New Holland 334T M2 Engine Service Manual 87458412NA - PDF DOWNLOAD

ENGINE SERVICE MANUAL 334T/M2

CONSTRUCTION 87458412NA

Issued March, 2004 • 87458412NA • Bur Copyright © 2004 CNH America LLC. All Rights Reserved.

IN--1

INTRODUCTION

TO THE READER - This manual was written for a skilled technician and contains all the technical information needed to repair this vehicle.

- Read this manual carefully for the information concerning repairing operations.

- For any question or comment, or should you notice any mistake concerning the content of this manual, please contact:

CNH AMERICA LLC 700 State Street Racine, WI 53404 U.S.A.

FURTHER REFERENCES PAGE NUMBER - Every page carries a number on the top right corner. Every page contains the following information:

Example: T 1 -- 2 -- 3

Progressive page number for each group Group number (if any) Section number S:

Safety rules

T:

Technical section

W:

Instruction section for excavator repairing

EW:

Instruction section for engine repairing

Operation principle Performance tests Fault diagnosis

SYMBOLS This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.

!

This symbol regards safety.

Use great care when you see this symbol because possible injuries to the personnel may occur.

Strictly observe the precautions marked with this symbol.

The safety warning symbol is used also to draw attention on the weight of a component or an element.

Make sure you are always using the right equipment and lifting techniques when handling heavy loads, in order to prevent injuries or damages.

IN--2

INTRODUCTION

UNIT OF MEASURE This manual adopts the units of measure based on the International System.

The MKSA system units of measure are indicated within brackets after the units of measure of the International System.

Example: 24.5 Mpa (250 kgf/cm2).

The following table converts the International System units of measure in some of the main units belonging to other systems.

Quantity Length

Volume Mass Force Torque

To convert from (IS) mm mm L L m3 kg N N N.m N.m

in (Others) in ft US gal US qt yd3 lb kgf lbf kgf.m lbf.ft

Multiply by 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 0.7375

Quantity Pressure Power Temperature Speed Capacity

To convert from (IS) MPa MPa kW kW qC km/h min --1 L/min mL/rev

in (Others) kgf/cm2 psi PS HP qF mph rpm US gpm cc/rev

Multiply by 10.197 145.0 1.360 1.341 qC x 1.8 + 32 0.6214 1.0 0.2642 1.0

REPAIR MANUAL

ENGINES

INDEX OF SECTIONS

Section 1 -- Diagnostics

EW--1--1

Section 2 -- Engine F4CE0354A overhaul

EW--2--1

Section 3 -- Recharging and start--up

EW--3--1

4

WE

MOTORI

SECTION 1

DIAGNOSTICS

INDEX Diagnostics . . . . . . . . . . . . . . . . . . . . . . .

EW--1--3

INDICE

EW--1--3

DIAGNOSTICS

Main engine operating anomalies: 1 2 3 4 5

------

1

Engine won’t start; Engine overheats; Engine lacks power and works erratically; Engine exhaust smoke black or dark grey; Engine exhaust smoke grey (verging on white);

6 -7 -8 -9 -10 -11 -12 --

Engine exhaust smoke light blue; Engine knocks irregularly; Engine stops; Engine exceeds max. revs number; Excessive or insufficient oil pressure; Excessive fuel consumption; Engine won’t stop.

ENGINE WON’T START

Connections to battery terminals are in working order

Clean, check, tighten or replace clamp nuts.

NO

YES

Batteries in working order NO

Carry out the checks described in the “Electric system” repair manual.

NO

Carry out the checks described in the “Electric system” repair manual.

YES

Starter motor in working order

YES

Thermal starter in working order

Replace.

NO

YES

Injection pump timed NO

Verify correct timing as described in the relevant chapter.

(to be continued)

EW--1--4

DIAGNOSTICS

Injectors in working order

Check operation and adjust.

NO

YES

The feeding circuit or injection pump does not show air penetration

Check and blow off.

NO

YES

The feeding circuit or pump does not show traces of water

NO

Check and clean the feeding circuit (including the tank).

YES

Prescribed compression ratio NO

Overhaul the engine or make repairs only on concerned parts (valves, piston rings, etc.).

YES

Fuel filters in working order

Replace.

NO

YES

Automatic advance variator and electric STOP device both in working order

Check and replace the concerned parts.

NO

YES

Fuel pump fed correctly

Check and replace (if necessary) the fuel pump.

NO

YES

Fuel tank supplied correctly

Refuel.

NO

EW--1--5

DIAGNOSTICS

2

ENGINE OVERHEATS

Coolant level correct

Check for leaks and restore the level.

NO

YES

Fan and water pump drive belts in working order

Check for leaks and restore the level.

NO

YES

Water pump in working order

Overhaul or replace the unit.

NO

YES

Thermostat in working order

Replace.

NO

YES

Radiator in working order NO

Wash down thoroughly, check for fluid leaks, replace (if necessary) the part.

YES

Air filter and circuit piping both in working order

Clean or replace faulty parts.

NO

YES

Openings for coolant flow to the head in working order

Wash down thoroughly.

NO

EW--1--6

DIAGNOSTICS

Valve timing correct

Check and perform correct timing.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

Cylinder head gasket in working order

Replace.

NO

YES

Fan in working order

Replace.

NO

3

ENGINE LACKS POWER AND WORKS ERRATICALLY

Air filter in working order NO

Clean the unit and replace (if necessary) the filter element.

NO

Replace by following the instructions given in the “Owner Handbook”.

NO

Check and make (if necessary) the required repairs.

YES

Fuel filters in working order

YES

Feeding circuit in working order

(to be continued)

EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ or traces of water

NO

Take off the pipes and injection pump, clean them thoroughly, then clean (if necessary) and dry the fuel tank.

YES

Thermostat in working order

Replace.

NO

YES

Fuel pump in working order

Replace.

NO

YES

Injectors in working order

Check operation and adjust them.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

Automatic advance variator (in injection pump) in working order

Check and bench--adjust the injection pump.

NO

YES

Distributing plunger (in injection pump) in working order

Check and bench--adjust the injection pump.

NO

(to be continued)

EW--1--8

DIAGNOSTICS

Injection pump rate correct

Check and bench--adjust the injection pump.

NO

YES

Speed governor (in injection pump) in working order at all speeds

Check and bench--adjust the injection pump.

NO

YES

Circuit and L.D.A. device both in working order

Check.

NO

YES

Injection pump with peak adjusting--screw fine-tuned

Fine--tune the peak adjusting--screw.

NO

YES

Correct play between the valves and rocker arms NO

Adjust the play between the valves and rocker arms.

YES

Prescribed compression ratio

Check and bench--adjust the injection pump.

NO

YES

Turbocharger in working order

Repair or replace the unit.

NO

YES

Correct tie rod length between the accelerator and injection pump

Adjust the tie rod length.

NO

EW--1--9

DIAGNOSTICS

4

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Air filter in working order

Replace.

NO

YES

Thermal starter in working order

Replace.

NO

YES

Automatic addition device comes into operation

Check and replace (if necessary).

NO

YES

Injectors in working order

Check operation and adjust them as described.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

L.D.A. device in working order

Ad just the L.D.A. device.

NO

YES

Injection pump adjusted as prescribed

Check and bench--adjust the injection pump.

NO

(to be continued)

EW--1--10

DIAGNOSTICS

Injection pipes intact NO

Check the condition of pipes and replace them (if necessary).

NO

Check by means of a Motometer 75301430 tool and carry out the necessary operations.

YES

Prescribed compression ratio

YES

High--quality diesel fuel

Clean the tank and replace the diesel oil filter.

NO

5

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

The thermostat comes into operation correctly

Replace.

NO

YES

Injectors in working order NO

Check operation and adjust as described in S.I. 1094.

NO

Check correct timing as described in the relevant paragraph.

YES

Injection pump timed

YES

Coolant level correct NO

Possible flow of coolant into the combustion chamber; replace the cylinder head gasket or overhaul the engine.

(to be continued)

EW--1--11

DIAGNOSTICS

High--quality diesel oil

Clean the tank and replace the diesel oil filters.

NO

6

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption YES

7

Check the oil vapour vent and cylinder compression. Overhaul, if necessary, the cylinder head or engine.

ENGINE KNOCKS IRREGULARLY

Knock detected in the injection pump YES

Perform correct timing of injection pump on the engine.

NO

Knock detected in the drive shaft YES

Check the following items: journal play and out-of--roundness; screw fastening for bed caps and engine flywheel; oil pressure. Replace the parts or overhaul the engine.

NO

Knock detected in the connecting rods YES

Check the following items: crankpin play and out--of--roundness; screw fastening for connecting rod caps; connecting rod squaring. Replace the parts or overhaul the engine.

YES

Check the following items: play between the pistons and the cylinder liners; integrity of piston rings; play between the pins and the piston hubs.

Replace the parts or overhaul the engine.

NO

Knock detected in pistons

(to be continued)

EW--1--12

DIAGNOSTICS

Knock detected in the cylinder head YES

Check the following items: operation play between the rocker arms and the valves; injection pump timing; valve timing. Adjust.

YES

Check and replace (if necessary) the gears; moreover, check for broken springs, for excessive play between the stems and guides, the tappets and seats. Adjust the play between the valves and rocker arms.

NO

Knock detected in the valve gear

NO

Knock detected in injectors YES

Check and adjust as described in S.I. 1094, then replace.

YES

Replace loose screws and tighten all screws to the specified torque and angles.

NO

Knock detected in the engine flywheel

NO

Knock detected in the fuel piping YES

8

Clean the pipes and replace the pipes that show evident dents; clean (if necessary) the injection pump.

ENGINE STOPS

Fuel tank filled

Refuel and drain (if necessary).

NO

YES

Fuel filters in working order

Replace.

NO

(to be continued)

EW--1--13

DIAGNOSTICS

Feeling circuit in working order

Check the circuit and drain.

NO

YES

Regular idle speed

Adjust.

NO

YES

Regular injection pump rates

Bench--check the flow rates.

NO

YES

Injection pump controls in working order

Replace worn parts and adjust.

NO

YES

Correct play between the valves and rocker arms NO

Ad just the play between the valves and rocker arms.

YES

Intact valves

Replace the valves.

NO

9

ENGINE EXCEEDS MAX. REVS NUMBER

Speed governor in working order

Check and replace (if necessary) the worn parts.

