the exchanger.

73092760

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Coolant line - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the water delivery pipe (1) from the exchanger.

93111630

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Fan and drive Belt - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Loosen the screw (1) and the relevant screw nut on the belt tensioning bracket (3).

2.

Loosen the alternator through bolt in order to withdraw the belt (2).

73092767

Next operation: Fan and drive Belt - Install (B.50.A)

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Fan and drive Belt tensioner - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the belt tensioning bracket (1).

73092767

Next operation: Fan and drive Belt - Install (B.50.A)

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Fan and drive - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the fan hub (1).

2.

Loosen the screw (2) and remove the pulley (3).

73092770

Next operation: Fan and drive Belt - Install (B.50.A)

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Fan and drive - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Prior operation: Fan and drive - Remove (B.50.A) 1.

Install the fan hub (1).

2.

Reassemble the pulley (3), tighten the fastening screw (2) to the prescribed torque setting.

73092792

Next operation: Fan and drive Belt - Install (B.50.A)

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Fan and drive Belt tensioner - Install Prior operation: Fan and drive Belt tensioner - Remove (B.50.A) 1.

Install the tensioner (1).

73092767

Next operation: Fan and drive Belt - Install (B.50.A)

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Fan and drive Belt - Install Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Fit the drive belt (1) on the pulley and the guide rollers.

2.

Tension the drive belt by tightening the screw (2).

73092767

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Fan and drive Belt - Remove 1.

Loosen the screw (1) and the relevant screw nut on the belt tensioning bracket (3).

2.

Loosen the alternator through bolt in order to withdraw the belt (2).

73092896

Next operation: Fan and drive Belt - Install (B.50.A)

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Fan and drive Belt tensioner - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the belt tensioning bracket (1).

73092896

Next operation: Fan and drive Belt - Install (B.50.A)

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Fan and drive - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the fan hub (1).

2.

Loosen the screw (2) and remove the pulley (3).

73092898A

Next operation: Fan and drive Belt - Install (B.50.A)

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Fan and drive - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Prior operation: Fan and drive - Remove (B.50.A) 1.

Install the fan hub (1).

2.

Reassemble the pulley (3), tighten the fastening screw (2) to the prescribed torque setting.

73092910

Next operation: Fan and drive Belt - Install (B.50.A)

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1

Index ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A Coolant line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Coolant line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sensing system Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Thermostat - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Water pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B LUBRICATION SYSTEM - 60.A

TECHNICAL DATA Oil pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Oil filter General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA LUBRICATION SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5C, F5A

Oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5C, F5A

Blowby re-circulation system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Oil cooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

SERVICE Oil pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Oil line Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

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Oil pump - General specification Rotating speed Feed pressure Rated flow Oil type Max. oil temperature

750 - 4200 RPM 2 - 4 bar (29 - 58 psi) 12.2 - 75.9 l/min (3.2 - 20.1 US gpm) SAE 20/30 80 °C (176 °F)

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Oil filter - General specification Booster pressure Dynamic pressure Operating temperature Torque wrench setting Maximum flow Load loss at the end of life cycle

20 bar (290 psi) 0 - 15 bar (0 - 218 psi) per 50,000 cycles -40 - 140 °C (-40 - 284 °F) 16 - 20 N·m (12 - 15 lb ft) 50 l/min (13.2 US gpm) 2.5 bar (36 psi)

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LUBRICATION SYSTEM - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is distributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed air system is also fitted.

73092738

1

LUBRICATION SYSTEM DIAGRAM

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ENGINE AND PTO IN - LUBRICATION SYSTEM

LUBRICATION SYSTEM - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is distributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed air system is also fitted.

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1

LUBRICATION SYSTEM LAYOUT

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Oil pump - Overview F5C, F5A

73092739

1

Oil pump (1) (2) (3) (4) (5)

Main gear Secondary gear Pump unit Drive shaft Secondary shaft

(6) Cover (7) Internal rotor (8) External rotor

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Oil filter - Overview F5C, F5A

73092740

1

Engine oil filter (1) Protective cover

(2) Cartridge

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Blowby re-circulation system - Overview On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop by gravity on the underlying tappet cover (3). The remaining non condensed vapours will be duly conveyed through the breather (2), for instance by suction.

73092741

1

ENGINE OIL VAPOR RECIRCULATION (1) Valve

(2) Breather

(3) Tappet cover

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Oil cooler - Overview

73092745

1

OIL COOLER The oil cooler within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing heat throughout the engine cooling liquid.

