Tigercat FPT C87 T4f ENGINE Service & Repair Manual - PDF DOWNLOAD

Tigercat FPT C87 T4f ENGINE

SERVICE AND REPAIR MANUAL

PRELIMINARY ISSUE 1.0, JUNE 2014 Tigercat Industries Inc.

42070AENG

P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

This publication provides unit and relevant component repair data, specifications, instructions and methodologies.

This publication has been drawn up for qualified and specialised personnel.

Before performing any operation check that the part relevant to the unit on which you must work is available along with all safety devices for accident-prevention, such as, goggles, helmet, gloves, shoes, etc. and hoisting and transporting equipment.

Operations are to be performed by following the indications included here, using the special equipment indicated and assuring proper repair, compliance with schedule and operator’s safety requirements.

Each repair must aim to restore operating efficiency and safety in compliance with the FPT provisions.

FPT cannot be held liable for modifications, alterations or other interventions non authorised by FPT on the vehicle and if the unit is warranted the above mentioned interventions will cause its expiration.

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the interventions and all the instructions that are not included on this publication.

Data included in this publication may not be up-to-date therefore subject to Manufacturer’s modifications that can be added at any time for technical or commercial purposes and also to meet new law regulations in other Countries.

If issues on this publication differ from what is actually noticed on the unit, please get in touch with the FPT network before starting any intervention”.

It is forbidden to copy this text or any of its parts and all illustrations included.

Publication edited by: FPT Industrial S.p.A Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print P2D32C010 E - 1st Ed. 06.2014

F2CFE613E ENGINES

INTRODUCTION

1

Introduction Page

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PREFACE TO USER’S GUIDELINE MANUAL . .

3

- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Service operations . . . . . . . . . . . . . . . . . . . . . .

3

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . .

5

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

7

- Bonding and screening . . . . . . . . . . . . . . . . . . .

8

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . .

9

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES . . . . . . . . . . . . . . . . . . . . . . . .

10

UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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INTRODUCTION

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PREFACE TO USER’S GUIDELINE MANUAL Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents.

The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations and maintenance schedules.

The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components.

Section 1 describes the engines illustrating its features and working in general.

Section 2 describes the fuel supply type and engine operation.

Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis of their specific use.

Section 4 describes scheduled maintenance and specific overhauling.

Section 5 deals with removal and refitting of the main engine components.

Section 6 describes general mechanical servicing of the engine on the revolving stand.

Section 7 gives engine technical characteristics such as data, installation clearances and tightening torques.

Section 8 is about the tools necessary for performing these operations.

The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place.

The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

!

General danger It includes the dangers of above described signals.

Environment protection Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible.

NOTE

It indicates an additional explanation for a piece of information.

Service operations Example

1

Ø 1 = Seat of small end bush α

Close applying the required torque + angular value

 2 Ø 2 = Seat of connecting rod bearings.

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INTRODUCTION

Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

α

ρ

Compression ratio

Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

Visual inspection Fitting position check

Preload

Measurement Value to find Check

Number of revolutions

Equipment

Temperature

Surface for machining Machine finish

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F2CFE613E ENGINES

bar

Pressure

Interference Strained assembly

Oversized Higher than.

Maximum, peak

Thickness Clearance

Undersized Less than.

Minimum

Lubrication Damp Grease

Selection Classes Oversizing

Sealant Adhesive

Temperature < 0 C Cold Winter

Air bleeding

Temperature > 0 C Hot Summer

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GENERAL WARNINGS

!

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly.

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist.

When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.

Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.

Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers.

Worn out, damaged or consumable parts must be replaced by original spares.

During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.

Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

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Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.

Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central units.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM

!

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.

Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central units.

NOTE

Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.

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F2CFE613E ENGINES

Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components: -

Electronic central units must be connected to system bonding when they are provided with a metallic shell.

-

Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

-

Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.

Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

-

Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

-

If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

-

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Figure 1

1.

NEGATIVE CABLES ”STAR” CONNECTION TO SYSTEM BONDING M Figure 2

88039

2.

SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR d. DISTANCE ! 0

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INTRODUCTION

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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued by FPT. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES Power 1 kW 1 kW 1 CV 1 CV 1 hp 1 hp NOTE

Torque 1 Nm 1 kgm

= = = = = =

OF

THE

1.36 CV 1.34 hp 0.735 kW 0.986 hp 0.746 kW 1.014 CV

The unit CV is converted into hp for simplicity according to a 1:1 ratio 1 hp = 1 CV.

= =

0.1019 kgm 9.81 Nm

Revolutions per time unit 1 rpm = 0.1047 rad/s 1 rad/s = 9.55 rpm Pressure 1 bar 1 kg/cm2 1 bar NOTE

= = =

1.02 kg/cm2 0.981 bar 105 Pa

Where accuracy is not particularly needed: - Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1 1 kgm

=

10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1 1 kg/cm2

=

1 bar.

Temperature 0 C = 273.15 K 0 F = 255.37 K 0 C = 32 ˚F (the conversion factor between Celsius and Fahrenheit is 1:1.8) Print P2D32C010 E

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F2CFE613E ENGINES

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle

Printout number

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Section title

Language Publication

Page number

Basic edition referred to month - year editorial phase closing

When month - year update is present (revi) to the basic edition

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INTRODUCTION

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UPDATING Section

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Section name

Description of change

Page

Date of revision

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F2CFE613E ENGINES

CURSOR SERIES TIER 4B

General Specifications

1

Main engine diagrams

2

Electrical equipment

3

Maintenance planning

4

Removal and installation of main engine components

5

Engine overhaul

6

Technical specifications

7

Tools

8

Safety prescriptions

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Appendix

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SECTION 1 - GENERAL SPECIFICATIONS

1

SECTION 1 General Specifications Page

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IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . .

3

HOMOLOGATION PLATE . . . . . . . . . . . . . . . .

3

MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING . . . . . . . . . .

4

TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . .

5

COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . .

6

PERSPECTIVE VIEW . . . . . . . . . . . . . . . . . . . . . .

7

- Torque and power typical curves . . . . . . . . . .

8

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

9

GENERAL CHARACTERISTICS . . . . . . . . . . . . .

12

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SECTION 1 - GENERAL SPECIFICATIONS

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3

IDENTIFICATION PLATE Figure 1

218007

1. Engine serial number - 2. Technical code

HOMOLOGATION PLATE Figure 2

218008

1. Technical code - 2. Engine serial number - 3. Month and year construction date 4. Engine rating (maximum power in kW and bhp) - 5. Common part of technical code (F2CFE613E*B)

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F2CFE613E ENGINES

MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING

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Technical Code

Commercial Code

F2CFE613E*B009 F2CFE613E*B010 F2CFE613E*B011

C87 ENT Z W

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SECTION 1 - GENERAL SPECIFICATIONS

5

TECHNICAL CODE The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize its application and power output level. It is stamped on a side of crank-case, close to oil filter.

F2

C

F

E

6

1

3

E

*

B

010 Variants to basic engine

Emissions level: A = TIER 4a B = TIER 4full/STAGE IV C = EURO 6 D = Not emissioned Performances: 1,2,3... A,B,C...= Engine power or torque level Application: 0 = Other application 1 = Trucks 2 = Buses 3 = Industrial / Agricultural 4 = Industrial / Agricultural

5 = Genset 6 = Marine 7 = Cars 8 = Railway 9 = Military

Engine main characteristics: 0 = Turbocharged CNG 1 = Turbocharged diesel i.d. aftercooled 2 = Naturally Aspirated diesel i.d 3 = Naturally Aspirated diesel i.i 4 = Naturally Aspirated petrol 5 = Naturally Aspirated CNG 6 = Turbocharged diesel i.d.

7 = Turbocharged diesel i.i.

8 = Turbocharged petrol 9 = Turbocharged diesel i.i. aftercooled

No. of cylinders Cylinder configuration: A = 4 stroke vertical B = 4 stroke horizontal C = 4 stroke vertical with EGR D = 4 stroke horizontal with EGR E = 4 stroke vertical with post-treat F = 4 stroke horizontal with post-treat G = 4 stroke horizontal with EGR + post

treat H = K = L = M= N=

4 stroke at V 4 stroke at V with post treat 4 stroke vertical with EGR + post treat 4 stroke at V with EGR 4 stroke at V with EGR+ post treatment

F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6 Code C

Type of engine: Cursor Tier4 / Euro 6

F2 = New Engine Family

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F2CFE613E ENGINES

COMMERCIAL CODE The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical purpose of recognizing the engine’s components, which is served by the ”ENGINE S/N”.

C

87

E

N

T

Z

W

ENGINE CONTROL UNIT: W = EDC17CV41

EMISSION LEVEL: Z = Stage IV - Tier 4B

AIR INTAKE: T = INTERCOOLED SUPERCHARGED

ENGINE BLOCK: N = NOT STRUCTURAL

FUEL SUPPLY: E = ELECTRONIC INJECTION DISPLACEMENT: 87 = 8700 cc NOMINAL

ENGINE FAMILY IDENTIFIER: C = CURSOR

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7

PERSPECTIVE VIEW Figure 3

218006

F2CFE613E ENGINES

The engine F2CFE613E is a 6-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the CURSOR series and operates according to a four-stroke diesel cycle.

The engine supply system is electronically-controlled and it’s based on the direct injection of the fuel in the combustion chamber by means of high pressure pump and common rail.

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SECTION 1 - GENERAL SPECIFICATIONS

F2CFE613E ENGINES

Torque and power typical curves Figure 4

Maximum Power Maximum Torque 218009

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9

ENGINE VIEWS

Figure 5

LEFT-HAND SIDE VIEW

218001

Figure 6

RIGHT-HAND SIDE VIEW Print P2D32C010 E

218002

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SECTION 1 - GENERAL SPECIFICATIONS

F2CFE613E ENGINES

Figure 7

218003

FRONT VIEW

Figure 8

218004

REAR VIEW Base - June 2014

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Figure 9

218005

TOP VIEW

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SECTION 1 - GENERAL SPECIFICATIONS

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GENERAL CHARACTERISTICS F2CFE613 Type E*B009 Cycle

E*B010

E*B011

4-stroke Diesel Turbocharged with intercooler

Fuel feed Injection

Direct - high pressure pump supply and common rail system

No. of cylinders

6 in line



+

+

ρ

Bore

mm

117

Stroke

mm

135

cm3

8709

+ Total displacement Compression ratio Maximum power Max. torque

15.9 : 1 kW hp rpm

245 (333) 2,100

Nm (kgm) rpm

1,510 (153.92) 1,500

Loadless engine idling

rpm

900 ± 50

Loadless engine peak

rpm

2290 ± 50 Turbocharged with intercooler Honeywell (HTT) Waste-gate turbocharger (WGT)

SUPERCHARGING Turbocharger type LUBRICATION Oil pressure (warm engine) (100 ˚C ± 5 ˚C)

Forced by gear pump, relief valve single action oil filter

bar

- idling

bar

- peak rpm

bar

COOLING Water pump control Thermostat - start of opening - max. opening

0.6 3.5 Liquid Through belt

˚C ˚C

85  1.5 95

NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided

by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

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13

F2CFE613 Type E*B009 REFILLING Cooling circuit (1) L (Kg) Lubrication circuit (2) total capacity (3) L (Kg) Periodic replacement: Sump at minimum level L (Kg) Sump at maximum levelL (Kg) Fuel tank (4) L (5) Urea tank L

E*B010

E*B011

14 30 (27) 19 (17.1) 28 (25.2) 43 / 80 / 135

(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and Actifull OT even during the summer months. As an alternative to Actifull OT, use another product that complies with FPI9.COOL002 or CNH MAT 3624 specifications.

(2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9. Recommended oil is SAE 10W-40 meeting FPI9.LUBR001 or CNH MAT 3521.

The oil consumption is considered to be acceptable until a quantity equalling 0.5% of fuel consumption is reached.

(3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.

(4) Use STANDARD fuel compliant to the ASTM D975 or EN 590. Instructions connected to the fuel tank capacity are the responsibility of the FITTER since these are subject to changes depending on the various vehicle configurations.

(5) Only use AdBlue/DEF in accordance with ISO 22241 specification.

!

!

Worning — Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided

by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

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SECTION 2 - MAIN ENGINE DIAGRAMS

1

SECTION 2 Main engine diagrams Page

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FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . .

3

FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . . .

4

MECHANICAL SUPPLY PUMP . . . . . . . . . . . . .

5

- Overpressure condition at outlet . . . . . . . . . . .

5

- Drain conditions . . . . . . . . . . . . . . . . . . . . . . .

5

- Normal operating conditions . . . . . . . . . . . . . .

5

CP3.3NH HIGH-PRESSURE PUMP . . . . . . . . . . .

6

HIGH-PRESSURE PUMP - INSIDE STRUCTURE

7

- Operating principle . . . . . . . . . . . . . . . . . . . . .

8

- Pressure regulator description . . . . . . . . . . . . .

10

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

- Overpressure valve . . . . . . . . . . . . . . . . . . . . .

11

RAIL (PRESSURE ACCUMULATOR) . . . . . . . . .

11

- CRIN 3 Electro-injectors . . . . . . . . . . . . . . . . .

12

- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . .

15

LUBRICATION CIRCUIT COMPONENTS . . . .

16

- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Overpressure valve . . . . . . . . . . . . . . . . . . . . .

17

- Oil pressure regulator valve . . . . . . . . . . . . . . .

18

- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .

19

- Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . .

20

- Replacing oil filter cartridge . . . . . . . . . . . . . . .

21

- Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Oil fume recycle (Blow-by) . . . . . . . . . . . . . . .

23

COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . .

24

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Base - June 2014

2

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Page COOLING CIRCUIT COMPONENTS . . . . . . . .

25

- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

INTAKE AND EXHAUST SYSTEM . . . . . . . . . . .

26

INTAKE AND EXHAUST SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

27

- Honeywell waste-gate Turbocharger . . . . . . .

27

- Motorised throttle valve . . . . . . . . . . . . . . . . .

28

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

- Schematic diagram . . . . . . . . . . . . . . . . . . . . .

29

- AdBlue specification . . . . . . . . . . . . . . . . . . . .

33

- System of cooling/heating ATS system . . . . . .

34

MAIN COMPONENTS OF THE ATS SYSTEM .

36

- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

- Ad Blue fluid level gauge control . . . . . . . . . . .

37

- DeNOx 2.2 Supply Module (SM) . . . . . . . . . .

39

- Filter disassembly . . . . . . . . . . . . . . . . . . . . . . .

40

- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . .

41

- DeNOx 2.2 Dosing module (DM) . . . . . . . . .

42

- Engine coolant 3 way valve . . . . . . . . . . . . . . .

42

- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . . .

44

- Exhaust gas temperature sensor . . . . . . . . . . .

45

- Humidity and temperature detecting sensor . .

46

ATS SYSTEM MAINTENANCE PLANNING . . .

47

Base - June 2014

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F2CFE613E ENGINES

3

SECTION 2 - MAIN ENGINE DIAGRAMS

FUEL SUPPLY SYSTEM The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.

Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.

When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the rail takes place.

Figure 1

Low Pressure

218517

High Pressure Fuel backflow 1. Common Rail - 2. Electro-injector - 3. Engine Control Unit EDC17CV41 - 4. Fuel high-pressure pump - 5. Fuel filter

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Base - June 2014

4

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

FUEL SUPPLY DIAGRAM Figure 2

Low Pressure High Pressure

189012

1. High-pressure pump - 2. Fuel filter - 3.Tank - 4. Fuel pre-filter - 5.ECU - 6. Electric injectors 7.Common Rail - 8. Pressure sensor

!

After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level.

(IT MUST NOT INCREASE).

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

MECHANICAL SUPPLY PUMP

5

Drain conditions

Gear pump, fitted on the rear side of the high pressure pump and used to supply it.

Figure 5

It is controlled by high pressure pump shaft.

Normal operating conditions Figure 3

72594

72592

A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves in close position

The by-pass valve (2) cuts in when, with engine off, the fuel system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed whereas by-pass valve (2) opens due to inlet pressure, and fuel is drained out through B.

Overpressure condition at outlet Figure 4

72593

The by-pass valve (1) cuts in when overpressure is generated at outlet B. The existing pressure, overcoming valve spring (1) elastic strength, makes inlet and outlet communicating through duct (2).

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Base - June 2014

6

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

CP3.3NH HIGH-PRESSURE PUMP Pump with 3 radial pistons controlled by the timing gear, without needing any setting. On the rear side of the high pressure pump is fitted the mechanical supply pump controlled by the high pressure pump shaft.

The high pressure pump cannot be serviced and should not therefore be removed and the fastening bolts should not be tampered with. The only possible service operations are: replacement of the drive gear.

Figure 6

188494

1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger 8. Fuel outlet fitting from supply pump to filter - 9. Mechanical supply pump.

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

7

HIGH-PRESSURE PUMP - INSIDE STRUCTURE Figure 7

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 therewith 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)

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Base - June 2014

8

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Operating principle Figure 8

Sec. D — D

72597

1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct 6. Pressure regulator supply duct - 7. Pressure regulator

Pumping element (3) is oriented to pump shaft (4) cam. During intake, the pumping element is supplied through supply duct (5).

The fuel amount to be sent to the pumping element is set by the pressure regulator (7). The pressure regulator meters fuel flow to pumping element according to the PWM signal received from ECU. During pumping element compression stage, fuel reaches the pressure required to open the delivery valve to common rail (2) and to feed it through outlet (1).

Base - June 2014

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F2CFE613E ENGINES

Figure 9

Sec. C — C

9

SECTION 2 - MAIN ENGINE DIAGRAMS

Figure 10

72598

Sec. A — A

72601

1. Pumping element inlet - 2. Pump lubrication ducts 3. Pumping element inlet - 4. Main pumping element supply duct - 5. Pressure regulator - 6. Pumping element inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief valve - 9. Fuel drain from regulator inlet

1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet from pump with high pressure pipe fitting for common rail.

Figure shows low pressure fuel paths inside the path and highlights: main pumping element supply duct (4), pumping element supply ducts (1 — 3 — 6), pump lubrication ducts (2), pressure regulator (5), 5 bar pressure relief valve (8) and fuel drain duct (7).

Figure 10 shows high pressure fuel flow through pumping element outlet ducts.

Pump shaft is lubricated by fuel through delivery and return ducts (2).

- avoid letting impurities into the pump pressure channels;

Pressure regulator (5) establishes the fuel amount to send to pumping elements; excess fuel is drained out through duct (9).

- tighten to the specified torque.

Replacing the pressure regulator - Greatest cleanliness must be ensured; - replace the O-rings and moisten them with Vaseline;

5 bar pressure relief valve acts as fuel exhaust manifold and keeps 5 bar constant pressure at regulator inlet.

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Base - June 2014

10

SECTION 2 - MAIN ENGINE DIAGRAMS

Pressure regulator description The fuel pressure regulator is fitted on the low pressure circuit of pump CP.3. The pressure regulator modulates the amount of fuel sent to the high-pressure circuit according to the commands received directly from the engine control unit.

