New Holland 667TA/EEG 667TA/EEC 667TA/EBF 667TA/EED 667TA/EBD Engines Repair Manual - PDF DOWNLOAD

REPAIR MANUAL FOR CNH U.K. ENGINES 667TA/EEG -- 667TA/EEC -- 667TA/EBF 667TA/EED -- 667TA/EBD The following models are to integrate repair manuals: NEW HOLLAND KOBELCO E265 -- E305 NEW HOLLAND D180 LGP -- D180 STD -- W170 -- W190

667TA/EEG -- 667TA/EEC

667TA/EBF -- 667TA/EED

667TA/EED -- 667TA/EBD Every information, illustration and specification contained in the present manual is based on the most recent informa-tion available at the time of printing.

NEW HOLLAND reserves the right, to modify the text at any time without prior communication.

NEW HOLLAND PRINT No. 604.13.689 Edition -- May 2006

2

WE

MOTORI

2

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 no-tice any mistake concerning the content of this manual, please contact: NEW HOLLAND Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax ++39 011 0077357

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

Example:: T 1 -- 2 -- 3

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 °C km/h min--1 L/min mL/rev

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

Multiply by 10.197 145.0 1.360 1.341 °C 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 -- 667TA engine overhaul

EW--2--1

Section 3 -- Recharging and start--up

EW--3--1

4

WE

MOTORI

SECTION 1

DIAGNOSTICS

INDEX Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3 CNH -- EST diagnostics tool . . . . . . . . . EW--1--4 Main engine operating anomalies . . . EW--1--5

INDICE

EW--1--3

DIAGNOSTICS DIAGNOSTICS FOREWORD A good diagnosis is carried out with the competence acquired from years of experience and taking part in repair courses.

When a user complains about a bad efficiency or ope-rating anomalies, his indications must be kept into due account, taking from them those useful informa-tion that will be used to guide our intervention.

After having detected the anomaly, it is advisable to carry out failure search operations by decoding self-diagnosis data of the central electronic unit of theEDC (Engine Diesel Control) system.

With the use of computerised tools, it is also possible to establish a bi--directional communication with the central unit with which it is possible not only to decode the error codes, but also to address the image in its memory to obtain those further necessary informa-tion to go back to the anomaly origin.

Every time an inconvenience occurs and its existence is detected, it is necessary to proceed with the elec-tronic unit query through one of the pointed--out ways and then proceed with the diagnostic survey through tests and measures through which an outline of ope-rating conditions is obtained and the real anomaly reasons are identified.

In case the electronic unit does not provide indica-tions, one will have to proceed with one’s experience by adopting traditional diagnostic modes.

EW--1--4

DIAGNOSTICS

CNH -- EST DIAGNOSTIC TOOL

88201

The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating para-meters of electronic control components (control units, sensors etc.) and the check of flow--rates, pressures and temperatures; it is further arranged for searching inconveniences and detect data for electronically--controlled CNH engines.

Code 380060157 380060158 380060159 380060160 380060161 380060162 380060163 380060164

Description

CE EST diagnostic kit

Language Italiano French English German Spanish Holland Danish Portuguese

EW--1--5

DIAGNOSTICS MAIN ENGINE OPERATING ANOMALIES 1 -2 -3 -4 -5 --

1

6 -7 -8 -9 -10 --

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);

Engine exhaust smoke light blue; Engine knocks irregularly; Engine stops; Excessive or insufficient oil pressure; Excessive fuel consumption;

ENGINE WON’T START

Connections to battery terminals are in working order

NO

Clean, check, tighten or replace clamp nuts.

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

Injectors efficient NO

Check using a diagnostic tester.

Check o--ring seal.

Replace.

YES

The feeding circuit or injection pump does not show air penetration

Check and eliminate causes of infiltration.

NO

(to be continued)

EW--1--6

DIAGNOSTICS

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

Pre--post heating system efficient

Check using a diagnostic tester.

NO

YES

High pressure pump efficient

Check using a diagnostic tester.

NO

2

ENGINE OVERHEATS

YES

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

(to be continued)

EW--1--7

DIAGNOSTICS

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, re-place (if necessary) the part.

YES

Air filter and circuit piping both in working order

Clean or replace faulty parts.

NO

YES

Openings for coolant flow to the head in working order

Wash down thoroughly.

NO

YES

Valve timing correct

Check and perform correct timing.

NO

YES

Cylinder head gasket in working order

Replace.

NO

YES

Fan in working order

Replace.

NO

EW--1--8

DIAGNOSTICS

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 re-pairs.

YES

Fuel filters in working order

YES

Feeding circuit in working order

YES

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

High pressure pump efficient NO

Check using a diagnostic tester and replace if necessary.

NO

Check using a diagnostic tester.

Replace.

YES

Injectors efficient

(to be continued)

EW--1--9

DIAGNOSTICS

Rail pressure relief valves efficient NO

Disconnect fuel return pipe from rail and check for leaks.

NO

Adjust the play between the valves and rocker arms.

YES

Correct play between the valves and rocker arms

YES

Prescribed compression ratio

Check using a diagnostic tester.

NO

YES

Turbocharger in working order

Repair or replace the unit.

NO

4

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Air filter in working order

Replace.

NO

YES

Injectors efficient NO

Check using a diagnostic tester.

Replace.

YES

Prescribed compression ratio

Check using a diagnostic tester.

NO

(to be continued)

EW--1--10

DIAGNOSTICS

High--quality diesel fuel

Clean the tank and replace the diesel oil filter.

NO

5

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

Injectors efficient NO

Check using a diagnostic tester.

Replace.

YES

Coolant level correct NO

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

YES

High--quality diesel oil

Clean the tank and replace the diesel oil filters.

NO

6

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption NO

Check: oil vapour breather; cylinder compres-sion. Leaks into or out of turbocharger. Leaks from valve guides Overhaul cylinder head or engine if necessary.

EW--1--11

DIAGNOSTICS

7

ENGINE KNOCKS IRREGULARLY

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 connect-ing rod caps; connecting rod squaring. Replace the parts or overhaul the engine.

YES

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

Replace the parts or overhaul the engine.

YES

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

NO

Knock detected in pistons

NO

Knock detected in the cylinder head

NO

Knock detected in the valve gear YES

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

NO

Knock detected in injectors YES

Check using a diagnostic tester.

Replace.

YES

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

NO

Knock detected in the engine flywheel

EW--1--12

DIAGNOSTICS

8

ENGINE STOPS

Fuel tank filled

Refuel and drain (if necessary).

NO

YES

Fuel filters in working order

Replace.

NO

YES

Feeling circuit in working order

Check the circuit and proceed as necessary.

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

EXCESSIVE OR INSUFFICIENT OIL PRESSURE

Pressure control valve in working order

NO

Check and replace (if necessary).

(to be continued)

EW--1--13

DIAGNOSTICS

Oil pump and delivery pipes both in working or-der

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 ad-equate viscosity.

NO

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

YES

Engine oil SAE viscosity conforming to stan-dards

10

EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes in working order

YES

Air filter in working order

Replace.

NO

YES

Injectors efficient NO

Check using a diagnostic tester.

Replace.

EW--1--14

DIAGNOSTICS

NOTES

SECTION 2

ENGINE OVERHAUL

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

Main engines features . . . . . . . . . . . . . .

General engines features . . . . . . . . . . .

Assembling play -- specifications . . .

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

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

Graphic indications and symbols . . .

667TA engines . . . . . . . . . . . . . . . . . . . . .

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

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

EGR exhaust gas recirculation system Internal EGR acting on the exhaust valves . . . . . . . . . . . . . . . . . . . . . .

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

Cylinder head engines: 667TA/EBF -667TA/EBD -- 667TA/EED . . . . . . . . . . . .

Cylinder head engines: 667TA/EEG -667TA/EEC . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Valve drive jumpers . . . . . . . . . . . . . . . . . .

Engine head grinder . . . . . . . . . . . . . . . . .

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

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

Engine lubrification . . . . . . . . . . . . . . . .

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

Oil pressure regulation valve . . . . . . . . .

By--pass valve . . . . . . . . . . . . . . . . . . . . . .

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

Oil sump engines: 667TA/EEG --667TA/ EEC -- 667TA/EBF -- 667TA/EED . . . . . .

Oil sump engines: 667TA/EED -667TA/EBD . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil vapour recirculation . . . . . . . .

Engine cooling . . . . . . . . . . . . . . . . . . . . .

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

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--4 EW--2--5 EW--2--6 EW--2--8 EW--2--14 EW--2--15 EW--2--16 EW--2--17 EW--2--18 EW--2--18 EW--2--19 EW--2--19 EW--2--20 EW--2--21 EW--2--22 EW--2--22 EW--2--22 EW--2--23 EW--2--24 EW--2--25 EW--2--26 EW--2--27 EW--2--27 EW--2--27 EW--2--28 EW--2--29 EW--2--30 EW--2--31 EW--2--31 EW--2--31 EW--2--32 EW--2--33 EW--2--34 EW--2--35 EW--2--36 EW--2--37 EW--2--37

High pressure electronic injection system (Common rail) . . . . . . . . . . . . . .

EDC 7 operation . . . . . . . . . . . . . . . . . . .

Supply system . . . . . . . . . . . . . . . . . . . . .

Supply system diagram . . . . . . . . . . . . .

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

Mechanical supply pump . . . . . . . . . . . . .

Normal operating condition . . . . . . . . . . .

Output overpressure condition . . . . . . . .

Drain conditions . . . . . . . . . . . . . . . . . . . . .

High--pressure pump type CP3.3 . . . . . .

High pressure pump--inside structure . .

Working principle . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . .

Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boost gauge valve . . . . . . . . . . . . . . . . .

Electro--injector . . . . . . . . . . . . . . . . . . . .

Electro--injector . . . . . . . . . . . . . . . . . . . . .

Pressure limiter for fuel return . . . . . .

Location of the main electrical components . . . . . . . . . . . . . . . . . . . . . . .

EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . .

Cable on engine . . . . . . . . . . . . . . . . . . . .

Injectors connector (A) . . . . . . . . . . . . . . .

Sensors connector (C) . . . . . . . . . . . . . . .

Crankshaft sensor . . . . . . . . . . . . . . . . . . .

Timing sensor . . . . . . . . . . . . . . . . . . . . . .

Supercharging air pressure -temperature sensor . . . . . . . . . . . . . . . . . .

Engine oil temperature--pressure sensor Fuel temperature and pressure sensor .

Electro--injectors . . . . . . . . . . . . . . . . . . . .

Pre--post heating resistance and contactor . . . . . . . . . . . . . . . . . . . . . . .

Coolant temperature sensor . . . . . . . . . .

Fuel temperature sensor . . . . . . . . . . . . .

High pressure pump -- pressure regulator Checking the fuel system . . . . . . . . . . .

Description of tests and checks that can be performed . . . . . . . . . . . . . .

Necessary equipment . . . . . . . . . . . . . . . .

Low pressure supply test . . . . . . . . . . . . .

Low--Pressure Pump . . . . . . . . . . . . . . . .

Test on the pressure relief valve on the rail . . . . . . . . . . . . . . . . . . . . . . . . . .

Test on fuel backflow from the return . . .

Engines overhaul at the bench . . . . . .

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

EW--2--38 EW--2--39 EW--2--40 EW--2--41 EW--2--42 EW--2--43 EW--2--43 EW--2--43 EW--2--44 EW--2--44 EW--2--46 EW--2--47 EW--2--49 EW--2--49 EW--2--50 EW--2--51 EW--2--52 EW--2--53 EW--2--54 EW--2--55 EW--2--56 EW--2--57 EW--2--57 EW--2--58 EW--2--58 EW--2--59 EW--2--59 EW--2--60 EW--2--61 EW--2--62 EW--2--63 EW--2--64 EW--2--65 EW--2--66 EW--2--66 EW--2--66 EW--2--67 EW--2--68 EW--2--69 EW--2--70 EW--2--72 EW--2--72

INDEX Repair operations . . . . . . . . . . . . . . . . . .

Cylinder unit . . . . . . . . . . . . . . . . . . . . . . .

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

Checking the eccentric lift and the pin alignment . . . . . . . . . . . . . . . . . . . .

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

Checking the surface supporting the head on the cylinder cluster . . . . . . .

Timing system . . . . . . . . . . . . . . . . . . . . .

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

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

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

Mounting the tappets -- Distributing shaft Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring the journals and crankpins . .

Replacing the oil pump drive gears . . . .

Measuring the journal assembling play .

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

Checking the drive shaft shoulder play .

Connecting rod--piston assembly . . .

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

Measuring the piston diameter . . . . . . . .

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

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

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

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

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

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

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

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

Mounting the connecting rod--piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

EW--2--81 EW--2--81 EW--2--81 EW--2--81 EW--2--81 EW--2--83 EW--2--83 EW--2--83 EW--2--84 EW--2--84 EW--2--84 EW--2--85 EW--2--85 EW--2--87 EW--2--87 EW--2--87 EW--2--88 EW--2--88 EW--2--89 EW--2--89 EW--2--90 EW--2--90 EW--2--90 EW--2--91 EW--2--91 EW--2--92 EW--2--92 EW--2--92 EW--2--92

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

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

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

Measuring the crankpin assembling play Checking piston protrusion . . . . . . . . . . .