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Sensing system Oil pressure - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

73092809

1

Characteristics Voltage Contact closure with decreasing pressure Contact opening with increasing pressure

12 - 24 V 0.2 bar (3 psi) 0.9 bar (13 psi)

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Sensing system Oil pressure - Overview F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

73092919

1

Characteristics Voltage Calibration Tightening torque

12 - 24 V 0.6 - 0.9 bar (9 - 13 psi) 35 N·m (26 lb ft)

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Oil pump - Remove 1.

Loosen the screws (1) and remove the oil pump (2).

73092778

Next operation: Oil pump - Install (B.60.A)

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Oil pump - Install Prior operation: Oil pump - Remove (B.60.A) 1.

Assemble the oil pump (2).

2.

Screw the fastening screws (1) without fully locking them.

3.

With magnetic base dial gauge, check the clearance among the engine crankshaft gear and the oil pump gear: It must be between 0.068 - 0.168 mm (0.003 0.007 in).

4.

Fully tighten the fastening screws (1).

73092784

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Oil pan - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Loosen the screws (2), disassemble the plate (3) and remove the oil pan (1).

NOTE: The shape and dimensions of the oil pan and the suction rose may vary depending on the engine appliance.

Hence, the figures provide a general indication of the operation to be executed. Yet, the herein description of the procedures is applicable.

2.

Loosen the suction rose support fastening screws (1).

3.

Loosen the suction rose (3) fastening screws (2) and then remove the suction rose.

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73092776

1

73092777

2

ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil pan - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

2.

3.

Reassemble the suction rose (3) tightening the support fastening screws (1) and the screw (2) fixing the suction rose to the prescribed torque setting.

73092777

1

73092800

2

73092776

3

Fit the new gasket (1) to the oil pan (2).

Assemble the oil pan (1) and fit the plate thereon (3).

Tighten the fastening screws (2) to the prescribed torque setting.

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Oil pan - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Turn the engine upside down.

2.

Remove the screws (2) and detach the oil pan (1).

3.

Remove the oil pick up tube.

73092901

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Oil pan - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Instal the oil pick up tube.

2.

Mount the oil pan (1) and tighten the screws (2) to the required torque.

NOTE: Before installing the pan, verify that the threads of the holes and the screws are not worn and dirty.

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Oil filter - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Remove the oil filter (1) and the oil filter base (2).

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Oil filter - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Install the oil filter support (1) and the oil filter (2).

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Oil filter - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Remove the oil filter (1) and the oil filter base (2).

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Oil filter - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Install the oil filter support (1) and the oil filter (2).

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Oil filter - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Remove the oil filter (1) and the oil filter base (2).

93111635

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil filter - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Install the oil filter support (1) and the oil filter (2).

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Piston lubrication Spray nozzle - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

Loosen the fastening screws (1) and disassemble the oil nozzles (2).

73092821

Next operation: Piston lubrication Spray nozzle - Install (B.60.A)

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Piston lubrication Spray nozzle - Install Prior operation: Piston lubrication Spray nozzle - Remove (B.60.A) 1.

Fit the nozzles (2) and tighten the fastening screws (1) to the prescribed torque setting.

73092837

Next operation: Oil pan - Install (B.60.A)

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Oil cooler - Remove 1.

Place a container under the heat exchanger (2) to collect the cooling liquid contained therein.

2.

Loosen the screws (1)and disassemble the heat exchanger unit (2).

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Oil cooler - Install 1.

Reassemble the heat exchanger (1) remember to replace the old gasket with a new one; tighten the fastening screws (2) to the prescribed torque setting.

73092769

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Oil line - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Loosen the clip and disconnect the pipe (1).

2.

Remove oil delivery pipe connected to the turbocharger (2) and then the oil return pipe (3).

73092760

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Oil line - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

1.

Reassemble the oil delivery pipe (2) and the return pipe (1).

73092760

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Oil line - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Remove oil delivery pipe connected to the turbocharger (2) and then the oil return pipe (1).

73092892

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil line - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Reassemble the oil delivery pipe (2) and the return pipe (1).

73092892

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Oil line - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Loosen the clip and disconnect the pipe (1).

2.

Remove oil delivery pipe connected to the turbocharger (2) and then the oil return pipe (3).

93111630

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Oil line - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Reassemble the oil delivery pipe (2) and the return pipe (1).