NO

EW--1--14

DIAGNOSTICS

10

EXCESSIVE OR INSUFFICIENT OIL PRESSURE

Pressure control valve in working order

Check and replace (if necessary).

NO

YES

Oil pump and delivery pipes both in working order

Check and replace (if necessary).

NO

YES

Main bearings and connecting rod bearings both in working order

NO

Replace the bearings and reface (if necessary) the drive shaft.

NO

Replace the engine oil with equivalent of adequate viscosity.

NO

Eliminate leaks (if any) and replace the worn parts.

YES

Engine oil SAE viscosity conforming to standards

11

EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes in working order

YES

Air filter in working order

Replace.

NO

(to be continued)

EW--1--15

DIAGNOSTICS

Correct injector adjustment

Check operation and adjust them.

NO

YES

Correct injection pump adjustment

Check and bench--adjust.

NO

YES

L.D.A. device in working order

Adjust the L.D.A. device.

NO

YES

Injection pump timed

Check static force--fit of the injection pump.

NO

12

ENGINE WON’T STOP

Cut--off electromagnet in working order

Replace the electromagnet.

NO

YES

Speed governor in working order at all speeds NO

Overhaul the injection pump and bench--adjust it according to the relevant adjustment table.

EW--1--16

DIAGNOSTICS

NOTES

SECTION 2

ENGINE F4CE0354A

ENGINE F4CE0354A OVERHAUL

INDEX Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coding of source engines . . . . . . . . . .

General engine features . . . . . . . . . . .

Assembling play -- specifications . .

Tightening torque . . . . . . . . . . . . . . . . .

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphic indications and symbols . . .

General remarks . . . . . . . . . . . . . . . . . .

Description of main mechanic engine components . . . . . . . . . . . . . . .

Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft seal rings . . . . . . . . . . . . . . .

Connecting rods . . . . . . . . . . . . . . . . . . . .

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributing shaft . . . . . . . . . . . . . . . . . . .

Valve control . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head . . . . . . . . . . . . . . . . . . . . . .

Valves and valve seats . . . . . . . . . . . . . .

Valve guides . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel . . . . . . . . . . . . . . . . . . . .

Auxiliary component drive . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . .

Heat exchanger . . . . . . . . . . . . . . . . . . . .

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil vapour recirculation . . . . . . . . . . . . . .

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump . . . . . . . . . . . . . . . . . . . . . . .

Mechanic injection supply system . .

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanic fuel pump . . . . . . . . . . . . . . . .

Injection assembly . . . . . . . . . . . . . . . .

Engine bench--overhaul . . . . . . . . . . . .

Disassembling the engine . . . . . . . . . . .

Removal of compensating units . . . . . .

Replacing the seal ring . . . . . . . . . . . . . .

Repair work on cylinder cluster . . . . .

Checks and measurements . . . . . . . . . .

Checking head supporting surface on cylinder unit . . . . . . . . . . . . . . . . . . . . .

Valve gear . . . . . . . . . . . . . . . . . . . . . . . .

Distributing shaft . . . . . . . . . . . . . . . . . . .

Checking the pin alignment . . . . . . . . . .

EW--2--3 EW--2--4 EW--2--5 EW--2--7 EW--2--13 EW--2--14 EW--2--15 EW--2--16 EW--2--17 EW--2--17 EW--2--17 EW--2--18 EW--2--19 EW--2--20 EW--2--21 EW--2--22 EW--2--23 EW--2--24 EW--2--25 EW--2--26 EW--2--27 EW--2--28 EW--2--29 EW--2--30 EW--2--31 EW--2--32 EW--2--33 EW--2--34 EW--2--34 EW--2--35 EW--2--36 EW--2--37 EW--2--37 EW--2--39 EW--2--41 EW--2--45 EW--2--45 EW--2--46 EW--2--47 EW--2--47 EW--2--47

Bushings . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--48

Replacing the bushings . . . . . . . . . . . . . .

EW--2--49

Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--49

Mounting the tappets – Distributing shaft EW--2--49 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--50

Measuring the journals and crankpins .

EW--2--50

Replacing the oil pump drive gears . . . .

EW--2--53

Mounting the main bearings . . . . . . . . . .

EW--2--53

Measuring the journal assembling play

EW--2--53

Checking the drive shaft shoulder play .

EW--2--54

Connecting rod--piston assembly . . .

EW--2--55

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--56

Measuring the piston diameter . . . . . . .

EW--2--56

Gudgeon pins . . . . . . . . . . . . . . . . . . . . . .

EW--2--57

Conditions for correct pin/piston matching. . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--57

Piston rings . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--57

Connecting rods . . . . . . . . . . . . . . . . . . . .

EW--2--58

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--59

Checking the connecting rods . . . . . . . .

EW--2--59

Checking the torsion . . . . . . . . . . . . . . . .

EW--2--59

Checking the flexion . . . . . . . . . . . . . . . .

EW--2--59

Fitting connecting rod--piston assembly.

EW--2--60

Connecting rod--piston coupling . . . . . .

EW--2--60

Mounting the piston rings . . . . . . . . . . . .

EW--2--60

Mounting the connecting rod/piston assemblies in the cylinder liners . . . . . .

EW--2--61

Measuring the crankpin assembling play EW--2--61 Checking piston protrusion . . . . . . . . . . .

EW--2--62

Valve timing . . . . . . . . . . . . . . . . . . . . . . .

EW--2--63

Engine flywheel . . . . . . . . . . . . . . . . . . .

EW--2--65

Mounting the oil and water pump . . . . .

EW--2--65

Mounting the water / oil heat exchanger

EW--2--66

Cylinder head . . . . . . . . . . . . . . . . . . . . . .

EW--2--67

Removing the valves . . . . . . . . . . . . . . . .

EW--2--67

Checking cylinder head wet seal . . . . . .

EW--2--68

Checking the cylinder head supporting surface . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--68

INDEX

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--69

Research of top dead centre

Valve descaling, check and grinding . . .

EW--2--69

by tool 380000977 . . . . . . . . . . . . . . . . . .

EW--2--79

Checking clearance between valve stem and valve guide and valve centring . . . . EW--2--69

Check of top dead centre . . . . . . . . . . . .

EW--2--79

Disassembly and assembly . . . . . . . . . .

EW--2--80

Valve guide . . . . . . . . . . . . . . . . . . . . . . .

EW--2--70

Valve seats . . . . . . . . . . . . . . . . . . . . . . .

EW--2--70

Ignition pump control and timing . . . . . .

EW--2--82

Regrinding – replacing the valve seats .

EW--2--70

Feed system bleed procedure . . . . . . . .

EW--2--82

Valve springs . . . . . . . . . . . . . . . . . . . . .

EW--2--71

Replacing the injectors . . . . . . . . . . . .

EW--2--83

Fitting cylinder head . . . . . . . . . . . . . . .

EW--2--72

Refitting the cylinder head . . . . . . . . . . .

EW--2--72

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--83

Rocker arm assembly . . . . . . . . . . . . . . .

EW--2--73

Reassembling . . . . . . . . . . . . . . . . . . . . . .

EW--2--83

Mounting the injectors . . . . . . . . . . . . . . .

EW--2--74

Rocker arm removal/reassembling . .

EW--2--84

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--84

Reassembling . . . . . . . . . . . . . . . . . . . . . .

EW--2--84

Adjusting the tappets . . . . . . . . . . . . . .

EW--2--84

Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . .

EW--2--78

Research of top dead centre by tool 380000988 . . . . . . . . . . . . . . . . . .

EW--2--79

EW--2--3

ENGINE F4CE0354A OVERHAUL ENGINE F4CE0354A Figure 1

90323

EW--2--4

ENGINE F4CE0354A OVERHAUL CODING OF SOURCE ENGINES

F

4

C

E

0

3

5

4

A

*

D

+

Emission level Approved rating Use Feeding / Injection D = TIER 2 Cylinder no.

Cylinder pattern: 0 = 4 strokes, vertical

Engine Type of crankcase: C = structural

3 = 3--cylinder

Group Engines

5 = Direct injection turbo diesel

4 = Earthmovers

X

Y

Y

X = 6 rotary, 2--valve injection pump Y = Engine model

Y

Y

Y

Y

Y

Manufacturing sequence number

Y

EW--2--5

ENGINE F4CE0354A OVERHAUL GENERAL ENGINE FEATURES Type

F4CE0354A *D

Cycle

4--stroke diesel engine

Feeding

Turbocharged

Injection

Direct

Number of cylinders

In--line, 3--cylinder

Bore

mm

104

Stroke

mm

132

Total displacement

cm3

3364

Compression ratio

17.5 : 1

Max. rating

Max. torque

kW min --1

Nm (kgm) min --1

58 2300

310 (31) 1400

No--load idle rpm

min

--1

—

No--load peak rpm

min

--1

—

BOOSTING Type of turbocompressor:

HOLSET HX20W Forced by means of a lobe pump, pressure modulating valve, oil filter

LUBRICATION Oil pressure with hot engine: at idle rpm at peak rpm

bar bar

1.2 3.8

EW--2--6

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

COOLING

By fluid Water pump drive: Thermostat: Start of opening:

Ambra Super Gold 15W40 10W30

REFUELLING Full filling capacity 1q

By means of belt qC litres kg

-- engine sump

litres kg

-- engine sump + filter

litres kg

FEEDING Bosch--type injection

Type of nozzle

Injection sequence

Injection pressure (bar)

—

8 9

VE3 / 12 F 1150 L 947

Pump setting

Start of delivery

81 r 2

—

mm

1 r 0.05

DSLA 145 P1255

1 -- 3 -- 2

260

EW--2--7

ENGINE F4CE0354A OVERHAUL ASSEMBLING PLAY -- SPECIFICATIONS Type

F4CE0354A *D

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

mm

Cylinder liners

1

104.000 to 104.024

Pistons: supplied with standard spares Measurement dimension Outer diameter Pin seat

X 1 2

59 103.730 to 103.748

Piston -- cylinder liners Piston diameter

0.252 to 0.294 1

Position of pistons from crankcase X

Gudgeon pin

3

Gudgeon pin -- Pin seat

Piston ring slots

38.010 to 38.016

0.4 -- 0.8

0.28 to 0.42

37.994 to 38.000

0.004 to 0.016 X1* X2 X3

2.705 to 2.735 2.440 to 2.460 4.030 to 4.050

S1* S2 S3

2.560 to 2.600 2.350 to 2.380 3.970 to 3.990

1 2 3

0.155 to 0.175 0.060 to 0.110 0.040 to 0.080

* measured on of 101 mm Piston rings * measured on of 101 mm Piston rings – Slots