The pressure regulator is mainly composed of the following components: -

connector,

-

casing,

-

solenoid,

-

pre-load spring

-

shutter cylinder.

F2CFE613E ENGINES

Operation Figure 11

When there is no signal, the pressure regulator is normally open, therefore with the pump providing maximum delivery.

The engine control unit, via the PWM (Pulse Width Modulation) signal, modulates the change in fuel flow rate in the high-pressure circuit by partially closing or opening the sections of passage of the fuel in the low-pressure circuit.

185436

1. Solenoid - 2. Magnetic core - 3. Shutter cylinder 4. Fuel inlet - 5. Fuel outlet.

When the engine control unit operates the pressure regulator (via PWM signal), the solenoid (1) is energized, which in turn generates the movement of the magnetic core (2). The shift of the core causes the shutter cylinder (3) to move axially, choking the flow of fuel.

Figure 12

185437

1. Solenoid - 2. Magnetic core - 3. Preload spring 4. Shutter cylinder.

When the solenoid (1) is not energized, the magnetic core is pushed into the rest position by the pre-load spring (3). In this position the shutter cylinder (4) allows the greatest section of passage for the fuel flow.

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F2CFE613E ENGINES

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).

SECTION 2 - MAIN ENGINE DIAGRAMS

11

RAIL (PRESSURE ACCUMULATOR) Figure 13

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 EDC17CV41 control unit through a PWM signal.

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

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

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

The rail delivery pressure is modulated by the electronic control unit, through the pressure regulator solenoid valve.

144833

1. Rail - 2. Fuel return - 3.Pipelines to injectors - 4. Fuel supply from high pressure pump - 5. Pressure sensor 6. Overpressure valve The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates.

It anyway has enough volume as to minimise use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.

A fuel pressure sensor (5) 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.

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.

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Overpressure valve Overpressure valve is mounted at one rail end. Overpressure valve task is to protect system components should rail pressure sensor or CP3 pump pressure regulator malfunctioning cause a pressure excessive increase in high pressure system.

When pressure in rail is reaching 1800 bar, the valve at start operates in order to make fuel flow and consequently decrease pressure to safety values, then mechanically regulates pressure in rail. The valve enables to operate engine for long times with limited performance and prevents fuel excessive overheating, so preserving pipes for fuel return to tank.

Base - June 2014

12

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

CRIN 3 Electro-injectors The electro-injectors are mounted on the cylinder head and operated by the engine control unit.

Figure 14

188493

INSTALLATION DIAGRAM FOR INJECTORS ON HEAD 1. Bracket - 2. Injector - 3. Cylinder heads- 4. Injector protrusion.

They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot valve.

Figure 15

114255

1. Fuel return to the LP circuit - 2. HP fuel coupling.

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

13

The electro-injector may be considered as mainly made up of two parts: - Actuator - nozzle composed of pressure rod (4), needle (5) and nozzle (6); - Control solenoid valve, consisting of a coil (1) and pilot valve.

Figure 16

188492

INJECTOR SECTION 1. Coil - 2. High-pressure fuel inlet fitting - 3. Filter - 4. Pressure rod - 5. Needle - 6. Nozzle 7. Pressure chamber - 8. Control volume - 9. Pilot valve shutter - 10. Fuel return.

Electro-injector operation is divided into three phases: ”Idle position” The coil (1) is not energised and the shutter (9) of the pilot valve is closed.

Under this condition, opening and closing forces are balanced as fuel pressure in the control volume (9) equals that of the pressure chamber (7). ”Start of injection” The coil (1) is energized and causes the shutter (9) to rise.

The fuel of the control volume (8) flows off towards the return manifold causing a drop in pressure. Simultaneously, the line pressure exerts an opening pressure in the pressure chamber (7) that lifts the needle (5) thus causing fuel to be injected into the cylinders. ”End of injection” The coil (1) is de-energized and makes the shutter (9) return to its closed position. This creates a balance in the forces acting upon the needle (5), causing it to return to its closed position and consequently halt the injection of fuel.

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Base - June 2014

14

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Fuel filter Figure 17

218518

1. Fuel inlet from mechanical pump - 2. Fuel outlet to high-pressure pump - 3. Vent plug - 4. Fuel filter support 5. Drain screw - 6. Fuel filter - 7. Fuel filter clogging (pressure drop) sensor - 8. Fuel temperature sensor Characteristics: - Max flow rate

500 l/h

- Nominal pressure

< 13 bar

- Operating temperature

-40˚C/+120˚C

- Pressure drop with new filter

< 0.45 bar @ 500 l/h (ISO 4020/6.3)

- Pressure drop with filter at end of life

> 1.5 bar

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

15

LUBRICATION CIRCUIT A gear pump, located at the rear of the crankcase, serves to circulate the lubricant; the oil pump is driven by the crown wheel keyed to the tang of the crankshaft.

The lubricant is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve actuation.

The lubrication circuit also includes the heat exchanger and the turbocharger.

The pump contains a safety valve, while an oil overpressure valve is fitted on the crankcase.

Figure 18

Routing of oil return by gravity Routing of oil under pressure 166171

LUBRICATION SYSTEM LAYOUT

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Base - June 2014

16

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

LUBRICATION CIRCUIT COMPONENTS Oil pump The oil pump (1) is housed in the rear of the crankcase (3). It’s a gear pump (6) commanded by helical gear (5).

It receives the motion from the crankshaft (4) by means of helical gear (2) fitted to the stub of the crankshaft (4).

Figure 19

218519

The overpressure valve (1) houses the oil pump body Figure 20

112327

OIL PUMP SECTION

NOTA

The oil pump shall not be overhauled.

If you find any damage, replace the entire oil pump.

Engine speed [rpm] 1000 2400 Base - June 2014

Pump speed [rpm] 1515 3636

Outlet pressure [bar] 2 6

Flow [lpm] 62 128 Print P2D32C010 E

F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

17

Overpressure valve The valve opening start pressure is 10.1 ± 0.7 bar.

Figure 21

191572

OVERPRESSURE VALVE SECTION 1. Housing valve - 2. Steel ball - 3. Cap - 4. Spring - 5. Circlip - 6. Seal ring.

Figure 22

898 N/mm

219641

OVERPRESSURE VALVE SPRING 1. Unloaded spring - 2. Opening start - 3. Opening end - 4. Spring stuck.

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Base - June 2014

18

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Oil pressure regulator valve The oil pressure control valve is located on the left-hand side of the crankcase.

Start of opening pressure 5 bar.

Figure 23

73542

OIL PRESSURE REGULATOR VALVE SECTION Figure 24

188496

OIL PRESSURE REGULATOR VALVE SPRING 1. Unloaded spring - 2. Opening start - 3. Opening end - 4. Spring stuck.

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

19

Heat exchanger The heat exchanger is mounted inside the engine crankcase on the left-hand side.

Figure 25

114246

1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4. Oil filter - 5. Oil filter seal

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Base - June 2014

20

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Engine oil filter Figure 26

114247

1. Closure cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tank O-ring - 6. Washer - 7. Washer - 8. Support 9. Plug M14x1.5 - 10. Plug M38x1.5 - 11. By-pass valve 3.4 bar.

Characteristics 1. Max working pressure: 13 bar

Filter by-pass valve Figure 27

2.

Working temperature: - 30 C  + 120 C

3.

By-pass valve opening value: 3.4  0.3 bar

Lock torques Cap (part 1):

60  5 Nm

Plug (part 9):

30  5 Nm

Plug (part 10):

90  5 Nm

Installation rule Use threadlock for plug (part 10).

73545

Valve opens quickly at 3.4  0.3 bar pressure.

Base - June 2014

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F2CFE613E ENGINES

SECTION 2 - MAIN ENGINE DIAGRAMS

Replacing oil filter cartridge

21

Figure 30

Dismantling Figure 28

115878

Move the upper part of the casing thread close to the first lower thread of the support (the cartridge cover element should be in contact with the oil outlet duct on the support).

115876

Remove the plug (2).

Proceed with tightening the cartridge-casing assembly (1) on the support (4).

Undo the filter casing (1) by a couple of turns and wait for a few minutes.

During this stage both the seal (3) for the oil outlet duct-cartridge element and the casing-support seal (2) will gradually be involved.

In this way the remaining oil in the casing starts firstly to drip and then to flow smoothly out.

Tighten the filter casing to a torque of 65 Nm.

Completely undo the casing and then replace the cartridge.

Figure 31 Refitting Figure 29

115877

Insert the cartridge in the casing aligning the centering tabs (2) on the upper plate (1) with the seats.

The cartridge should be pushed into the container until the action of the attachment system at the bottom of the casing is overcome.

At the same time, the tabs on the upper plate should slide into the housings.

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115879

Tighten the protective cap (1) on the filter casing.

Base - June 2014

22

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Oil sump The oil sump has a new type of anchorage to the crankcase: rubber diaphragm.

The edge of the sump (1) is sealed within a thick “C“ rubber gasket (2), and the assembly is contained inside and supported by an aluminium element (3) bolted to the crankcase with screws (4).

This solution prevents noise and improves seal quality, while using less screws than the traditional system.

Yet another benefit is that the gasket does not require replacement at every removal.

Figure 32

218525

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F2CFE613E ENGINES

23

SECTION 2 - MAIN ENGINE DIAGRAMS

Oil fume recycle (Crankcase venƟlaƟon) Part of gas produced by combusƟon during engine operaƟon leaks through piston elasƟc ring openings into sump, mixing with oil fumes in sump.

This mixture, conveyed upward, is parƟally separated from oil by a device located in Ɵming cover upper part and introduced in air intake circuit.

The device mainly consists of a rotary filter (1) secured on camshaŌ and by a front cover (2) housing the valve (3) controlling mixture flow.

Figure 33

Gas with oil contents greater than 10 g/h Gas with oil contents approx. 0,2 g/h Condensed oil returning to oil sump

E00027

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24

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

COOLING CIRCUIT Description The engine cooling system is of the closed-circuit, forced circulation type.

It consists mainly of the following components: - expansion tank, not supplied (by FPT); - a heat exchanger to cool down lubrication oil; - a water pump with centrifugal system incorporated in the cylinder block; - fan, not supplied; - thermostat controlling the coolant circulation.

Operation The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan.

Figure 34

Water circulating in the engine Water to radiator

218520

Water coming into pump

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SECTION 2 - MAIN ENGINE DIAGRAMS

25

COOLING CIRCUIT COMPONENTS Water pump Figure 35

218528

CROSS-SECTION OF THE WATER PUMP The water pump consists of: rotor, shaft with bearing, T-gasket and drive pulley with dust shield.

NOTE Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.

Thermostat The thermostat is inserted into the water inlet pipe into the pump; it is an N/C valve.

The valve begins to open with temperatures exceeding 85 ˚C. When the valve is closed, the water arriving from the heat exchanger on the gearbox, recirculates inside the engine via the water pump.

When the valve is open, the water arriving from the heat exchanger on the gearbox is sent directly to the radiator where it is then cooled.

Figure 36

191251

TERMOSTAT SECTION - The valve starts to open at:

85 ˚C ± 1.5 ˚C

- The stroke is at least:

9 mm at 95 ˚C

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26

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

INTAKE AND EXHAUST SYSTEM Ignition from the panel allows crankshaft rotation, the phase in which the pistons compress the air/fuel mixture inside the combustion chamber.

After combustion, the exhaust gases cause rotation of the turbine splined to the centrifugal compressor by means of a connecting shaft. Rotation of the turbine involves the rotation of the compressor which compresses the air coming from the filter. This compression of the latter causes an increase in temperature and hence its expansion.

In order to introduce a greater quantity of mixture into the combustion chamber, the air is inter-cooled to increase its density at the same pressure.

A greater quantity of air introduced, corresponds to a greater quantity of fuel injected and, therefore, increased power.

Hence, to obtain an optimal mixture which generates increased power, the correct stoichiometric air-fuel ratio must be observed, so as to ensure the complete consumption of both during combustion.

The cycle is completed with the introduction of inter-cooled air from the intercooler into the intake manifold and then to the pistons to be used in combustion.

Figure 37

218527

Engine exhaust gas Compressed air Inlet air

DIAGRAM OF TURBOCHARGING Base - June 2014

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SECTION 2 - MAIN ENGINE DIAGRAMS

27

INTAKE AND EXHAUST SYSTEM COMPONENTS Honeywell waste-gate Turbocharger The turbocharger is fitted onto the exhaust manifold.

Figure 38

189008

1. Gasket - 2. Exhaust gas intake - 3. Waste gate valve 4. Compressed air outlet - 5. Air intake.

The turbocharger mainly consists of: - a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor impellers; - a turbine casing and a compressor casing mounted on the end of the central body; - an overpressure relief valve (waste-gate) fitted to the turbine body. The function of this valve is to choke the exhaust gas outlet, by conveying part of the gas directly into the exhaust pipe, when the boosting pressure downstream the turbocharger reaches the calibration value.

Figure 39

Closed throttle valve

Throttle valve open

75532

DEMONSTRATIVE CROSS-SECTION OF A TURBOCHARGER WITH WASTE-GATE VALVE Print P2D32C010 E

Base - June 2014

28

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Motorised throttle valve A throttle valve, powered by an electric actuator, is introduced into the exhaust pipe downstream of the turbine.

The valve is controlled by the ECU through an electric actuator which is cooled by the coolant from the engine.

The main novelty is the electric actuator that makes it possible to choke the exhaust gas outlet to increase its output temperature.

This possibility is used to rapidly bring the catalytic converter to its thermal operating condition (reduction of cold engine emissions).

Figure 40

188487

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SECTION 2 - MAIN ENGINE DIAGRAMS

29

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS) Schematic diagram Figure 41 Exhaust gas Compressed air Intake air Coolant engine Electric line AdBlue

CAN CAN

CAN

C U C

SCR

DO C

185019

1. Intake manifold - 2. Exhaust manifold - 3. Air Intercooler - 4. Air Filter - 5. Intake air humidity & temperature sensor 6. T/C compressor - 7. T/C turbine - 8. Exhaust flap module - 9. Nox sensor - 10. Exhaust gas temperature sensor 11. Dosing module - 12. Temperature sensor - 13. Exhaust gas temperature sensor - 14. Exhaust gas temperature sensor 15. NOx sensor - 16. NH3 sensor - 17. NH3 sensor ECU - 18. Supply module Denox 2.2 - 19. AdBlue tank - 20. AdBlue tank level sensor - 21. Urea Quality sensor - 22. Engine coolant 3 way valve - 23. Engine Control Module (EDC17CV41).

In order to reduce exhaust gas emissions to within the limits required by current standards, it has proved necessary to adopt the exhaust gas after-treatment system (ATS) which combines two devices: - two catalytic converters for the treatment of HC (unburned hydrocarbons) and CO (carbon monoxide); - the device DeNOx 2.2 for the treatment of NOx (nitrogen oxides).

The ATS system is electronically managed by the ECU EDC17CV41 which, based on the number of engine revs, delivered torque, exhaust gas temperature, amount of nitrogen oxides and air humidity intake, regulates the flow rate of the AdBlue solution to be introduced into the system.

The pump module draws the reagent solution from the tank and sends it under pressure to the mixing and injection module to be injected into the exhaust pipe.

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30

SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Figure 42

AdBlue Electric line Coolant engine 185020

1. Can line - 2. AdBlue tank - 3. AdBlue tank level sensor - 4. Urea quality sensor (UQS) - 5. AdBlue temperature sensor 6. Engine Control Module (EDC17CV41) - 7. Humidity and temperature sensor (after air filter) - 8. NOx sensor ECU 9. NH3 sensor ECU - 10. Supply module Denox 2.2 - 11. Urea pressure sensor - 12. NH3 sensor - 13. NOx sensor 14. SCR downstream exhaust gas temperature sensor - 15. Clean Up Catalyst (CUC) 16. Selective catalyst reduction (SCR) - 17. SCR upstream exhaust gas temperature sensor - 18. Mixer 19. Dosing module - 20. Exhaust gas temperature sensor - 21. Diesel Oxidation Catalyst (DOC) 22. DOC upstream exhaust gas temperature sensor - 23. NOx sensor 24. Engine coolant 3 way valve - 25. NOx sensor ECU. The ATS system is essentially composed of: - a DOC catalytic converter (Diesel Oxidation Catalyst); - an SCR catalytic converter (Selective Catalyst Reduction); - a CUC filter (Clean Up Catalyst) - a tank of the reagent solution (water + urea: AdBlue) with level indicator, temperature sensor and Urea quality sensor; - a H2O switch valve; - a supply module; - a dosing module; - three exhaust gas temperature sensors; - a humidity sensor mounted on the engine air suction pipe downstream of the air filter.

- two sensors to detect the amount of nitrogen oxides (NOx); - a sensor to detect the presence of NH3 (ammonia) upon exit of exhaust gases.

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31

Figure 43

185021

The catalytic converters perform two functions: - the first is composed of a DOC (Diesel Oxidation Catalyst) which removes HC (unburned hydrocarbons) and CO (carbon monoxide) from the exhaust gases; - the second is composed of the SCR (Selective Catalyst Reduction) and the CUC (Clean Up Catalyst) upstream of which are located the AdBlue dosing module and the mixer; this is where the reduction reactions of the NOx (nitrogen oxides) take place.

In the first phase the exhaust gases exiting the turbine are conveyed into the DOC catalytic converter in which the hydrocarbons (HC) and carbon monoxide (CO) added to oxygen O2 are converted into carbon dioxide (CO2) and water (H2O) through oxidation reactions.

In the second phase the dosing module, located in the exhaust pipe upstream of the SCR catalytic converter, introduces a water and urea solution (AdBlue) into the exhaust gases by means of a dosing injector.

The final phase of the process is realised in the SCR catalytic converter: the reagent solution, due to the temperature of the exhaust gases, instantly evaporates and, by hydrolysis, is converted into ammonia (2NH3) and carbon dioxide (CO2), at the same time; the evaporation of the solution causes the lowering of the exhaust gas temperature, bringing it close to the optimum temperature required for the process.

By reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

The engine control unit, based on the number of engine revs, delivered torque, exhaust gas temperature, air humidity intake, the amount of nitrogen oxides and urea present in the exhaust gases (detected by the respective sensors), regulates the flow rate of the AdBlue solution to be introduced into the system.

The amount of AdBlue injected is controlled by the NH3 sensor located downstream of the SCR. It detects the presence of ammonia in the exhaust gases and transmits a signal to the engine control unit, thus supplying a feedback signal.