Distribution gearbox case . . . . . . . . . . . .

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

Flywheel cover case . . . . . . . . . . . . . . . . .

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

Replacing the engine flywheel ring gear Cylinder head . . . . . . . . . . . . . . . . . . . . . .

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

Checking the cylinder head water seal .

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

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

Valve descaling, check and grinding . . .

Checking the play between the valve stem, valve guide and valve centring . . . . . . . . . . . . . . . . . . . . . . .

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

Valves seats . . . . . . . . . . . . . . . . . . . . . . .

Valve seat reconditioning -- replacement Valve springs . . . . . . . . . . . . . . . . . . . . . .

Mounting the cylinder head . . . . . . . . .

Reattaching the cylinder head . . . . . . . . .

Fitting injectors . . . . . . . . . . . . . . . . . . . . . .

Rods and tappets . . . . . . . . . . . . . . . . . .

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

Tappet clearance adjustment . . . . . . . . .

Wiring support . . . . . . . . . . . . . . . . . . . . . .

EW--2--92 EW--2--93 EW--2--93 EW--2--94 EW--2--95 EW--2--95 EW--2--96 EW--2--96 EW--2--97 EW--2--97 EW--2--101 EW--2--101 EW--2--102 EW--2--102 EW--2--103 EW--2--103 EW--2--103 EW--2--103 EW--2--104 EW--2--104 EW--2--105 EW--2--106 EW--2--106 EW--2--107 EW--2--108 EW--2--108 EW--2--109 EW--2--111

EW--2--3

667TA ENGINE OVERHAUL Figure 1

Figure 2

114201

114199

ENGINES: 667TA/EEG -- 667TA/EEC

ENGINES: 667TA/EED -- 667TA/EBF

Figure 3

114200

ENGINES: 667TA/EED -- 667TA/EBD

EW--2--4

667TA ENGINE OVERHAUL CODING OF SOURCE ENGINES

6

6

7

T

A

E

D

+

B

Engine (power)

calibration

Compression ratio: B = 16.5:1 > 130 kW D = 17.5:1 ≤ 130 kW E = 17.5:1 > 130 kW

Electronic injection (common rail)

Intercooler

Turbocharged

67 = cylinder capacity

6 = no. of cylinders

EW--2--5

667TA ENGINE OVERHAUL MAIN ENGINES FEATURES

A

E265

E305

D180 LGP

D180 STD

W170

W190

B

667TA

667TA

667TA

667TA

667TA

667TA

C

EEG

EEC

EBF

EED

EED

EBD

145 kW 2000 rpm

145 kW 2000 rpm

169 kW 2000 rpm

D 6728 cm3

E F

137 kW 2100 rpm

148 kW 2100 rpm

157 kW 2000 rpm

Net power at flywheel (ISO 14396) G

Direct injection

H

(common rail)

I

T.A.A. (Boosted by intercooler)

A B C D

Machine type T Type off engine i Engine model Number of cylinders

E F G H I

Total displacement Max. power currently available Type of injection Injection system Air supply system

EW--2--6

667TA ENGINE OVERHAUL GENERAL ENGINES FEATURES 667TA Type

EEG

EEC

EED

Cycle

4--stroke diesel engine

Feeding

Boosted by intercooler

Injection

Direct

Number of cylinders

EBD

6 in--line

Bore

mm

104

Stroke

mm

132

Total displacement

cm3

6728 cm3

Compression ratio

--

Max. rating*

kW min --1

137 2100

148 2100

157 2000

145 2000

169 2000

Max. torque

Nm (kgm) min --1

710 1400

810 1400

952 1400

860 1400

1002 1400

No--load idle rpm

min --1

700

No--load peak rpm

min --1

--

BOOSTING Type of turbocompressor:

With intercooler HOLSET HX35 Forced by means of gear pump. pressure relief valve. oil filter

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

EBF

Net power at flywheel (ISO 14396)

bar bar

1.2 3.8

EW--2--7

667TA ENGINE OVERHAUL 667TA Type

EEC

EEG

COOLING

EED

EBD

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

Ambra Mastergold HSP

EBF

FILLING Total capacity 1st filling:

By means of belt 81± 2

°C

litres kg

---

---

-- engine sump

litres kg

---

---

-- engine sump + filter

litres kg

17 --

19 --

FEEDING Bosch--type injection

high pressure Common Rail

Pump setting

Start of delivery

mm

Type of injector

CRIN 1

Injection sequence

Injection pressure

CRIN 2

1 -- 5 -- 3 -- 6 -- 2 -- 4

bar

--

250 to 1600

250 to 1400

250 to 1600

EW--2--8

667TA ENGINE OVERHAUL ASSEMBLING PLAY -- SPECIFICATIONS 667TA Type

EEG

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

∅1

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

X ∅1 ∅2

Piston -- cylinder liners

Position of pistons from crankcase

Gudgeon pin

EED

104.000 to 104.024

49.5 103.759 to 103.777 38.010 to 38.016 0.235 to 0.273

∅1

X

∅3

Gudgeon pin--Pin seat Type of piston Piston ring slots

EBF mm

Cylinder liners

Piston diameter

EEC

0.4

--

37.994 to 38.000

0.01 to 0.022 X1* X2 X3

2.705 to 2.735 2.420 to 2.440 4.03 to 4.05

* measured on ∅ of 101 mm S1* S2 S3 * measured 1.5 mm away from the external ∅ Piston rings

Piston rings – Slots

Piston rings

1 2 3

2.560 to 2.605 2.350 to 2.380 3.977 to 3.990 0.100 to 0.175 0.04 to 0.09 0.040 to 0.083 0.4

EBD

EW--2--9

667TA ENGINE OVERHAUL 667TA Type

EEG

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

EBF

EED

mm

Piston ring end opening in cylinder liner: X1 X2 X3

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

EEC

∅1 ∅2

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

0.3 to 0.4 0.6 to 0.8 0.3 to 0.55

40.987 to 41.013 72.987 to 73.013

41.279 to 41.553 38.019 to 38.033

Connecting rod small--end bushing – seat

0.266 to 0.566

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--7 n. 2--3--4--5--6

∅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

EBD

EW--2--10

667TA ENGINE OVERHAUL 667TA Type

EEG

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

EEC

EBF

EED

mm

Half bearings -- journals: n. 1--7 n. 2--3--4--5--6

0.044 to 0.106 0.041 to 0.103

Half bearings -- crankpins

0.039 to 0.111

Main half bearings Connecting rod half bearings

+ 0.250; + 0.500

Shoulder journal

X1

Shoulder bed support

X2

Shoulder half rings

X3

Drive shaft shoulder

37.475 to 37.545

25.98 to 26.48

37.28 to 37.38

0.095 to 0.265

EBD

EW--2--11

667TA ENGINE OVERHAUL 667TA Type

EEG

VALVE GEAR – CYLINDER ASSEMBLY Valve guide seats on cylinder head

EEC

EBF

EED

mm

∅1

7.042 to 7.062

∅4 α ∅4 α

6.970 to 6.999 60° ± 0.25° 6.970 to 6.999 45° ± 0.25°

Valves:

Valve stem and respective guide

0.043 to 0.092

Seat on head for valve seat: ∅1

34.837 to 34.863

∅1

34.837 to 34.863

Valve seat outer diameter; inclination of valve seats on cylinder head: ∅2 α ∅2 α Hollow

Between the valve seat and the head

34.917 to 34.931 60° 34.917 to 34.931 45°

X

0.59 to 1.11

X

0.96 to 1.48 0.054 to 0.094 0.054 to 0.094

Valve seats

--

EBD

EW--2--12

667TA ENGINE OVERHAUL 667TA Type

EEG

VALVE GEAR – CYLINDER ASSEMBLY Valve spring height: free spring under a load of: 339.8 N ± 19 N 741 N ± 39 N

Injector protrusion

EEC

EBF

EED

mm H

47.75

H1 H2

35.33 25.2

X

not adjustable

Seats for distributing shaft bushings no.

7 Sedi albero distribuzione n.

1--2--3--4--5--6

59.222 to 59.248 54.089 to 54.139

Distributing shaft support pins: 1⇒7

∅

53.995 to 54.045

External diameter of the bushing for the camshaft with a load of 3.3 kN

∅

59.222 to 59.248

Bushing inner diameter

∅

54.083 to 54.147

Bushing and seat in crankcase

0.113 to 0.165

Bushing and support pin

0.038 to 0.162

Eccentric working lift: 6.045 7.239

EBD

EW--2--13

667TA ENGINE OVERHAUL 667TA Type

EEG

VALVE GEAR – CYLINDER ASSEMBLY

∅1

∅2 ∅3

Seat for tappet collar in the crankcase

EEC

EBF

EED

mm

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.970

Outer diameter of tappet collar:

∅2

Between the tappets and the seats Tappets

0.030 to 0.070 --

∅1 Rocker arm shaft

∅1

21.965 to 21.977

Rocker arms

∅2

22.001 to 22.0027

∅2 Between the rocker arm and the shaft

0.024 to 0.0377

EBD

EW--2--14

667TA ENGINE OVERHAUL TIGHTENING TORQUE PART Cylinder y head fastening g screw 1st p phase: screws M12x1.75x70 screws M12x1.75x140 screws M12x1.75x180 nd 2 p phase: 3rdd phase: (only for screws 140 and 180 mm long) phase 1st p 2nd p phase rd 3 phase g rod cap p fastening g 1st p phase Connecting nd 2 phase g y g screws p g Engine flywheel fastening pre--tighten Angle Injector fastening Sump oil drain plug 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 ± 5 (5 ± 0.5) 40 ± 5 (4 ± 0.5) 70 ± 5 (7 ± 0.5) 90° 90° 50 ± 6 (5 ± 0.6) 80 ± 6 (8 ± 0.6) 90° ± 5° 50 ± 5 (5 ± 0.5) 60° ± 5° 30 ± 5 (3 ± 0.5) 60° ± 5° 60 ± 5 (6 ± 0.5) 60 ± 5 (6 ± 0.5) contact + 3/4 turn 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 53 ± 5 (5.3 ± 0.5) 25 ± 5 (2.5 ± 0.5) 48 ± 8 (4.8 ± 0.8) 25 ± 5 (2.5 ± 0.5) 50 ± 5 (5 ± 0.5) 90° ± 5° 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 12 ± 5 (1.2 ± 0.5) 45 ± 5 (4.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 55 ± 5 (5.5 ± 0.5) 45 ± 5 (4.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) contact + 3/4 turn 45 ± 5 (4.5 ± 0.5)

EW--2--15

667TA ENGINE OVERHAUL TOOLS 380000158

1--6 Nm dynamometric screw driver for calibrating injector solenoid valve connector check nut (Common Rail)

380000978

Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)

380000980

Tool for removing the drive shaft front gasket

380000981

Tool for removing the drive shaft rear gasket

380000982

Injector extracting tool

380000983

Coupler for mounting the drive shaft front gasket

380000984

Coupler for mounting the drive shaft rear gasket (except engines: 667TA/EBF -- 667TA/EED)

380000985

Cartridge filter removing tool

380000986

Pliers for removing and reassembling the piston rings (65--110 mm)

380000987

Tool for removing and reassembling the engine valves

380000988

Tool for rotating the engine flywheel (except engines: 667TA/EBF -- 667TA/EED)

380000990

Engine flywheel retaining tool (except engines: 667TA/EEG -- 667TA/EEC)

380000991

Beater for removing and reassembling the distributing shaft bushings (to be used with 380000999)

380000992

Drive shaft lifting tool

380000993

Swing bar for engine detachment and reattachment

380000994

Band for inserting the piston into the cylinder liner (60--125 mm)

380000995

Brackets for fastening the engine to the rotary stand 380000978

380000996

Gasket extracting tool

380000999

Handle for interchangeable beaters

380001000

Comparator holder base for miscellaneous measurements (to be used with 380001004)

380001001

Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount

380001004

Comparator (0--5 mm)

380001099

Tool for extracting electric injectors (Common Rail)

EW--2--16

667TA ENGINE OVERHAUL GRAPHIC INDICATIONS AND SYMBOLS Detachment Disconnect

Intake

Reattachment Connect

Exhaust

Removing Disassembling

Operation

Mounting Assembling

α

!

ρ

Compression ratio

Torque--tighten

Tolerance Weight difference

Torque--tighten + angular value

Dragging torque

Countersink

Rotation

Adjustment Setting

Angle Angular value

Warning Note

Preload

Visual check Mounting position check

Revs number

Measurement Dimension to be measured Check

Temperature

Equipment

bar

Pressure

Surface to be machined Machining finish

Increase Greater than .....

Maximum

Interference Forced mounting

Decrease Smaller than ....