Piston rings

0.4 to 0.8

EW--2--8

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

mm

Piston ring end opening in cylinder liner: X1 X2 X3

0.30 to 0.40 0.60 to 0.80

1 2

40.987 to 41.013 72.987 to 73.013

Connecting rod small--end bushing diameter Outer 4 Inner 3

— 38.019 to 38.033

Connecting rod small--end bushing seat Connecting rod bearing seat

Connecting rod small--end bushing – seat

0.30 to 0.55

—

Gudgeon pin – Bushing

0.019 to 0.039

Measurement dimension

X

—

Max. error on connecting rod axis parallelism

=

—

Journals Crankpins Main half bearings Connecting rod half bearings * supplied with spares Bed supports no.: n. 1--4 n. 2--3

1 2 S1* S2*

82.99 to 83.01 68.987 to 69.013 2.456 to 2.464 1.955 to 1.968

3

87.982 to 88.008 87.977 to 88.013

EW--2--9

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

mm

Half bearings -- journals: n. 1--4 n. 2--3

0.064 to 0.095 0.059 to 0.100

Half bearings -- crankpins

0.033 to 0.041

Main half bearings Connecting rod half bearings

+ 0.250; + 0.500

Shoulder journal

X1

37.475 to 37.550

Shoulder bed support

X2

31.730 to 32.280

Shoulder half rings

X3

37.28 to 37.38

Drive shaft shoulder

0.095 to 0.270

EW--2--10

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

VALVE GEAR – CYLINDER ASSEMBLY

Valve guide seats on cylinder head

mm

1

8.019 to 8.039

4 D 4 D

7.96 to 7.98 60q 7.96 to 7.98

Valves:

Valve stem and respective guide

45q 0.039 to 0.079

Seat on head for valve seat: 1

46.987 to 47.013

1

43.637 to 43.663

2 D 2 D

47.063 to 47.089 60q 43.713 to 43.739 45q

Valve seat outer diameter; inclination of valve seats on cylinder head:

Hollow

Between the valve seat and the head

X

0.356 to 1.102

X

0.104 to 0.840 0.050 to 0.102 0.050 to 0.102

Valve seats

—

EW--2--11

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

VALVE GEAR – CYLINDER ASSEMBLY Valve spring height: free spring under a load of: 329 N 641 N

Injector protrusion

mm

H

63.5

H1 H2

49.02

X

not adjustable

Seat for distributing shaft bushing no. 4 Distributing shaft seats no. 1--2--3

38.20

59.222 to 59.248 54.089 to 54.139

Distributing shaft support pins: 1 4

53.995 to 54.045

Bushing outer diameter for distributing shaft:

—

Bushing inner diameter

54.083 to 54.147

Bushings and seats in crankcase Bushings and support pins

— 0.038 to 0.152

Eccentric working lift: — —

EW--2--12

ENGINE F4CE0354A OVERHAUL

Type

F4CE0354A *D

VALVE GEAR – CYLINDER ASSEMBLY

1

Seat for tappet collar in the crankcase

mm

1

16.000 to 16.030

2 3

15.929 to 15.959 15.965 to 15.980

2 3

Outer diameter of tappet collar:

2

Between the tappets and the seats Tappets

0.020 to 0.065 --

1 Rocker arm shaft

1

18.963 to 18.975

Rocker arms

2

19.000 to 19.026

2 Between the rocker arm and the shaft

0.025 to 0.063

EW--2--13

ENGINE F4CE0354A OVERHAUL TIGHTENING TORQUE PART Cylinder y head fastening g screw 1st p phase:

2nd p phase: 3rdd phase:

screws M12x1.75x70 screws M12x1.75x140 screws M12x1.75x180 (only for screws 140 and 180 mm long)

phase 1st p nd 2 p phase 3rd phase g rod cap p fastening g screws phase Connecting 1st p 2nd p phase rd 3 phase g y g screws p g Engine flywheel fastening pre--tighten Angle Injector fastening Fuel filter Injection pump gear cover fastening screw Valve gear cover and case fastening screw Container fastening screw Intake manifold fastening screw Fuel pump fastening screw Exhaust manifold fastening screw Tappet cover fastening nut Rocker arm support fastening screw Nut for rocker arm adjusting screw Screw fastening the pulley on drive shaft pre--tighten Angle Distributing shaft shoulder plate fastening screw Fan support fastening screw Injection pump fastening screw Fan pulley fastening screw Turbocompressor fastening screw Heat exchanger fastening screw Oil pump and front cover fastening screw Starter motor fastening screw Alternator fastening screw Water pump fastening screw Oil filter Belt stretcher fastening screw p fastening g screws Bed cap

-- Lubrication with oil

TORQUE Nm (kgm) 50 r 5 (5 r 0.5) 40 r 5 (4 r 0.5) 70 r 5 (7 r 0.5) 90q 90q 50 r 6 (5 r 0.6) 80 r 6 (8 r 0.6) 90q 30 r 5 (3 r 0.5) 50 r 5 (5 r 0.5) 60q r 5q 30 r 5 (3 r 0.5) 60q r 5q 60 r 5 (6 r 0.5) contact + 3/4 turn 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 53 r 5 (5.3 r 0.5) 25 r 5 (2.5 r 0.5) 48 r 8 (4.8 r 0.8) 25 r 5 (2.5 r 0.5) 50 r 5 (5 r 0.5) 90q 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 12 r 5 (1.2 r 0.5) 45 r 5 (4.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 55 r 5 (5.5 r 0.5) 45 r 5 (4.5 r 0.5) 25 r 5 (2.5 r 0.5) contact + 3/4 turn 45 r 5 (4.5 r 0.5)

EW--2--14

ENGINE F4CE0354A OVERHAUL TOOLS 380000216

Rocking sling for removing/installing engine

380000220

Compression tool for fitting engine piston (60--125 mm)

380000221

Piston ring removal and refitting pliers (65--110 mm)

380000228

Dial gauge (0--5 mm)

380000301

Assemblies overhaul revolving stand (capacity 1000 daN, torque 120 daN/m)

380000302

Engine valves remover/installer

380000304

Gauges pair for the angular tightening with 1/2” and 3/4” square connection

380000362

Crakshaft lifting tackle

380000364

Comparator holder base for different surveys (use with 380000228)

380000661

Brackets fixing engine to revolving stand 380000301 Bracket fixing engine to revolving stand 380000301 (use with 380000661)

380000663

Tool to remove crankshaft rear gasket

380000664

Crankshaft rear seal installer

380000665

Tool to remove crankshaft front gasket

380000666

Crankshaft front seal installer

380000667

Cramshaft bush assembly and disassembly punch (use with 380000668)

380000668

Handle interchangeable driver

380000669

Tools for removing gaskets

380000670

Remove cartridge filter

380000671

Tool to remove injectors

380000975

Box with valve seat regrinding tools and attachments

380000976

Spring load tester

380000977

Tool to check top dead centre (use with 380001005)

380000988

Flywheel crank handle

380000989

Adapter cylinder compression test (use with 380001006)

380000998

Hand pump to measure pressure and vacuums

380001002

Universal Goniometer/Clinometer

380001003

Square complete for checking connecting rods perpendicularity

380001005

Dial gauge (0--10 mm)

380001006

Diesel engine cylinder compression tester

380001084

Dial gauge holder for rotary injectiion pump timing (use with 380000228)

380001990

Locking PIN

EW--2--15

ENGINE F4CE0354A OVERHAUL GRAPHIC INDICATIONS AND SYMBOLS Detachment Disconnect

Intake

Reattachment Connect

Exhaust

Removing Disassembling

Operation

Mounting Assembling

§

!

¸

Compression ratio

Torque--tighten

Tolerance Weight difference

Torque--tighten + angular value

Dragging torque

Countersink

Replacement Genuine spares

Adjustment Setting

Rotation

Warning Note

Angle Angular value

Visual check Mounting position check

Preload

Measurement Dimension to be measured Check

Revs number

Equipment

Temperature

Surface to be machined Machining finish

bar

Pressure

Interference Forced mounting

Increase Greater than .....

Maximum

Thickness Play

Decrease Smaller than ....

Minimum

Lubricate Moisten Grease

Selection Classes Increases

Sealant

Temperature < 0 qC Cold Winter

Air bleed

Temperature < 0 qC Hot Summer

EW--2--16

ENGINE F4CE0354A OVERHAUL GENERAL REMARKS Figure 2

90324

1. Turbocharger -- 2. Belt tensioner – 3. Fan pulley – 4. Alternator – 5. Fan, alternator and water pump drive belt – 6. Water pump – 7. Pulley on crankshaft – 8. Injection pump – 9. Grid heater – 10. Blow--by

EW--2--17

ENGINE F4CE0354A OVERHAUL DESCRIPTION OF MAIN MECHANIC ENGINE COMPONENTS Drive shaft It is made of steel and rests on four induction--hardened supports.

Inside the drive shaft are the lubricating oil ducts.

The following items are force--fitted on the front shank: oil pump drive gear, damper flywheel and auxiliary component drive pulley.

The following items are force--fitted on the rear shank: distributing shaft drive gear and engine flywheel mounting hub.

The main half bearings are made of steel with anti-friction alloy coating.

The second main half bearing is equipped with a shoulder to restrain the drive shaft end play.

Parts (1) and (3) are mounted in an interfering manner on the rear shank and cannot be replaced.

Figure 3

88723

1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear Drive shaft seal rings The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools 380000665 and 380000663, and mounted by means of tools 380000666 and 380000664.

EW--2--18

ENGINE F4CE0354A OVERHAUL Connecting rods They are steel--stamped, of the oblique cut type, with separation of the cap obtained by an advanced technology (fracture split) instead of mechanic machining.

The connecting rod half bearings are made of steel, with anti--friction alloy coating.

Each connecting rod is marked: - By a number (on the connecting rod body and cap) indicating its respective match and the cylinder in which it is mounted.

- By a letter (on the connecting rod body) indicating the weight class of the factory--assembled connecting rod.