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Figure 44

218526

1. DOC upstream NOx sensor - 2. Engine coolant 3 way valve - 3. Dosing module DeNOx 2.2 4. Intake air humidity and temperature sensor - 5. Supply module DeNOx 2.2 - 6. AdBlue tank 7. AdBlue tank level sensor - 8. Urea quality sensor (UQS) - 9. Selective catalyst reduction (SCR) 10. SCR upstream exhaust gas temperature sensor - 11. Exhaust flap module - 12. Diesel Oxidation Catalyst (DOC) 13. DOC upstream exhaust gas temperature sensor - 14. SCR downstream exhaust gas temperature sensor 15. NH3 sensor - 16. NH3 sensor ECU - 17. SCR downstream NOx sensor

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33

AdBlue specification ISO 22241 / AUS32 / DIN V 70070 Urea 32.5% - solution in water

Urea content Density at 20˚C Refracting index at 20˚C Alkalinity as NH3 Biuret Aldehyde Insolubles Phosphate (PO4) Calcium Iron Copper Zinc Chromium Nickel Aluminium Magnesium Sodium Potassium

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Min

Max

31.8 1.087 1.3814

33.2 1.093 1.3843 0.2 0.3 5 20 0.5 0.5 0.5 0.2 0.2 0.2 0.2 0.5 0.5 0.5 0.5

% by weight g/cm3 % % mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg

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System of cooling/heating ATS system The system performs two functions: - continuous cooling of the dosing module; - heating of the AdBlue tank, the supply module and AdBlue pipes and, at the same time, cooling of the dosing module.

Figure 45

Coolant engine AdBlue

185019

COOLING CONDITION 1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.

The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures reached by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously cooled.

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35

Figure 46

Coolant engine AdBlue 185023

CONDITION OF SIMULTANEOUS HEATING AND COOLING 1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.

Please note that AdBlue may freeze below temperatures of -11˚C. When the temperature of AdBlue in the tank falls below the acceptable limit, the switch valve (2) is activated which enables the flow of the engine coolant into the heating coil inside the tank (3) and hence into the supply module (4).

In this phase, the engine cooling temperature is such as to carry out the function of heating the components as described above.

Afterwards the engine coolant is conveyed towards the dosing module in order to cool its temperature.

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MAIN COMPONENTS OF THE ATS SYSTEM Tank Figure 47

215387

The tank has a level indicator command (1) and contains the reducing substance, consisting of a 33% urea and water solution called AdBlue. The inlet (4) is equipped with a mesh filter (3). A urea quality sensor (2) and a temperature sensor are incorporated in the tank.

NOTE

FPT recommends maintaining AdBlue temperature below 50 ˚C in the tank during operating conditions.

Tank ventilation: the circuit must be protected from dust.

Base - June 2014

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SECTION 2 - MAIN ENGINE DIAGRAMS

37

Ad Blue fluid level gauge control Figure 48

215388

1. AdBlue suction - 2. AdBlue return - 3. Engine coolant outlet - 4. Engine coolant outlet pipe - 5. AdBlue heating coil 6. Engine coolant inlet pipe - 7. Connector - 8. Engine coolant inlet - 9. Ad Blue suction pipe - 10. Filter 11. Bottom plate (AdBlue NTC temperature sensor) - 12. Float (AdBlue level sensor) - 13. Reed pipe 14. AdBlue return pipe

The AdBlue fluid level gauge control consists of - a float (level sensor); - an NTC temperature sensor; - a liquid heating coil in case of low temperatures.

Frozen AdBlue can be melted by means of a coolant heater coil (5).

A solenoid which is actuated by the ECU controls the engine coolant flow through the AdBlue circuit / tank heater.

Urea quality sensor is integrated in the tank unit to fulfil rapid anti-tampering.

NOTE

Ensure connectors are properly sealed with a moisture proof plug prior to AdBlue tank leak testing.

Temperature sensor:

NTC type; 1kOhm +/-5% @ 25˚C

Level sensor recommended characteristic:

70 Ohm at low level; 20kOhm at high level

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SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

Electrical connections: Figure 49

215389

Description

Ref. 1 2 3

Base - June 2014

Level Common ground NTC signal (temperature)

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39

SECTION 2 - MAIN ENGINE DIAGRAMS

DeNOx 2.2 Supply Module (SM) Figure 50

185025

1. Main filter - 2. Electrical connector - 3. Pressure compensation membrane - 4. Supply pipe from tank - 5. Fluid input pipe of pump module heating - 6. AdBlue return pipe to tank - 7. Fluid output pipe of pump module heating - 8. Delivery pipe to dosing module The AdBlue supply module is essentially composed of a diaphragm pump which draws the AdBlue from the tank and conveys it to the dosing module.

It is equipped with a circuit connected to the engine cooling system which, in the event of low temperatures, prevents the AdBlue from freezing. A pressure sensor is located inside it.

The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and depend on the operating conditions of the engine and the signals sent from the sensors.

Electric power requirements of DeNOx 2.2 Supply Module (SM) for 7.2 kg/h: 24 Volt systems:

max 2750 mA @ 28 Volt battery voltage

Figure 51

185029

1. Coolant connector - 2. AdBlue inlet from tank - 3. AdBlue back-flow to tank - 4. AdBlue outlet to DM - 5. Pressure sensor - 6. Main filter - 7. Membrane pump - 8. 4/2 Way valve.

To prevent damage to the pump and dosing module, the supply module contains a filter which removes any impurities from the AdBlue.

Please refer to the following procedure for replacement of the filter.

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Filter disassembly

Figure 55

Figure 52

185430 185435

NOTE During installation of the supply module on the vehicle, take into account the minimum aperture for filter replacement.

- Insert the tool (1) in the correct direction in the filter, based on the colour of the filter supplied

Figure 56

The minimum value is approx. 155 mm.

Figure 53

185431

- Insert the appropriate tool (1) until a click is felt which indicates the complete engagement of the filter (2).

185428

- Unscrew and remove the filter cover (1).

Figure 57 Figure 54

185432

185429

- Remove the equalizing element (1).

Base - June 2014

- Remove the filter (1).

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Filter assembly

41

Figure 61

Figure 58

185428 185433

- Carefully clean the contact surface with water (1).

- Carefully clean the filter cover (1).

- Tighten the filter cover to a torque of 20 ± 5 Nm.

Figure 59 Figure 62

185434

- Oil gaskets and assembly new filter (1).

185435

Figure 60 NOTE During installation of the supply module on the vehicle, take into account the minimum aperture for filter replacement.

The minimum value is approx. 155 mm.

185429

- Assembly a new equalizing element (1).

NOTE Check that the filter cover and the contact surface of the supply module are not cracked or damaged.

If necessary, replace any damaged components.

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SECTION 2 - MAIN ENGINE DIAGRAMS

F2CFE613E ENGINES

DeNOx 2.2 Dosing module (DM) Figure 63

193974

1. Electrical connector - 2. AdBlue inlet - 3. Coolant engine inlet/outlet The dosing module is controlled by the engine control unit. Its function is to measure the AdBlue solution to be injected into the exhaust pipe upstream of the SCR catalytic converter.

It is mounted on the catalytic converter and whilst operating is constantly subjected to high temperatures, hence it is connected to the engine cooling circuit by means of the pipes (3).

Maximum AdBlue injection pressure: 9 bar.

Hydraulic Capability of DeNOx 2.2 Dosing module (DM): Normal circulation and no injection: ~ 8 kg/h Maximum with the small urea injector: ~ 15 kg/h (8 kg/h + 7 kg/h) Maximum with the large urea injector: ~ 20 kg/h (8 kg/h + 12 kg/h)

Engine coolant 3 way valve Figure 64

180580

1. Electrical connector - 2. AdBlue tank heating fluid pipe - 3. Dosing module coolant pipe - 4. Engine coolant pipe.

The switch valve is of solenoid valve 2 position/3-way type. Depending on the temperatures detected by the NTC sensor, the switch valve closes or opens the passage of the engine coolant into the AdBlue tank heating coil. The cooling circuit of the dosing module instead always stays open.

The first position, in fact, allows the cooling of the dosing module (DM - Dosing Module) whereas the second position allows the cooling of the AdBlue tank, the supply module (SM - Supply Module) and the relevant pipes, besides heating the DM.

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43

NH3 sensor Figure 65

185027

The NH3 sensor is connected to the engine control unit and, by detecting the presence of ammonia (NH3) in the exhaust gases exiting the catalytic converter, enables a more accurate regulation of the amount of AdBlue to be injected.

Figure 66

185028

A. Vehicle connector - B. Sensor connector.

101. Supply - 102. Can H - 103. Can L - 104. Ground.

NH3 SENSOR CHARACTERISTICS Normal operating voltage Average current Max current Temperature / humidity rating

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NOMINAL 10 to 32 V 1.2 A 4.0 A -40 to 105 ˚C

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Nitric oxide sensor Figure 67

102302

1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare The NOx sensor detects the amount of nitrogen oxides in the exhaust gases entering and exiting the catalytic converters.

Based on this information the engine control unit regulates the amount of AdBlue to be injected and also measures the efficiency of the catalytic converters.

CHARACTERISTICS OF NOx SENSOR Ambient temperature electronics:

Wire temperature:

Base - June 2014

VALUE - 40 to +105 ˚C (+105 to +115 ˚C allowed for up to 10 min) 230 ˚C allowed for up to 100 h

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SECTION 2 - MAIN ENGINE DIAGRAMS

45

Exhaust gas temperature sensor Figure 68

102303

Figure 69

102304

FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) 5. Ground cable (white) - 6. Sensor.

The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system.

CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR Power supply Output voltage @ Temperature -40 to 1000 ˚C Pull up resistance Lead resistance

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VALUE 5.00 V ± 0.1% 0.727 to 2.297 V 1000  ± 0.1% 1

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Humidity and temperature detecting sensor Figure 70

125531

1. Supply - 2. Moisture indicator - 3. Ground connection - 4. Temperature This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to the control unit. These data are used by the ECU to determine the level of nitrogen oxide emissions.

Figure 71

102312

ELECTRIC BLOCK DIAGRAM 1. Power supply - 2. Moisture percentage - 3. Ground - 4. Temperature A. Sample frequency generator - B. Base oscillator - C. NTC temperature sensor - D. Amplifier low pass filter CHARACTERISTICS OF HUMIDITY SENSOR Voltage supply Current consumption Humidity operating range Output impedance Isolation resistance

VALUE 5.00 ± 0.25 VDC 10 mA 0% RH ÷ 100% RH 70  1 M @ 500 V

CHARACTERISTICS OF TEMPERATURE SENSOR Temperature operating range Resistance at 25 ˚C Max power at 25 ˚C

VALUE -40 to 125 ˚C NTC 2.186 k ± 1% 100 mW

Base - June 2014

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47

SECTION 2 - MAIN ENGINE DIAGRAMS

ATS SYSTEM MAINTENANCE PLANNING The general checking/inspec on intervals which must be carried out on the ATS system components are as follows.

The frequency of the maintenance opera ons is just an indica on since the use of the engine is the main characteris c to determine and evaluate replacements and checks.

It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling opera ons even if not being included in the ones listed here below but that may be suggested by common sense and by the specific condi ons in which the engine is run.

In case of evident system malfunc on immediately intervene in order to find the causes.

We wish to remind that each maintenance opera on, even the most simple must be performed in compliance with the accident preven on standards for the safety of maintenance personnel in charge.

Component Tank Pre-Filter (200μm)

Function Protect tank during filling

SM Pre-Filter (100μm) SM Inlet-Filter (100μm)

Protect SM from dirt coming from tank Protect SM during 1ststart-up

SM Main-Filter (100μm)

Protect DM

Service-Requirement No regular service planned (Cleaning, if required) Cleaning @ every oil change interval No regular service planned (Replacement, if required) Change every 250 hours

SM Backflow-Filter (100μm) Protect thro le in back flow connector from dirt No regular service planned (Replacement, coming from pressure line or dirt introduced during if required) change of SM Main-Filter Dosing Valve Filter (36μm)

Protect DM during 1ststart-up

Cannot be serviced

Figure 72

FILTER LOCATION

E00028

1. Dosing valve filter - 2. Dosing module - 3. SM Backflow-Filter - 4. SM Pre-Filter - 5. Tank pre-filter - 6. AdBlue tank 7. SM Inlet-Filter - 8. Supply module - 9. SM main filter.

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SECTION 2 - MAIN ENGINE DIAGRAMS

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F2CFE613E ENGINES

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F2CFE613E ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

1

SECTION 3 Electrical equipment Page

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MAIN ENGINE ELECTRICAL COMPONENTS .

3

- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . .

4

- Engine Control Unit (EDC17CV41) . . . . . . . .

5

EDC SYSTEM FUNCTIONS . . . . . . . . . . . . . . . .

6

- EDC 17CV41 control unit wiring diagram Vehicle side (part 1/2) . . . . . . . . . . . . . . . . . . .

8

- EDC 17CV41 control unit wiring diagram Vehicle side (part 2/2) . . . . . . . . . . . . . . . . . . .

9

- Pin out EDC 17CV41 control unit Vehicle side connector (connector 1) . . . . . . .

10

- EDC 17CV41 control unit wiring diagram Engine side . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

- Pin out EDC 17CV41 control unit Engine side connector (connector 2) . . . . . . .

14

- Electro-injectors (CRIN 3) . . . . . . . . . . . . . . .

17

- Fuel high pressure pump metering unit . . . . . .

18

- Rail pressure sensor (RDS4.4) . . . . . . . . . . . . .

19

- Crankcase pressure sensor . . . . . . . . . . . . . . .

19

- Increment speed sensor (Crankshaft) . . . . . . .

20

- Segment speed sensor (Camshaft) . . . . . . . . .

21

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

22

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

23

- Oil pressure and temperature sensor . . . . . . .

23

- Boost pressure and temperature sensor . . . . .

24

- Main fuel filter clogging switch . . . . . . . . . . . . .

24

- Motorized throttle valve actuator connector (Exhaust flap) . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Grid-heater resistance for engine pre-heating .

26

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SECTION 3 - ELECTRICAL EQUIPMENT

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F2CFE613E ENGINES

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SECTION 3 - ELECTRICAL EQUIPMENT

3

MAIN ENGINE ELECTRICAL COMPONENTS Figure 1

218030

1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Fuel temperature and filter clogging (pressure drop) sensor 4. Coolant temperature sensor - 5. Crankcase pressure sensor - 6. Grid-heater resistance for engine pre-heating - 7. Boost pressure and air temperature sensor - 8. Engine oil pressure and temperature sensor - 9. Engine Control Unit EDC17CV41 10. Fuel high pressure pump metering unit - 11. Starter electric motor - 12. Flywheel increment speed sensor (crankshaft) 13. Motorized throttle valve actuator connector (Exhaust flap) - 14. Timing segment speed sensor (camshaft) 15. Exhaust gas absolute pressure sensor

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SECTION 3 - ELECTRICAL EQUIPMENT

Figure 2

Base - June 2014

1. Electro-injector (cylinder 6) - 2. Electro-injector (cylinder 5) - 3. Electro-injector (cylinder 4) - 4. Electro-injector (cylinder 3) - 5. Electro-injector (cylinder 2) 6. Rail pressure sensor - 7. Electro-injector (cylinder 1) - 8. Bulkhead connector (wires passage) - 9. Crankcase pressure sensor - 10. Coolant temperature sensor 11. EDC engine side connector 96 pin - 12. In line vehicle side connector 7 pin - 13. Engine oil pressure and temperature sensor 14. Boost pressure and air temperature sensor - 15. Timing segment speed sensor (camshaft) - 16. Fuel high pressure pump metering unit 17. Fuel filter clogging (pressure drop) sensor - 18. Exhaust gas absolute pressure sensor - 19. Motorized throttle valve actuator connector (Exhaust flap) 20. Fuel temperature sensor - 21. Flywheel increment speed sensor (crankshaft)

4 F2CFE613E ENGINES

Engine cable

218024

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5

SECTION 3 - ELECTRICAL EQUIPMENT

Engine Control Unit (EDC17CV41) The connection of the ECU to the components of the EDC system is achieved by two connectors mechanically polarized in the coupling system in order to prevent mismatching: - Connector 1 for vehicle side connections; - Connector 2 for core engine components.

There is an internal ambient pressure sensor used to further improve the injection system control

Figure 3

189003

1. Vehicle connector (Connector 1) - 2. Engine connector (Connector 2)

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EDC SYSTEM FUNCTIONS The EDC 17CV41 electronic center manages the following main functions: Fuel injection Accessory functions such as cruise control, speed limiter, PTO and the like Self-diagnosis Recovery It also enables: Interfacing with other electronic systems (if any) available on the vehicle Diagnosis Fuel dosing Fuel dosing is calculated based on: - accelerator position - engine rpm - quantity of air admitted.

The result can be corrected based on: - water temperature or to prevent: - noise - fumes - overloads - overheating Pressure can be adjusted in case of: - motorised throttle valve actuation - serious defects involving load reduction or engine stop.

After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.

Delivery correction based on water temperature When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays are not optimized yet.

Fuel injected also tends to condense on cold metal surfaces.

Fuel dosing with a cold engine is therefore greater than when hot.

Delivery correction to prevent noise, fumes or overloads Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center to prevent them.

De-rating In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

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SECTION 3 - ELECTRICAL EQUIPMENT

7

Injection lead electronic control Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.

Lead is corrected as required: - during acceleration - according to water temperature and to obtain: - reduced emissions, noise abatement and no overload - better vehicle acceleration High injection lead is set at start, based on water temperature.

Delivery start feedback is given by injection electro valve impedance variation.

Engine start Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn by the starter motor.

Run Up When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run), and diagnoses the system.

After Run At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom) memory to make tem available for the next start (Cf. Run Up).

These data essentially consists of: - miscellaneous settings, such as engine idling and the like - settings of some components - breakdown memory The process lasts for some seconds, typically from 2 to 60 according to the amount of data to be stored, after which the ECU sends a command to the main relay and makes it disconnect from the battery.

This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before 10 seconds at least after engine cutout.

In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown memory and the engine operates at lower performance at next start while the EDC warning light stays on.

Repeated procedure interruptions could in fact lead to center damage.

Cut-off It refers to the supply cut-off function during deceleration.

Cylinder Balancing Individual cylinder balancing contributes to increasing comfort and operability.

This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each cylinder, to compensate for injector hydraulic tolerances.

The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.

Synchronization search The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.

If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence and start the engine.