Minimum

Thickness Play

Selection Classes Increases

Lubricate Moisten Grease

Temperature < 0 °C Cold Winter

Sealant

Temperature < 0 °C Hot Summer

Air bleed

EW--2--17

667TA ENGINE OVERHAUL 667TA ENGINES Figure 4

114058

1. Turbocompressor -- 2. Automatic belt stretcher -- 3. Alternator -- 4. Fixed guide pulley -5. Water pump -- 6. Damper flywhee -- 7. Oil sump -- 8. Electronic central unit -9. High pressure pump with feed pump -- 10. Diesel oil filter -- 11. Common rail

EW--2--18

667TA ENGINE OVERHAUL DESCRIPTION OF MAIN MECHANIC ENGINE COMPONENTS Crankcase It consists of a cast----iron structure in which the following items are realized: cylinder liners (1); bed supports (5) and seats for: distributing shaft bushings (3), tappets, water/oil heat exchanger (7), water pump (2) and oil pump (4).

It also incorporates the coolant circulation chambers and the engine member lubricating circuit ducts.

Plate (6) is fitted to the lower part of the crankcase and ensures greater resistance to forces and stress.

Figure 5

1

2 7

3

4

5

6

86605

EW--2--19

667TA ENGINE OVERHAUL Drive shaft It ismade of steel and rests on seven 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, phonic wheel, 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 antifriction alloy coating.

The penultimate main half bearings are equipped with a shoulder to restrain the drive shaft end play.

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

Figure 6

84037

1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear -4. Flywheel attachment hub 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 380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.

EW--2--20

667TA ENGINE 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 aremade 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 7

84038

EW--2--21

667TA ENGINE 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.

Recesses, housing spring rings, are three; the 1st one is made of a cast iron insert.

The following reference data are engraved on the piston crown: 1. Spare part number and design modification number 2. Inscription (facing the crankcase front side) indicating the mounting sign of the piston in the cylinder liner.

3. Date of manufacture; 4. Stamping indicating 1st recess insert testing.

Figure 8

86549

EW--2--22

667TA ENGINE OVERHAUL Distributing shaft

EGR EXHAUST GAS RECIRCULATION SYSTEM

The distributing shaft rests on seven supports in the crankcase.

The exhaust gases can be partially conveyed back into the cylinders to lower the maximum values of the combustion temperature that are responsible for the production of nitrogen oxides (NOx).

The exhaust gas recirculation system (EGR), lowering the combustion temperature by decreasing the concentration of oxygen in the combustion chamber, is therefore an effective system to control the emission of NOx. Internal EGR acting on the exhaust valves The internal EGR system, thanks to an appropriate exhaust cam design permits some of the exhaust gases to be reintroduced back into the engine cylinders.

This type of EGR, internal EGR is not provided with any electronically controlled element: the system is always on. Its configuration doesn’t need any additional elements such as control valves, pipes or heat exchangers.

The exhaust cam, besides the main lobe, has an additional lobe (C) compared to the configuration without EGR. During the intake stroke of the cylinder under examination, this lobe permits briefly opening the exhaust valve. In this way, recirculation is generated on the cylinder in the intake stroke due to the greater pressure of the exhaust gases compared to the intake gases.

The rear bearing is equipped with steel bushes coated with friction--resistant material that are fitted with interference. There are two drive cams per 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 9

70164

C

114501

EW--2--23

667TA ENGINE OVERHAUL Valve control Figure 10

003198t

1. Rocker arm -- 2. Arbour -- 3. Adjusting screw -- 4. Rod -- 5. Jumper -- 6. Lock cones -- 7. Cup -8. Spring -- 9. Tappet -- 10. Distributing shaft

EW--2--24

667TA ENGINE OVERHAUL Cylinder head engines: 667TA/EBF -- 667TA/EBD -- 667TA/EED The seats of the following parts are obtained on the cast--iron cylinder head:

Moreover, the following components are inserted onthe heads:

- inserted valve seats (4);

- single--block exhaust manifold (1);

- injectors (6); - thermostat (5);

- intake manifold (2) with seat for cold start air heater (3).

Figure 11

114059

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--25

667TA ENGINE OVERHAUL Cylinder head engines: 667TA/EEG -- 667TA/EEC The seats of the following parts are obtained on the cast--iron cylinder (8) head:

Moreover, the following components are inserted on the heads:

- inserted valve seats (10);

- exhaust manifold (1) in two parts

- injectors (2);

- intake manifold (2) with seat for cold start air heater (3).

- thermostat (4);

- support (7) with injector wiring harness (3).

Figure 12

114060

EW--2--26

667TA ENGINE OVERHAUL Valves and valve seats Figure 13

70319

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side Valve seats have following angles: - 45° (exhaust valves) - 60° (intake valves)

Exhaust valves 2 have a distinctive notch at the centre of the head.

Figure 14

70334

Figure 14 shows the oil seals mounted on valve stems.

EW--2--27

667TA ENGINE OVERHAUL Valves and valve seats Le guide valvole non sono riportate Figure 15

INTAKE

Valve drive jumpers When remounting the cylinder head, the orientation of valve drive jumpers must be observed.

EXHAUST

79457

Jumpers must be positioned with marks (→) towards exhaust manifold.

Figure 16

70345

1. Jumper -- 2. Rods Engine head grinder Cylinder head nominal thickness is 105 ± 0.25 mm and maximum removal enabled by metal must not exceed 0.13 mm.

A single thickness gasket is available as a spare part.

Figure 17

70325

EW--2--28

667TA ENGINE OVERHAUL Engine flywheel The flywheel (1) does not need being positioned in a fixed manner on the drive shaft, since it does not bear any stamping, notch or reference hole for sen-

Figure 18

sors or timing. The equidistance of fastening screw holes (2) allows it to be mounted in any position.

Figure 20

114086

MOTORI: 667TA/EBF -- 667TA/EED

ENGINES: 667TA/EEG -- 667TA/EEC Figure 19

86454

MOTORI: 667TA/EED -- 667TA/EBD

86488

EW--2--29

667TA ENGINE OVERHAUL Auxiliary component drive A Poly--V belt (4) transmits the motion of drive shaft (5) to water pump (3) and to alternator (2).

The belt is stretched by means of automatic belt stretcher (1).

Figure 21

114061

1. Automatic belt stretcher -- 2. Alternator -- 3. Water pump -- 4. Poly--V belt -- 5. Drive shaft

EW--2--30

667TA ENGINE OVERHAUL ENGINE LUBRIFICATION Forced circulation lubrication is performed by the following components: - rotor--equipped oil pump (5), housed in the crankcase front part, controlled by the straight tooth gear force--fitted on the drive shaft shank; - water / oil heat exchanger (3), housed in the en-

gine crankcase, with oil filter adapter; - oil pressure control valve (1) built into the oil filter adapter; - by--pass valve (4) for clogged oil filter cut--off, built into the oil filter adapter; - cartridge--type oil filter (2).

Figure 22

Pressure oil path Oil return drop----type path Oil introduction

114087

A. B.

Engine oil sump: 667TA/EED -- 667TA/EBD Engine oil sump: 667TA/EEG -- 667TA/EEC -- 667TA/EBF -- 667TA/EED

EW--2--31

667TA ENGINE OVERHAUL Heat exchanger Figure 23

114062

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between exchanger unit and engine block – 5*. Oil return to filter – 6*. Oil inflow from filter -- 7. Oil filter *

Only engines: 667TA/EEG -- 667TA/EEC

Oil pressure regulation valve

By--pass valve

Figure 24

Figure 25

Flow

107419

PRINCIPAL DATA FOR OIL PRESSURE REGULATION VALVE SPRING CHECKING Pressure regulating calibration at 100_C oil temperature -- minimum speed 1.2 bar; -- maximum speed 3.8 bar.

70483

Blow--by max: 20 cm3/l’ with 0.83 bar pressure and 26.7 _C oil temperature.

EW--2--32

667TA ENGINE OVERHAUL Oil pump Figure 26

84052

Figure 27

70150

1. Drive shaft with oil pump drive gear

EW--2--33

667TA ENGINE OVERHAUL Oil sump engines: 667TA/EEG -- 667TA/EEC -- 667TA/EBF -- 667TA/EED The steel oil sump (1) is flexibly secured to the engine block by an aluminium plate (3), Figure 29.

The C--section rubber gasket (2), fitted onto the oil sump leading profile, enhances sealing properties and also deaden noise.

This type of gasket can only be replaced in case of deterioration or break, and not necessarily at every single disassembling operation.

Figure 28

84054

Figure 29

84055

EW--2--34

667TA ENGINE OVERHAUL Oil sump engines: 667TA/EED -- 667TA/EBD The cast iron oil sump is secured to the engine block by bolts with interposed flat washers.

Figure 30

003202t

003203t

EW--2--35

667TA ENGINE OVERHAUL Engine oil vapour recirculation In tappet cover, a pre--separator (1) is housed, the shape and position of which determines an increase in the speed of outgoing oil vapours while condensig them partially. Condensed oil comes back into oil sump while residual vapours are being conveyed, collected and filtered in blow--by system (3).

In blow--by system (3), vapours partially condense and come back into oil sump while the remaining part is being recirculated as sucked through piping (2).

Figure 31

Oil condensate Oil vapours

1. Pre--separator -- 2. Sucking recirculation -- 3. Filter -- 4. Engine return

000966t

EW--2--36

667TA ENGINE OVERHAUL ENGINE COOLING The engine cooling system is of the forced, closed-circuit circulation type and is made up of the following components: - heat exchanger, used to cool the lubricating oil (lubrificatiion see);

- centrifugal water pump, housed in the engine crankcase front part; - thermostat, used to regulate coolant flow.

Figure 32

Water coming out from thermostat Water recirculating in engine Water going into pump 86494

EW--2--37

667TA ENGINE OVERHAUL WATER PUMP

Thermostat

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

Figure 35

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

Figure 33

79458

A = stroke start at 79.0 ÷ 83.0 °C; B = stroke at 96 _C ≥ 7.5 mm.

84058

Figure 34

84059

EW--2--38

667TA ENGINE OVERHAUL HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL) Introduction Extremely high injection pressures are necessary in order to reduce PARTICULATE emissions.

The common rail system makes it possible to inject fuel at pressures of up to 1450 -- 1600 bar, while the injection precision obtained by electronic control of the system serves to optimise operation of the engine while limiting emissions and fuel consumption.

For engines more powerful than 152 kW, the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar, whilst for engines less powerful

than 152 kW, DSLA nozzles are fitted which work a pressures up to 1450 bar.

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

Figure 36

107851

1. Connection to Electro--injectors -- 2. Sensor monitoring temperature of engine’s cooling liquid -3. Fuel pressure sensor cable -- 4. Sensor of engine’s oil temperature and pressure -5. Driving shaft sensor -- 6. Electro--injector -- 7. Temperature and air pressure sensor -8. Camshaft sensor -- 9. Fuel heater cable and fuel temperature sensor -10. Pressure gauge cabling -- 11. EDC 7 gearbox.

EW--2--39

667TA ENGINE OVERHAUL EDC 7 OPERATION

Smoke control under acceleration

Engine preheating element control Pre--post heating is activated when even just one of the water, air or fuel temperature sensors detects a temperature ≤ 5 °C. Phase recognition By means of signals transmitted by the camshaft and crankshaft sensors, the cylinder into which fuel must be injected is determined at the time of starting.

Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre--injection and main injection mode.

On F4 engines pre--injection is activated at all engine speeds.

Injection pressure closed loop control On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control unit administrates the regulator to maintain injection pressure at constantly optimal values.

Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping.

Idle speed control The control unit processes signals transmitted by the various sensors and adjusts the quantity of fuel injected.

It also controls the pressure regulator and modulates injection duration of the electro--injectors.

Within specific limits, the control unit also monitors battery voltage.

Overheating protection If the water temperature reaches 110 °C, the control unit reduces engine performance.

When the temperature returns below 100 °C, the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature).

Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits.

When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling energization time of the electro--injectors.

In some applications the maximum limiting response consists in stopping the engine.

Cut Off Fuel cut--off in release phases is managed by the control unit with the following logical interventions: - disactivation of the electro--injectors;

With intense load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro--injectors to prevent the emission of smoke from the exhaust.

- reactivation of electro--injectors immediately prior to arrival at idle speed; - control of fuel pressure regulator.

After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started.

Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque i.e. it increases the amount of fuel injected in order to restore the engine to maximum power.

Recovery strategies Recovery strategies are characterized by certain differences as application varies, i.e.

- Control of fuel leaks In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained with a low number of revs and high torque values in order to inject the maximum quantity of fuel.

- Control of pressure in the rail When the pressure in the rail exceeds safety values, the engine reduces power.

- Synchronism problems In the case of synchronism problems, faulty rev sensors, the system controls the engine by increasing the number of revs in order to improve interpretation of the signals.

- Power restrictions as operating temperature increases When the temperature of the supercharging air rises above 88 °C, power reduction is started; when a temperature of 120 °C is reached, performance is further reduced and is comparable to that of the same engine if it were aspirated.

- Reduction of power as reference temperature varies In normal operating conditions, the system knows the supercharging air, oil and water temperatures.

If the temperature of the engine water is not available, the system takes the temperature of the oil as reference and when this reaches the threshold of 103 °C, it starts to reduce the power available.

On reaching 113 °C, power is reduced to 50%.