93111630

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1

Index ENGINE AND PTO IN - B LUBRICATION SYSTEM - 60.A Blowby re-circulation system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Oil cooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Oil filter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5C, F5A

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E

Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Oil pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F5C, F5A

Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E

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Contents ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

TECHNICAL DATA Cold start aid General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

FUNCTIONAL DATA Cold start aid Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

SERVICE Cold start aid Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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Cold start aid - General specification F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Protrusion length Diameter of heating element Heat up time to 850 °C Temperature T60 Switch on current at 11 V Operating current at 11 V after 20 s Runout heating element

30.4 mm +/- 0.25 mm 4 mm +/- 0.1 mm Less than 5 s 950 - 1010 °C Less than 19 A 5 A +/- 1.0 A 0.4 mm

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Cold start aid - Overview F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

93111647

1

A glow plug typically comprises a heating coil in a metal tube closed at one end and filled with electrically insulating ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface temperature of more than 1000°C within a few seconds. The air-fuel spray generated by the injection ignites close to the glow plug and initiates combustion.

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Engine starter - Overview F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

73092815

Manufacturer Electrical system Rated output

1

BOSCH 12 V 3 kW (4 Hp)

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Cold start aid - Remove F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

NOTE: Three glow plugs (1) have direct access and are easily removed.

NOTE: The fourth glow plug (2) requires removal of the turbo intake (3).

1.

2.

3.

Disconnect electrical connections (A) and (B) and move out of the way.

93111637

1

93111637

2

93111637

3

Remove the adjustable pipe connector bolt (4).

Loosen the lower pipe connector bolt (5).

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4.

5.

6.

7.

Rotate the pipe (6) away from the intake.

93111638

4

93111638

5

93111638

6

93111639

7

Remove the four bolts (7) from the heat exchanger to rear intake flange.

Remove the four bolts (8) from the top of the intake.

Loosen the two hose clamps (C) from the elbow hose (9) and remove hose.

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8.

Remove the intake (3) and the spacer (10).

NOTE: Now you have free access to remove the fourth glow plug.

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93111639

8

93111640

9

ENGINE AND PTO IN - STARTING SYSTEM

Cold start aid - Install F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Install the four new glow plugs and torque to 8 N·m (70.8 lb in) before installing the air intake manifold.

2.

Replace the gaskets and install the spacer (1) and air intake manifold (2).

3.

4.

93111639

1

93111638

2

93111638

3

Install the four bolts (3) through the top of the air intake.

Install the four bolts (4) securing heat exchanger to the rear air intake flange.

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5.

6.

7.

8.

Install the elbow hose (5) and tighten the two hose clamps (A) securing it from the turbo to the air intake.

93111637

4

93111637

5

93111637

6

93111637

7

Rotate the pipe (6) in and secure it to the air intake (2) with the adjustable pipe connector bolt (7).

Tighten the lower pipe connector bolt (8).

Connect the two electrical connections (9).

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Engine starter - Remove F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Hold the starter (1), unscrew the fastening screws and remove the starter.

73092761

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ENGINE AND PTO IN - STARTING SYSTEM

Engine starter - Install F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

1.

Fit the starter (1) and tighten the fastening screws to the prescribed torque setting.

73092761

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ENGINE AND PTO IN - STARTING SYSTEM

Engine starter - Remove F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Hold the starter (1), unscrew the fastening screws and remove the starter.

73092892

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1

ENGINE AND PTO IN - STARTING SYSTEM

Engine starter - Install F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

1.

Fit the starter (1) and tighten the fastening screws to the prescribed torque setting.

73092892

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1

Index ENGINE AND PTO IN - B STARTING SYSTEM - 80.A Cold start aid - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Cold start aid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Cold start aid - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Cold start aid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

Engine starter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003

Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

84465357 28/02/2011

SPECIAL TOOL INDEX IU

Genuine 380000134 [Valve Guide Seal Installer - for use with 7.8L & 9.0L Cursor Engines] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000219 [Valve Guide Remover/Installer - used on 4.5L & 6.7L NEF Engines Same as 291046] 380000220 [Piston Ring Clamp (60 - 125 mm)] 380000221 [Piston Ring Pliers (65 - 110 mm)] 380000222 [Valve Guide Reemer - used on 4.5L & 6.7L NEF Engines] 380000228 [Dial Gauge (0 - 5 mm)] 380000302 [Cylinder Head Valve Spring Compressor] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000364 [Piston Protrusion Check, Gauge Base] 380000667 [Camshaft Bushing Remover And Installer] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000978 [Motore NEF Vedi Allegato] 380000999 [Adaptor 7/16 UNF Male] 380001006 [Cylinder Compression Tester] 380000732 [Engine Turning Tool] 380100072 [Special Tool] 380100074 [Special Tool] 380100075 [Special Tool] 380100076 [Special Tool] 380000134 [Valve Guide Seal Installer - for use with 7.8L & 9.0L Cursor Engines] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000219 [Valve Guide Remover/Installer - used on 4.5L & 6.7L NEF Engines Same as 291046] 380000220 [Piston Ring Clamp (60 - 125 mm)]