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SECTION 3 - ELECTRICAL EQUIPMENT

Figure 4

218026

Base - June 2014

1. Vehicle connector EDC 96 pin - 2. CAN BUS to Customer’s application computer - 3. Diagnostic connector - 4. Controller Area Network C - 5. SCR downstream NOx ECU - 6. SCR downstream NOx sensor - 7. DOC upstream NOx ECU - 8. DOC upstream NOx sensor - 9. NH3 ECU - 10. NH3 sensor - 11. Urea Quality sensor 12. In line connector - 13. Battery Disconnection Switch (BDS) - 14. Alternator - 15. Alternator connector kit (J1) - 16. Starter electric motor - 17. Battery 18. Battery charge warning lamp - 19. SCR hose suction line heater - 20. Fuel pre-filter heater relay - 21. Fuel pre-filter heater - 22. SCR electrical heater 23. SCR heater relay - 24. Fuel filter/pre-filter heater relay - 25. Fuel filter heater - 26. Grid-heater relay - 27. Water in fuel switch - 28. ATS intelligent sensors auxiliary relay 29. Grid-heater - 30. Starter control relay - 31. Starter relay - 32. Body controller starter interlock (Vehicle safety) - 33. Body controller starter interlock relay - 34. Key switch 35. Alternative connections (A. ECU under time relay - B. ECU under BDS - C. ECU not under BDS)

8 F2CFE613E ENGINES

EDC 17CV41 control unit wiring diagram - Vehicle side (part 1/2)

Print P2D32C010 E

1. Vehicle connector EDC 96 pin - 2. Controller Area Network B - 3. SCR tank level and temperature sensor - 4. Diagnostic LED - 5. DEF dosing module 6. SCR downstream exhaust gas temperature sensor - 7. SCR upstream exhaust gas temperature sensor - 8. DOC upstream exhaust gas temperature sensor 9. Humidity and ambient temperature sensor - 10. SCR tank heating valve - 11. SCR Pump module (A. SCR pressure sensor - B. SCR reverting valve - C. SCR pump motor)

F2CFE613E ENGINES

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SECTION 3 - ELECTRICAL EQUIPMENT

9

EDC 17CV41 control unit wiring diagram - Vehicle side (part 2/2) Figure 5

218027

Base - June 2014

10

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Pin out EDC 17CV41 control unit - Vehicle side connector (connector 1)

Figure 6

189004

Pin

Signal

01

V_V_BAT +4

02

O_T_RL 11

03

G_G_BAT -1

04

O_T_RL 14

05

G_G_BAT -4

06

-

07

I_A_AN 23

SCR pressure sensor

08

I_A_AN 25

SCR temperature sensor

09

I_A_AN 22

Catalyst downstream temperature sensor

10

G_R_AN 10

Common ground

11

-

12

-

13

I_S_DIG 01

14

-

15

I_A_AN 04

Humidity sensor

16

I_A_AN 13

Exhaust gas temperature upstream sensor

17

-

18

-

19

O_S_RH 04

Starter relay

20

O_T_RH 03

ATS intelligent sensors Auxiliary Relay (H)

21

-

22

-

23

O_T_RH 01

24

-

25

V_V_BAT +3

Battery plus 3

26

V_V_BAT +5

Battery plus 5

27

O_V_RH 31

Common battery plus

28

G_G_BAT -2

Battery minus 2

Base - June 2014

Component Battery plus 4 SCR heater Battery minus 1 SCR hose suction line heater Battery minus 4 -

Water in fuel switch

DEF Dosing Module

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

Pin

Signal

29

G_G_RL 11

30

-

31

I_A_AN 12

SCR level sensor

32

I_A_AN 24

Catalyst upstream temperature sensor

33

-

34

O_F_ENGN

35

.

36

.

37

.

38

.

39

G_R_AN 12

Common ground

40

I_A_AN 14

Air temperature sensor

41

-

42

-

43

G_R_AN 14

Common ground

44

O_S_RL 24

OBD led

45

O_T_RL 18

ATS intelligent sensors Auxiliary Relay (L)

46

B_D_CANH0

CAN high

47

B_D_CANL0

CAN low

48

-

49

V_V_BAT +2

Battery plus 2

50

O_V_RH 11

Common battery plus

51

G_G_RL 07

Diagnostic LED ground

52

G_G_BAT -5

Battery minus 5

53

-

54

-

55

-

56

-

57

-

58

-

59

-

60

-

61

O_S_RL 20

62

-

63

I_S_T 50

64

-

65

-

66

-

67

-

68

V_V_5VSS1D

69

I_S_T 15

Print P2D32C010 E

11

Component Ground for low side power stage 11

Engine speed output

Fuel filter / pre-filter heating relay Start switch term. 50 input signal

Common supply KL15

Base - June 2014

12

SECTION 3 - ELECTRICAL EQUIPMENT

Pin

Signal

70

B_D_ISOK

71

B_D_CANH1

72

O_S_RL 12

73

V_V_BAT +1

Battery plus 1

74

O_V_RH 21

Common battery plus

75

G_G_BAT -3

Battery minus 3

76

G_G_RL 14

Ground for low side power stage 14

77

O_S_RH 07

Diagnostic LED plus

78

-

79

-

80

-

81

-

82

-

83

O_S_RL 22

Grid heater relay

84

O_T_RL 13

SCR pump motor

85

O_T_RL 16

SCR reverting valve

86

-

87

-

88

O_S_RL21

Low side source driver 21

89

G_G_RL 13

SCR pump motor

90

V_V_5VSS3A

Common supply

91

-

92

-

93

O_S_RL 27

94

-

95

B_D_CANL1

96

0_T_RL 10

Base - June 2014

F2CFE613E ENGINES

Component ISO-K interface Controller area network 1 (high) SCR Tank Heating Valve

Auxiliary relay / SCR heater relay Controller area network 1 (low) DEF Dosing Module

Print P2D32C010 E

218025

Print P2D32C010 E

1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Engine oil pressure and temperature sensor 5. Boost pressure and air temperature sensor - 6. Fuel filter clogging (pressure drop) switch - 7. Motorized throttle valve actuator connector (Exhaust flap) 8. In line connector - 9.Crankcase pressure sensor - 10. Timing segment speed sensor (camshaft) - 11. Flywheel increment speed sensor (crankshaft) 12. Fuel high pressure pump metering unit - 13. Exhaust gas absolute pressure sensor - 14. Bulkhead connector (wires passage) - 15. Rail pressure sensor (RDS4) 16. Electro-injector (cylinder 6) - 17. Electro-injector (cylinder 5) - 18. Electro-injector (cylinder 4) - 19. Electro-injector (cylinder 3) 20. Electro-injector (cylinder 2) - 21. Electro-injector (cylinder 1)

F2CFE613E ENGINES SECTION 3 - ELECTRICAL EQUIPMENT

13

EDC 17CV41 control unit wiring diagram - Engine side Figure 7

Base - June 2014

14

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Pin out EDC 17CV41 control unit - Engine side connector (connector 2) Figure 8 Colour legend C ORANGE A SKY BLUE B WHITE L BLUE G YELLOW H GREY M BROWN N BLACK W LIGHT BROWN S PINK R RED V GREEN Z PURPLE

189005

Pin

Cable colour

Signal

01

-

O_P_SVL21

Injector 1 “low”, Bank 2, Cylinder 4

02

-

O_P_SVL22

Injector 2 ”low”, Bank 2, Cylinder 6

03

-

O_P_SVL23

Injector 3 ”low”, Bank 2, Cylinder 5

04

-

-

Free

05

-

-

Free

06

G

G_R_DF03

07

V

V_V_5VSS21A

08

-

-

Free

09

-

-

Free

10

-

-

Free

11

G

V_V_5VSS3B

12

H

I_A_AN18

Fuel temperature sensor: NTC temperature signal

13

V

I_A_AN15

Engine oil pressure and temperature sensor: NTC temperature signal

14

-

-

Free

15

-

-

Free

16

G

I_A_AN02

17

G

B_D_CANH2

Motorised throttle valve actuator connector (Exhaust flap): Controller Area Network 2 high (CAN H)

18

C

B_D_CANL2

Motorised throttle valve actuator connector (Exhaust flap): Controller Area Network 2 low (CAN L)

19

Z

G_R_AN02

20

-

-

Free

21

-

-

Free

22

-

-

Free

23

-

-

Free

Base - June 2014

Component

Engine oil pressure and temperature sensor: ground for frequency input 3 Boost pressure and air temperature sensor: supply +5V

Rail pressure sensor: supply +5V

Exhaust gas absolute pressure sensor (P3): pressure signal

Exhaust gas absolute pressure sensor (P3): ground

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

Pin

Cable colour

24

-

-

25

-

O_P_SVH21

Injector 1 “high”, Bank 2, Cylinder 4

26

-

O_P_SVH22

Injector 2 ”high”, Bank 2, Cylinder 6

27

-

O_P_SVH23

Injector 3 ”high”, Bank 2, Cylinder 5

28

-

-

Free

29

-

-

Free

30

-

-

Free

31

R

V_V_5VSS1F

Engine oil pressure and temperature sensor: supply +5V

32

L

V_V_5VSS1E

Crankcase pressure sensor: supply +5V

33

H

V_V_5VSS2B

Exhaust gas absolute pressure sensor (P3): supply + 5V

34

-

-

35

-

I_A_AN01

Engine oil pressure and temperature sensor: pressure signal

36

S

I_A_RAILPS

Rail pressure sensor: pressure signal

37

R

I_A_AN16

Boost pressure and air temperature sensor: NTC temperature signal

38

-

-

39

H

I_A_AN17

40

-

-

Free

41

-

-

Free

42

Z

G_R_AN20

43

-

-

Free

44

-

-

Free

-

Free

45

Signal

15

Component Free

Free

Free Coolant temperature sensor: NTC temperature signal

Crankcase pressure sensor: ground

46

-

-

Free

47

-

-

Free

48

-

-

Free

49

-

O_P_SVH11

Injector 1 ”high”, Bank 1, Cylinder 1

50

-

O_P_SVH12

Injector 2 ”high”, Bank 1, Cylinder 2

51

-

O_P_SVH13

Injector 3 ”high”, Bank 1, Cylinder 3

52

-

-

Free

53

-

-

Free

54

-

-

Free

55

-

-

Free

56

-

-

Free

57

-

-

Free

58

S

O_V_MEU

Fuel high pressure pump metering unit: supply

59

L

G_R_AN18

Fuel/coolant temperature sensor: common ground analog input 18

60

N

G_R_RAILPS

Rail pressure sensor: ground

61

G

I_A_AN03

62

-

-

Print P2D32C010 E

Crankcase pressure sensor: pressure signal Free

Base - June 2014

16

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Pin

Cable colour

Signal

63

-

-

Free

64

-

-

Free

65

N

G_R_CRS

Flywheel increment speed sensor (crankshaft): signal negative

66

B

I_F_CRS

Flywheel increment speed sensor (crankshaft): signal positive

67

N

G_R_CAS

Timing segment speed sensor (camshaft): signal negative

68

B

I_F_CAS

Timing segment speed sensor (camshaft): signal positive

69

-

G_R_AN07

70

-

-

Free

71

-

-

Free

72

-

-

Free

73

-

O_P_SVL11

Injector 1 “low”, Bank 1, Cylinder 1

74

-

O_P_SVL12

Injector 2 ”low”, Bank 1, Cylinder 2

75

-

O_P_SVL13

Injector 3 “low”, Bank 1, Cylinder 3

76

-

-

Free

77

-

-

Free

78

H

G_R_DF02

79

Z

I_F_DF02

80

-

-

Free

81

-

-

Free

82

-

-

Free

83

V

O_T_MEU

84

-

-

Free

85

-

-

Free

86

Z

I_A_AN05

87

-

-

Free

88

-

-

Free

89

-

-

Free

90

G

G_R_AN05

91

-

-

Free

92

-

-

Free

93

-

-

Free

94

-

-

Free

95

-

-

Free

96

-

-

Free

Base - June 2014

Component

Common ground analog input 7

Fuel filter clogging sensor: ground Fuel filter clogging sensor: pressure drop signal

Fuel high pressure pump metering unit: signal

Boost pressure and air temperature sensor: pressure signal

Boost pressure and air temperature sensor: ground analog input 5

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

17

Electro-injectors (CRIN 3) Figure 9

114255

The electro-injectors are mounted on the cylinder head and operated by the engine control unit.

They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot valve.

It is an N.A. type solenoid valve. The solenoid valve controls the lift of the nozzle needle.

The resistance of the coil of each individual injector is 0.56 ÷ 0.57 .

The injectors are connected to the control unit via the engine cable.

Injector No. 1 2 3 4 5 6

Print P2D32C010 E

Injector PIN

Control unit PIN

1

49

2

73

1

50

2

74

1

51

2

75

1

25

2

01

1

27

2

03

1

26

2

02 Base - June 2014

18

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Fuel high pressure pump metering unit

Figure 10

A. Fuel drain outlet fitting to filter support B. Fuel inlet fitting from ECU heat exchanger C. Fuel inlet fitting from fuel filter D. Fuel outlet fitting from supply pump to filter E. Fuel outlet fitting to rail 1. High-pressure pump 2. Supply pump 3. Pressure regulator (NO solenoid valve modulated by ECU with PWM signal).

Pressure regulator Located at high-pressure pump inlet, on low pressure system, it modulates the amount of fuel for high-pressure pump supply based on commands received from ECU. It mainly consists of parts below: - rapezoidal-section lock pin; - valve control pin; - pre-load valve; - coils.

A

When no control signal is present, the pressure regulator is normally open, therefore the high pressure pump is in max delivery condition.

The ECU modulates a PWM control signal to extend or reduce section of fuel supply line to high-pressure pump.

B C D

The component cannot be replaced as an individual part, therefore it cannot be removed.

The quantity of high-pressure supply fuel is metered by a proportional valve positioned on low-pressure system and it is managed by the ECU. The delivery pressure to rail is modulated between 250 and 1400 bars by ECU operating on pressure regulator solenoid valve.

It is a NO solenoid valve.

3 E

191577

Its resistance is  3,2 .

PIN

DESCRIPTION

TO

1 2

Supply Signal

EDC17, pin 2/58 EDC17, pin 2/83

Base - June 2014

Cable colour S V

Print P2D32C010 E

F2CFE613E ENGINES

19

SECTION 3 - ELECTRICAL EQUIPMENT

Rail pressure sensor (RDS4.4)

Crankcase pressure sensor

The injection pressure sensor is used to determine the duration of the injection electric control.

The crankcase pressure sensor is used to measure engine internal pressure.

Figure 11

Figure 12

190509

190512

PIN

DESCRIPTION

TO

Cable colour

PIN

DESCRIPTION

TO

Cable colour

1 2 3

Ground (-) Signal (Output) Supply Voltage (+)

EDC17, pin 2/60 EDC17, pin 2/36 EDC17, pin 2/11

N S G

1 2 3

Supply Ground Signal

EDC17, pin 2/32 EDC17, pin 2/42 EDC17, pin 2/61

L Z G

CHARACTERISTIC

VALUE

Pressure range

0  2400 bar

Supply Voltage

5V

Output voltage

0.5  4.5V

Tightening torque

140 Nm

Print P2D32C010 E

Base - June 2014

20

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Increment speed sensor (Crankshaft)

Figure 14

This inductive sensor is located on the flywheel.

NOTE

If this signal fails the rev counter will not function.

S

WARNING This sensor’s air gap is not adjustable.

Figure 13

190511

The flywheel has 60 sections, 58 holes and two missing-hole.

The EDC 17 uses this signal to: - recognise the position of the pistons during normal operation; - determine the engine speed.

190510

PIN

DESCRIPTION

TO

Cable colour

1 2

Signal (+) Signal (-)

EDC17, pin 2/66 EDC17, pin 2/65

B N

CHARACTERISTIC

VALUE

Resistance

850  870 

Tightening torque

6  10 Nm

Figure 15

190599

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

Segment speed sensor (Camshaft)

21

Figure 17

This inductive sensor is located on the camshaft.

The signal generated by this sensor is used by the EDC17 electronic control unit as the injection timing signal.

WARNING This sensor’s air gap is not adjustable.

S

Figure 16

190511

The sensor generates signals obtained from the magnetic flux lines which close through the teeth of the phonic wheel fitted on the same shaft (number of teeth: 7).

Figure 18

190510

PIN

DESCRIPTION

TO

Cable colour

1 2

Signal (+) Signal (-)

EDC17, pin 2/68 EDC17, pin 2/67

B N

CHARACTERISTIC

VALUE

Resistance

850  870 

Tightening torque

6  10 Nm

Print P2D32C010 E

6+1

115825

Base - June 2014

22

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Fuel temperature sensor

Figure 20

It is an N.T.C. sensor located on the fuel filter.

It measure the fuel temperature, thus enabling the ECU to determine the fuel density and volume, therefore adjusting its delivery.

Figure 19

1

2 190515

Figure 21

113561

PIN

DESCRIPTION

TO

Cable colour

1 2

Signal (+) Signal (-)

EDC17, pin 2/12 EDC17, pin 2/59*

H L

* Common

CHARACTERISTIC

VALUE

Tightening torque

20 ± 5 Nm

Base - June 2014

190516

ground

Print P2D32C010 E

F2CFE613E ENGINES

23

SECTION 3 - ELECTRICAL EQUIPMENT

Coolant temperature sensor

Oil pressure and temperature sensor

It is an N.T.C. sensor located on the cylinder head water outlet manifold; it detects the coolant temperature.

It is a component that measures the engine oil temperature and pressure. It is mounted on thecrankcase.

This to enrich the mixture when the engine is cold.

Signals measured are transmitted to the EDC17 electronic control unit which, in turn, sends the information to the instrument panel (indicator/low pressure warning light).

Figure 22

Figure 24

1 2 3 4

113561

PIN

DESCRIPTION

TO

Cable colour

1 2

Signal (+) Signal (-)

EDC17, pin 2/39 EDC17, pin 2/59*

H L

* Common

CHARACTERISTIC

VALUE

Tightening torque

25 Nm

ground

Figure 23

190517

PIN

DESCRIPTION

TO

Cable colour

1

Ground Temperature Signal

EDC17, pin 2/6

G

EDC17, pin 2/13

V

EDC17, pin 2/31 EDC17, pin 2/35

R Z

2 3 4

Supply (+5V) Pressure Signal

Figure 25

1 2 3 PRESSURESENSOR

1

190515

Print P2D32C010 E

4

2 190518

Base - June 2014

24

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Boost pressure and temperature sensor

Main fuel filter clogging switch

It is mounted on the intake manifold.

This is an electrically normally-closed sensor which identifies the clogging of the fuel filter, looking if there is a delta pressure between its two ports - exceeding a certain threshold.

Figure 26 Figure 28

210296

190523

PIN

DESCRIPTION

TO

Cable colour

PIN

DESCRIPTION

TO

Cable colour

1 2

Ground Temperature Signal

EDC17, pin 2/90 EDC17, pin 2/37

G R

1 2

Ground Signal

EDC17, pin 2/78 EDC17, pin 2/79

H Z

3 4

Supply (+5V) Pressure Signal

EDC17, pin 2/7 EDC17, pin 2/86

V Z

Figure 27

1

CHARACTERISTIC

VALUE

Nominal Voltage

12 / 24 Vcc

Maximum switched tension

200 mA

Differential opening pressure

150 ± 10 KPa

Maximum working pressure

500 KPa

Operating temperature

- 40˚C / +120˚C

Tightening torque

30 ± 2 Nm

Figure 29

2 3 PRESSURESENSOR

P

4

190518

Base - June 2014

190524

Print P2D32C010 E

F2CFE613E ENGINES

25

SECTION 3 - ELECTRICAL EQUIPMENT

Motorized throttle valve actuator connector (Exhaust flap) The sensor serves to actuate the throttle valve installed on the exhaust pipe of the turbocharger.