EW--2--40

667TA ENGINE OVERHAUL SUPPLY SYSTEM Figure 37

High pressure Low pressure Fuel outlet

108607

1. Electro--injector -- 2. Common rail -- 3. Pressure limiting device for fuel return -- 4. Common rail pressure relief valve -- 5. Pre--filter mounted on the frame -- 6. High--pressure pump -7. Mechanical vane pump -- 8. Fuel filter The common rail system has a special pump that continually keeps the fuel at high pressure, irrespective of the phase and the cylinder that must receive the injection and it accumulates it in a duct common to all the electro--injectors.

At the electro--injector inlet there is therefore always fuel at the injection pressure calculated by the electronic control unit.

When the solenoid valve of an electro--injector is energized by the electronic control unit, fuel taken directly from the rail is injected into the relevant cylinder.

The fuel system is composed of a low--pressure circuit and a high--pressure circuit.

The high--pressure circuit is composed of the following pipes: - pipe connecting the high--pressure pump outlet to the common rail; - pipes supplying the electro--injectors from the common rail.

The low--pressure circuit is composed of the following pipes: - fuel pipe from fuel tank to prefilter; - pipes supplying the mechanical supply pump through the heat exchanger of the control unit, the manual priming pump and the pre--filter; - pipes supplying the high pressure pump via the fuel filter.

The fuel system is completed by the fuel outlet circuit from the common rail, injectors and high--pressure pump cooling circuit.

EW--2--41

667TA ENGINE OVERHAUL SUPPLY SYSTEM DIAGRAM Figure 38

OUTLET INTAKE (LOW PRESSURE) HIGH--PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE

108608

1. High pressure pump -- 2. Relief valve on the high--pressure pump, 5 bar -- 3. Adjuster valve fitted on the fuel return from the electro--injectors, 1.3 -- 2 bar -- 4. Over--pressure valve of the Common Rail -- 5. Common Rail -- 6. Pressure sensor -- 7. Electro--injector -- 8. Return pipe -- 9. Heat exchanger of the control unit -- 10. Mechanical priming pump -- 11. Prefilter fitted on chassis -- 12. Fuel tank -13. Mechanical fuel supply pump -- 14. Fuel filter -- 15. Pressure regulator -- 16. Backflow pipe from high-pressure pump -- 17. By--pass valve -- 18. By--pass valve.

The pressure regulator, upstream from the high-pressure pump, controls the flow of fuel needed in the low--pressure system. Then the high--pressure pump correctly supplies the common rail. This solution, pressurizing only the necessary fuel, improves energy efficiency and limits the heating of the fuel in the system.

The relief valve (2) fitted on the high pressure pump serves the purpose of maintaining the pressure at the pressure regulator inlet at a constant level of five bars regardless of the efficiency of the fuel filter and the upstream system.

Relief valve (2) operates to increase fuel flow in the high pressure pump cooling circuit through pipe (16) carrying fluid into and out of pipe (8).

The relief valve (3) housed on the cylinder head, fitted on the electro--injector return, governs the flow of fuel returning from the electro--injectors at a pressure of 1,3 ÷ 2 bars.

In parallel with the mechanical supply pump there are two by--pass valves.

The by--pass valve 18 makes it possible to have the fuel flow back from the mechanical pump outlet to its inlet, when the pressure at the fuel filter inlet exceeds the permissible limit. The by--pass valve 17 makes it possible to fill the supply system via the manual priming pump (10).

EW--2--42

667TA ENGINE OVERHAUL Fuel filter It is placed on engine cylinder block in the circuit between supply pump and high--pressure pump (CP3).

The following are placed on the support: fuel temperature sensors and heater resistance.

Heater is activated if the fuel temperature is ≤ 0 °C and is heated till it reaches 5 °C. Fuel temperature, signalled by the related sensor to EDC control unit 7, allows a very accurate computation of fuel flow--rate to be injected into the cylinders.

Figure 39

003206t

1. Fuel filter support -- 2. Heater connector -- 3. Electric fuel heater -- 4. Fuel filter -- 5. Fuel temperature sensor -- A. High--pressure pump outlet fitting -- B. Fuel exhaust inlet fitting from Common Rail and cylinder head (injectors) -- C. Exhaust fitting from high--pressure pump -- D. Inlet fitting from supply pump -E. Fuel exhaust outlet fitting to tank.

EW--2--43

667TA ENGINE OVERHAUL Mechanical supply pump Normal operating condition Geared pump, assembled in the rear part of the high-pressure pump; its function is supplying the same. It is controlled by the high--pressure pump shaft.

Under normal operating conditions, the fuel flow inside the mechanical pump is shown in the figure.

Figure 40

001237t

A. Fuel inlet from tank -- B. Fuel outlet to filter 1 -- 2. By--pass valves in closure position Output overpressure condition The by--pass valve (1) triggers when an overpressure is generated as output (B).

The current pressure, overcoming the elastic resistance of spring (1), communicates outlet with inlet through duct (2).

Figure 41

001238t

EW--2--44

667TA ENGINE OVERHAUL Drain conditions The by--pass valve (2) triggers when, with turned--off engine, the supply system has to be filled in through the priming pump.

Under this situation, the by--pass valve (2) is opened, due to the inlet pressure, and the fuel flows to outlet (B).

Figure 42

001239t

High--pressure pump type CP3.3 Pump with 3 radial pumping elements controlled through distribution gear, it does not need to be phased--up.

On the read high--pressure pump side, the mechanical supply pump is assembled, controlled by the high--pressure pump shaft.

Figure 43

001250t

1. Fuel outlet fitting to rail -- 2. High--pressure pump -- 3. Pressure regulator -- 4. Fuel inlet fitting from filter -- 5. Fuel outlet fitting to filter support -- 6. Fuel inlet fitting from control unit heat exchanger -7. Fuel outlet fitting from mechanical pump to filter -- 8. Mechanical supply pump.

IMPORTANT -- The high pressure pump unit -- feeding pump is not subject to overhaul , therefore it must not be disassembled neither the fixing screws must be tampered.

The only allowed interventions concern control gear and pressure regulator replacement.

EW--2--45

667TA ENGINE OVERHAUL Figure 44

001967t

1. Mechanical supply pump -- 2. Fuel return from high--pressure pump -- 3. Delivery valve to Common Rail -4. Single pumping element -- 5. By--pass valves on supply pump -- 6. Pump shaft -- 7. Fuel inlet from filter -8. 5--bar limiting valve -- 9. Pressure regulator.

EW--2--46

667TA ENGINE OVERHAUL High pressure pump--inside structure Figure 45

Sec. B-B

Sec. C-C

70498

1. Cylinder. – 2. Three--lobe element. – 3. Cap intake valve. – 4. Ball delivery valve. – 5. Piston. – 6-- Pump shaft. – 7. Low--pressure fuel inlet. – 8. Pumping elements supplying fuel ducts

Every pumping unit is composed of: - a piston (5) actuated by a three--lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate there-

with but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements; - cap intake valve (3); - ball delivery valve (4).

EW--2--47

667TA ENGINE OVERHAUL Working principle Figure 46

Sec. B-B

Sec. D-D

72597

1. Rail delivery outlet -- 2. Rail delivery valve -- 3. Pumping element -- 4. Pump shaft -- 5. Pumping element supply duct -- 6. Pressure regulator supply duct -- 7. Pressure regulator The pumping element (3) is orientated towards the pump’s camshaft (4). During the intake phase, the pumping element is fed through the feeding line (5).

The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge (7).

The pressure regulating gauge, according to the

PWM command received by the engine control module, stops the fuel flow to the pumping element.

During compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by--pass valve to common rail (2), feeding it through the exhaust unit (I).

EW--2--48

667TA ENGINE OVERHAUL Figure 47 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1--3--6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7).

The pump shaft is lubricated by the fuel through the feeding and recovery lines.

The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9).

The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.

Figure 47

Sec. C-C

72598

1. Pumping element inlet -- 2. Pump lubricating ducts -- 3. Pumping element inlet -- 4. Main pumping elements supplying duct -- 5. Pressure regulator -- 6. Pumping element inlet -- 7. Regulator exhaust duct -8. 5--bar limiting valve -- 9. Fuel exhaust from regulator inlet.

Figure 48 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

Figure 48

Sec. A-A

72601

1. Fuel exhaust flue -- 2. Fuel exhaust gallery -- 3 Fuel exhaust flowing from pump with connector to high pressure pipe for common rail

EW--2--49

667TA ENGINE OVERHAUL Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements (about 2 bars).

The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed.

The amount of fuel supplying the high--pressure pump is metered by the pressure regulator, placed on the low--pressure system; the pressure regulator is controlled by the EDC7 control unit through a PWM signal.

When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, not being able to come out, is compressed above the supply pressure value existing in the rail.

The thereby--generated pressure makes the exhaust valve open and the compressed fuel reaches the high--pressure circuit.

The pumping element compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

The delivery valves must always be free in their movements, free from impurities and oxidation.

The rail delivery pressure is modulated between 250 and 1600 bars by the electronic control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The radialjet pump disconnection – reconnection time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require setting.

If the pipe between fuel filter and high--pressure pump is to be removed--refitted, be sure that hands and components are absolutely clean.

RAIL Figure 49

108609

The rail volume is comparatively small to allow a quick pressurisation at startup, at idle and in case of high flow--rates.

It anyway has enough volume as to minimise system spikes and the use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further en-

abled by a calibrated hole being set downstream of the high--pressure pump.

A fuel pressure sensor (1) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed--back information, depending on which the rail pressure value is checked and, if necessary, corrected.

EW--2--50

667TA ENGINE OVERHAUL BOOST GAUGE VALVE The boost valve (1750 bars) is assembled to the rail with the purpose to protect the system’s components in case of excessive increase of pressure within the high pressure system. Pressure limiter.

The valve can be single--stage (as the one showed in the picture) or double--stage with double working limit (1750 bars and 800 bars).

In the second case, when the pressure within the high pressure system reaches 1750 bars, the valve is activated as a single--stage one to exhaust the fuel and consequently reduce the pressure until reaching

safety parameters. Then it provides mechanically gauging the pressure into rail to aprx. 800 bars.

This way the valve enables working of the engine for extended timing at limited performances, avoiding the fuel’s overheating and preserving the exhaust galleries.

If the above mentioned valve is activated, the engine control module excludes by isolation the pressure gauge and records the errore code 8.4.

The pump will flow the maximum delivery to the rail.

Figure 50

70502

1. Body – 2. Small piston – 3. Stop – 4. Spring – 5. Direct tank discharge – 6. Seat on rail

A

Normally, the tapered piston end keeps closed the discharge towards the tank.

B

If the 1750 bar fuel pressure is exceeded in rail, the small piston is displaced and the excess pressure is discharged into the tank.

EW--2--51

667TA ENGINE OVERHAUL ELECTRO--INJECTOR

Injection start

The injector is similar as construction to the traditional ones, apart from the absence of plunger return springs.

The injector can be deemed as composed of two parts: - actuator – spray nozzle composed of pressure rod (1), plunger (2) and nozzle (3); - control solenoid valve composed of coil (4) and pilot valve (5).

The solenoid valve controls spray nozzle plunger lift.

Figure 52

Injector in rest position 15

Figure 51

15

70506

When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder.

70505

1. Pressure rod – 2. Plunger – 3. Nozzle – 4. Coil – 5. Pilot valve – 6. Ball shutter – 7. Control area – 8. Pressure chamber – 9. Control volume – 10. Control duct – 11. Supply duct – 12. Control fuel outlet – 13. Electric connection – 14. Spring – 15. High--pressure fuel inlet.

Injection end When coil (4) is de--energised, shutter (6) goes back to its closing position, in order to re--create such a force balance as to make plunger (2) go back to its closing position and end the injection.

IMPORTANT -- The injector cannot be overhauled and therefore it must not be disassembled.

EW--2--52

667TA ENGINE OVERHAUL Electro--injector The injectors are BOSCH CRIN 1 and CRIN 2, fitted according to the power developed by the engine.

Injectors

Jet

Engines

Pressures

CRIN 1

--

667TA/EEG -- 667TA/EEC

--

CRIN 2

DLLA 137 PV 3

667TA/EBF -- 667TA/EBD

250 ÷ 1600 bar

CRIN 2

DSLA 143 PV 3

667TA/EED

250 ÷ 1400 bar

Figure 53

108610

1. Jet

EW--2--53

667TA ENGINE OVERHAUL PRESSURE LIMITER FOR FUEL RETURN It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at a pressure 1.3 and 2 bars. By guaranteeing this pres-

sure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.

Figure 54

70507

A. To tank -- B. From injectors

EW--2--54

667TA ENGINE OVERHAUL LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 55

108641

The engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling its cooling, utilising rubber buffers to reduce vibration originated by the engine.

Through the engine control module it is possible to verify the correct working of the engine. (See part three of the hereby user’s guide specifically dedicated to diagnostic).

The electrical and electronic components of the engine are listed here following: 1. Coolant temperature sensor.