Figure 4

84038

EW--2--19

ENGINE F4CE0354A OVERHAUL Pistons The combustion chamber is found on the piston crown. The crown is cooled by the engine oil delivered by the nozzle fitted to the crankcase.

Three slots (piston ring seats) are provided: the first one and the second one are obtained from a cast-iron insert with trapezoidal section.

The piston rings carry out different functions and have different shapes.

Piston ring 1 and 2, trapezoidal in shape and with ceramic chrome coating.

Ring 3, with double scraper ring shoe with inner spring.

The identification number and manufacturing data (1) are shown on the piston crown.

Figure 5

88724

EW--2--20

ENGINE F4CE0354A OVERHAUL Distributing shaft The distributing shaft rests on five supports in the crankcase.

The supports (front and rear) are equipped with steel bushings mounted in an interfering manner and coated with anti--friction material; two control eccentrics are provided for each cylinder.

A. Intake valve control B. Exhaust valve control The distributing shaft is controlled directly by the drive shaft by means of straight--tooth gears.

Figure 6

70164

88725

EW--2--21

ENGINE F4CE0354A OVERHAUL Valve control Figure 7

88726

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring – 8. Tappet – 9. Distributing shaft

EW--2--22

ENGINE F4CE0354A OVERHAUL Cylinder head The seats of the following parts are obtained from the cast--iron cylinder head: - inserted valve seats (4); - injector (6); - thermostat (5).

Moreover, the following components are inserted on the heads: - single--block exhaust manifold (1); - intake manifold (2) with seat for cold start air heater (3).

Figure 8

88727

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--23

ENGINE F4CE0354A OVERHAUL Valves and valve seats Figure 9

88728

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side The valve seats inserted on the cylinder head have the following inclination: - 45q (exhaust valves) - 60q (intake valves).

The exhaust valves (2) differ from intake valves in that they have only one notch at the stem end.

Figure 10

88729

Figure 10 shows the oil seals mounted on valve stems.

EW--2--24

ENGINE F4CE0354A OVERHAUL Valve guides Figure 11

INTAKE

EXHAUST 84046

DETAIL OF VALVE GUIDES AND SEATS

EW--2--25

ENGINE F4CE0354A OVERHAUL Engine flywheel The flywheel needs a fixed position on the engine shaft because a reference hole is made on it.

Figure 12

86454

1. Flywheel -- 2. Fixing screws

EW--2--26

ENGINE F4CE0354A OVERHAUL Auxiliary component drive A Poly--V belt (5) transmits the motion of drive shaft to water pump (4), alternator (2) and fan pulley (3).

The belt is stretched by means of belt tensioner (1).

Figure 13

90325

1. Belt tensioner -- 2. Alternator -- 3. Fan pulley -- 4. Water pump -- 5. Poly--V belt

EW--2--27

ENGINE F4CE0354A OVERHAUL LUBRICATION Forced circulation lubrication is performed by the following components: - oil lobe pump fitted in the front part of the basement, driven by the splined bush, keyed on the hold of the engine drive shaft;

- water / oil heat exchanger housed in the crankcase; - oil pressure regulating valve incorporated in the oil filter support; - bypass valve for bypassing the clogged oil filter, in the oil filter support; - cartridge--type oil filter.

Figure 14

Pressure oil path Oil return drop--type path

87397

EW--2--28

ENGINE F4CE0354A OVERHAUL Heat exchanger Figure 15

88732

1. Heat exchanger body – 2. Inner gasket – 3. Spacer -- 4. Water / oil heat exchanger

EW--2--29

ENGINE F4CE0354A OVERHAUL Oil pump Figure 16

88733

1. Rotating shaft seal -- 2. Oil pump -- 3. Seal

EW--2--30

ENGINE F4CE0354A OVERHAUL Oil sump The oil sump (1) is fixed with screws to the base and is used as a flywheel covering box.

A seal (2) is inserted between the base and the oil sump, it is divided in four parts: a front part, a rear part and two side parts in other words it assures better seal and dampens the noise.

Figure 17

90326

1. Oil sump -- 2. Seal

EW--2--31

ENGINE F4CE0354A OVERHAUL Oil vapour recirculation Oil vapour recirculation takes place by means of valve (1) placed above the tappet cover (2).

The vapour condensed therein fall below the tappet cover (2) due to gravity, whereas the remaining vapour is recovered by vent (3) and properly conveyed to the intake phase.

Figure 18

84056

EW--2--32

ENGINE F4CE0354A OVERHAUL COOLING The engine cooling system is of the forced, closed-circuit circulation type and is made up of the following components:

- centrifugal water pump, housed in the crankcase front part;

- heat exchanger, to cool the lubricating oil;

- thermostat, to regulate coolant flow.

Figure 19 TO RADIATOR

FROM RADIATOR

87398

Water flowing out of the thermostat Water recirculating in the engine Water flowing into the pump

EW--2--33

ENGINE F4CE0354A OVERHAUL Water pump The water pump is housed in a seat obtained from the crankcase and is controlled by means of a poly--V belt.

The nearly total absence of outer pipes, sleeves and clamps eliminates many connections, thus reducing possible leak points.

The engine temperature is controlled by a thermostat.

The coolant flows also in the oil heat exchanger.

Figure 20

84058

Figure 21

84059

EW--2--34

ENGINE F4CE0354A OVERHAUL MECHANICAL INJECTION SUPPLY SYSTEM FUEL FILTER The filter is positioned next to the supply and priming pump, it holds impurities and separates the water container in the fuel.

On the base of the filtering cartridge there is a water discharge screw for periodical discharging.

Figure 22

88210

1. Fuel filter support -- 2. Filtering cartridge -- 3. Water discharge screw

EW--2--35

ENGINE F4CE0354A OVERHAUL Mechanic fuel pump Displacement pump mounted on the engine left side; it is used to feed the injection pump and is controlled by the distributing shaft.

Figure 23

84249

1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank

Figure 24

88209

1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--36

ENGINE F4CE0354A OVERHAUL INJECTION ASSEMBLY

Figure 25

87400

1. Injector fuel pipe -- 2. Fuel exhaust pipes from injectors -- 3. Fuel feed rotary pump -- 4. Connector for LDA pressure gauge pipe within suction collector -- 5. KSB thermal bulb -- 6. Electro--valve -- 7. Injector

EW--2--37

ENGINE F4CE0354A OVERHAUL ENGINE BENCH--OVERHAUL

Figure 28

Disassembling the engine Figure 26

87744 87683

In order to apply the brackets 380000661 the engine block to fix it on to the stand 380000301 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disassemble lubrication oil exhaust pipe (2) from the turbo--blower: Underneath the turbo--blower loosen the screws (1); finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo--blower.

On the left hand side: - assemble the second bracket 380000661 throughout the screw--threaded ports (1).

- Lift the engine using the rocker arm 380000216 and put it on the turning stand 380000301.

- Drain the oil through the cap underneath the plug.

Figure 29

- oil level rod (4);

1

- oil filter (3).

Figure 27

75675

Proceed disassembling the supercharger:

87712

- Disassemble the starter; properly hold the starter (2) and loosen the two fixing screws (1); assemble the supporting bracket 380000661 using the threaded ports on the block.

- Loosen the fixing nut (1) and remove the lubrication pipe from the turbocharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger.

- Loosen the screw nuts fixing the supercharger on the exhaust manifold.

- Hold up the turbocharger and after lifting it remove the gasket.

EW--2--38

ENGINE F4CE0354A OVERHAUL Figure 30

Figure 32

4 3 1

2 1

87404 87405

- Place a container under the fuel filter and screw out the condense drain cap underneath said filter. Carry out complete drainage of the fuel contained therein.

- Screw out completely the faucet and, using equipment 380000670 disassemble fuel filter (1).

- Disconnect fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump.

- Remove the fuel filter bracket (4) from the bracket fixed to the engine head.

Figure 31

Disconnect the LDA pipe (1) from the head and from the feed pump. Pipe the ends of the pipelines as well as the feed pump and the engine head.

Figure 33

87406

Remove tappet caps: loosen the fixing screws (1) and lift the caps (2); remove the gaskets.

70126

Act on fork (1) as shown in the figure (detail A), then remove the adapter. To avoid damaging the same, bring fork (1) back to the locking position (detail B) after adapter hes been removed.

IMPORTANT -- On the central cap there is a blow--by valve for the lubrication oil vapours.

All the gaskets shall always be replaced during assembly.

EW--2--39

ENGINE F4CE0354A OVERHAUL Removal of compensating units

Figure 34

Figure 36 2

1 87407

- Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines; pipe the pipeline ends.

75683

- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods.

Repeat the operation for all the remaining rocker arm bearings.

- Disassemble water temperature transmitter (1).

Figure 37

- Disassemble the injectors and remove them from their slot: remove the gaskets.

Figure 35

87410

Loosen the two fastening screws (2) and remove the priming pump (1).

87409

Disassemble suction and exhaust manifolds: loosen the screws (1) fixing the suction manifold plate to the cylinder head; from the exhaust manifold side, loosen the eight (2) fixing screws; remove the gaskets.

For dismounting the injection pump, see what described at page EW--2--78 in Rotary feed pump disassembly and assembly procedure.

EW--2--40

ENGINE F4CE0354A OVERHAUL Figure 38

Figure 41

87411

- Loosen the screw (1) adjusting the belt tightening pulley in order to release the belt (2) until enabling to withdraw it from the convey and drive pulleys.

- Remove the belt tightening pulley (3).

87414

Loosen the screws (1) and withdraw the alternator bearing (2).

Figure 42

Figure 39

87412

Disassemble thermostat unit; loosen the three fixing screws (1), disassemble the thermostat unit (2) and remove the gasket (3) and the thermostat (4).

87415

- Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2), the interlayer plate and remove the relating gaskets.

- Disassemble injection pump (see specific procedure) and the power take--off underneath (if available).

Figure 43

Figure 40

87416

87413

Duly hold the alternator (2) removing it from its support by loosening the screw (3) and from the bracket by loosening the screw (1); recover nuts and washers.

- Loosen the four screws (1) and disassemble the pulley (2) from the bearing underneath.

- Proceed disassembling the bearing.

EW--2--41

ENGINE F4CE0354A OVERHAUL Figure 44

Figure 46

87417

Disassemble the cylinder head: - loosen the fastening screws (1) and (2) remove the cylinder head (3); - remove the sheath (4).

Hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.