Figure 30

188487

PIN

DESCRIPTION

TO

Cable colour

1

-

-

L

2

-

-

R

3

Ground

EDC17, pin 2/18

C

4

Power Supply

EDC17, pin 2/17

G

Print P2D32C010 E

Base - June 2014

26

SECTION 3 - ELECTRICAL EQUIPMENT

F2CFE613E ENGINES

Grid-heater resistance for engine pre-heating This element is located on the intake manifold.

It is utilised to heat the air in the operations of pre / post-heating. It is powered via contactor.

Its resistance is of approx.. 0.5 .

Figure 31

188489

Rated voltage:

D.C. 24V

Steady current:

120A ÷ 150A @ 24V

Pick-up current:

160A ÷ 290A @ 24V

Insulation resistance:

>1 M @ 500 V D.C.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 4 - MAINTENANCE PLANNING

1

SECTION 4 Maintenance planning Page

Print P2D32C010 E

MAINTENANCE PLANNING . . . . . . . . . . . . . .

3

- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Planning of controls and periodical intervention . . . . . . . . . . . . . . .

3

- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . .

4

MAINTENANCE PROCEDURES . . . . . . . . . . . .

5

- Checks (in periods of use) . . . . . . . . . . . . . . .

5

- Planned maintenance . . . . . . . . . . . . . . . . . . .

7

- Special maintenance . . . . . . . . . . . . . . . . . . . .

8

Base - June 2014

2

SECTION 4 - MAINTENANCE PLANNING

Base - June 2014

F2CFE613E ENGINES

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 4 - MAINTENANCE PLANNING

3

MAINTENANCE PLANNING Recovery To ensure op mized working condi ons, in the following pages we are providing instruc ons for the overhaul control interven ons, checks and se ng opera ons that must be performed on the engine at due planned dates.

The frequency of the maintenance opera ons is just an indica on since the use of the engine is the main characteris c to determine and evaluate replacements and checks.

It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling opera ons even if not being included in the ones listed here below but that may be suggested by common sense and by the specific condi ons in which the engine is run.

In case of evident engine malfunc on, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure, immediately intervene in order to find the causes.

We wish to remind that each maintenance opera on, even the most simple must be performed in compliance with the accident preven on standards for the safety of maintenance personnel in charge.

Planning of controls and periodical intervention

Checks (in periods of use) Check engine lubricant oil level Check engine coolant level Engine visual inspec on Drain water from fuel pre-filter Check tension and condi on of auxiliary belt Check condi on of the exhaust duct(s) Check using ECU

Frequency Every start Every start 50 hours 150 hours(1) 300 hours Six - months In the case of a fault

Planned maintenance Change engine lubricant oil Change oil filter Change fuel pre-filter Change fuel filter Change auxiliary belt Turbocharger visual inspec on Change crankcase ven la on filter

Frequency 250 hours(2) (3) 250 hours(2) (3) (4) 250 hours(1) 250 hours(2) (1) (4) 1,200 hours 1,200 hours 1,500 hours(2)

Special maintenance Adjust valves/rocker arms clearance Change engine coolant

Frequency 2,400 hours 3,000 hours(5)

1) Maximum period rela ve to the use of high quality fuel, (specifica on ASTM D975 or EN 590); this is reduced based on fuel contamina on and the alarm signals due to filter clogging and/or the presence of water in the pre-filter. The filter clogging signal indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off a er drainage, the filter must be replaced.

2) To be performed every year even if the specified opera ng hours interval has not been reached.

3) The frequencies are applicable for lubricants which meet the interna onal standards API CJ-4 / ACEA E9as specified in the REFILLING table.

4) Only use filters with the following specifica ons: - degree of filtering < 12μm - filtering efficiency 99.5% (ß > 200).

5) To be performed every two years even if the specified opera ng hours interval has not been reached.

Print P2D32C010 E

Base - June 2014

4

SECTION 4 - MAINTENANCE PLANNING

F2CFE613E ENGINES

NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks.

The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided

by CURSOR. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

NOTE Diesel fuel for low temperatures. Standard EN590 defines different classes of Diesel fuels, identifying the characteristics of those most suitable for use in low ambient temperatures.

Compliance with the regulations regarding the distribution of fuels suitable for the climatic and geographic conditions of the various countries is entirely up to the oil companies.

The time intervals given in this plan are merely approximate as they refer to using the engines in an industrial environment with average use in relation to displacement.

Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

- Notify the maintenance if any inconvenience is detected of if any filling is necessary.

After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits.

- Verify absence of noise or unusual rattle during engine working.

- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.

- Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

MAINTENANCE PROCEDURES Checks (in periods of use) Lubricating system check The check must be executed both when the engine disconnected and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water and detergent.

Adequately protect the skin and the eyes, operate in full compliance with safety regulations.

SECTION 4 - MAINTENANCE PLANNING

5

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.

Check of belt’s tear and wear status Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.

Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur.

Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.

Disposal must be carried out properly, and in full compliance with the law and regulations in force.

Combustion system inspection The check must be executed both when the engine disconnected and when it is running.

The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head.

Special attention must be paid to the connections on the high pressure pipelines.

Due to the high pressure within the pipelines running from the high-pressure pump to the rail diffuser and from this last one to the electro-injectors, special attention must be aid also in checking presence of any leakage or blow-by.

Protect the eyes and the skin from any eventual high pressure jet: these may deeply penetrate under the skin surface provoking serious poisoning.

Cooling system inspection The check must be executed both when the engine disconnected and when it is running.

Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips.

Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.

Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling.

Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.

Inspection of water presence within fuel filter or pre-filter

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year.

NOTE The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

NOTE In case of new filling, proceed bleeding system, through the bleeds on the engine.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.

Print P2D32C010 E

Base - June 2014

6

SECTION 4 - MAINTENANCE PLANNING

F2CFE613E ENGINES

Check engine lubricant oil level The check must be executed when the engine is disconnected and possibly cool.

The check can be made using the specially provided flexible rod (2).

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water and detergent.

Adequately protect the skin and the eyes, operate in full compliance with safety regulations.

Disposal must be carried out properly, and in full compliance with the law and regulations in force.

Figure 1 Check engine coolant level Only proceed when the engine is not turning, and is at low temperature, so as not to run the risk of burns.

- Remove the pressurization cap from the expansion tank.

- Check that the coolant in the expansion tank is above the minimum level.

- If necessary, top up the expansion tank with a mixture of 50% water and Actifull OT, as contained in the table REFILLING. Do not fill the expansion tank to the brim.

- When the engine is cold, make sure that the coolant level is a few centimetres below the filling hole.

In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by making sure that the coolant does not overfill the internal volume of the exchanger in order to allow the expansion of coolant volume during increases in temperature.

218529

Draw off the rod (2) from its slot and check that the level is within the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed cleaning the rod (2) using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.

Always ensure the oil added has the same characteristics of the oil contained in the sump.

Mixing is not allowed as this would not guarantee correct lubrication of the internal parts of the engine.

Top up with lubricant oil which meets the international specifications ACEA E9, as indicated in the REFILLING table.

Remove the lubricant oil cap (1 or 3) and pour engine lubricant oil through the hole.

Use the oil dipstick (2) to check that the lubricant oil level does not exceed the “Max” limit.

Make sure that the oil dipstick (2) is fully inserted and that the oil filler caps (1 and 3) are fully tightened in a clockwise direction.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 4 - MAINTENANCE PLANNING

Planned maintenance

7

NOTE Use only the recommended oil or oil having the requested features for the corrrect motor functioning.

In case of topping up, don’t mix oils having different features.

If you don’t comply with theses rules, the service warranty is no more valid.

Change engine lubricant oil Figure 2

- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.

Change oil filter Figure 3

218529

We recommend to carry out the oil drainage when the motor is hot.

Warning: We recommend to wear proper protections because of high motor service temperature.

The motor oil reaches very high temperature: you must always wear protection gloves.

219642

NOTE Warning: the oil filter contains inside a quantity of oil of about 1 kg.

- Place a proper container for the oil collecting under the pan connected with the drain plug (5).

- Unscrew the plug (5) and then take out the control dipsick (2) and the inserting plug (1 and 3) to ease the downflow of the lubrication oil.

Place properly a container for the liquid.

Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water.

The motor oil is very pollutant: it must be disposed of according to the rules.

The oil motor is very pollutant and harmful.

In case of contact with the skin, wash with much water and detergent.

Protect properly skin and eyes: operate according to safety rules.

Dispose of the residual properly following the rules.

- Wait until the oil sump (4) has completely emptied, then retighten the lubricant oil drain plug (5) under the sump (4).

- Proceed with the refilling operation through the hole (1) situated on the tappet cover or the pipe (3) connected to the crankcase: add the specified quantity of recommended lubricant oil that meets the international standards ACEA E9, as indicated in the REFILLING table.

Print P2D32C010 E

NOTE Before refitting the new cartridge, wet seal using engine oil.

Unscrew and remove the filter (4) from its relative support (1) by suitable tool.

Replace the filter element (3) and the sealing gasket (2) contained inside the filter (4).

Carefully clean the surfaces of the support (1) in contact with the sealing gasket (2).

Moisten the sealing gasket (2) of the new filter (4) with a thin layer of oil.

Manually tighten the new filter (4) on the support (1) until it comes into contact with the gasket (2). Additionally tighten it using a specific tool to a torque of 60 ± 5 Nm. Operate the engine for a few minutes and then check the level using the dipstick. If necessary, top up to compensate for the quantity of oil used to fill up the filtering cartridge.

Base - June 2014

8

SECTION 4 - MAINTENANCE PLANNING

F2CFE613E ENGINES

Change crankcase venƟlaƟon filter

Change fuel filter

Figure 4

Figure 5

E00030

E00029

Unscrew the fastening screws (4) and remove the Ɵming cover (3).

During this operaƟon don’t smoke and don’t use free flames.

Unscrew the fastening screws (2) and remove the crankcase venƟlaƟon filter (1).

Avoid to breathe the vapors coming from filter.

Replace and install the centrifugal filter element (1) on the Ɵming gear (5) and Ɵghten the fastening screws (2).

Fit the Ɵming cover (3) and Ɵghten the fastening screws (4).

!

AŌer filter replacement the supply equipment deaeraƟon must be carried out.

Place a container for collecƟng the diesel under the filter support (2).

Drain the fuel from the fuel filter (5) by loosing the drain screw (6).

Remove the filter (5) by unscrewing it from its relaƟve support (2).

Replace the filter element (4) and the O-ring seal (3) contained inside the filter (5).

Carefully clean the surfaces of the support (2) in contact with the O-ring seal (3).

Smear the O-ring seal (3) of the new filter with oil. Manually Ɵghten the new filter (5) onto the support (2) unƟl it comes into contact with the gasket (3).

AddiƟonally Ɵghten it using a specific tool to a torque of 32.5 ± 2.5 Nm.

!

When replacing the filter cartridge (5) do NOT fill it.

This operaƟon is banned to avoid impuriƟes entering into the circuit, which would damage the injector/pump system components.

Fuel bleeding AŌer the fuel filter (5) has been replaced it is possible that air bubbles get trapped inside the fuel supply circuit.

Bleed residual air from the fuel filter (5) by loosing the vent plug (1) connecƟng it to a suitable container by a transparent flexible hose.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 4 - MAINTENANCE PLANNING

9

Special maintenance

Figure 6

Replacing coolant Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.

- Provide suitable containers to ensure that no coolant is dispersed into the environment.

- Loosen the seal elements, remove the sleeves connecting the engine circuit to the heat exchanger and wait until it has emptied completely. When empty, repair the circuit making sure that the sleeves are perfectly sealed.

- Fill up the circuit.

145887

With the hand pump (2) of the fuel pre-filter (1) pump until fuel completely free of air bubbles flows from the bleed screw.

After the operation, tighten the bleed screw.

- Refill the engine and the heat exchanger until complete top up.

- With the filler cap open, start the engine and keep it idling for nearly one minute. This phase facilitates the cooling liquid air bleed.

Start the engine and allow it to run at minimum for a few minutes to expel any remaining air.

- Stop the engine and top up again.

Change auxiliary belt

Adjustment of valve/rocker arm clearance

Figure 7

Figure 8

171162

Use appropriate equipment (5) on the belt tensioner (6) in the direction shown by the arrow and extract the belt (4) from the pulleys of the alternator (1), of the coolant pump (2) and from the idler pulleys (3).

193948

Unscrew the screws (2).

Remove cylinder head cover (1) and its gasket.

- Replace the worn belt with a new one.

- Place the belt on the pulleys and the guide rollers.

- Place the automatic tightener in order to key the belt in the functioning position.

- Further adjustments are not required.

Turbocharger visual inspection Only proceed when the engine is not turning over. Visually check that the turbine and compressor impellers and the relative inlet and outlet ducts are not obstructed or damaged, otherwise replace them.

Print P2D32C010 E

Base - June 2014

10

SECTION 4 - MAINTENANCE PLANNING

F2CFE613E ENGINES

IGNITION ORDER 1-4-2-6-3-5

Figure 9

START AND ROTATION CLOCKWISE

BALANCE VALVES OF CYLINDER No.

ADJUST CLEARANCE OF VALVES CYLINDER No.

1 and 6 at TDC 120˚ 120˚ 120˚ 120˚ 120˚

6 3 5 1 4 2

1 4 2 6 3 5

114287

Adjustment of clearance between rocker arms and intake/exhaust valve control crosspieces must be performed with utmost care. Bring to blast phase cylinder to be adjusted; the valves of this cylinder are closed while the symmetric cylinder valves are balanced.

Symmetric cylinders are 1-6; 2-5 and 3-4.

In order to perform these operations correctly, refer to procedure and table below.

- Use a polygonal spanner to release lock nut (1) of rocker arm adjustment screw (2).

- Insert filler gage (3) having same value of operating clearance shown in ”Characteristic and data” tables.

- Use special spanner to lock/unlock adjustment screw.

- Check that filler gage (3) slides with a low friction.

- Lock nut (1) retaining the adjustment screw.

Follow the firing order indicated in the table below.

NOTE

In order to correctly carry out adjustments above, it is mandatory to perform the sequence indicated in the table, checking exact positioning at each phase by means of pin 99360612.

Figure 10

193948

Install cylinder head cover (1) and lock screws (2) at required torque.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

1

SECTION 5 Removal and refitting of main engine components Page

Print P2D32C010 E

ANCILLARY DEVICE BELT REMOVAL / REFITTING . . . . . . . . . . . . . . . .

3

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

ALTERNATOR REMOVAL / REFITTING . . . . . .

3

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

WATER PUMP REMOVAL / REFITTING . . . . . . . . . . . . . . . .

4

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

THERMOSTAT REMOVAL / REFITTING . . . . .

4

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

ENGINE CONTROL UNIT REMOVAL / REFITTING . . . . . . . . . . . . . . . .

5

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

FUEL FILTER SUPPORT REMOVAL / REFITTING . . . . . . . . . . . . . . . .

6

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

FUEL HIGH-PRESSURE PUMP REMOVAL / REFITTING . . . . . . . . . . . . . . . .

7

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

COMMON RAIL REMOVAL / REFITTING . . . .

9

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Base - June 2014

2

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

F2CFE613E ENGINES

Page

Page ROCKER ARM SHAFT REMOVAL / REFITTING . . . . . . . . . . . . . . . . .

11

STARTER REMOVAL / REFITTING . . . . . . . . . .

24

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Intake and exhaust rocker arm clearance adjustment . . . . . . . . . . . . . . . . . . . .

12

OIL SUMP REMOVAL / REFITTING . . . . . . . . . .

24

INJECTOR REMOVAL / REFITTING . . . . . . . . . .

13

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Intake and exhaust rocker arm clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

TURBOCHARGER REMOVAL / REFITTING . . . . . . . . . . . . . . . . .

18

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

EXHAUST MANIFOLD REMOVAL / REFITTING . . . . . . . . . . . . . . . . .

19

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

OIL FILTER REMOVAL / REFITTING . . . . . . . . .

20

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

OIL COOLER REMOVAL / REFITTING . . . . . . . . . . . . . . . . .

21

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

BLOW-BY REMOVAL / REFITTING . . . . . . . . . .

22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

INTAKE MANIFOLD REMOVAL / REFITTING . . . . . . . . . . . . . . . . .

23

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

3

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

ANCILLARY DEVICE BELT REMOVAL / REFITTING

ALTERNATOR REMOVAL / REFITTING Removal

Removal

Disconnect the electrical connections of the alternator.

Remove the auxiliary components drive belt as described in the relative procedure.

Figure 1

Figure 2

218010

169282

Remove the belt by acting on the automatic belt tensioner (5) with the appropriate tool (4) from alternator, water pump (1), fan control pulley, crankshaft pulley with damper (3) and fixed guide roller (2).

Unscrew fastening screws (1 and 3) and remove the alternator (2).

Refitting

Refitting

Fit the Poly-V belt on the pulleys and guide roller.

Fit alternator support (4) and tighten two fastening screws.

Use the appropriate tool (4) on the automatic belt tensioner (5) in order to fit the new belt in the operating position.

Install alternator (2) on support and tighten fastening screws (1 and 3) to the prescribed torque.

Additional adjustments are not required. The belt tension is adjusted automatically by the calibrated spring in the automatic belt tensioner (5).

Install the auxiliary components drive belt as described in the relative procedure.

Unscrew fastening screws and remove alternator support (4).

Connect the alternator electrical connections.

Operate the engine for a few hours and check that the belt is properly fit.

Print P2D32C010 E

Base - June 2014

4

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

WATER PUMP REMOVAL / REFITTING

F2CFE613E ENGINES

THERMOSTAT REMOVAL / REFITTING Removal

Removal Drain off the coolant..

Figure 4

Remove the auxiliary components drive belt as described in the relative procedure.

Position a suitable container to catch any coolant.

Figure 3

218012

Unplug the engine cable (4) from the coolant temperature sensor (3), as described in the relative section.

Open the strap (1) holding the engine cable (4) to the engine coolant outlet pipe (2) and remove it.

218011

Unscrew the fastening screws (3) and remove the water pump (2) complete with gasket (1).

Figure 5 Ref (3)

No. Description 4 M8x1.25x25

Refitting Apply a new seal ring (1) to the coolant pump (2).

Assemble the water pump (2) complete with its sealing gasket (1) and tighten the fastening screws (3) to the prescribed torque.

218013

Ref (3)

No. Description 4 M8x1.25x25

Tightening torques 24.5 ± 2.5 Nm

Install the auxiliary components drive belt as described in the relative procedure.

NOTE

Once installed, fill the engine coolant circuit.