2. Electro--injector.

3. RAIL pressure sensor.

4. Air temperature/pressure sensor.

5. Starter motor.

6. Timing sensor.

7. Solenoid valve for pressure regulator.

8. Fuel temperature sensor.

9. EDC electronic control unit.

10. Crankshaft sensor.

11. Engine oil pressure/temperature sensor.

12. Heating element for pre--post heating.

EW--2--55

667TA ENGINE OVERHAUL EDC7 ECU Figure 56

01525t

A -- Connector to injectors; B -- Connector to chassis (Provide reference of the vehicle to which the engine is assembled); C -- Connector to sensors

EW--2--56

667TA ENGINE OVERHAUL Cable on engine All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.

Figure 57

114296

1. Injectors for cylinders 1--2 -- 2 Injectors for cylinders 3--4 -- 3. Injectors for cylinders 5--6 -- 4. Engine rpm sensor -- 5. Timing sensor -- 6. Engine oil pressure and temperature sensor -- 7. Fuel temperature sensor -8. Coolant temperature sensor -- 9. Air temperature and pressure sensor -- 10. Rail temperature and pressure sensor -- 11. Pressure regulator -- 12. Connector C EDC control unit (signal) -- 13. Connector A EDC control unit (power).

EW--2--57

667TA ENGINE OVERHAUL Injectors connector (A)

ECU PIN 1 2 3 4 5 6 7 8 9 10 11

FUNCTION Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector --Pressure regulator Pressure regulator Cylinder 2 injector

Sensors connector (C)

ECU PIN 1 2 3 4 5 6 7 8 9 10 11

12

Cylinder 3 injector

12

13

Cylinder 1 injector

13

14

Cylinder 4 injector

14

15 16

Cylinder 6 injector Cylinder 5 injector

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

FUNCTION --------Timing sensor Timing sensor -Negative for rail temperature and pressure sensor Positive for rail temperature and pressure sensor Signal from rail temperature and pressure sensor Coolant temperature sensor --Signal from fuel temperature sensor Engine rpm sensor ---Engine rpm sensor Negative for engine oil pressure and temperature sensor Negative for air temperature and pressure sensor Coolant temperature sensor Signal from engine oil pressure sensor Signal from engine oil temperature sensor ---Positive for engine oil pressure and temperature sensor Positive for air temperature and pressure sensor Signal from air pressure sensor Negative for fuel temperature sensor Signal from air temperature sensor

EW--2--58

667TA ENGINE OVERHAUL Crankshaft sensor This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted

on the crankshaft.

The crankshaft sensor is connected to the control unit on pins 19C -- 23C. The sensor impedance is ∼900 Ω.

Figure 58

50319

Crankshaft sensor Timing sensor This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft.

The signal generated by this sensor is utilized by the

electronic control unit as an injection phase signal.

Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.

The timing sensor is connected to the control unit on pins 9C -- 10C. The sensor impedance is ∼900 Ω.

Figure 59

50320

Timing sensor 3

2

1

50288 50342

Connector

Ref Ref. 1 2 3

Wiring diagram

Description Signal Signal Schield

ECU pin Camshaft sensor 19C 23C

Timing sensor 10C 9C

EW--2--59

667TA ENGINE OVERHAUL Supercharging air pressure -- temperature sensor his component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the control unit on pins 25C -- 36C -- 33C -- 34C.

The power supply is 5 volt Voltage at the sensor output is proportional to the detected pressure or temperature.

Engine oil temperature--pressure sensor This component is analogous to the air temperature-pressure sensor.

The engine oil temperature--pressure sensor is installed on the engine oil filter support in a vertical position.

This sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 24C -- 28C -- 32C -- 27C.

The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges -- this value is used exclusively by the control unit.

Pin 25C -- 36C Temperature Pin 33C -- 34C Pressure

Pin 24C -- 28C Temperature Pin 32C -- 27C Pressure

Figure 60

50324

50344

Wiring diagram

Ref Ref. 1 2 3 4

Description Ground NTC signal (temperature) +5 V power unit Signal (pressure)

ECU Pin Oil 24C 28C 32C 27C

Air 25C 36C 34C 34C

EW--2--60

667TA ENGINE OVERHAUL Fuel temperature and pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).

The injection pressure value is used as a pressure control feedback signal and to determine the duration

of the electrical injection command.

This sensor is connected to the control unit on pins 12C -- 14C-- 13C. The power supply is 5 Volt.

Figure 61

0051065t

Fuel pressure sensor connector

Ref. 1 2 3

Description Ground Signal Power supply

ECU Pin 12C 14C 13C

EW--2--61

667TA ENGINE OVERHAUL Electro--injectors The electro--injectors are effectively N.O. solenoid valves.

Each injector is connected to the EDC control unit on

Ref. CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

connector A. The impedance of the coil of each injector is 0.56 -0.57 Ω.

Description 1 2 3 4 1 2 3 4 1 2 3 4

Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector Cylinder 6 injector Cylinder 6 injector Cylinder 5 injector Cylinder 5 injector

ECU Pin 11 A 6A 13 A 4A 14 A 3A 12 A 5A 15 A 2A 1A 16 A

Figure 62

50343

Figure 63

50349

EW--2--62

667TA ENGINE OVERHAUL Pre--post heating resistance and contactor The pre--post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post

heating operations. This resistance is powered by a contactor on the left hand side of the chassis.

The resistance impedance is approximately 0.5 Ω.

Figure 64

003215t

Resistance

Figure 65

002371t

A. Control contactor The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 °C. The contactor impedance is approximately 15 Ω.

WARNING -- Do not use flammable liquids or gases to help starting the engine.

These substances could easily catch fire once in contact with the resistance, causing very dangerous situations.

EW--2--63

667TA ENGINE OVERHAUL Coolant temperature sensor This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine.

The same signal is utilized by the control unit to drive

an instrument panel gauge, if present.

This sensor is connected to the control unit on pins 15C -- 26C. The impedance of the coolant temperature sensor at 20 °C is approximately 2.50 Ω.

Figure 66

107471

EW--2--64

667TA ENGINE OVERHAUL Fuel temperature sensor This sensor is identical to the coolant temperature sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.

The fuel temperature sensor is connected to the control unit on pins 35C -- 18C. The sensor impedance at 20 °C is approximately 2.50 Ω.

Figure 67

0051140t

1. Fuel temperature sensor -- 2. Filter heating resistance The ECU drives the filter heater contactor at fuel temperature ≤ 5 °C.

Figure 68

107799

107798

Connector

Ref Ref. 1 2

Description Ground Temperature signal

ECU Pin Coolant 15C 26C

Fuel 35C 18C

EW--2--65

667TA ENGINE OVERHAUL High pressure pump -- pressure regulator

Figure 69

000912t

A. Pressure regulator

The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the pressure regulator is managed by the EDC7 control unit.

Delivery pressure to the rail is modulated between 250 and 1450 bar by the electronic control unit by controlling the pressure regulator solenoid valve.

- This component is a N.O. solenoid valve.

- The solenoid is connected to the control unit on pins 9A -- 10A. - The solenoid valve impedance is approximately 3.2 Ω..

EW--2--66

667TA ENGINE OVERHAUL CHECKING THE FUEL SYSTEM This section analyses the tests for correctly troubleshooting and checking the fuel circuit and the common rail injection system. The stated procedure can be used in the event of trouble with the engine injec-

Error 8.1

8.2 8.4 8.5

tion system correlated with error codes 8.x saved in the control unit, or not accompanied by any error code and the user notices a drop in performance. The following table gives descriptions of error codes 8.x.

Description -- Negative deviation of the fuel pressure (actual pressure higher than the objective pressure).

-- Positive deviation of the fuel pressure (actual pressure lower than the objective pressure).

-- Drop in fuel pressure with vehicle in motion (lack of diesel).

-- Drop in fuel pressure with vehicle in motion: downhill with throttle pedal released (lack of diesel).

-- Drop in fuel pressure with the engine idling (lack of diesel).

-- Fuel pressure sensor on rail.

-- Backflow valve control (opening the pressure relief valve DBV).

-- Fuel pressure in the rail too high.

-- Fuel pressure in the rail too low.

DESCRIPTION OF TESTS AND CHECKS THAT CAN BE PERFORMED

Necessary equipment Use an appropriate set as described in the figure.

The contemplated tests are: - Low pressure supply test - Test on the pressure relief valve on the rail - Test on fuel backflow from the injector return

Figure 70

108599

1. Pressure gauge 1 (0 -- 15bar) and standard couplings -- 2. Pressure gauge 2 and standard couplings -3. 2--litre container -- 4. Pressure gauge pipes -- 5. Graduated container of 100ml -- 6. Plug for rail -7. Closed Voss coupling.

EW--2--67

667TA ENGINE OVERHAUL Low pressure supply test The figure shows a diagram describing the use of the components available in the specific set.

Figure 71

108600

A. Fuel tank -- B. Prefilter -- C. Low--pressure pump -- D. Fuel delivery circuit -E. Fuel filter -- F. High--pressure pump CP3.3 -- G. High--pressure circuit -- H. Common rail -I. Fuel recirculation circuit -- L. Injectors -- M1. Pressure gauge 1 fuel filter inlet -M2. Pressure gauge 2 fuel filter outlet -- N. External container.

Figure 72

108601

EW--2--68

667TA ENGINE OVERHAUL Low--Pressure Pump The function of the gear pump is to supply the high-pressure pump CP3.3. It is driven by the shaft of the high--pressure pump and is fitted on its rear portion.

Under normal operating conditions, the flow of fuel inside the pump is as shown in the figure.

Figure 73

108602

On completing the fuel supply system and with the battery charged to 24.7V, the engine must start within the 20 seconds of activation of the starter motor, drawing fuel from the external container placed at most 1 metre lower than the engine. If the pump is not able to draw up fuel in the stated time and therefore start the engine, replace it.

After starting the engine, check the pressure at 1500 rpm:

- On pressure gauge M1 it must be between 6 and 9 bar: -- if lower than 6 bar: replace the pump, -- if higher than 9 bar: replace the diesel filter.

- On pressure gauge M2 it must be greater than 5 bar: -- if lower, replace the diesel filter, -- if the trouble persists, check the seals of the couplings of the fuel filter support and of the high--pressure pump inlet.

EW--2--69

667TA ENGINE OVERHAUL Test on the pressure relief valve on the rail Fitted at one end of the rail, its function is to protect the system’s components if any malfunctioning causes an excessive increase in the pressure of the high--pressure system.

Figure 74

108603

Disconnect recirculation pipe (1) from the pressure relief valve and plug with the Voss fitting in the appropriate set. No diesel must come out of the valve at any engine speed. If the diagnosis system signals fault code 8.4 ”Engine -- backflow valve control”, it means that the EDC control unit has recognised that the valve has opened after a significant change in the pressure of the rail (greater than 1700bar). Since its opening is to be considered a consequence of the abnormal increase in pressure, the valve is NOT defec-

tive even though a great amount of diesel flows out.

Whereas, if the valve seeps diesel without fault code 8.4, then replace it.

With the overpressure sensor disconnected or with a bundle of defective cables fault code 8.2 is generated and the rail pressure is set to 710bar (measurable with the diagnosis instrument). Therefore the trouble is to be found in the wiring and it is not necessary to replace the component.

IMPORTANT -- The experience acquired to date shows that the defectiveness is RARELY due to the sensor.

EW--2--70

667TA ENGINE OVERHAUL Test on fuel backflow from the return Permits establishing the operating status of the injectors. The engine speed and power are controlled through the injectors. The power required by the user, through the accelerator, is converted into the

quantity of fuel injected per cycle. In its turn, this is converted into microseconds of injector opening according to the rail pressure.

Figure 75

108604

Notes: The injectors may have problems of both a mechanical and an electrical nature; before proceeding with the following analysis, it is wise to rule out the presence of water in the tank and in the fuel prefilter.

When the EDC warning light comes on occasionally

(fault code 8.1) in the phase of acceleration and/or cold start trouble, make the following checks.

- Possible incorrect tightening of the nut (1) locking the injector duct on the cylinder head. The prescribed torque setting is 50 ± 5 Nm.

Figure 76

108605

EW--2--71

667TA ENGINE OVERHAUL - Proceed with the injector fuel backflow tests.

Remove the duct (1) from the cylinder head, plug it (2) and fit on the coupled transparent pipe (3).

Figure 77

108606

Make sure first of all that the engine idling speed is as set in the factory. Check the quantities of fuel recirculation from the cylinder head. The conditions for measuring the quantities of injector return fuel are: - engine idling and without air compressor or air conditioner working; - engine at temperature (> 50 °C).

The quantity that flows out must be no greater than 80ml of diesel in one minute. Excessive recirculation (more than 80ml of diesel a minute) could be caused by: - incorrect coupling between one or more injectors and the related ”needles”; - problem of internal leakage of the injector.

To identify the defective injector, follow the method described hereunder. Measure the quantity of fuel

flowing out in one minute from the coupling on the cylinder head by means of a graduated container. Once you have ensured that recirculation exceeds 80ml per minute, plug the rail outlet of one injector (4) at a time, using the rail plugs in the set. The defective injector is the one whose exclusion caused a significant reduction in recirculation. In addition, remember that when changing an injector it is necessary to change the duct. After identifying the injectors / ducts with a high recirculation, check that the tightness of the ducts is as designed (50Nm ± 5) and tighten them if they are loose and then check the recirculation values again. If on the other hand the tightness is correct, remove the pipe and check that the spherical end towards the injector is not out of shape; replace it if it is and then check the recirculation value again.