Figure 45

87418

- Loosen the screws (1) and withdraw water pump (2).

- Loosen the screws (3) and remove the pulley (4).

Replacing the seal ring Figure 47

87747

- Use the tool 380000988 to operate on the flywheel cover box (1) in order to block flywheel rotation (2).

- Loosen the flywheel fixing screws (3) to engine drive shaft.

78256

Apply tool 380000665 (4) on drive shaft front shank (2).

Drill inner seal ring (1), through tool 380000665 (4) guide holes, with an inset ( 3.5 mm) down to a depth of 5 mm.

Secure tool 380000665 (4) to ring (1) by screwing the 6 screws (5) provided.

Take off ring (1) by fastening screw (3).

EW--2--42

ENGINE F4CE0354A OVERHAUL Figure 48

Figure 50

78257

Apply the proper tension rod (3) of tool 380000669 to outer seal ring (2) as shown in the figure, then take the same off front cover (1) by means of lever (4).

Remove the front cover.

87420

- Screw out the opposite screws (1) from the ports and introduce the withdrawal pins (see picture following).

Figure 49

- Loosen remaining flywheel fixing screws (3) to the engine drive shaft (2).

- Remove the flywheel block tool (2).

Figure 51

87419

- Loosen the screws (2) and remove the front cover (1).

- Remove the gasket.

IMPORTANT -- Take note of the screw (2) assembly position, since the screws have different length.

87421

Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist.

Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.

EW--2--43

ENGINE F4CE0354A OVERHAUL Figure 52

Figure 54

87422 78258

Apply tool 380000663 (3) on drive shaft rear shank (5).

Loosen the screws (2) and remove the flywheel cover box (1).

Drill inner seal ring (1), through tool 380000663 (3) guide holes, with an inset ( 3.5 mm) down to a depth of 5 mm.

IMPORTANT -- Take note of the screw (2) assembly position, since the screws have different length.

Secure tool 380000663 (3) to ring (1) by fastening the 6 screws (4) provided.

Take off ring (1) by fastening screw (2).

Figure 55

Figure 53

87423

78257

Apply the proper torsion bar (3) of tool 380000669 to outer seal ring (2) as shown in the figure, then take the same off flywheel cover case (1) by means of lever (4).

- Turn the engine upside--down.

- Loosen the screws (2), take out the oil sump (1) keep the seals.

EW--2--44

ENGINE F4CE0354A OVERHAUL Figure 56

Figure 59

70159

87655

Remove the gear (1) transmitting motion to the ignition pump and the relevant support.

Remove screws (1) and take off bed caps (2).

Figure 60

Figure 57

70160

87424

Remove the screws (1) and disassemble the gears (3) and (4) from the camshaft (2).

Figure 58

The penultimate bed cap (1) and its respective support have half bearing (2) provided with shoulder.

IMPORTANT -- Take note of the mounting position of lower and upper half bearings; in fact, if they have to be used again, they must be mounted in the same position they had prior to being taken off.

Figure 61

70158

Remove connecting rod cap (2) fastening screws (1), then take off the caps.

Remove the pistons (complete with connecting rods) from the crankcase upper part.

IMPORTANT -- Half bearings must be kept in their respective housings; in fact, if they have to be used again, they must be mounted in the same position they had prior to being taken off.

87722

Remove the output shaft (1) from the block.

EW--2--45

ENGINE F4CE0354A OVERHAUL Figure 62

Figure 65

70165 70162

Remove tappets (1) from the engine crankcase.

Take off main half bearings (1).

Remove screws (2) and take off oil nozzles (3).

Figure 63

REPAIR WORK ON CYLINDER CLUSTER Checks and measurements After the engine has been dismantled, clean the crankcase--cylinder cluster thoroughly.

70163

Use proper rings to move the cylinder cluster.

Check the crankcase carefully for cracks.

Remove screws (1) and take off distributing shaft (3) retaining plate (2).

IMPORTANT -- Take note of plate (2) mounting position.

Figure 64

70164

Carefully remove the distributing shaft from the crankcase.

Check the condition of working caps. They must be replaced if they are rusty or their sealing properties are in doubt.

Inspect the cylinder liner surfaces; they must not show traces of seizing, scoring, out--of--roundness, taper and excessive wear.

EW--2--46

ENGINE F4CE0354A OVERHAUL Figure 66

Figure 68

70166

The check of cylinder liner inner diameter (in order to measure the amount of out--of--roundness, taper and wear) is carried out by means of bore gauge (1) equipped with a comparator previously reset on the ring gauge (2) of the cylinder liner diameter.

-

§

NOTE – If no ring gauge is available, use a micrometer to perform reset.

Figure 67

87753

IMPORTANT -- In case of reconditioning, all the liners must be machined to the same increase (0.4 -0.8 mm).

Check the main bearing seats as follows:

70167

Measurements must be taken for each single cylinder, at three different heights of the liner and on two planes perpendicular to each other: one parallel to the engine longitudinal axis (A), the other perpendicular (B); the greatest amount of wear is usually found on the latter plane and during the first measurement.

When detecting out--of--roundness, taper or wear, the cylinder liners must be bored and refaced. Cylinder liner reconditioning must be performed with regard to the spare piston diameter increased by 0.5 mm of the rated value, and to the prescribed assembling play.

- mount the bed caps on the supports without bearings; - tighten the fastening screws to the specified torque; - check, by means of an adequate internal comparator, that the seat diameter is the same as the specified value.

If a greater value is found, replace the crankcase.

Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit.

Planarity error shall not exceed 0.075 mm.

Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.

EW--2--47

ENGINE F4CE0354A OVERHAUL VALVE GEAR Distributing shaft Figure 69

87723

MAIN FEATURES OF DISTRIBUTING SHAFT The features given below refer to the normal diameter of pins

The shaft support pin and eccentric surfaces must be perfectly smooth; if, on the contrary, they show traces of seizing and scoring, it is advisable to replace the shaft and its respective bushings.

Figure 70

Checking the pin alignment Place the shaft on back centres and check, by means of a centesimal comparator placed on the middle support, that the alignment error is not greater than 0.04 mm; otherwise, replace the shaft.

70171

Check the diameter of distributing shaft support pins (2) by means of a micrometer (1) on two axes perpendicular to each other.

EW--2--48

ENGINE F4CE0354A OVERHAUL BUSHINGS

Figure 71

The distributing shaft bushings (2) must be force-fitted into their respective seats.

The inner surfaces must show no traces of seizing or wear.

Use bore gauge (3) to measure the diameter of front and rear bushings (2) and of distributing shaft intermediate seats (1).

Measurements must be taken on two axes perpendicular to each other.

70172

Figure 72

87724

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS * Dimension to be obtained after driving the bushings

EW--2--49

ENGINE F4CE0354A OVERHAUL Replacing the bushings

Mounting the tappets – Distributing shaft

Figure 73

Figure 75

70174

70176

To replace front and rear bushings (1), use beater 380000667 (2) and handle 380000668 (3) to remove and reassemble the bushings.

Lubricate tappets (1) and fit them to their respective seats of the crankcase.

IMPORTANT -- Bushings (1) must, upon mounting, be turned in such a way that the lubricating holes match with the holes available on the crankcase seats.

Tappets Figure 76

Figure 74

84053

MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE SEATS ON THE CRANKCASE

70164

Lubricate the distributing shaft support bushings and mount distributing shaft taking care not to damage the bushings or supporting seats during operation.

EW--2--50

ENGINE F4CE0354A OVERHAUL Figure 77

Figure 79

70238

70180

Place distributing shaft (3) retaining plate (1) with the slotted hole facing the crankcase upper side and the stamping facing the operator, then fasten screws (2) to the specified torque.

Mount nozzles (2) and tighten fastening screws (1) to the specified torque.

DRIVE SHAFT Measuring the journals and crankpins

Figure 78

Figure 80

70179 70182

Check the distributing shaft end play (1).

If traces of excessive seizing, scoring or out--of-roundness are found on journals and crankpins, it is necessary to reface the pins by grinding. Prior to grinding pins (2), measure the journals by means of a micrometer (1) so as to determine the amount (diameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured values on a table.

See Figure 81.

EW--2--51

ENGINE F4CE0354A OVERHAUL Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must always be ground to the same reduction class.

The reduction carried out on journals and crankpins must be marked with a special stamping made on the side of crank arm 1.

For reduced crankpins, use letter M. For reduced journals, use letter B. For reduced crankpins and journals, use letters MB.

Figure 81

87726

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE WRITTEN DOWN * Rated value

EW--2--52

ENGINE F4CE0354A OVERHAUL Figure 82

87727

TOLERANCES SHAPE

DIRECTION POSITION OSCILLATION

TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL

/ / //

GRAPHIC SYMBOL

CRITICAL

¤

IMPORTANT

ĭ

SECONDARY

Figure 83

87728

EW--2--53

ENGINE F4CE0354A OVERHAUL Replacing the oil pump drive gears

Measuring the journal assembling play

Figure 84

Figure 86

87741

Verify that the teeth of gear (1) force--fitted on drive shaft (2) are not damaged or worn; otherwise, proceed with removal by means of a suitable extractor (3).

87722

Mount the drive shaft (1).

When fitting the new gear, the latter must be heated for 6 minutes in a small furnace at a temperature of 160 qC and force--fitted onto the drive shaft by putting the key in between.

Mounting the main bearings Figure 87

Figure 85

70185

IMPORTANT -- If main bearings do not need replacing, they must be fitted in the same order and positions they had when removed.

Main bearings (1) are supplied as spares reduced on their inner diameter by 0.250 – 0.500 mm.

IMPORTANT -- No matching operation must be carried out on bearings.

Clean thoroughly the main half bearings (1) provided with lubrication holes, then fit them to their seats.

The penultimate main half bearing (1) is provided with shoulder half rings.

70186

Check the play between the drive shaft journals and their respective bearings by following the procedure below: - clean thoroughly the parts and eliminate traces (if any) of oil; - place a piece of gauged wire (3) (parallel to the longitudinal axis) on drive shaft pins (4); - mount caps (1), complete with half bearings (2), on their respective supports.

EW--2--54

ENGINE F4CE0354A OVERHAUL Figure 88

Figure 90

70187

Fasten pre--lubricated screws (1) by tightening them in three subsequent phases.

- 1st phase with a torque wrench at 50 r6 Nm. - 2nd phase with a torque wrench at 80 r6 Nm.