Unscrew the fastening screws (4) and disassemble the thermostat unit: remove the engine coolant outlet pipe (5) together with its gasket (3), the sealing ring (2) and the thermostat (1).

Ref (4)

No. Description 5 M8x1.25x70

Start the engine and check for coolant leaks.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

5

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting

ENGINE CONTROL UNIT REMOVAL / REFITTING

Figure 6

Removal Figure 8

218013

Assemble the thermostat unit: fit the thermostat (1), a new sealing ring (2) and the engine coolant outlet pipe (5) complete with its gasket (3); tighten the fastening screws (4) to the prescribed torque.

Ref (4)

No. Description 5 M8x1.25x70

Tightening torques 24.5 ± 2.5 Nm

Figure 7

218014

Disconnect the engine cable (1) from the ECU (5), as described in the relative section.

Position a suitable container to catch any fuel.

Disconnect the retainer (2) and remove the low pressure fuel pipe from fuel pre-filter to the engine control unit heat exchanger.

Disconnect the retainer (4) and remove the low pressure fuel pipe from the engine control unit heat exchanger to to mechanical pump, as described in the relative section.

Unscrew the fastening nuts (3), and remove the ECU (5), including the heat exchanger.

Ref (3) (4)

No. Description 3 M8x1.25 1 M16x1.5

Refitting

218012

Connect the engine cable (4) to the coolant temperature sensor (3), as described in the relative section.

Close the strap (1) retaining the engine cable (4) to the engine coolant outlet pipe (2).

Fit the ECU (5) including the heat exchanger on the crankcase and tighten the fastening nuts (3) to the prescribed torque.

Connect the low pressure fuel pipe from the mechanical pump to the engine control unit heat exchanger by means of the retainer (4), as described in the relative procedure.

Connect the low pressure fuel pipe from fuel pre-filter to the engine control unit heat exchanger by means of the retainer (2).

Connect the engine cable (1) to the ECU (5), as described in the relative section.

Ref (3) (4) Print P2D32C010 E

No. Description 3 M8x1.25 1 M16x1.5

Tightening torques 24 ± 3 Nm 30 ± 5 Nm Base - June 2014

6

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

FUEL FILTER SUPPORT REMOVAL / REFITTING

F2CFE613E ENGINES

Refitting Figure 11

Removal Figure 9

218015

During this operation don’t smoke and don’t use free flames.

Avoid to breathe the vapours coming from filter.

218016

Fit the fuel filter support (2) together with the fuel filter clogging (pressure drop) sensor (5) and NTC temperature sensor (4) on the engine cable supporting bracket (1) and tighten the fastening screws (3) to the prescribed torque.

Disconnect the sensor connections (4) of the engine cable (2) from the fuel filter support (3), as described in the relative procedure.

Disconnect the fittings (1) of the low pressure fuel pipes from fuel filter to high pressure pump and from mechanical pump to fuel filter.

Ref (1)

No. Description 2 M16x1.5

Ref (3)

Figure 10

No. Description 4 M8x1.25x30

Figure 12

218016

Place a container for collecting diesel under the fuel filter support (2).

Unscrew the fastening screws (3) and remove the fuel filter support (2) together with the fuel filter clogging (pressure drop) sensor (5) and NTC temperature sensor (4) from the engine cable supporting bracket (1).

Ref (3)

No. Description 4 M8x1.25x30

Base - June 2014

Tightening torques 24 ± 3 Nm

218015

Connect the fittings (1) of the low pressure fuel pipes from fuel filter to high pressure pump and from mechanical pump to fuel filter.

Connect the sensor connections (4) of the engine cable (2) to the fuel filter support (3), as described in the relative procedure.

Ref (1)

No. Description 2 M16x1.5

Tightening torques 40 ± 5 Nm Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

FUEL HIGH-PRESSURE PUMP REMOVAL / REFITTING

7

Figure 14

Removal Remove the fuel filter support as described in the relative procedure.

Figure 13

218018

Disconnect the fittings (4 and 8) and the screw (1) to remove the low pressure fuel pipe (3) from ECU to mechanical pump.

218017

Disconnect the engine cable from the fuel high-pressure pump metering unit (8), as described in the relative procedure.

Disconnect the fittings (7 and 9) to remove the low pressure fuel pipe (11) from fuel filter to high-pressure pump and the pipe (12) from mechanical pump to fuel filter.

Unscrew the hose couplings (3 and 10) and the screw (6) to remove the high-pressure fuel pipe (5) from high-pressure pump to cylinder head.

Unscrew the fastening screws (2 and 4) and remove the fuel filter bracket (1).

Disconnect the fittings (2 and 7) and the screw (5) to remove the backflow fuel pipe (6) from high-pressure pump to fuel tank.

Ref No. Description (4,8) 2 M16x1.5 (2,7) 2 M16x1.5 (1) 1 M8x1.25x25 (5) 1 M8x1.25x16

Figure 15

Ref No. Description (7,9) 2 M16x1.5 (3,10) 2 M14x1.5 (6) 1 M6x16 (2) 3 M8x1.25x35 (4) 1 M8x25 (4) 1 M10x25

218019

Ensure that the the fuel high-pressure pump (1) is suitably supported.

Unscrew the fastening screws (3) and remove the fuel high-pressure pump (1) complete with the mechanical pump (2) and the gear (4) from the flywheel housing-gear box carter (5).

Ref (3) Print P2D32C010 E

No. Description 3 M8x1.25x40 Base - June 2014

8

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting

F2CFE613E ENGINES

Figure 18

Figure 16

218017

218019

Fit the fuel high-pressure pump (1) complete with the mechanical pump (2) and the gear (4) into the flywheel housing-gear box carter (5).

Tighten the fastening screws (3) to the prescribed torque.

Ref (3)

No. Description 3 M8x1.25x40

Tightening torques 33 ± 3 Nm

Fit the fuel filter bracket (1) and tighten the fastening screws (2 and 4) to the prescribed torque.

Connect the the high-pressure fuel pipe (5) from high-pressure pump to cylinder head and tighten the hose couplings (3 and 10) and the screw (6) to the prescribed torque.

Connect the low pressure fuel pipe (11) from fuel filter to high-pressure pump and the pipe (12) from mechanical pump to fuel filter and tighten the fittings (7 and 9) to the prescribed torque.

Fasten the engine cable to the retainers and connect the electrical connection to the fuel high-pressure pump metering unit (8), as described in the relative procedure.

Figure 17 Ref No. Description (7,9) 2 M16x1.5 (3,10) 2 M14x1.5 (6) 1 M6x16 (2) 3 M8x1.25x35 (4) 1 M8x25 (4) 1 M10x25

Tightening torques 30 ± 5 Nm 35 ± 2 Nm 10 ± 1 Nm 24 ± 3 Nm 24 ± 3 Nm 37.5 ± 7.5 Nm

Install the fuel filter support as described in the relative procedure.

218018

Connect the backflow fuel pipe (6) from high-pressure pump to fuel tank and tighten the fittings (2 and 7) and the screw (5) to the prescribed torque.

Connect the low pressure fuel pipe (3) from ECU to mechanical pump and tighten the fittings (4 and 8) and the screw (1) to the prescribed torque.

Ref No. Description (4,8) 2 M16x1.5 (2,7) 2 M16x1.5 (1) 1 M8x1.25x25 (5) 1 M8x1.25x16

Base - June 2014

Tightening torques 30 ± 5 Nm 45 ± 5 Nm 24.5 ± 2.5 Nm 24.5 ± 2.5 Nm

Print P2D32C010 E

F2CFE613E ENGINES

9

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

COMMON RAIL REMOVAL / REFITTING Removal

Figure 21

Figure 19

193948

Unscrew the screws (2).

218022

Unscrew n˚ 3 screws (1); remove common rail (2) and spacers (3).

Remove cylinder head cover (1) and gasket.

Remove cable on head.

Ref (2)

No. Description 20 M6x1x50

Ref (1)

No. Description 3 M8

Refitting Figure 20

Figure 22

218022

218023

Disconnect fuel delivery pipes (5) between common rail (4) and electro-injectors, fuel supply pipe (3) between high-pressure pump and common rail (4) and fuel return pipe (1) between common rail (4) and cylinder head.

Install rail (2) and spacers (3) on cylinder head.

Lock n˚ 3 retaining screws (1) by hand.

Unscrew the fastening screws (2) and remove the bracket (6) from the cylinder head.

Ref (1)

Ref (5) (5) (3) (3) (1)

No. 6 6 1 1 2

Print P2D32C010 E

Description M18x1.5 M14x1.5 M18x1.5 M14x1.5 M16x1.5

No. Description 3 M8

Tightening torques 23 ± 2 Nm

The previously removed pipes ca no longer be refit and must be replaced.

Base - June 2014

10

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Figure 23

F2CFE613E ENGINES

NOTE

!

218021

Install the common rail (3) and high-pressure fuel delivery pipes by proceeding as follows: - Fit the common rail (3) on the cylinder head (5) and manually tighten the fastening screws (12).

- Check that the injectors are installed in correct position (equidistant from the springs) and locked to required torque.

- Fit the high-pressure fuel delivery pipes (6 and 8) and manually tighten the hose couplings (4, 7 and 13) first of all from common rail side and then from injector -cylinder head side;

The high-pressure fuel delivery pipes must be replaced every time they are removed. The hose couplings must be tightened to torque using spanner 99368542 and torque wrench 99389833.

After fitting the high-pressure pipelines, during the following 20 hours of work, frequently check engine oil level (IT MUST NOT INCREASE).

NOTE After the assembly procedure, the fuel lines must definitely not touch each other so as not to get damaged because of the high stress due to engine vibration.

The MINIMUM distance between the individual pipes must NOT be LESS than 2 mm.

End assembly procedure by connecting engine cable on head to injectors and rail sensor.

Figure 24

- Fit the low-pressure fuel backflow pipe (1) and manually tighten the hose couplings (2) first of all from common rail side and then from cylinder head side; - Tighten the hose couplings (2, 7 and 13) of injectorcylinder head side to the prescribed torque.

- Tighten the screws (12) fixing the common rail (3) onto cylinder head (5) to the prescribed torque.

- Tighten the hose couplings (2 and 4) of common rail side to the prescribed torque.

- Mount the bracket (10) and manually tighten the fastening screw (9).

- Tighten the screw (11) locking the high-pressure fuel delivery pipe (8) to the prescribed torque.

193948

- Tighten the fastening screw (9) fixing the bracket (10) onto cylinder head (5) to the prescribed torque.

Fit the valve cover (1) with the related gasket and insert all the screws (2).

Tighten the fastening screws (2) to the prescribed torque following order and mode shown in the figure below.

Ref No. Description (2) 2 M16x1.5 (4) 7 M18x1.5 (7) 6 M14x1.5 (9) 1 M8x1.25x16 (11) 1 M6x16 (12) 3 M 8x45 (13) 1 M14x1.5

Base - June 2014

Tightening torques 35 ± 2 Nm 40 ± 2 Nm 35 ± 2 Nm 24 ± 3 Nm 10 ± 1 Nm 24 ± 3 Nm 35 ± 2 Nm

Ref (2)

No. Description 20 M6x1x50

Tightening torques 8.5 ± 1.5 Nm

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

11

ROCKER ARM SHAFT REMOVAL / REFITTING

Figure 25

Removal Remove cylinder head cover and its gasket.

Remove cable on head.

Figure 26

218020

Tightening order layout for valve cover fastening screws Drive the screws to spacer contact in this order: 1-14-11-12-13.

Tighten all the fastening screws to the prescribed torque following the scheme.

169829

Unlock rocker arm shaft retaining screws (1).

Ref (1)

No. Description 7 M12x1.75

Figure 27

114025

Apply tool 99360558 (1) to rocker arm shaft (2) and remove shaft, remove crosspieces (3) from cylinder head.

Print P2D32C010 E

Base - June 2014

12

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting NOTE

F2CFE613E ENGINES

Intake and exhaust rocker arm clearance adjustment

Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.

Figure 30

Figure 28

114287

114025

Install crosspieces (3) on valve rod.

Apply tool 99360558 (1) to rocker arm shaft (2) and install shaft on cylinder head.

Tighten the fastening screws to the prescribed torque following order shown in the figure below.

Remove tool 99360558 (1).

Ref (-)

No. Description 7 M12x1.75

Tightening torques 104.5 ± 10.5 Nm

Adjustment of clearance between rocker arms and intake/exhaust valve control crosspieces must be performed with utmost care. Bring to blast phase cylinder to be adjusted; the valves of this cylinder are closed while the symmetric cylinder valves are balanced.

Symmetric cylinders are 1-6; 2-5 and 3-4.

In order to perform these operations correctly, refer to procedure and table below.

- Use a polygonal spanner to release lock nut (1) of rocker arm adjustment screw (2).

- Insert filler gage (3) having same value of operating clearance shown in ”Characteristic and data” tables.

- Use special spanner to lock/unlock adjustment screw.

- Check that filler gage (3) slides with a low friction.

- Lock nut (1) retaining the adjustment screw.

Ref (1)

Figure 29

No. Description 12 M10x1.25

Tightening torques 39 ± 5 Nm

IGNITION ORDER 1-4-2-6-3-5

70567A

Tightening order layout for rocker arm fastening screws.

START AND ROTATION CLOCKWISE

BALANCE VALVES OF CYLINDER No.

ADJUST CLEARANCE OF VALVES CYLINDER No.

1 and 6 at TDC 120˚ 120˚ 120˚ 120˚ 120˚

6 3 5 1 4 2

1 4 2 6 3 5

NOTE In order to correctly carry out adjustments above, it is mandatory to perform the sequence indicated in the table, checking exact positioning at each phase by means of pin 99360612.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

13

INJECTOR REMOVAL / REFITTING Removal

Figure 31

Remove cylinder head cover and its gasket.

Remove cable on head.

Figure 34

115880

Fit the head internal electric wire (injectors + pressure sensor) and securing it using bands as illustrated in the diagram ().

114024

Figure 32

Disconnect fuel pipelines (1) from injector rail, fuel supply line (2) of high pressure pump to rail and return line (3).

Unlock rocker arm shaft retaining screws (4).

Figure 35

166177

Install cylinder head cover (1) and lock screws (2) at required torque.

Ref (2)

No. Description 20 M6x1x50

Tightening torques 8.5 ± 1.5 Nm 114025

Figure 33

Apply tool 99360558 (1) to rocker arm shaft (2) and remove shaft, remove crosspieces (3) from cylinder head.

218020

Lock screws following the tightening order shown in the figure.

Print P2D32C010 E

Base - June 2014

14

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Figure 38

F2CFE613E ENGINES

Figure 37

169827

Remove screws (1) from brackets (2) fixing injectors.

Ref (1)

No. Description 6 M10x1.5x40

169828

Drive out the injector (1) complete with bracket and seal (2).

Figure 36

169826

Position the tool 99342157 (1) and hook on the injector (2).

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting

15

Figure 40

Lubricate the injector fastening O-Rings using the following lubricants: PDE SILIKONFETT 22, NLG 12, PDE LUBRICOMET GR 220 NLG12.

Install the injector comprehensive of bracket and seal in the seat on the cylinder head.

Figure 39

169816

Install new pipes on rail and lock fittings by hand.

- supply line (2) of high pressure pump to rail; - return line (3); - n˚ 6 fuel pipelines (1) between injectors and rail.

169827

Tighten screws on injector fixing brackets to prescribed torque.

Ref (1)

No. Description 6 M10x1.5x40

Tightening torques 41 ± 2 Nm

The previously removed pipes ca no longer be refit and must be replaced.

NOTE Be very careful when fitting high pressure fuel pipes.

Print P2D32C010 E

Base - June 2014

16

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

F2CFE613E ENGINES

Figure 41

193973

!

Check that the injectors (2) are equidistant from the springs (1). Distance ”X” which separates them should always be the same.

Lock fittings on rail (A, C) at required torque.

Lock fittings on injectors and head (B, C) at required torque.

TYPE A B C Base - June 2014

DESCRIPTION M18 x 1.5 M14 x 1.5 M16 x 1.5

LOCK TORQUE 40 ± 2 Nm 35 ± 2 Nm 40 ± 2 Nm

!

After fitting the high-pressure pipelines, during the following 20 hours of work, frequently check engine oil level (IT MUST NOT INCREASE).

NOTE After the assembly procedure, the fuel lines must definitely not touch each other so as not to get damaged because of the high stress due to engine vibration.

The MINIMUM distance between the individual pipes must NOT be LESS than 2 mm.

NOTE Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.

Print P2D32C010 E

F2CFE613E ENGINES

17

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Intake and exhaust rocker arm clearance adjustment

Figure 42

Figure 43

114025

Install crosspieces (3) on valve rod.

Apply tool 99360558 (1) to rocker arm shaft (2) and install shaft on cylinder head.

Tighten the fastening screws to the prescribed torque.

Remove tool 99360558 (1).

Ref (-)

No. Description 7 M12x1.75

Tightening torques 104.5 ± 10.5 Nm

114287

Adjustment of clearance between rocker arms and intake/exhaust valve control crosspieces must be performed with utmost care. Bring to blast phase cylinder to be adjusted; the valves of this cylinder are closed while the symmetric cylinder valves are balanced.

Symmetric cylinders are 1-6; 2-5 and 3-4.

In order to perform these operations correctly, refer to procedure and table below.

Use a polygonal spanner to release lock nut (1) of rocker arm adjustment screw (2).

- Insert filler gage (3) having same value of operating clearance shown in “Characteristic and data“ tables.

- Use special spanner to lock/unlock adjustment screw.

- Check that filler gage (3) slides with a low friction.

- Lock nut (1) retaining the adjustment screw.

Ref (1)

No. Description 12 M10x1.25

Tightening torques 39 ± 5 Nm

IGNITION ORDER 1-4-2-6-3-5 START AND ROTATION CLOCKWISE

BALANCE VALVES OF CYLINDER No.

ADJUST CLEARANCE OF VALVES CYLINDER No.

1 and 6 at TDC 120˚ 120˚ 120˚ 120˚ 120˚

6 3 5 1 4 2

1 4 2 6 3 5

NOTE In order to correctly carry out adjustments above, it is mandatory to perform the sequence indicated in the table, checking exact positioning at each phase by means of pin 99360612.

Print P2D32C010 E

Base - June 2014

18

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

F2CFE613E ENGINES

TURBOCHARGER REMOVAL / REFITTING

Figure 44

Removal Figure 47

115880

Fit the head internal electric wire (injectors + pressure sensor) and securing it using bands as illustrated in the diagram ().

169819

Disconnect oil return pipe (1) and oil delivery pipe (2).

Ref (1) (1) (2)

Figure 45

No. 2 1 2

Description M8x1.25 M30x2 M16x1.5

Figure 48

166177

Install cylinder head cover (1) and lock screws (2) at required torque.

Ref (2)

No. Description 20 M6x1x50

Tightening torques 8.5 ± 1.5 Nm

Figure 46

169820

Unscrew n˚ 4 nuts (1).