If the duct is not out of shape either, then replace the injector and duct because there must be a leak inside the injector. Check the recirculation value again.

EW--2--72

667TA ENGINE OVERHAUL ENGINES OVERHAUL AT THE BENCH

Figure 80

Disassembling the engine - Exhaust the engine oil by removing plug from sump.

Figure 78

86500

Disconnect fuel piping (1) from rail and from high-pressure pump (5) and detach it removing securing screws (2).

70125

To apply to the engine block the brackets for fastening the engine to the overhaul stand, proceed as follows (working from the left side of the engine):

IMPORTANT -- When unlocking fitting (3) of piping (1), it is necessary, with a suitable wrench, to prevent fitting (4) of high--pressure pump (5) from rotating.

- use tool 380000985 to remove the fuel filter (5) from the support (1); - disconnect the low pressure fuel pipes (2 -- 3 -- 4) from the support (1); - remove the support (1) bracket from the engine block.

From the right side: Figure 81

Figure 79

70126 70128

IMPORTANTE -- Press clamp (1), as shown in Figure B, to disconnect the low p ressure fuel pipes (2 -- 3 -- 4, Figure 78) from the corresponding connections. After disconnecting the pipe, reset the clamp (1) in locking position (Figure A) to prevent distortions.

Remove the screws (2) and remove the oil pipe (3) from the supercharger pipe (1) and from the engine block.

Remove the starter (5) from the flywheel housing (4).

Apply brackets 380000995 to engine block and use them to secure the engine to the revolving stand 380000978.

EW--2--73

667TA ENGINE OVERHAUL Figure 82

70129

1. Injector connections -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil temperature and pressure sensor -- 5. Output shaft sensor -- 6. Injector -- 7. Air temperature/pressure sensor -- 8. Timing sensor -- 9. Fuel heater and fuel temperature sensor -- 10. Pressure limiter -- 11. EDC7 ECU

Disconnect the engine cable by disconnecting the connectors: (1) from injector wiring (6); (7) air pressure/ temperature sensor; (3) fuel pressure sensor; (11) ECU; (10) high pressure pump sensor; (8) timing sensor; (2) engine coolant temperature sensor on thermostat; (5) engine speed sensor.

Figure 83

(Demonstration)

91576

Disconnect fromthe rail (2): the fuel pipe (4) according to procedures described in Figure 79. Disconnect fuel pipes (5) from rail (2) and injector manifolds (3).

Remove the screws (1) and disconnect the rail (2).

EW--2--74

667TA ENGINE OVERHAUL Figure 84

Figure 86

74170

Disconnect pipe (2) from fuel return pressure limiter (1), as shown in Figure 79.

Remove the nut, loosen the retaining collar and disconnect the oil vapour pipe (5). Remove bolts (3) and take off the blow--by filter (4).

Remove nuts and remove the tappet cover including the gasket.

70132

Loosen tappet adjustment fastening nuts (1) and unscrew the adjusters. Remove the screws (2), remove the rocker assembly (3), consisting of: bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8).

Figure 85

Figure 87

86501

Remove nuts (7) and disconnect the electrical cables from injectors (8). Remove screws (1) and disconnect injector wiring support (2) including the gasket.

Remove screws (5), disconnect air pressure/temperature sensor (6). Remove nuts (3) and remove fuel manifolds (4).

IMPORTANT -- Disassembled fuel manifolds (4) must not be used again, but however replaced with other new ones.

70133

Remove injector fastening screws. Use tool 380001099 (1) to remove injectors (2) from the cylinder head.

EW--2--75

667TA ENGINE OVERHAUL Figure 88

Figure 90

86504

114064

Remove shroud (5), if present, from turbocharger (1).

Disconnect oil piping (4) from heat exchanger / oil filter support.

Remove nuts (2) and detach turbo--supercharger (1) from exhaust manifold (3).

Remove bolts (1) and disconnect exhaust manifold and heater air shroud (2). Remove the screws (4), and take out the cover (3) and the thermostat set underneath.

Remove the cylinder head (6) fastening screws (5).

IMPORTANT -- Pointed out external screws are shorter.

Figure 91

(Demonstration)

Figure 89

70137

Hook brackets (1) with metal ropes and remove cylinder head (2) from block using hoist.

Figure 92

70511

Remove securing screws (1) and detach exhaust manifold in two sections (2--3) with related gaskets.

72498

Remove cylinder head gasket (1).

EW--2--76

667TA ENGINE OVERHAUL Figure 93

Figure 96

114168

Release on the drive belt tensioner (2) and extract the belt (3) from the belt pulleys from the water pump ones and from the belt rebound pulleys.

Disassemble the belt tensioner (2).

Loosen the screws fixing the alternator (1) to the support and disassemble it.

Figure 94

108549

Use tool 380000985 to remove the oil filter (1).

Except 667TA/EEG--/EEC engines Remove bolts (2) and disconnect the alternator mount (3).

70142

Remove the screws (1) and disconnect the ECU (2) including the heat exchanger.

Figure 97

70145

Remove the nut (1) and disconnect the timing sensor (2).

Remove the nuts (3) and disconnect the high pressure pump (4) including the feed pump (5).

Figure 95 Figure 98

70141

Remove the screws (4) and disconnect the oil temperature/pressure sensor (3). Remove the screws (1) and then remove: heat exchanger/oil filter support (2), intermediate plate (6) and relevant gaskets.

Remove the oil level sensor (5).

70146

Fit tool 380000990 (2) to the flywheel housing (1) to stop flywheel (3) rotation. Loosen the screws (4).

EW--2--77

667TA ENGINE OVERHAUL Figure 99

Figure 102

108548

Remove the screws (3) and disassemble the damping flywheel (2) and the pulley (1).

Figure 100

00904t

Using the specific tie rod (3) of the tool 99363204 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

Figure 103

108549

Remove the screws (1) and disconnect the water pump (2). Remove the screw (3) and the roller (4).

Remove the screw (3) and disconnect the engine speed sensor (4).

Figure 101

70149

Remove the screws (1) and take out the front cover (2).

IMPORTANT -- Note the installation position of bolts (1) because they are of different lengths.

Figure 104

00900t

Remove the ring sealing the engine’s driving shaft from the front cover. Use the tool (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill (diam. 3,5 mm) for the depth of 5mm. Fix the tool to the ring tightening the 6 screws provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).

70150

Remove screws (1) and take off gear oil pump.

IMPORTANT – Oil pump (2) cannot be overhauled..

EW--2--78

667TA ENGINE OVERHAUL Figure 105

Figure 108

74775 70151

Remove tool 380000990 (2).

Remove screws (1), securing engine flywheel (3) to drive shaft (4).

Figure 106

Only engines: 667TA/EEG -- /EEC -- /EBF -- /EED Remove the screws (2), disassemble the plate (3) and disconnect the oil sump (1).

Figure 109

70152

Screw two pins (2) of adequate length into drive shaft holes (3).

Take out engine flywheel (1) so that it can be harnessed by means of a hoist and placed into its own container.

86516

Remove the screws (1 and 4) and disassemble the oil suction tube (5). Remove the screws (2) and disassemble the stiffening plate (3).

Figure 107 Only engines: 667TA/EED -- /EBD Figure 110

70153

Remove screws (2) and take off rear cover (1).

IMPORTANT -- Take note of themounting position of screws (1), due to the different size of the latter.

Put engine upside down.

86505

Put engine upside down, remove screws (2) and disconnect oil sump (1) with underlying gasket.

EW--2--79

667TA ENGINE OVERHAUL Figure 111

Figure 114

70158

86506

Remove screws (1) and (4) and dismantle oil suction strainer (5).

Remove screws (2) and dismantle stiffening plate (3).

Figure 112

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

Figure 115

70156

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

70159

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

Figure 113

Figure 116

70157

Remove screws (2) and take off timing gear case (1).

IMPORTANT -- Take note of themounting position of screws (2), due to the different size of the latter.

70160

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

IMPORTANT -- Take note of themounting 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.

EW--2--80

667TA ENGINE OVERHAUL Figure 117

Figure 120

70164 84086

Remove drive shaft (2) from crankcase by means of tool 380000992 (1) and a hoist.

Carefully remove distributing shaft (1) from the engine crankcase.

Figure 118

70162

Take off main half bearings (1).

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

Figure 119

Figure 121

70163

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

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

70165

Remove tappets (1) from the engine crankcase.

EW--2--81

667TA ENGINE OVERHAUL REPAIR OPERATIONS CYLINDER UNIT

Checking the eccentric lift and the pin alignment

Checks and measurements Figure 122

Place the shaft on back centres and check, bymeans of a centesimal comparator placed on themiddle support, that the alignment error is not greater than 0.04 mm; otherwise, replace the shaft. Also check the eccentric lift, which must be equal to 7.582 mm (for exhaust eccentrics) and 6.045 mm (for intake eccentrics). If different values are found, replace the shaft.

Figure 124

70166

After the engine has been dismantled, clean the crankcase--cylinder cluster thoroughly. Use proper rings to move the cylinder cluster. Check the crankcase carefully for cracks. Check the condition of working caps. They must be replaced if they arerusty 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. 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.

IMPORTANT -- If no ring gauge is available, use amicrometer to perform reset.

70171

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

BUSHINGS Figure 125

Figure 123

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.

70172

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.

EW--2--82

667TA ENGINE OVERHAUL Figure 126

sec. A--A

107268

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

EW--2--83

667TA ENGINE OVERHAUL Checking the surface supporting the head on the cylinder cluster Figure 128

Figure 127

α

84088

Verify that the head supporting plane on the cylinder cluster does not show deformations. This check can be carried out by taking off dowels (4) by means of a gauged rule (2) and thickness gauge (3). After detecting the deformed areas, flatten the supporting surface by means of a grinder. The flatness error must not be greater than 0.075 mm.

80585

IMPORTANT -- In case of reconditioning, all the linersmust bemachined to the same increase (0.5 mm).

Check the main bearing seats as follows: - 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.

IMPORTANT -- Crankcase flattening may be carried out only after making sure, when the repair work has been completed, that the protrusion of the piston fromthe cylinder liner is not greater than the specified value.

Check the condition of cylinder cluster working caps (1); they must be replaced if they are rusty or their sealing properties are in doubt.

After flattening, restore the cylinder liner countersink, as shown in Figure 127.

TIMING SYSTEM Distributing shaft Figure 129

84089

MAIN FEATURES OF DISTRIBUTING SHAFT The features described 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.

EW--2--84

667TA ENGINE OVERHAUL Replacing the bushings

Mounting the tappets

Figure 130

Distributing shaft

Figure 132

70176

70174

When replacing bush (1) use drift 380000991 (2) and handle 380000999 (3) to remove and refit.

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

Figure 133

IMPORTANT -- On refitting, bush (1) must be aligned so that the lubrication holes are aligned with the holes on the engine block seat.

70164

Lubricate the distributing shaft support bushings and mount distributing shaft (1) taking care not to damage the bushings or supporting seats.

Tappets Figure 131

Figure 134

86507

MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE SEATS ON THE CRANKCASE

70238

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.

EW--2--85

667TA ENGINE OVERHAUL DRIVE SHAFT

Figure 135

Measuring the journals and crankpins Figure 137

70179

Check the distributing shaft end play (1).

It must result of 0,23 ÷ 0,13 mm.

70182

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.

Figure 136

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

See Figure 138.

Reduction classes are 0.250 and 0.500 mm.

70180

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

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 138

70514

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

EW--2--86

667TA ENGINE OVERHAUL Figure 139

84091

MAIN TOLERANCES OF DRIVE SHAFT TOLERANCES CONCERNING: SHAPE ORIENTATION POSITION OSCILLATION

TOLERANCE--RELATED FEATURE Roundness Cylindricality Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper

GRAPHIC SYMBOL f /f/ //

GRAPHIC SYMBOL

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES

CRITICAL

©

IMPORTANT SECONDARY Figure 140 BEARINGS ON TIMING SIDE

BEARINGS ON TIMING SIDE

FIRST BEARING ON UPPER SIDE

84275

EW--2--87

667TA ENGINE OVERHAUL Measuring the journal assembling play

Replacing the oil pump drive gears Figure 141

Figure 143

84092

70184

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

Mount drive shaft (1).

Check the play between the drive shaft journals and their respective bearings by following the procedure below: Figure 144

When fitting the new gear, the latter must be heated for 10 minutes in a small furnace at a temperature of 160 ± 10% °C and force--fitted onto the drive shaft by putting the key in between.

Mounting the main bearings Figure 142 70186

- 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.

Figure 145 70185

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

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.

70187

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

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

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

- 1st phase with a torque wrench at 50 ± 6 Nm. - 2nd phase with a torque wrench at 80 ± 6 Nm.

EW--2--88

667TA ENGINE OVERHAUL Checking the drive shaft shoulder play

Figure 146

Figure 148 α

70188

- 3rd phase with tool 380001001 (1) placed as shown in the figure: tighten screws (2) further to an angle of 90° ± 5°.