70189

- Take the caps off the supports.

The play between the main bearings and their respective pins can be measured by comparing the width taken on by gauged wire (2) at the point where it is flattened most, with the scale graduation shown on gauged wire envelope (1).

The numbers shown on the scale indicate the matching play (mm).

If the measured play is different from the specified one, replace half bearings and repeat the check; once the prescribed play has been obtained, lubricate main bearings and mount the supports definitely by tightening the fastening screws as described above.

Checking the drive shaft shoulder play Figure 89

Figure 91

§

70188

70190

- 3rd phase with tool 380000304 (1) placed as shown in the figure: tighten screws (2) further to an angle of 60q r5q.

The shoulder play is checked by placing a magnetic comparator (2) on drive shaft (3) as shown in the figure: normal assembling play is 0.068 to 0.410 mm.

If a greater play is found, replace the main thrust half bearings of the penultimate support (1), then check again the play between the drive shaft pins and the main half bearings.

EW--2--55

ENGINE F4CE0354A OVERHAUL CONNECTING ROD--PISTON ASSEMBLY Figure 92

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY 1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -6. Half bearings -- 7. Connecting rod -- 8. Bushing NOTE -- Pistons are supplied as spares increased by 0.5 mm.

Figure 93

Figure 94

32613

Taking piston rings (1) off piston (2) by means of pliers 380000221 (3).

32614

The piston rings (2) retaining the piston pin (1) are removed by means of a mark scraper (3).

EW--2--56

ENGINE F4CE0354A OVERHAUL Figure 95

87730

MAIN DATA OF PISTON

Pistons Measuring the piston diameter Figure 96

Figure 97

84096

Measuring the piston diameter (1) by means of a micrometer (2) to determine the assembling play.

NOTE -- The diameter must be measured 58 mm far from the piston skirt base.

70192

The play between the piston and the cylinder liner can also be measured by means of a thickness gauge (1) as shown in the figure.

EW--2--57

ENGINE F4CE0354A OVERHAUL Gudgeon pins

Figure 101

Figure 98

84097

Measuring the gudgeon pin diameter (1) by means of a micrometer (2).

84100

Use a thickness gauge (1) to check the play between the seal rings (3) of the 3rd slot and the respective seats on piston (2).

Conditions for correct pin/piston matching Figure 99

Figure 102 84098

Lubricate pin (1) and its respective seat on piston hubs with engine oil; the pin must be inserted into the piston by pressing with your fingers slightly and must not come out of the same due to gravity.

Piston rings Figure 100

84101

84099

Check the thickness of seal rings (2) by means of a micrometer (1).

SCHEME FOR MEASURING PLAY X FOR THE TRAPEZOIDAL RING Due to the peculiar shape of the first trapezoidal cross-sectioned seal ring, the play between the slot and the ring itself must be measured as follows; allow piston (1) to protrude from the crankcase so that ring (2) at issue comes out of about half from cylinder liner (3).

In this position, check, by means of a thickness gauge, the play (X) between the ring and the slot: it must correspond to the specified value.

EW--2--58

ENGINE F4CE0354A OVERHAUL Figure 103

Figure 105

CONNECTING ROD BODY

70194

Measuring the play between the ends of piston rings (2) inserted into cylinder liner (3), by means of a thickness gauge (1).

CONNECTING ROD NO.

WEIGHT

Connecting rods Figure 104

CONNECTING ROD CAP CONNECTING ROD CAP * *

YEAR

DAY

*

88730

IMPORTANT -- Each connecting rod is marked as follows:

70195

MAIN DATA OF CONNECTING ROD, GUDGEON PIN BUSHING AND HALF BEARINGS * Dimension of inner diameter to be obtained after driving into the connecting rod small--end and refacing by means of a reamer. ** This dimension cannot be measured in a free state.

IMPORTANT -- The connecting rod--connecting rod cap matching surfaces are knurled to ensure better match.

Therefore, it is recommended not to remove knurls.

- By a number (on the body and cap) which indicates the connecting rod match and the cylinder on which it is mounted. In case of replacement, it is therefore necessary to number the new connecting rod with the same number as the replaced one.

- By a letter (on the connecting rod body) which indicates the weight class of the factory--assembled connecting rod: -- V, 1600 to 1640 (marked in yellow); -- W, 1641 to 1680 (marked in green); -- X, 1681 to 1720 (marked in blue).

Replacement rods are supplied class W and marked in green *.

Material removal is not permitted.

EW--2--59

ENGINE F4CE0354A OVERHAUL Bushings

Checking the torsion

Verify that the bushing in the connecting rod small-end is not loosened and does not show traces of scoring or seizing. Otherwise, replace it.

Figure 107

Removing and reassembling are carried out with the same suitable beater.

When driving, take the greatest care that the holes allowing oil to flow onto the bushing and the connecting rod small--end correspond to each other. Use a reamer to reface the bushing so as to obtain the required diameter.

Checking the connecting rods Figure 106

61694

Check connecting rod torsion (5) by comparing two points (A and B) of pin (3) on the horizontal plane of the connecting rod axis.

Place comparator (2) support (1) so that the comparator is preloaded by a 0.5 mm on pin (3) at point A, then set comparator (2) to zero. Move spindle (4) with connecting rod (5), then compare the deviation (if any) on opposite side (B) of pin (3): the difference between A and B must not be greater than 0.08 mm.

Checking the flexion Figure 108

61696

Check the parallelism of connecting rod axes (1) by means of device 380001003 (5). Proceed as follows: - mount connecting rod (1) on tool 380001003 (5) spindle, then secure it by means of screw (4); - place spindle (3) on V--shaped block squares by putting connecting rod (1) on stop bar (2).

61695

Check connecting rod flexion (5) by comparing two points C and D of pin (3) on the vertical plane of the connecting rod axis. Place comparator (2) vertical support (1) so that the comparator rests on pin (3) at point C. Swing the connecting rod to and fro, looking for the highest position of the pin; under such condition, set comparator (2) to zero. Move the spindle with connecting rod (5) and repeat the highest point check on opposite side (D) of pin (3). The difference between points C and D must not be greater than 0.08 mm.

EW--2--60

ENGINE F4CE0354A OVERHAUL Fitting connecting rod--piston assembly

Figure 111

Connecting rod--piston coupling Figure 109

72705

Insert pin (1) fastening piston rings (2).

87731

The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Date of production (only for pistons of supercharged engines); 4. Marking showing 1st slot insert testing.

Mounting the piston rings Figure 112

Figure 110

84093

Use pliers 380000221 (3) to fit piston rings (1) on piston (2).

The rings must be mounted with the writing “TOP” facing upwards; moreover, the ring apertures must be turned in such a way that they are offset to each other by 120q.

87732

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers marked on the connecting rod (5) are read as shown in the figure.

IMPORTANT -- Spare piston rings are supplied in the following dimensions: -- standard, marked with yellow paint; -- increased by 0.5 mm, marked with yellow/green paint.

EW--2--61

ENGINE F4CE0354A OVERHAUL Figure 113

Figure 115

87733 70200

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

DIAGRAM FOR CONNECTING ROD--PISTON ASSEMBLY FITTING INTO BARREL

IMPORTANT -- If connecting rod bearings do not need replacing, they must be fitted in the same order and positions they had prior to being taken off.

- Split ring openings shall be displaced with each other by 120q; - connecting rod--piston assemblies shall have the same weight;

No matching operation must be carried out on half bearings.

Mounting the connecting rod/piston assemblies in the cylinder liners

- the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

Measuring the crankpin assembling play

Figure 114

Figure 116

70201 70203

Lubricate thoroughly the pistons, including the piston rings and the cylinder liner inside.

The play can be measured by following the procedure below:

Use band 380000220 (2) to mount the connecting rod--piston assemblies (1) into the cylinder liners; moreover, verify that:

- clean thoroughly the parts and eliminate any trace of oil;

- the number of each connecting rod corresponds to the cap matching number.

- place a piece of gauged wire (2) on drive shaft pins (1); - mount the connecting rod caps (3) with their respective half bearings (4);

EW--2--62

ENGINE F4CE0354A OVERHAUL Figure 117

Figure 120

70204

- tighten screws (1) (previously lubricated with engine oil) to the specified torque by means of a torque wrench (2).

70207

If the measured play is different from the specified one, replace half bearings and repeat the check.

Once the specified play has been obtained, lubricate the connecting rod half bearings and mount them definitely by tightening the connecting rod cap fastening screws as described.

Figure 118 §

IMPORTANT -- Prior to mounting the connecting rod cap fastening screws definitely, verify that the diameter of the same (as measured at the middle of the thread length) is not smaller than 0.1 mm of the diameter measured at about 10 mm from the screw end.

70205

- Apply tool 380000304 (1) on the compass wrench, then tighten screws (2) further in a criss-cross sequence.

Figure 119

Check manually that connecting rods (1) run axially on the drive shaft pins, and that the end play of the same (as measured by means of a thickness gauge (2) is 0.250 to 0.275 mm.

Checking piston protrusion Figure 121

70206

- Take off the cap and calculate the existing play by comparing the width of gauged wire (1) with the scale graduation shown on the wire envelope (2).

70208

After the connecting rod--piston assemblies have been mounted, check, by means of comparator 380000228 (1) equipped with base 380000364 (2), the protrusion of pistons (3) at the top dead centre relative to the crankcase upper plane.

Said protrusion must be 0.18 to 0.42 mm.

EW--2--63

ENGINE F4CE0354A OVERHAUL Valve timing

Figure 124

Figure 122

87653

70211

Mark, with a felt--tip pen, the tooth of drive gear (1) mounted on drive shaft (2), the side surface of which bears a stamped notch (o) for timing.

- Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is included in the range between 0,076 -0,280 mm.

Figure 125

Figure 123

87654 87652

Orient the engine drive shaft (3) and the camshaft (4) ensuring that while assembling the conveyed gear (1) on the latter, the marks printed on the gears (1 and 2) coincide.

- Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed pair.

Figure 126

87655

- Spline the gear (1) transferring motion to the ignition pump.

EW--2--64

ENGINE F4CE0354A OVERHAUL Figure 127

Figure 129

87656

- Fit the power take--off gear (2) (if available) into the specially provided housing and fasten the screws (1).

Figure 128

87658

- Re--assemble the box (1) to the engine basement.

- Tighten the fastening screws (2) to the same position detected before disassembly.