Remove turbocharger (3) and gasket (2).

218020

Lock screws following the tightening order shown in the figure.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting Mount a new gasket on exhaust manifold; fit the turbocharger and screw n˚ 4 nuts.

Figure 49

19

EXHAUST MANIFOLD REMOVAL / REFITTING Removal Figure 50

169821 169819

End the assembly procedure by connecting oil pipes.

Ref (1) (1) (2)

No. 2 1 2

Description M8x1.25 M30x2 M16x1.5

Tightening torques 25 ± 5 Nm 25 ± 5 Nm 42 ± 2 Nm

To dismount the exhaust manifold (1), proceed as follows.

Proceed with the disassembly of the turbocharger: - disconnect oil return pipe; - disconnect oil delivery pipe; - unscrew n˚ 4 nuts; - remove turbocharger and gasket.

Figure 51

169822

Unscrew n˚ 24 M10 screws (2).

Remove exhaust manifold (3) and n˚ 6 gasket (1).

Ref (2)

Print P2D32C010 E

No. Description 24 M10x1.5x38

Base - June 2014

20

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting Mount 6 new gaskets and fit exhaust manifold.

Tighten the fastening screws (2) to the prescribed torque following order and mode shown in the figure below.

Ref (2)

No. Description Tightening torques M10x1.5x38 24 1st phase 30 ± 5 Nm 2nd phase 60 ± 5 Nm

F2CFE613E ENGINES

OIL FILTER REMOVAL / REFITTING Removal WARNING: the oil filter contains inside a quantity of oil of about 1 kg.

Place properly a container for the liquid.

Avoid the contact of skin with the motor oil: in case of contact wash the skin with running water.

The motor oil is very pollutant: it must be disposed of according to the rules.

Figure 52 Figure 53

171168

Tightening order layout for exhaust manifold fastening screws.

The central section of the exhaust manifold (1) must be tightened first.

119976

Use tool 99360252 to slacken the oil filters (1).

Figure 54

169823

Remove bracket fixing oil delivery pipe to turbocharger unscrewing n˚ 3 M8 screws.

Unscrew n˚ 2 M8 screws (1); remove oil filter body (2) and gasket (3).

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

Ref (1) (-) (-)

No. 2 2 1

OIL COOLER REMOVAL / REFITTING

Description M8x1.25x90 M8x1.25x60 M8x1.25x20

Removal

Refitting Fit oil body filter with new gasket; screw n˚ 2 M8 screws to prescribed torque.

NOTE Under oil cooler place a container for engine coolant drain.

Install bracket fixing oil delivery pipe.

Ref (1) (-) (-)

No. 2 2 1

Description M8x1.25x90 M8x1.25x60 M8x1.25x20

21

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Figure 55 Tightening torques 24.5 ± 2.5 Nm 24.5 ± 2.5 Nm 24 ± 3 Nm

NOTE Before refitting the new cartridge, wet seal using engine oil.

Screw the oil filter by hand until it touches the support, then tighten 3/4 of a turn to the required torque.

Add the required amount of recommended engine oil through the filler.

169824

Unscrew n˚ 16 M8 screws (1).

Remove oil cooler body (4) and its gasket (2).

Unscrew n˚ 2 screws (5).

Separate oil cooler (3) from oil body cooler.

Ref (1) (5)

No. Description 16 M8x1.25x50 2 M12x1.75x30

Refitting Assemble the oil cooler body with oil cooler, screwing in 2 screws.

Mount the oil cooler complete with new gasket to the crankcase housing.

Ref (1) (5)

Print P2D32C010 E

No. Description M8x1.25x50 16 1st phase 2nd phase 2 M12x1.75x30

Tightening torques 11.5 ± 3.5 Nm 24.5 ± 2.5 Nm 63 ± 7 Nm

Base - June 2014

22

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

CRANKCASE VENTILATION REMOVAL / REFITTING Removal

F2CFE613E ENGINES

Refiƫng Install centrifugal filter on tune wheel and lock n˚ 3M6screws at required torque.

Install Ɵming cover and lock n˚ 6 M8 retaining screws at required torque.

Figure 56

Figure 58

E00031

E00031

Remove n˚ 3 M6 screws (1) and blow-by box (2).

Ref (1)

Install crankcase venƟlaƟon body (2) with related seal and lock screws n˚3M6(1) at required torque.

No. DescripƟon 3 M6x1

Ref (1)

Figure 57

No. DescripƟon 3 M6x1

Figure 59

E00032

Unscrew the fastening screws (4) and remove the Ɵming cover (3).

Unscrew the fastening screws (2) and remove the blow-by filter (1).

Ref (2) (4)

No. 3 6

Base - June 2014

Tightening torques 9±1Nm

DescripƟon M6x1x16

E00032

Install the centrifugal filter element (1) on the Ɵming gear (5) and Ɵghten the fastening screws (2).

Fit the Ɵming cover (3) and Ɵghten the fastening screws (4).

Ref (2) (4)

No. DescripƟon 3 M6x1x16 6

Tightening torques 9±1Nm

Print P2D32C010 E

F2CFE613E ENGINES

23

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

INTAKE MANIFOLD REMOVAL / REFITTING

Refitting

Removal

Figure 62

Figure 60

193049

Fit the intake manifold (1) together with new gaskets (4) and heater (3) on the cylinder head (5).

193047

Fasten the screws (2) and tighten to the prescribed torque.

Remove engine cable connection from air temperature sensor (1).

Ref (2) (2) (2)

Figure 61

No. 2 3 1

Description M10x1.5x110 M10x1.5x100 M10x1.5x150

Tightening torques 43 ± 3 Nm 43 ± 3 Nm 43 ± 3 Nm

Figure 63

193048

Unscrew n˚ 6 bolts (2).

Remove following components: - Intake manifold (1);

193047

Connect the electrical connection to the relative air temperature sensor (1).

- Gasket (4); - Grid heater (3); - Gasket (4).

Ref (2) (2) (2)

No. 2 3 1

Print P2D32C010 E

Description M10x1.5x110 M10x1.5x100 M10x1.5x150

Base - June 2014

24

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

F2CFE613E ENGINES

OIL SUMP REMOVAL / REFITTING Removal

STARTER REMOVAL / REFITTING Removal Figure 64

NOTE

Place a proper container for the oil collecting under the sump connected with the drain plug.

Figure 65

193050

Unscrew the fastening nuts (2) and remove the starter electric motor (1).

Remove the studs.

Ref (2) (2)

218521

Unscrew drain plug (4) from oil sump (5) and then take out oil level dipstick (1) and oil filler cup (3) to ease the down flow of lubrication oil.

Remove the oil filter (2) as described in the relative procedure.

No. Description 3 M10x1.5 3 M10x1.5x30

Figure 66

Refitting Screw the studs into flywheel housing and fit starter electric motor (1).

Tighten fastening nuts (2) to prescribed torque.

Ref (2) (2)

No. Description 3 M10x1.5 3 M10x1.5x30

Tightening torques 43 ± 3 Nm -

218522

Unscrew fastening screws (1) and remove oil sump (3) together with spacer (2) and gasket (5) from crankcase (4).

Ref (1)

Base - June 2014

No. Description 26 M10x1.5x45

Print P2D32C010 E

F2CFE613E ENGINES

25

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Refitting

Figure 67

Figure 68

170127

218523

Unscrew fastening screws (4) and remove brackets (1 and 3).

Turn engine.

Unscrew fastening screws (5) and remove oil suction strainer (2) and pipe (6).

Ref (1) (4) (5)

No. 1 2 2

Description M10x1.5x12 M10x1.5x25 M10x1.5x20

The oil motor is very pollutant and harmful. In case of contact with the skin, wash with much water and detergent.

NOTE Before assembling the suction rose, it is necessary to seal the contact area between basement, flywheel casing and front cover with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing impurities and oil residuals.

Apply silicon LOCTITE 5970 (1) as shown in the picture.

The diameter of the sealing string must be 1.5 ± 0.5/0.2 mm.

Figure 69

Protect properly skin and eyes: operate according to safety rules. Dispose of the residual properly following the rules.

218523

Fit oil suction strainer (2) and pipe (6) and tighten fastening screws (5) to prescribed torque.

Install brackets (1 and 3) and tighten fastening screws (4) to prescribed torque.

Ref (1) (4) (5) Print P2D32C010 E

No. 1 2 2

Description M10x1.5x12 M10x1.5x25 M10x1.5x20

Tightening torques 41.5 ± 3.5 Nm 41.5 ± 3.5 Nm 41.5 ± 3.5 Nm Base - June 2014

26

SECTION 5 - REMOVAL AND REFITTING OF MAIN ENGINE COMPONENTS

Figure 70

F2CFE613E ENGINES

Figure 72

218522

Install gasket (5) onto the oil sump (3) and fit the oil sump (3) together with spacer (2) on the crankcase (4).

Tighten fastening screws (1) to prescribed torque following order and mode shown in the figure below.

Ref (1)

No. Description 26 M10x1.5x45

Tightening torques 41.5 ± 3.5 Nm

Figure 71

218521

Lock drain plug (4) under oil sump (5) at prescribed torque.

Install the oil filter (2) as described in the relative procedure.

Add the required amount of recommended lubricant oil through the filler cup (3) and refit oil level dipstick (1) and oil filler cup (3).

NOTE

Use only the recommended oil or oil having the requested features for the correct motor functioning.

In case of topping up, don’t mix oils having different features.

If you don’t comply with theses rules, the service warranty is no more valid.

218524

Lock screws following the tightening order shown in the figure.

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Figure 73

193945

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

1

SECTION 6 Engine overhaul Page

Print P2D32C010 E

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .

5

FITTING THE ENGINE TO THE ROTATING STAND . . . . . . . . . . . . . . .

6

- Engine lifting . . . . . . . . . . . . . . . . . . . . . . . . . .

6

- Engine cleaning . . . . . . . . . . . . . . . . . . . . . . . .

7

- Engine cable removal . . . . . . . . . . . . . . . . . . .

7

- Engine coolant and lubricant oil drain . . . . . . .

8

- Removal of components hindering bracket assembly . . . . . . . . . . . . . . . . . . . . . . .

8

- Engine brackets and rotating stand installation

10

ENGINE DISASSEMBLY AT BENCH (FRONT SIDE COMPONENTS) . . . . . . . . . .

11

ENGINE DISASSEMBLY AT BENCH (RIGHT HAND SIDE COMPONENTS) . . . .

12

ENGINE DISASSEMBLY AT BENCH (LEFT HAND SIDE COMPONENTS) . . . . . .

13

ENGINE DISASSEMBLY AT BENCH (REAR SIDE COMPONENTS) . . . . . . . . . . . .

15

ENGINE DISASSEMBLY AT BENCH (BOTTOM SIDE COMPONENTS) . . . . . . . .

16

ENGINE DISASSEMBLY AT BENCH (REAR SIDE COMPONENTS) . . . . . . . . . . . .

17

ENGINE DISASSEMBLY AT BENCH (TOP SIDE COMPONENTS) . . . . . . . . . . . .

17

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .

18

ENGINE REMOVAL AT THE BENCH . . . . . . . .

18

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .

20

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .

20

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

20

CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . .

21

- Replacing cylinder liners . . . . . . . . . . . . . . . . .

23

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Base - June 2014

2

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Page

Page 25

- Intermediate gear pin . . . . . . . . . . . . . . . . . . .

49

PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA . .

26

- Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

- Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . .

49

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

49

- Measuring main journals and crank pins . . . . .

- Selecting the main and big end bearing shells .

27

- Replacing the timing control gear and the oil pump . . . . . . . . . . . . . . . . . . . . . .

37

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

- Checking main journal installation clearance . .

37

- Checking cam lift and pin alignment . . . . . . . .

50

- Checking crankshaft end float . . . . . . . . . . . . .

37

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

PISTON-CONNECTING ROD ASSEMBLY . . . .

39

- Use beater 99360505 to change bushings . . .

52

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

52

- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

- Fitting the valves and oil seal ring . . . . . . . . . .

52

CONNECTING ROD . . . . . . . . . . . . . . . . . . . . .

42

ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .

53

- Conditions for correct gudgeon pin-piston coupling . . . . . . . . . . . . . . . . . . . . .

44

- Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

- Mounting the connecting rod - piston assembly

44

- Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

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

44

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

- High pressure pump installation . . . . . . . . . . .

58

ENGINE FLYWHEEL

58

- Fitting the connecting rod-piston assembly into the piston liners . . . . . . . . . . . . . . . . . . . .

44

- Piston protrusion check . . . . . . . . . . . . . . . . .

45

- Checking assembly clearance of big end pins .

45

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .

46

- Dismounting the valves . . . . . . . . . . . . . . . . . .

46

- Checking the planarity of the head on the cylinder block . . . . . . . . . . . . . . . . . . .

46

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

- Removing deposits and checking the valves . .

47

VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . .

47

- Replacing of valve guides . . . . . . . . . . . . . . . .

48

- Replacing - Reaming the valve seats . . . . . . . .

48

TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . .

49

Base - June 2014

.....................

- Engine flywheel installation . . . . . . . . . . . . . . .

59

- Camshaft installation . . . . . . . . . . . . . . . . . . . .

62

TIMING CAMSHAFT AND FLYWHEEL USING TOOL 99395223 . . . . . . . . . . . . . . . .

63

- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . .

63

- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . .

65

TIMING CAMSHAFT AND FLYWHEEL WITHOUT TOOL 99395223 . . . . . . . . . . . . .

65

- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . .

65

- Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . .

69

- Intake and exhaust rocker arm clearance adjustment . . . . . . . . . . . . . . . . . . .

69

ENGINE ASSEMBLY AT BENCH (LEFT HAND SIDE COMPONENTS) . . . . . . .

72

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SECTION 6 - ENGINE OVERHAUL

3

Page ENGINE ASSEMBLY AT BENCH (RIGHT HAND SIDE COMPONENTS) . . . . .

74

ENGINE ASSEMBLY AT BENCH (FRONT HAND SIDE COMPONENTS) . . . .

76

REMOVING THE ENGINE FROM THE ROTATING STAND . . . . . . . . . . . . . . . .

77

COMPLETING ENGINE ASSEMBLY . . . . . . . . . .

77

- Engine cable refitting . . . . . . . . . . . . . . . . . . . .

79

CHECKS AND INSPECTIONS . . . . . . . . . . . . . .

80

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Base - June 2014

4

SECTION 6 - ENGINE OVERHAUL

Base - June 2014

F2CFE613E ENGINES

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

5

INTRODUCTION The following description covers general mechanical overhaul starting from the engine which has been removed from the vehicle.

NOTE

Refer to the specific publication for removing the engine from the vehicle.

Engine removal operations, as with overhauling, must be carried out by specialised personnel with specific equipment.

This section contains: - the operations to perform for mounting the engine on the rotating stand - the sequence of removal operations for the main components - overhaul of the engine block and the cylinder head - the sequence of refitting operations for the main components - operations required for completing engine assembly after removal from the rotating stand - final checks and tests.

Part of the operations covered in this section can be performed directly on the engine still fitted in the vehicle, in relation to their accessibility in the engine compartment and on the vehicle version; these are listed in Section 5 - Removal/refitting of main the engine components.

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6

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

FITTING THE ENGINE TO THE ROTATING STAND Engine lifting Figure 1

218031

Install the lifting eyelets (3) and tighten the screws to the prescribed torque.

Apply the engine lifting sling 99360585 (2) to lifting eyelets (3) and to hoist (1).

Adjust the lifting points on the tool so that the engine remains in equilibrium when it is raised.

Ref (3)

No. 6

NOTE

Description M12x1.75x25

Tightening torques 74 ± 8 Nm

Use extreme caution when lifting and never stay with any part of the body under the engine while it is being lifted or suspended.

Base - June 2014

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SECTION 6 - ENGINE OVERHAUL

7

Engine cleaning Plug all openings (air intake, exhaust duct, fuel pipes, coolant pipes).

Remove the main electrical components (engine control unit, starter electric motor, alternator).

Cover all electrical components not removed (sensors, cables, connectors, ECU) with plastic and tape before washing with high-pressure water jets in order to prevent damage.

Engine cable removal

Figure 2

218032

1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor - 4. Crankcase pressure sensor 5. Fuel temperature and filter clogging (pressure drop) sensor - 6. Boost pressure and air temperature sensor 7. In line connector - 8. Engine Control Unit EDC17CV41 - 9. Engine oil pressure and temperature sensor 10. Fuel high pressure pump metering unit - 11. Flywheel increment speed sensor (crankshaft) 12. Timing segment speed sensor (camshaft) - 13. Motorized throttle valve actuator connector (Exhaust flap) 14. Exhaust gas absolute pressure sensor

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Before fitting the engine onto the rotating stand 99322230, remove the engine cable by unplugging it from the engine control unit (9), from the motorized throttle valve actuator connector (13) and from all the sensors and transmitters to which it is connected.Open the straps holding the engine cable to the engine block and remove it completely.

Figure 3

Engine coolant and lubricant oil drain Drain the engine coolant if not already done.

Place a suitable container for collecting the spent oil under the oil sump next to the lubricant oil drain plug. Unscrew the lubricant oil drain plug; afterwards extract the oil level dipstick and remove the lubricant oil cap to assist the flow of the engine lubricant oil.

Wait until the oil sump has completely emptied, then retighten the lubricant oil drain plug.

Removal of components hindering bracket assembly Remove all those parts that can interfere with the assembly of the brackets 99361046 to the engine block for fastening the engine to the rotating stand 99322230.

218033

Position a suitable container to catch any oil.

Remove the turbocharger lubrication oil discharge pipe (2) by proceeding as follows: - unscrew the fastening screws (1) in the lower part of the turbocharger, recovering the relevant gasket; - unscrew the coupling (4) from the crankcase.

Unscrew the nut (3) and remove the oil level dipstick pipe (6) from the crankcase.

Remove the lubrication oil filling pipe (7) by proceeding as follows: - unscrew the screw (9) and remove the bracket (8) retaining the oil filling pipe (7) to the cranckcase; - unscrew the fastening screws (5) and remove the oil filling pipe (7) from the cranckcase.

Ref (1) (3) (4) (5) (9)

Base - June 2014

No. 2 1 1 2 1

Description M8x1.25x25 M18x1.5 M30x2 M8x1.25x60 M12x1.75x30

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 4

Figure 6

218034

Position a suitable container to catch any coolant.

Remove engine coolant delivery (4) and return (7) pipes of the motorized throttle valve actuator by proceeding as follows: - unscrew the fittings (1 and 3) and remove the engine coolant delivery pipe (4); - unscrew the retaining screws (5 and 6) and the fittings (2 and 8) and remove the engine coolant return pipe (7).

Ref (1) (3) (2,8) (5,6)

No. 1 1 2 2

9

218036

Position a suitable container under lubricant oil heat exchanger to catch any coolant.