70190

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.

Figure 147 CONNECTING ROD--PISTON ASSEMBLY Figure 149

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 thematching 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.

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 IMPORTANT -- Pistons are supplied as spares increased by 0.4 mm.

EW--2--89

667TA ENGINE OVERHAUL Pistons Measuring the piston diameter Figure 152

Figure 150

32613

Taking piston rings (1) off piston (2) by means of pliers 380000986 (3).

Figure 151

32615

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

IMPORTANT -- The diameter must be measured 49.5 mm far from the piston skirt base.

Figure 153

32614

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

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.

Figure 154

X = 0,6 ± 0,15 114088

MAIN DATA ABOUT PISTON, PINS AND SPRING RINGS* * Dimension is taken on 101 mm diameter

EW--2--90

667TA ENGINE OVERHAUL Gudgeon pins Figure 155

Figure 158

32620

18857

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

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

Conditions for correct pin/piston matching Figure 156

Figure 159 32619

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 157

41104

16552

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 two 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--91

667TA ENGINE OVERHAUL Figure 160

Figure 162

Y

70194

D H

Year of manufacture Day of manufacture Weight class

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

Connecting rods Figure 161

114314

IMPORTANT -- Each connecting rod is marked as follows: - 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, 1560 to 1600 (marked in yellow); -- W, 1601 to 1640 (marked in green); -- X, 1641 to 1680 (marked in blue); 86498

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.

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

Material removal is not permitted.

Bushings 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.

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.

EW--2--92

667TA ENGINE OVERHAUL Checking the connecting rods Figure 163

Checking the flexion Figure 165

61695 61696

Check the centrelines of connecting rods (1) are parallel using proper device (5) as follows: - mount connecting rod (1) on tool (5) spindle, then secure it by means of screw (4); - place spindle (3) on V--shaped block squares by putting connecting rod (1) on stop bar (2).

Checking the torsion Figure 164

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.

Mounting the connecting rod--piston assembly Connecting rod--piston coupling Figure 166

86550 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 ∼ 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.

The following reference data are engraved on the piston crown: 1. Spare part number and design modification number; 2. Inscription (facing the crankcase front side) indicating the mounting sign of the piston in the cylinder liner.

3. Date of manufacture; 4. Stamping indicating 1st recess insert testing.

EW--2--93

667TA ENGINE OVERHAUL Figure 167

IMPORTANT -- Spare piston rings are supplied in the following dimensions: -- standard, marked with yellow paint; -- increased by 0.4 mm, marked with yellow/green paint; Figure 170

86551

Connect piston (2) to connecting rod (4) by means of pin (3) so that reference inscription (1) for mounting piston (2) in the cylinder liner and the numbers stamped on connecting rod (4) can be seen as shown in the figure.

Figure 168 70200

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

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.

No matching operation must be carried out on half bearings.

72705

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

Mounting the connecting rod/piston assemblies in the cylinder liners Figure 171

Mounting the piston rings Figure 169

70201

32613

Use pliers 380000986 (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 120°.

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

Use band 380000994 (2) to mount the connecting rod--piston assemblies (1) into the cylinder liners; moreover, verify that: - the number of each connecting rod corresponds to the cap matching number.

EW--2--94

667TA ENGINE OVERHAUL Figure 172

Figure 174

α

70204 70202

SCHEME FOR MOUNTING THE CONNECTING ROD----PISTON ASSEMBLY INTO THE TUNNEL - the piston ring apertures are offset to each other by 120°; - all the connecting rod/piston assemblies weigh the same; - the writing stamped on the piston crown faces the crankcase front side, or the notch obtained on the piston skirt corresponds to the position of oil nozzles.

- Tighten screws (1) (previously lubricated with engine oil) to the specified torque by means of a torque wrench (2); Figure 175 α

Measuring the crankpin assembling play Figure 173

70205

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

Figure 176

70203

The play can be measured by following the procedure below: - clean thoroughly the parts and eliminate any trace of oil; - place a piece of gauged wire (2) on drive shaft pins (1); - mount the connecting rod caps (3) with their respective half bearings (4).

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).

EW--2--95

667TA ENGINE OVERHAUL Distribution gearbox case

Figure 177

Figure 179

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.

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.

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 0.10 to 0.33 mm.

70209

SCHEME FOR SEALANT LOCTITE 5205 APPLICATION AREA Clean thoroughly distribution gearbox case (1) and the engine crankcase.

Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal.

Apply sealant Loctite 5205 on the case so as to make a bead with a diameter of a few millimetres. The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps.

Any defect must be corrected as soon as practicable.

Avoid using excess material to seal the joint.

An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages.

After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes).

Figure 180

Checking piston protrusion Figure 178

70210

70208

After the connecting rod--piston assemblies have been mounted, check, by means of comparator 380001004 (1) equipped with base 380001000 (2), the protrusion of pistons (3) at the top dead centre relative to the crankcase upper plane.

It must result of 0.28 -- 0.52 mm.

SCHEME FOR REAR GEARBOX CASE FASTENING SCREW TIGHTENING SEQUENCE Reconnect box (1) to engine block. Screw securing screws in the position found out on dismounting and lock screws at tightening torques below indicated according to the order shown in figure.

Screws M12 65 ÷ 89 Nm Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm

EW--2--96

667TA ENGINE OVERHAUL Valve timing

Flywheel cover case Figure 184

Figure 181

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 (→) for timing.

70214

SCHEME FOR SEALANT LOCTITE 5205 APPLICATION AREA Clean thoroughly the attaching surfaces of flywheel case (1) and distribution gearbox case.

Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal.

Apply sealant Loctite 5205 on the case (1) so as to make a bead with a diameter of a few millimetres.

The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps.

Any defect must be corrected as soon as practicable.

Avoid using excess material to seal the joint.

An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages.

After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes).

Figure 182

70212

Turn drive shaft (4) and distributing shaft (2) in such a direction that whenmounting driven gear (1) on the distributing shaft, the stamped marks on gears (1 and 3) correspond to each other.

Figure 185

Figure 183

70216

70213

Tighten gear (2) fastening screws (1) to distributing shaft (3), then fasten them to the specified torque.

SCHEME FOR FLYWHEEL COVER CASE FASTENING SCREW TIGHTENING SEQUENCE Reconnect box (1) to engine block, screw securing screws in the position found out on dismounting and thighten them at torque below indicated according to the order shown in figure.

Screws M12 75 ÷ 95 Nm Screws M10 44 ÷ 53 Nm

EW--2--97

667TA ENGINE OVERHAUL Figure 186

Figure 188

70152 70216

Apply part (5) of tool 380000983 on drive shaft rear shank (6), secure it by means of screws (4) and force--fit the new seal ring (3) on the same.

Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in flywheel cover case (7).

Screw down two pins (2) of adequate length into the shaft holes (3), then remove the engine flywheel (1) by means of suitable harnesses and a hoist.

Figure 189

ENGINE FLYWHEEL Figure 187

70218

Apply tool 380000990 (2, except for 667TA/EEG -667TA/EEC engines) to the flywheel cover case (1) to stop engine flywheel (3) rotation.

Tighten screws (4) fastening engine flywheel (3) to the drive shaft.

Figure 190 α

114066

A engines: 667TA/EEG -- 667TA/EEC B engines: 667TA/EBF -- 667TA/EED C engines: 667TA/EED -- 667TA/EBD Replacing the engine flywheel ring gear Check the condition of ring gear (2) teeth. If breaks or excessive tooth wear is found, remove the ring gear from the engine flywheel (1, Figure 187) by using a normal beater, then mount the new gear ring after previously heating it to 150 °C for 15′ to 20′; the countersink made on the gear ring inner diameter must face the engine flywheel.

70219

Tighten engine flywheel (2) fastening screws (1) in two separate phases: - 1st phase: tighten to a torque of 30 ± 4 Nm by means of a torque wrench; - 2nd phase: angle--tighten to 60° ± 5°.

IMPORTANT -- Angle tightening is carried out by means of tool 380000304.

EW--2--98

667TA ENGINE OVERHAUL Figure 191

Figure 194

70220

Mount oil pump (1).

Screw down fastening screws (2) and tighten them to the specified torque.

Figure 192

70223

Take seal ring (2) off front cover (1), clean thoroughly the attaching surface and apply sealant Loctite 5205 onto the same.

Figure 195

70224

70221

Apply a new seal ring (2) onto water pump (1).

Clean thoroughly the surface of front cover (2) attaching base, then mount front cover.

Fasten screws (1) and tighten them to the specified torque.

Figure 196

Figure 193

70225 70222

Mount water pump (1).

Fasten screws (2) and tighten them to the specifiedtorque.

Apply part (5) of tool 380000983 on drive shaft front shank (6), secure it by means of screws (4) and force--fit the new seal ring (3) onto the same. Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in front cover (7).

EW--2--99

667TA ENGINE OVERHAUL Only engines: 667TA/EED -- /EBD

Figure 200

Figure 197

Set the gasket (1) on the oil sump (2).

86506

Mount plate (3) and strainer (5), then screw down fastening screws (1--2--4) and tighten them to the specified torque.

Figure 198

Figure 201

Fit the oil sump (1) and apply the plate (3) to it.

Tighten the screws (2) to the specified torque.

86505

Mount oil sump (1) and apply plate (3) on the same.

Fasten screws (2) and tighten them to the specified torque.

Only engines: 667TA/EEG -- /EEC -- /EBF -- /EED

74775

Figure 202

α

Figure 199

70363

Key phonic wheel (1) and hub (2) on drive shaft.

Screw securing screws (3) and tighten them in two steps.

- 1st step, tightening with a dynamometric wrench at 50 ± 5 Nm torque.

- 2nd step, locking with 90° angle.

IMPORTANT -- Angle tightening is carried out by means of tool 380001001 (4).

108553

Fit the plate (1), the oil pick up tube (2) and tighten the fastening screws (3) to the specified torque.

Mount damper flywheel (5) and pulley (6).

Screw securing screws (7) and tighten them at 68 ± 7 Nm torque.

EW--2--100

667TA ENGINE OVERHAUL Figure 203

Figure 205

70230

Mount a new seal ring on rpm sensor (3).

Fit rpm sensor (3) in front cover (1) and tighten screw (2) for securing at prescribed torque.

70232

Lubricate the sealing ring (2) with engine oil and set it on the oil filter (3).

Screw manually to seat the oil filter (3) on the support connection (1) and then screw again the oil filter (3) by 3/4 turn (except for 667TA/EEG -- 667TA/EEC engines).

Apply a new sealing ring on the oil temperature/pressure sensor (4) and fit it on the support (1).

Tighten the screws (5) to the specified torque.

Fit a new sealing ring (6) in the engine block seat.

Figure 206

Figure 204

70234

Position the alternator support (1) so that pins (3 and 4) are set against the engine block.

Tighten the screws (2) to the specified torque.

70231

Mount the following items on the crankcase: a new gasket (1), heat exchanger (2), a new gasket (3), and oil filter support (4).

Fasten screws (5) and tighten them to the specified torque.

EW--2--101

667TA ENGINE OVERHAUL CYLINDER HEAD

Figure 207

Removing the valves Figure 210

114170

Reconnect alternator (1) and tighten the bolts to the specified torque.

Reconnect automatic tensioner (4) and tighten bolt (3) to the specified torque.

Turn the automatic belt tensioner (4) to fit the belt (2) on pulleys and guide rollers.

Figure 208

70319

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

The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.

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

A = intake side -- S = exhaust side

70145

Refit the high pressure pump (5) including the feed pump (6) and tighten the nuts (3) to the specified torque. Fit the support (4) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the relevant fastening nut (1) to the specified torque.

Figure 211

Figure 209

70321

70320

Refit the ECU (3) including the heat exchanger to the engine block and tighten the screws (2) to the specified torque.

IMPORTANT -- Replace support elastic elements (1).

Valves can be removed by means of tool 380000987 (1) by pressing slightly on collar (3) so that lock cones (2) can be removed by compressing springs (4).

Then remove collar (3) and springs (4).

Repeat the operation on all valves.

Turn the head upside down and remove the valves (5).

EW--2--102

667TA ENGINE OVERHAUL Checking the cylinder head supporting surface

Figure 212

Figure 214

70322

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

IMPORTANT -- Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

70324

The plane of the supporting surface of head (1) to cylinder cluster is checked by means of a ruler (2) and a thickness gauge (3).

The deformation found on the entire length of the cylinder head must not be greater than 0.20 mm.

If greater values are found, reface the cylinder head according to the values and instructions given in the next figure.

Checking the cylinder head water seal Figure 213

Figure 215

70323

Check the water seal by means of suitable equipment.

Use a pump to feed water heated to ∼90 °C at a pressure of 2 to 3 bar.

If leaks are detected from the caps, the latter must be replaced by using a suitable beater for disassembling/ assembling operations.

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

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

70325

The rated thickness A of the cylinder head is 105 ± 0,25 mm; maximum allowed metal removal must not exceed thickness B by 0.13 mm.

IMPORTANT -- After reconditioning, check valve hollow and recondition, if necessary, the valve seats to obtain the prescribed hollow.