PAGE

Special tools

12

Special tools

12

Special tools

12

Special tools

12

Special tools

13

Special tools

13

Special tools

13

Special tools

14

Special tools

14

Special tools

14

Special tools

14

Special tools

15

Special tools

15

Special tools

15

Special tools

15

Special tools

16

Special Special Special Special Special

tools tools tools tools tools

16 16 16 17 18

Special tools

18

Special tools

18

Special tools

18

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IU

Genuine 380000221 [Piston Ring Pliers (65 - 110 mm)] 380000222 [Valve Guide Reemer - used on 4.5L & 6.7L NEF Engines] 380000228 [Dial Gauge (0 - 5 mm)] 380000302 [Cylinder Head Valve Spring Compressor] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000364 [Piston Protrusion Check, Gauge Base] 380000667 [Camshaft Bushing Remover And Installer] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000978 [Motore NEF Vedi Allegato] 380000732 [Engine Turning Tool] 380000999 [Adaptor 7/16 UNF Male] 380001006 [Cylinder Compression Tester] 380100072 [Special Tool] 380100073 [Special Tool] 380100074 [Special Tool] 380100076 [Special Tool] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000667 [Camshaft Bushing Remover And Installer] 380000999 [Adaptor 7/16 UNF Male] 380100076 [Special Tool] 380000362 [Crankshaft Lifting Hook] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000362 [Crankshaft Lifting Hook]

PAGE

Special tools

19

Special tools

19

Special tools

19

Special tools

20

Special tools

20

Special tools

20

Special tools

20

Special tools

21

Special tools

21

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21

Special tools

21

Special tools

22

Special tools Special tools Special tools Special tools ENGINE - Service instruction - Finding Top Dead Center

22 22 22 23 B.10.A / 35

ENGINE - Service instruction - Finding Top Dead Center

B.10.A / 35

ENGINE - Service instruction - Finding Top Dead Center

B.10.A / 36

ENGINE - Service instruction - Finding Top Dead Center

B.10.A / 36

Camshaft Bushing - Replace

B.10.A / 48

Camshaft Bushing - Replace

B.10.A / 48

Crankshaft Rear seal - Install Crankshaft - Remove

B.10.A / 55 B.10.A / 58

Crankshaft Journal - Measure

B.10.A / 63

Crankshaft - Remove

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IU

Genuine 380000324 [110-150 Diameter Piston Ring Pliers] 380000221 [Piston Ring Pliers (65 - 110 mm)] 380000220 [Piston Ring Clamp (60 - 125 mm)] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380002385 [Flywheel Crank Handle] 380002385 [Flywheel Crank Handle] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380002385 [Flywheel Crank Handle] 380002385 [Flywheel Crank Handle] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380002385 [Flywheel Crank Handle] 380002385 [Flywheel Crank Handle] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000302 [Cylinder Head Valve Spring Compressor] 380000134 [Valve Guide Seal Installer - for use with 7.8L & 9.0L Cursor Engines] 380000302 [Cylinder Head Valve Spring Compressor] 380000150 [Top Dead Center Setting Tool for use on 7.8L, 10.3L & 12.9L (13L) Cursor Engines] 380000228 [Dial Gauge (0 - 5 mm)]

PAGE

Connecting rod and piston - Disassemble

B.10.A / 77

Connecting rod and piston - Assemble

B.10.A / 82

Connecting rod and piston - Install

B.10.A / 83

Connecting rod and piston - Install

B.10.A / 85

Flywheel - Remove

B.10.A / 86

Flywheel - Install

B.10.A / 87

Flywheel - Install

B.10.A / 87

Flywheel - Remove

B.10.A / 88

Flywheel - Install

B.10.A / 89

Flywheel - Install

B.10.A / 89

Flywheel - Remove

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Flywheel - Install

B.10.A / 91

Flywheel - Install

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Cylinder head - Disassemble

B.10.A / 99

Cylinder head - Assemble

B.10.A / 103

Cylinder head - Assemble

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Fuel injection pump - Remove

B.20.A / 18

Fuel injection pump - Timing adjust

B.20.A / 21

Kit

IU

380000229 [Measuring Special tools Adapter used with 380000228] 380000229 [Measuring Special tools Adapter used with 380000228]

PAGE 13 19

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

84465357 28/02/2011