IMPORTANT -- Before assembly, always check that the threads of the ports and of the screws have no evidence of wear and tear or dirt.

Figure 130

87657

DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.

87659

Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones.

- Apply to the rear tongs hold (3) of the engine drive shaft the part (6) of the tool 380000664, fix it with the screws (1) and spline the new tight ring to it (2).

Any eventual imperfection shall be correct as soon as possible.

- Place the part (5) on the part (6), tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.

Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages.

After having completed seal application, the joints must be immediately assembled (10--20 minutes time).

EW--2--65

ENGINE F4CE0354A OVERHAUL Figure 134

ENGINE FLYWHEEL Figure 131

§

87663

87660

- Check the laying surface (1) of the clutch disk: if it is scratched proceed with facing.

Tighten the engine flywheel (1) fixing screws (2) in two phases:

- Check the tooth conditions of the toothed rim (2), replace it in case of broken tooth or excessive wear. Fit the new one, previously heated at the temperature of 150 qC for 15’y20’.

- 1st phase; tightening by means of dynamometric wrench to couple 30 4 Nm; - 2nd phase, 60º 5º angle dwell.

Figure 132

IMPORTANT -- Angle dwell shall always be performed using 380000304 tool.

Mounting the oil and water pump Figure 135

87661

- Screw tighten two pins (2) of appropriate length into the ports of the engine drive shaft (3) and assemble the engine flywheel (1) using the specially provided sling.

Figure 133

87664 - Fit the sheath.

- Assemble the oil pump (1).

- Fit the fastening screws (2) and tighten them.

Figure 136

87662

- Spline the flywheel (1) on the engine drive shaft by tightening the screws (2) manually.

- Duly lock the flywheel before proceeding with tightening the relevant screws to the prescribed pair.

87665

- Arrange the new seals on the base.

- Assemble the oil pan (1).

- Fit the screws (3) and tighten them to the prescribed pair.

- Tighten the exhaust caps (2) to the prescribed pair.

EW--2--66

ENGINE F4CE0354A OVERHAUL p

Figure 137

Figure 140

87666 87668

- Fit part (4) of the tool 380000666 on the front tang (3) of the engine drive shaft; fasten it with the screws (5) and spline the new tight ring on it (6).

- Fit part (1) on part (4), screw--tighten the nut (7) until the assembly of the tight ring (6) into the front cover (2) is completed.

- Assemble the water pump (1).

- Tighten the screws (2) and lock them to the prescribed couple.

Mounting the water / oil heat exchanger Figure 141

Figure 138

87415 87667

Spline the pulley (2) on the engine drive shaft and tighten the screws to the prescribed pair and angle (1).

- Assemble the following elements to the block: heat exchanger (2), new gasket, oil filter bearing.

Tighten the screws (1) and lock them to the prescribed couple.

Figure 142

Figure 139

87669

70221

Apply to the water pump (1) a new fixing ring (2).

- Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3).

- Manually start the oil filter (3) on the bearing union (1) until counter--boring, further screw up the oil filter (3) by 3/4 turn.

EW--2--67

ENGINE F4CE0354A OVERHAUL Figure 143

Figure 146

1

2 3 4 6

5 75751

87414

Fit the alternator support (1) and tighten the screws (2) fastening them to the prescribed pair.

Figure 144

Valve removal shall be performed using tool 380000302 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4).

Repeat this operation for all the valves.

Overturn the cylinder head and withdraw the valves (5).

IMPORTANT -- Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position.

Figure 147

87676

2

Fit the bracket (1) back to fix the alternator (2) to the engine basement. Tighten the screws (3) fastening the alternator to the support.

Cylinder head Removing the valves Figure 145

1 75752

Remove sealing rings (1 and 2) from the valve guide.

90331

Intake (1) and exhaust (2) valves have heads with the same diameter.

EW--2--68

ENGINE F4CE0354A OVERHAUL Checking cylinder head wet seal

Checking cylinder head supporting surface

Figure 148

Distortion found along the whole cylinder head shall not exceed 0.10 mm.

If higher values are found grind the cylinder head according to values and indications shown in the following figure.

Figure 149

A

B

87736

This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90qC and 2 to 3 bar pressure.

87735

Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting.

The rated thickness A for the cylinder head is 95 r0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm.

IMPORTANT -- Prior to mounting the caps, apply water--repellent sealant on the sealing surface of the same.

IMPORTANT -- After regrinding, check valve sinking and regrind valve seats if required, to obtain the required value.

If leaks are detected from the cylinder head, the latter must be replaced.

EW--2--69

ENGINE F4CE0354A OVERHAUL VALVES

Figure 152

Figure 150 INTAKE VALVE

EXHAUST VALVE

18882

Check the valve stem (1) using a micrometer (2), it shall be 7.960 -- 7.980.

87737

MAIN DATA OF INTAKE AND EXHAUST VALVES Valve descaling, check and grinding Figure 151

Checking clearance between valve stem and valve guide and valve centering Figure 153

87738 84186

Remove the carbon deposits from the valves by means of the special metal brush.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 -- 0.092 mm.

Verify that the valves do not show traces of seizing, crimping or burns.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm.

Reface, if necessary, the valve seats by means of a grinder 380000975, by removing as less material as possible.

EW--2--70

ENGINE F4CE0354A OVERHAUL VALVE GUIDE

VALVE SEATS

Figure 154

Regrinding – replacing the valve seats Figure 155

90327

Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool 380000975 (1) according to the angle values shown in Figure 156.

INTAKE

EXHAUST 84046

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

Figure 156

88368

VALVE SEAT MAIN DATA (dimensions in mm) A = exhaust valve B = intake valve

EW--2--71

ENGINE F4CE0354A OVERHAUL Figure 157

88369

VALVE SEAT HOUSING MAIN DATA (dimensions in mm) A = exhaust valve B = intake valve If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By using the same tool 380000975 (1, Figure 155) and taking care not to indent the cylinder head, remove as much material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.

Heat the cylinder head to 80 to 100 qC, then mount the new valve seats (previously cooled) onto the head by means of a suitable beater.

Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 156.

VALVE SPRINGS Figure 158

Figure 159

50676

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use tool 380000976 to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.

87740

After regrinding, check that valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

Height

Under a load of

mm

N

H (free) 63,50

no load

H1

49,02

P1

329

H2

38,20

P2

641

EW--2--72

ENGINE F4CE0354A OVERHAUL Refitting the cylinder head

FITTING CYLINDER HEAD Figure 160

3

Figure 162

1

1 2 87670

75759

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

Fit the sealing rings (2 and 3) on the valve guide.

Figure 161

1

2 3

Check that the of cylinder head connection surface and the basement are clean.

Do not foul the cylinder head sheath.

Fit the cylinder head sheath (1) with the “TOP” (1) mark towards the cylinder head direction.

The arrow indicates the point in which the sheath thickness is indicated.

IMPORTANT -- It is recommended to keep the sheath inside its container until it the time of assembly to the cylinder head.

4 Figure 163

6

5 75751

Position on the cylinder head: the protection cap (5), the spring (4), the upper cap (3); use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (6) by the cotters (2).

87417

Fit the head (3) on the sheath (4) assembled to the block and insert the screws (1) and (2).

EW--2--73

ENGINE F4CE0354A OVERHAUL Figure 164

Figure 166

18.975 18.963

19.000 19.026

19.000 19.026

32655 75704

SHAFT AND ROCKER ARM BASIC DATA Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them.

The rods driving the suction and exhaust valves are identical and therefore interchangeable.

Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary.

Figure 167 1

Rocker arm assembly Figure 165

19.00 16.00

4 3 2 1

1 ROCKER ARM ADJUSTMENT SCREW 2

3 75705

- Carry out the assembly of the rocker arms after previous check of the components.

ROCKER ARM UNIT COMPONENTS: 1. Elastic ring -- 2. Spacer-3. Rocker arms-- -- 4. Support.

75702

If unscrewed, check adjustment quota.

Tighten the screw--threaded nut (1) to the 4 -- 6 Nm couple.

EW--2--74

ENGINE F4CE0354A OVERHAUL Mounting the injectors

Figure 168 2

Figure 170

1

1

75683

- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1).

75707

- Assemble injectors after having replaced the sealing gasket (1).

Figure 169 IMPORTANT -- During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.

Figure 171

87673

Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2).

Correct working slack is: -- suction valves 0.25 á0.05 mm -- exhaust valves 0.50 á0.05 mm.

87406

- Assemble cylinder covers (2) with the respective gaskets.

In order carry out a quicker adjustment of the working slack between rocker arms and valves, proceed as following: rotate the engine drive shaft taking cylinder no. 1 to end of compression phase and adjust the valves marked with the star as indicated in the table: Cylinder nq

1

2

3

Suction

*

*

--

Exhaust

*

--

*

Rotate by 360q the engine drive shaft and adjust the valves marked with the star as indicated in the diagram: Cylinder nq

1

2

3

Suction

--

--

*

Exhaust

--

*

--

- Fit the seal nods and tighten the screws (1) fixing them to the prescribed couple.

EW--2--75

ENGINE F4CE0354A OVERHAUL Figure 172

Figure 175

87675

- Assemble exhaust manifold (1) providing new gaskets (2).

Figure 173

90328

Assemble the support (1) of the fan pulley throughout the screws (2) tightening them to the prescribed pair.

Figure 176

87412

- Assemble thermostat unit (2) including thermostat (4) and gasket (3).

90329

- Tighten the screws (1) to the prescribed couple.

Assemble the fan pulley (2) to the support (1) throughout the screws (3) tightening them to the pair.

IMPORTANT -- The gasket must be new.

Figure 177 Figure 174

90330 87677

Assemble the injection pump unit (1) into the gearbox housing (2) and fix it, without tightening, throughout the screws (3).

Assemble the belt tightening pulley (1) throughout the screw (2) tightening it to pair.

EW--2--76

ENGINE F4CE0354A OVERHAUL Figure 178

Figure 180

2 1 90325

- Fit the Poli--V belt (5) on the pulley of the engine drive shaft, on the water pump (4), on the alternator (2) and on the fan pulley (3).

- Execute belt tightening correct operation working on the belt tensioner (1).

IMPORTANT -- If the old belt is to be reassembled examine it carefully in order to see if there may be incisions or evident signs of yielding.

75700

Moreover, assemble the fastening brackets (1) of the injector fuel pipes using the fastening screws (2).