EW--2--103

667TA ENGINE OVERHAUL VALVES

Checking the play between the valve stem, valve guide and valve centring

Figure 216 EXAUST VALVE

INTAKE VALVE

Figure 219

70326

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

70327

Check can be made by means of a magnetic comparator (1) placed as shown. Assembling play must be equal to 0.039 to 0.079 mm.

Figure 217

Check, by making valve (2) rotate, that the centring error is not greater than 0.03 mm.

VALVE GUIDE 18625

Figure 220

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

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

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

Figure 218

INTAKE

18882

Use a micrometer (2) to measure valve stem (1), which must be equal to 7.96 to 7.98.

EXHAUST

79457

Use a bore gauge to measure the valve guide inner diameter, which must be equal to the value shown in the figure.

EW--2--104

667TA ENGINE OVERHAUL VALVES SEATS Valve seat reconditioning -- replacement Figure 221

70330

Check valve seats (2). If slight burns or scoring are found, proceed with reconditioning by means of the proper tool (1) according to the inclination values shown in Figure 222.

Figure 222

INTAKE

EXHAUST

107283

MAIN DATA ABOUT VALVE SEATS ON CYLINDER HEAD

EW--2--105

667TA ENGINE OVERHAUL Figure 223

EXHAUST

INTAKE

70332

MEAN FEATURES VALVE SEAT If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts.

By using the same tool (1, Figure 221) and taking care not to indent the cylinder head, remove as much material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.

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

Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 222.

VALVE SPRINGS Figure 225

Figure 224

50676

MAIN DATA FOR INTAKE AND EXHAUST VALVE SPRING CHECK

70333

After the reconditioning operations, verify, by means of base 380001000 (2) and comparator 380001004 (1), that valve hollow (3) corresponds to the specified value.

Prior to mounting, check the valve spring flexibility by means of the proper tool. Compare the elastic strain and load data with those relative to the new springs shown in the table below.

H H1 H2

Height mm 47.75 35.33 25.2

Under a load of N Free P 339.8 ± 9 N P2 741 ± 39 N

EW--2--106

667TA ENGINE OVERHAUL MOUNTING THE CYLINDER HEAD

Reattaching the cylinder head

Figure 226

Figure 228

70334

Lubricate the valve stem (1) and insert into the respective valve guide according to the position marked upon disassembling.

Mount seal rings (2 and 3) onto the valve guide.

IMPORTANT -- Seal rings (2) for aspiration valves are yellow: seal rings (3) for exhaust valves are green.

70335

Verify that the cylinder head attaching plane and the crankcase attaching plane are both clean.

Do not spoil the cylinder head gasket.

Arrange gasket (1) for cylinder head with writing “TOP” (1) towards head.

The arrow shows where gasket shim is inserted.

IMPORTANT -- Prior to reusing the cylinder head fastening screws, verify that they do not show traces of wear or deformations; otherwise, replace them.

Figure 227 Figure 229

α

70336

77032

Position spring (4) and upper collar (3) on the cylinder head: use tool 380000987 (1) to compress spring (4) and link the parts to the valve by means of lock cones (2).

Mount cylinder head (1), screw screws (2) and tighten them in three successive steps, following order and modalities indicated in next figure.

IMPORTANT -- Angle tightening is carried out by means of tool 380001001 (3).

EW--2--107

667TA ENGINE OVERHAUL Figure 230

Figure 232

α

A

70476

Scheme of cylinder head fastening screw tightening sequence: - 1st phase: pre--fastening by means of a torque wrench: • screw 12x1,75x130 ( ) 35 ± 5 Nm • screw 12x1,75x150 ( ) 55 ± 5 Nm

70339

s

- 2nd phase: angle tightening: 90° ± 5°

Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

- 3rd phase: angle tightening: 90° ± 5° A = Front side

Figure 233

Fitting injectors Figure 231

70338

Fit a new sealing ring (2) lubricated with vaseline and a new sealing washer (3) on injector (1).

70133

Use tool 380001099 (1) to fit the injector (2) into its seat.

Screw injector fastening screws without tightening them.

EW--2--108

667TA ENGINE OVERHAUL RODS AND TAPPETS

Figure 234

Figure 236

32655

70341

Fit a new sealing ring (3) lubricated with vaseline on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).

Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.

Rocker arm assembly Figure 237

IMPORTANT -- Disassembled fuel manifolds (2) must not be used again, but however replaced with other new ones.

Screw the fastening nuts (2, Figure 235) without locking them.

IMPORTANTE -- During this operation, the injector (1) shall be moved so that the manifold (2) is properly inserted into the fuel inlet hole (2, Figure 232).

70343

PARTS MAKING UP THE ROCKER ARM ASSEMBLY: 1. Screws -- 2. Support -- 3. Arbour -- 4. Rocker arm

Figure 235

Figure 238

70342

Use the dynamometric wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 ± 0.8 Nm torque.

Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque.

70344

MAIN DATA OF ARBOUR--ROCKER ARM Check that shaft/rocker coupling surfaces are not showing excessive wear or damages.

EW--2--109

667TA ENGINE OVERHAUL Tappet clearance adjustment

Figure 239

Figure 241

70345

Fit the rods (2).

Position jumpers (1) on valves with marks (→) facing the exhaust manifold.

70520

Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Working clearance shall be as follows: -- intake valves: 0,25 ± 0,05 mm -- exhaust valves: 0,51 ± 0,05 mm IMPORTANT -- Due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.

Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

Figure 240

70346

Check that tappet adjusters (1) are loosen to prevent their balking on the rods (2, Figure 239) when refitting the rocker assembly.

Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure themto the cylinder head by tightening the fastening screws (2) to 36 Nm torque.

EW--2--110

667TA ENGINE OVERHAUL Figure 242

Figure 244

74762

Connect new fuel pipes (1) to rail (3) and injector manifolds (2).

IMPORTANT -- When removed, pipes (1) shall always be replaced.

Figure 245 s

114067

Apply LOCTITE 5999 to the contact surfaces of intake manifold (1) and fit the manifold and heater to the cylinder head.

Screw in bolts (2) and tighten to the specified torque.

Fit air intake (3) with a new gasket (5) and tighten bolts (4) to the specified torque.

The figure shows the air intake for 667TA/EEG -667TA/EEC engines.

99226

IMPORTANT -- Pipe (7) connections shall be tightened to 20 Nm torque, using the proper wrench (5) and the dynamometric wrench 380000158 (4).

Connect the fuel pipe (3) to the rail (2) following the procedure shown in the following figure.

Figure 243

Figure 246

70126

74761

Fit the rail (2) and tighten the screws (1) to the specified torque, connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut (5) to the specified torque.

Press the clamp (1) in arrow direction (Figure B) and connect the pipe to the rail (2, Figure 245), reset the clamp to the initial locking position “A”.

IMPORTANT -- Check proper fuel pipe connection.

EW--2--111

667TA ENGINE OVERHAUL Wiring support

Figure 250

Figure 247

72501

Check electrical cable (5) conditions, replace if damaged by cutting the support (2) clamps and removing the screws (5) that secure it to connections (3).

Fit a new gasket (1) on the support (2).

72502

Fit a new gasket (2) on the tappet cover (1).

Figure 251

Figure 248

72511

Fit the tappet cover (1) and tighten the nuts (2) to the specified torque.

70353

Fit the wiring support (2) and tighten the screws (1) to the specified torque.

Figure 252

Figure 249

114068

70354

Connect the electrical cables (1) to the injectors (3) and use the dynamometric wrench 380000158 (4) to tighten the fastening nuts (2) to the specified torque.

Re--attach exhaust manifold (3) with new gaskets.

Screw securing screws (6) and tighten them at the required torque.

Re--attach turbo--supercharger (1) to exhaust collector (3) with a new gasket and tighten securing nuts (2) at the required torque.

Connect piping (5) to turbo--supercharger (1) support (7).

Connect oil piping (4) toheat exchanger support.

EW--2--112

667TA ENGINE OVERHAUL Figure 253

Figure 255

114069

Connect the air duct (2) to the turbosupercharger (3) and lock it by clamp (1).

70126

Press the clamp (1) in arrow direction (Figure B) and connect the pipe.

Reset the clamp to the initial locking position A.

IMPORTANT -- Check proper fuel pipe connection.

Figure 254

1

6 2

5 4

3

74170

Insert the blow--by filter (4) tightening the screws.

Connect the pipeline (6) and fix the oil vapour recover pipe through the clamp (5); lock up the nut fixing it to the upper edge.

Connect the pipeline (2) to the pressure-- limiter (1).

EW--2--113

667TA ENGINE OVERHAUL Figure 256

70129

1. Connections for electro--injectors -- 2. Engine cooling liquid temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil temperature and pressure sensor -- 5. Drive shaft sensor -- 6. Electro--injector -- 7. Air temperature and pressure sensor -- 8. Distribution phase sensor -- 9. Fuel heater and fuel temperature sensor -10. Pressure regulator -- 11. Control unit

Re--attach engine cable by connecting electro--injectors (6) wiring connectors (1); (7) air pressure/temperature sensor; (3) rail pressure sensor; (11) control unit; (10) high--pressure pump sensor; (8) distribution phase sensor; (2) engine cooling liquid temperature sensor on thermostat; (5) engine revolutions sensor.

Apply rocker lever 380000216 to engine lifting hooks, hook the rocker lever to hoist and detach engine from rotating stand. Disassemble brackets 380000995.

EW--2--114

667TA ENGINE OVERHAUL Figure 257

Figure 259

70125 70128

Complete engine refitting as follows: Form the right side: Refit the starter (5) to the flywheel housing (4) and tighten the fastening nuts to the specified torque.

Fit the oil pipe (3) with a new sealing ring into the engine block and secure it to the turbosupercharger (1) by the screws (2) tightened to the specified torque.

Figure 258

Screw manually the fuel filter to the support (1), screw the filter by 3/4 turn, connect the pipes (2--3--4) to the relevant support connections (1) as shown in the following figure.

Figure 260

70362

Refit the bracket (2) including the fuel filter support (1) to the engine block, tighten the screws (3) to the specified torque.

70126

Press the clamp (1) as shown in figure B. After disconnecting the pipe, reset the clamp (1) to the initial locking position A, to prevent deformations.

When refitting is over, fill engine with the prescribed lubricating oil in the specified quantity.

SECTION 3

RECHARGING AND START--UP

INDEX Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--3--3

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--6

Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--3

Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--6

BOSCH 24 V -- 4 kW . . . . . . . . . . . . . . . . EW--3--4

Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--3--7

ISKRA 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--3--5

INDICE

EW--3--3

RECHARGING AND STRAT--UP STARTER MOTOR BOSCH -- 24 V -- 4 kW -- For engines: 667TA/EEG 667TA/EEC ISKRA -- For engines: 667TA/EBF 667TA/EED

Quick diagnosis Fault

Possible causes

Remedy

Dragging torque insufficient

1. Batteries run down

Restore

2. Circuit connections oxidized or loose

Replace the component

3. Brushes not in working order

Replace the component

4. Short--circuited field windings

Replace the component

5. Interruptedor short circuited ar-mature

Replace the component

6. Out--of--round collector

Replace the component

Dragging torque sufficient, but the engine won’t start

1. Free wheel or faulty electro--ma-gnet

Replace the component

Pinion won t engage

1. Bevelled ring gear

Restore

EW--3--4

RECHARGING AND STRAT--UP Bosch 24 V -- 4 kW 6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.

Clockwise direction of rotation Rated voltage 24 V Power 4 kW Figura 1

Figura 3

84262

84267

WIRING DIAGRAM

3/4 VIEW

Figura 2

Figura 4

84268

CHARACTERISTIC CURVES

84269

PINION ADJUSTER

EW--3--5

RECHARGING AND STRAT--UP ISKRA 24 V -- 4 kW Fork mesh type, driven by an electromagnet.

Clockwise direction of rotation Rated voltage 24 V Power 4 kW Figura 5

Figura 6

114183

WIRING DIAGRAM

114184

3/4 VIEW

EW--3--6

RECHARGING AND STRAT--UP ALTERNATOR

BOSCH

NCBI 28 V 35--70 A -- For engines:

667TA/EEG 667TA/EEC

Quick diagnosis Fault

Possible causes

Remedy

No recharge

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

Check the recharge circuit con-nections, clean and tighten the cable terminals on the alterna-tor and battery

2. Voltage regulator not in wor-king 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 ter-minals and cable terminals of batteries, starter motor and al-ternator

2. Voltage regulator not in wor-king order

Replace the component

3. Earth fault

Check earth connections

Poor recharge

Excessive recharge

EW--3--7

RECHARGING AND STRAT--UP Bosch NCBI 28 V 35--70 A Thre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.

Direction of rotation (control side) clockwise Current delivered at 6.000 min--1 ≥ 55A Rated voltage 28,5V Figura 7

Figura 9

84270

84271

WIRING DIAGRAM

3/4 VIEW

Figura 8

Figura 10

84272

CHARACTERISTIC CURVES OF CURRENT DELIVERY

84274

CHARACTERISTIC CURVES OF VOLTAGE REGULATOR

EW--3--8

RECHARGING AND STRAT--UP