Figure 179

Figure 181

87682

- Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple.

- Install grid heater (4) (optional) or spacer plate (4) if removed.

87410

- If the pipe (6) of the suction manifold plate (1) has been removed, reassemble it after having fit a new gasket (5).

Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple.

- Tighten the screws (7) to the prescribed couple.

EW--2--77

ENGINE F4CE0354A OVERHAUL Figure 182

Figure 184

4 3 2 1

87404 87407

- Assemble the fuel filter bearing (4) to the bracket fixed to the engine head.

Assemble the pipes (1) and (2) providing fuel feed and recovery between pump and injectors.

Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.

- Connect the fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to feed pump.

- Using 380000670 equipment assemble fuel filter (1).

NOTE -- The filter shall be priory filled with fuel to facilitate feed system bleed operations.

Figure 183

Figure 185

1

70126

87405

- Fix the LDA pipeline (1) to the engine head and to the feed pump.

Press clip (1) in the direction of the arrow (detail B), then connect the piping. Bring the clip back to the initial locking position (detail A).

EW--2--78

ENGINE F4CE0354A OVERHAUL Figure 186

Figure 188 1

75675

Proceed assembling the turbocharger: - Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket.

- Screw up the fixing nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple.

- Tighten the lubrication pipe fixing ring (1). Operate in the same way on the other end of the pipe.

Connect it to the upper part of the heat exchanger.

To complete engine assembly it is necessary to remove it from the turning stand.

- Using rocker arm 380000216 hold the engine and loosen the screws fixing the brackets to the turning stand 9380000301.

- Disassemble the brackets from the engine after having properly put it on a wooden bearing.

Figure 187

87712

- Reassemble the starter; properly hold the starter (2) and tighten the fixing screws (1) to the prescribed couple.

- Fill up engine oil.

- Install the engine on the machine (for installation operations please apply to specific issue).

ROTARY FEED PUMP DISASSEMBLY AND ASSEMBLY PROCEDURE This procedure prescribes that: - The fuel pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump) shall all be disassembled.

- Electrical connection to feed pump shall be disconnected.

- Accelerator cable shall be disconnected.

In case feed pump replacement is necessary, this shall be supplied pre--set already as spare part.

On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr--set it while it is still assembled to the engine and disassemble it only afterwards.

87683

On the right hand side: - reassemble the lubrication oil exhaust pipeline (2) from the turbocharger; from underneath the turbocharger tighten the screws (1).

Tighten the union (5) to the block.

- The oil level rod (4).

The following procedure analyses this second hypothesis since it is the more complex.

EW--2--79

ENGINE F4CE0354A OVERHAUL Research of top dead centre by tool 380000977

Figure 189

Figure 191

87712

- Disassemble the starter (2) removing the screws (1).

88101

Remove the first injector, fit the tool 380000977 (2) and the relevant dial gauge 380001005 (1) and remove the tappet cover (3).

Research of top dead centre by tool 380000988 Figure 190

Fit the tool 380000988 and make the engine drive shaft rotate until taking it to the condition of 1st cylinder to TDC. The condition of 1st cylinder to TDC at end of compression phase is obtained when the dial gauge pointer reaches maximum value and suction and exhaust valves are both closed and not balancing.

Check of top dead centre Figure 192

88232

- Mount the bracket of tool 380000988 (1) for checking the flywheel, which bracket is complete with rotary reel (2).

- Cautiously rotate the flywheel according to its rotation direction in order to suppress the clearance of gears.

87714

- Rotate the flywheel until pin 380001990 (4) provided with tool 380000988 fits into the groove on flywheel (3).

After having disconnected fuel pipes of the priming pump, loosen the fastening screws (2) and remove the pump (1) from the basement (3).

EW--2--80

ENGINE F4CE0354A OVERHAUL Figure 193

Figure 195

87715

Check, through the priming pump housing, that the camshaft (1) is in (TDC) end of compression phase, throughout the notches (2) on said shaft.

If the notches are not visible, withdraw the pin from the flywheel and rotate the engine by 360q until when the notches are visible. Fit the locking pin back.

84073

- Remove cover (1) from gear covering case (2).

- Loosen nut (3) securing the injection pump drive gear (4).

Figure 196

Disassembly and assembly Figure 194

87717

87716

- Loosen the screw (2), remove the “L” spacer (1) and lock the screw (2) to keep the pump timed with the engine flywheel.

- Duly keep the “L” spacer with the pump unit.

- Remove the three nuts (2), (3), (5) fastening the injection pump (1) to the block (4) and withdraw it from their own housing.

- Reattach the injection pump following the same order followed to execute disassembly, in reverse.

EW--2--81

ENGINE F4CE0354A OVERHAUL Figure 197

Figure 199

84115

Torque--tighten nut (1) by means of torque wrench (2).

Figure 198

87718

- At the time of assembling the feed pump to the engine it is necessary to ensure T.D.C. conditions to the cylinder no.1 in phase of compression, as described previously.

- Assemble the injection pump unit (1), preset, into the gearbox housing (2) and fasten it, without tightening it, throughout the screws (3).

IMPORTANT -- The gasket removed during pump disassembly shall not be utilised again.

Always use original spare parts.

Figure 200

84116

Apply sealant (1) as shown in the figure, then put on small cover (2).

87719

- Partially loosen the screw (1) locking the rotation of the pump shaft and insert the spacing washer (2). Tighten the screw locking said washer: this way the feed pump shaft will be free to rotate.

- Withdraw the pin of the engine flywheel locking tool.

- Remove the flywheel rotation locking tool 380000988; place the starter into its housing.

EW--2--82

ENGINE F4CE0354A OVERHAUL Ignition pump control and timing

Figure 202

Figure 201

87721 87720

- With the ignition pump fitting into its housing and with loosened fastening screws, remove the closure cap placed over the pump cover.

- Fit the dial gauge 380000228 (2) and the relevant tool 380001084 (1), pre--loading the rod by 2.5 mm.

- Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposite direction until recovering the condition of the 1st cylinder to TDC in phase of compression.

In this position, the relating value of presetting (1 r 0.05 mm) should be read on the dial gauge.

- Rotate the pump in anti--clockwise direction if the stroke is shorter or in clockwise direction if the stroke is longer, until obtaining the stroke prescribed.

- Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair.

- Assemble the priming pump (1) to the block (3) and tighten the fastening screws (2) to the prescribed pair.

- Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump).

- Connect electrical connections to electro--magnets on the hydraulic head and on KSB. IMPORTANT -- In case pump removal has been carried out while the engine was assembled, connect acceleration cable.

Feed system bleed procedure Figure 203

87751

In case any operation has been executed on the components of the feed circuit, it is necessary to execute bleeding of air within the system.

- Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump.

- Continue the operation until when fuel outflows.

- Connect the (1) to the filter.

EW--2--83

ENGINE F4CE0354A OVERHAUL Reassembling

REPLACING THE INJECTORS

Figure 206

Removal Figure 204

84289

- Disconnect engine oil vapour recovery pipe (2) from blow--by;

84201

- take off tappet cover (1); - disconnect the fuel manifold pipes from injectors (3).

Mount a new seal ring (2) lubricated with petrolatum and a new seal washer (3) on injector (1).

Mount the injectors on their seats on the cylinder head, then tighten them by means of a torque wrench.

Figure 205

Mount new seal rings on fuel manifolds.

Connect the manifolds to the injectors, by tightening the fastening nuts to a torque of 50 Nm. Reassemble the tappet cover.

Re--connect the engine oil vapour recovery pipe to the blow--by.

84082

Remove injectors (2) by means of tool 380000671 (1) and take them off the cylinder head.

EW--2--84

ENGINE F4CE0354A OVERHAUL ROCKER ARM REMOVAL/REASSEMBLING

ADJUSTING THE TAPPETS Figure 208

Removal Figure 207

84200

84081

Loosen tappet adjuster fastening nuts (3), then unscrew adjusters (2).

Remove screws (4) and dismount rocker arm assembly (1) made up of the rocker arm support and arbours, then take off valves.

Reassembling Verify that the tappet adjusters are unscrewed to prevent the latter from crawling on the rods when the rocker arm assembly is mounted.

Mount the rocker arm assemblies made up of rocker arm support and arbours, then secure them to the cylinder head by tightening the fastening screws to a torque of 36 Nm. Ad just the tappets as described above.

Ad just the play between the rocker arms and the valves by means of an Allen wrench (2), box wrench (3) and thickness gauge (1).

The operation play is: –

intake valves: 0.25 r0.05 mm

--

exhaust valves: 0.50 r0.05 mm.

In order carry out a quicker adjustment of the working slack between rocker arms and valves, proceed as following: rotate the engine drive shaft taking cylinder no. 1 to end of compression phase and adjust the valves marked with the star as indicated in the table: Cylinder nq

1

2

3

Suction

*

*

--

Exhaust

*

--

*

Rotate by 360q the engine drive shaft and adjust the valves marked with the star as indicated in the diagram: Cylinder nq 1 2 3 Suction

--

--

*

Exhaust

--

*

--

SECTION 3

RECHARGE AND START--UP

INDEX Alternator . . . . . . . . . . . . . . . . . . . . . . . . .

EW--3--3

INDEX

EW--3--3

RECHARGE AND START--UP ALTERNATOR BOSH 6 033 G20 19B Characteristics: 12V -- 95A Room temperature (¥C)

r.p.m. (min --1)

I (A)

25

1500

20

25

6000

95

88317

Quick diagnosis Fault

Possible causes

Remedy

No recharge

1. Interruption of recharge circuit (warning light, fuse, connector, etc.)

Check the recharge circuit connections, clean and tighten the cable terminals on the alternator and battery

2. Voltage regulator not in working order

Replace the component

3. Interrupted rotor winding

Replace the component

4. Worn brushes

Replace the component

1. Loose belt

Apply correct tension

2. Faulty voltage regulator

Replace the component

3. Excessive wear of rotor rings or brushes

Replace the component

4. Short--circuited diodes

Replace the component

5. Short--circuited rotor winding(s)

Replace the component

1. Loose circuit connections

Check the connections to terminals and cable terminals of batteries, starter motor and alternator

2. Voltage regulator not in working order

Replace the component

3. Earth fault

Check earth connections

Poor recharge

Excessive recharge

EW--3--4

RECHARGE AND START--UP