Unscrew fastening screws (2) together with spacers (3) and remove lubricant oil heat exchanger (4) complete with relevant gasket (1) from crankcase (5).

Ref (2)

Description M14x1.5 M16x1.5 M14x1.5 M8x1.25x18

No. 16

Description M8x1.25x50

Figure 7

Figure 5

218037

Unscrew the fastening screws (1) and remove the cover (6), retrieving relative sealing O-ring.

218035

Unscrew fastening screw (3) and loosen V-clamping collar (1) to remove motorized throttle valve (2) together with actuator (4) from turbocharger (5).

If the power take-off (PTO) is present, remove the power steering pump and the service air/conditioning compressor with relative coolant pipes.

Ensure that the starter electric motor (3) is suitably supported.

Unscrew the fastening nuts (2) and remove the starter electric motor (3).

Unscrew the studs (4) from the flywheel housing (5).

Ref (3)

No. 1

Print P2D32C010 E

Description M8x1.25x70

Ref (1) (2) (4)

No. 3 3 3

Description M12x1.75x25 M10x1.5 M10x1.5x30 Base - June 2014

10

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Engine brackets and rotating stand installation Figure 8

218038

Fit brackets 99361046 to the engine block and mount the engine on the rotating stand 99322230.

Base - June 2014

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SECTION 6 - ENGINE OVERHAUL

ENGINE DISASSEMBLY AT BENCH (FRONT SIDE COMPONENTS)

11

Figure 10

Figure 9

218039

Unscrew the fastening screw (9) and remove the automatic belt tensioner (10).

Unscrew the fastening screws (11 and 12) and remove the alternator support (13).

Unscrew the fastening screws (6) together with washers (5) and remove the damper pulley (4) from the crankshaft pulley (8).

218040

Unscrew the fastening screws (3) and disassemble the thermostat unit: remove the engine coolant outlet pipe (7) together with the coolant temperature sensor (2); remove the gasket (1), the sealing ring (8) and the thermostat (9) from the cylinder head.

Unscrew the screws (6) and remove the engine coolant inlet pipe (5) from the crankcase together with the sealing ring (4).

Unscrew the fastening screw (2) and remove the idler guide pulley (1).

Unscrew the fastening screws (7) and remove the crankshaft pulley (8) from the crankshaft (3).

Ref No. (2) 1 (6) 6 (7) 6 (9) 1 (11) 1 (11) 1 (12) 1 NOTE

Description M12x1.75x70 M12x1.75x30 M14x2x60 M10x1.5x70 M10x1.5x140 M10x1.5x120 M10x1.5x100

Ref (3) (6)

No. 5 2

Description M8x1.25x70 M8x1.25x50

Figure 11

The flywheel blocking device can aid the removal of the damper pulley (4) fitted onto the crankshaft pulley (8).

218041

Unscrew the fastening screws (3) and remove the water pump (2) together with its sealing gasket (1).

Ref (3) Print P2D32C010 E

No. 4

Description M8x1.25x25 Base - June 2014

12

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE DISASSEMBLY AT BENCH (RIGHT HAND SIDE COMPONENTS)

Figure 14

Figure 12

218017

218042

Position a suitable container to catch any fuel.

Disconnect the fitting (5) and remove the low pressure fuel pipe from the engine control unit heat exchanger to mechanical pump.

Unscrew the fastening nuts (3) and remove the ECU (2) including the heat exchanger.

Unscrew the fastening screws (6) and remove the engine oil pressure and temperature sensor (1) from the crankcase.

Unscrew the spacers (4).

Ref (3) (4) (5)

No. 3 3 1

Description M8x1.25 M8x1.25x47 M16x1.5

Figure 13

Disconnect the engine cable from the fuel high-pressure pump metering unit (8), as described in the relative procedure.

Disconnect the fittings (7 and 9) to remove the low pressure fuel pipe (11) from fuel filter to high-pressure pump and the pipe (12) from mechanical pump to fuel filter.

Unscrew the hose couplings (3 and 10) and the screw (6) to remove the high-pressure fuel pipe (5) from high-pressure pump to cylinder head.

Unscrew the fastening screws (2 and 4) and remove the fuel filter bracket (1).

Ref No. Description (7,9) 2 M16x1.5 (3,10) 2 M14x1.5 (6) 1 M6x16 (2) 3 M8x1.25x35 (4) 1 M8x25 (4) 1 M10x25 Figure 15

218016

218043

Place a container for collecting diesel under the fuel filter support (2).

Disconnect the fittings (4 and 8) and the screw (1) to remove the low pressure fuel pipe (3) from ECU to mechanical pump.

Unscrew the fastening screws (3) and remove the fuel filter support (2) together with the fuel filter clogging (pressure drop) sensor (5) and NTC temperature sensor (4) from the engine cable supporting bracket (1).

Disconnect the fittings (2 and 7) and the screw (5) to remove the backflow fuel pipe (6) from high-pressure pump to fuel tank.

Ref No. Description (4,8) 2 M16x1.5 (2,7) 2 M16x1.5 (1) 1 M8x1.25x25 (5) 1 M8x1.25x16

Ref (3)

No. 4

Base - June 2014

Description M8x1.25x30

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

13

ENGINE DISASSEMBLY AT BENCH (LEFT HAND SIDE COMPONENTS)

Figure 16

Figure 18

218044

Unscrew the fastening screws (6 and 7) and remove the bracket (5).

218046

Unscrew the fastening screw (3) and remove the crankcase pressure sensor (2).

Unscrew the screw (3) fixing the lubrication oil delivery pipe (2) to oil filter bracket (4)

Unscrew the fastening screw (4) and remove the air intake duct (1).

Position a suitable container to catch any oil.

Ref (3) (4) (6) (7)

No. 1 1 1 1

Description M12x1.5

Unscrew the hose couplings (1 and 5) and remove the lubrication oil delivery pipe (2) from crankcase to turbocharger.

Ref (1,5) (3)

M10x1.5x16 M8x1.25x16

No. 2 1

Description M18x1.5 M8x1.25x20

Figure 19

Figure 17

218045

Unscrew the fastening screws (2 and 3) and remove the intake manifold (1) together with boost pressure and air temperature sensor (4) from the cylinder head, recovering grid-heater resistance (6) and relative gasket (5).

218047

Unscrew the hose couplings (1 and 6) and remove the exhaust gas pipe (2) from exhaust manifold.

Unscrew the fastening screws (3 and 7) and remove the bracket (4) together with the exhaust gas absolute pressure sensor (5).

Unscrew fastening screw (9) and loosen V-clamping collar (8) to remove turbocharger air outlet duct (10) to intercooler.

Ref (2) (3) (3)

No. 2 3 1

Print P2D32C010 E

Description M10x1.5x110 M10x1.5x100 M10x1.5x150

Ref (1,6) (3,7) (9)

No. 2 2 1

Description M14x1.5 M6x1x14 M6x1x50 Base - June 2014

14

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 20

Figure 22

218048

Position a suitable container to catch any oil.

Unscrew the fastening screws (6 and 7) and remove the oil filter (5) with its support recovering relative gasket (2) and the bracket (1).

Unscrew the fastening screws (4) and remove the oil pressure relief valve (3) from the crankcase.

Ref (4) (6) (7)

No. 2 2 2

Description M8x1.25x20 M8x1.25x90 M8x1.25x60

218050

Unscrew fastening screws (4) and remove exhaust manifold (1) recovering relevant gaskets (3) from cylinder head (2).

Ref (4)

No. 24

Description M10x1.5x38

Figure 21

218049

Unscrew the fastening nuts (4 and 7) and remove the turbocharger (6), recovering relevant gasket (2).

Unscrew the studs (3 and 5) from the exhaust manifold (1).

Ref (3,5) (4,7)

No. 4 4

Base - June 2014

Description M10x1.5x30 M10x1.25

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

ENGINE DISASSEMBLY AT BENCH (REAR SIDE COMPONENTS)

15

Figure 25

Figure 23

192060

Unscrew the screws (1) and remove the high pressure pump (2).

114018

Unlock screws (2) and remove cover (1). Remove centrifugal filter (3) below.

Ref (3) (2)

No. 3 6

Ref (1)

No. 3

Description M8x1.25x40

Figure 26

Description M6x1x16

Figure 24

114020

Unlock screws (1) and remove thrust plate (2).

Use specific spanner to unlock screws (4) and remove relay gear (5).

Remove high pressure pump mount flange (3).

192059

Use specific spanner to unlock screws (2) and remove gear (3) complete with tune wheel.

Unlock nut (4) and remove control gear (5) of high pressure pump.

Remove rpm sensor (1).

Ref (2) (4) (1)

No. 4 1 1

Ref (1) (4)

No. 5 3

Description M8x1.25x20 M12x1.5

Description M10x1.5x45 M18x1.5 M6x1

NOTE In case removal of gear (5) is difficult, release high pressure pump screws with light beater strokes on control shaft and remove gear (5).

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE DISASSEMBLY AT BENCH (BOTTOM SIDE COMPONENTS)

Figure 27

Figure 28

192061

Remove the crankshaft rpm sensor (3).

Use specific tool 99360351 lock engine flywheel (2) rotation, unlock retaining screws (1) and remove engine flywheel.

218530

Unscrew fastening screws (1) and remove oil sump (3) together with spacer (2) and gasket (5) from crankcase (4).

Ref (3) (1)

No. 1 8

Description M6x1 M18x1.5x72

Ref (1)

No. 26

Description M10x1.5x45

Figure 29

192063

Unlock screws and remove suction rose (1).

Ref (1) (1) (1)

Base - June 2014

No. 1 2 2

Description M10x1.5x12 M10x1.5x25 M10x1.5x20

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

ENGINE DISASSEMBLY AT BENCH (REAR SIDE COMPONENTS)

17

ENGINE DISASSEMBLY AT BENCH (TOP SIDE COMPONENTS)

Figure 30

Figure 32

114022 192067

Apply extractor and remove crankshaft rear seal.

Unlock rocker arm shaft retaining screws (4).

Unlock screws (1) and remove flywheel box (2).

Ref (1) (1) (1) (1) (1) (1)

No. 1 3 1 1 7 2

Disconnect fuel pipelines (1) from injector rail, fuel supply line (2) of high pressure pump to rail and return line (3).

Description M10x1.5x110 M10x1.5x35 M12x1.75x120 M10x1.5x180 M12x1.75x80 M12x1.75x193

Ref (1) (1) (2) (2) (4)

No. 6 6 1 1 7

Description M18x1.5 M14x1.5 M18x1.5 M14x1.5 M12x1.75

Figure 31 Figure 33

114023

Remove screws (2) and double gear (3).

192075

Apply tool 99360558 (1) to rocker arm shaft (2) and remove shaft, remove crosspieces from cylinder head.

Remove retaining screw (5) and connecting rod (4).

Remove oil pump (1).

Ref (1) (1) (2) (5)

No. 3 5 3 1

Print P2D32C010 E

Description M8x1.25x45 M8x1.25x60 M12x1.75x90 M8x1.25x16 Base - June 2014

18

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH

Figure 34

The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.

The section illustrates therefore all the most important engine overhaul procedures.

Figure 36

114027

Remove retaining brackets (3) and remove injectors (4).

Remove retaining screws (1) and remove rail (2).

Ref (1) (3)

No. 3 1

Description M8 M10x1.5x40

115882

Rotate the block to the vertical position.

Untighten screws (2) fixing the connecting rod cap (3) and remove it. Remove the connecting rod-piston (1) assembly from the upper side.

Repeat these operations for the other pistons.

Figure 35

Ref (2)

No. 12

Description M10x1.5x20

Keep the big end bearing shells in their respective housings and/or note down their assembly position since, if reusing them, they will need to be fitted in the position found upon removal.

192068

Remove camshaft and remove cylinder head retaining screws.

Use metallic ropes to lift cylinder head (1) and remove seal (2).

Ref (-)

No. 26

Base - June 2014

Description M16x2x170

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 37

19

Figure 38

114035

Using tool 99360500 (1), remove the crankshaft (2).

Figure 39

191584

Use adequate hexagonal spanner, unlock screws (1 and 3) and remove stiffening plate (2) as well as main journals (4).

Ref (1) (3)

No. 8 14

Description M10x1.5x20 M16x2x168 47571

NOTE Note down the assembly position of the top and bottom main bearing shells since, if reusing them, they will need to be fitted in the position found upon removal.

Remove the main bearing shells (1), unscrew the screws and take out the oil nozzles (2).

Remove the cylinder liners as described under the relevant subheading on Replacing cylinder liners paragraph.

Ref (2)

No. 6

Description M8

After disassembling the engine, thoroughly clean disassembled parts and check their integrity.

Instructions for main checks and measures are given in the following pages, in order to determine whether the parts can be re-used.

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20

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

REPAIR OPERATIONS CYLINDER BLOCK Checks and measurements Figure 40

Figure 42

(Demonstration)

225036 34994

Internal diameter of the cylinder liners is checked for ovalization, taper and wear, using a bore dial (1) centesimal gauge 99395687 (2) previously reset to ring gauge (3), diameter 117 mm.

NOTE If dia.117 mm ring gage is not available, use a micrometer.

Figure 41

A = Selection class  117 — 117.012 mm B = Selection class  117.010 — 117.022 mm In case of maximum wear >0.150 mm or maximum ovalization >0.100 mm compared to the values indicated in the figure, the liners must be replaced as they cannot be ground, lapped or trued.

NOTE Cylinder liners are equipped with spare parts with “A“ selection class.

Figure 43

114035

1 = 1st measuring 2 = 2nd measuring 3 = 3rd measuring Carry out measurings on each cylinder liner at three different levels and on two (A-B) surfaces, to one another perpendicular, as shown in Figure.

Base - June 2014

114037

A = Ø 130.500 to 130.525 mm B = Ø 129.510 to 129.535 mm C = Ø 130.461 to 130.486 D = Ø 129.475 to 129.500 mm The figure shows the outer diameters of the cylinder liners and the relative seat inner diameters.

The cylinder liners can be extracted and installed several times in different seats, if necessary.

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SECTION 6 - ENGINE OVERHAUL

21

CYLINDER LINERS Figure 44

114038

CYLINDER BLOCK ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS Figure 45

193967

CYLINDER LINERS MAIN DATA Selection class

A mm 117.000 to 117.012 B mm 117.010 to 117.022

X = Selection class marking area Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 46

DETAIL A 145837

Figure 47

DETAIL B 145838

Base - June 2014

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Replacing cylinder liners

23

Figure 50

Removal Figure 48

77812

Check cylinder barrel protrusion with tool 99360334 (1-2-3-4) and tighten screw (1) to 225 Nm. 47577

Place details 99360706 (1 and 2) and plate 99360724 (4) as shown in the figure, by making sure that the plate (4) is properly placed on the cylinder liners.

Tighten the screw nut (1) and remove the cylinder liner (3) from the block.

With dial gauge 99395603 (5) placed on base 99370415 (6) measure the cylinder barrel protrusion compared to the cylinder head supporting plane, it must be 0,035 to 0,065 mm (figure below); otherwise replace the adjusting ring (1, previous figure) fitted with spare parts having different thickness.

Figure 51

Fitting and checking protrusion Figure 49

114041

CYLINDER LINER PROTRUSION Figure 52

16798

Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2); lubricate lower part of liner and install it in the cylinder unit using the proper tool.

NOTE The adjustment ring (1) is supplied as spare parts in the following thicknesses: 0.08 mm - 0.10 mm - 0.12 mm.

Print P2D32C010 E

35012

When the installation is completed, block the cylinder liners (1) to the block (2) with studs 99360703 (3).

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

CRANKSHAFT Figure 53

Upper main journal half bearing

Lower main journal half bearings

144835

MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.

The data given refer to the normal diameter of the pins.

Figure 54

Figure 55

114043

X. Detail of main journals connections Base - June 2014

114044

Y. Detail of crank pins connections Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Measuring main journals and crank pins

25

Figure 57

Before grinding the crank pins using a micrometer (1), measure the main journals and the crank pins (2) and decide, on the basis of the undersizing of the bearings, the final diameter to which the pins are to be ground.

Figure 56

47536

MEASURING CRANK PINS

47535

During grinding, pay attention to journal and crank pins values specified previous figures.

MEASURING THE MAIN JOURNALS NOTE It is advisable to enter the values found in a table (Figure below).

NOTE All journals and crank pins must also be ground to the same undersizing class, in order to avoid any alteration to shaft balance.

Figure 58 Fill in this table with the measurements of the main journals and the crank pins.

MAIN JOURNALS

Ø MIN. Ø MAX.

Ø MIN. Ø MAX.

CRANK PINS Print P2D32C010 E

114045

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA For each of the journals of the crankshaft, it is necessary to carry out the following operations: MAIN JOURNALS: - Determine the class of diameter of the seat in the crankcase.

CRANKPINS: - Determine the class of diameter of the seat in the connecting rod.

- Determine the class of diameter of the main journal.

- Determine the class of diameter of the crankpin.

- Select the class of the bearing shells to mount.

- Select the class of the bearing shells to mount.

DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE On the front of the crankcase, two sets of numbers are marked in the position shown (Figure below at top).

- The first set of digits (four) is the coupling number of the crankcase with its base (Figure below at bottom).

- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure below at bottom).

- Each of these digits may be 1, 2 or 3.

Figure 59 CLASS

MAIN BEARING HOUSING NOMINAL DIAMETER

99.000 to 89.009 99.010 to 99.019 99.020 to 99.030

114046

Base - June 2014

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SECTION 6 - ENGINE OVERHAUL

27

Selecting the main and big end bearing shells NOTE

To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described hereunder.

This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary, can have different classes from one journal to another).

Depending on the thickness, the bearing shells are selected in classes of tolerance marked by a coloured sign (red-green — red/black — green/black).

The following tables give the specifications of the main and big end bearing shells available as spares in the standard sizes (STD) and in the permissible oversizes (+0.127, +0.254, +0.508).

Figure 60 STD red

1.994 to 2.002

red/black green

2.057 to 2.065 2.002 to 2.010

green/black yellow*

2.065 to 2.073 2.010 to 2.018 2.073 to 2.081

yellow/black*

STD red

3.031 to 3.041 2.978 to 2.988

green/black yellow*

+0.127

2.968 to 2.978

red/black green

+0.127

3.041 to 3.051 2.988 to 2.998

yellow/black*

3.051 to 3061

* Fitted in production only and not supplied as spares Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter) Main journals and crankpins: determining the class of diameter of the journals.

Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure below at top): - The first number, of five digits, is the part number of the shaft.

- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins they refer to (Figure below at top).

- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the main journals they refer to (Figure below at bottom).

Figure 61 CLASS

CRANKPIN NOMINAL DIAMETER

81.915 to 81.925 81.925 to 81.935 81.935 to 81.945

CLASS

MAIN JOURNALS NOMINAL DIAMETER

92.970 to 92.980 92.980 to 92.990 92.990 to 93.000 Base - June 2014

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SECTION 6 - ENGINE OVERHAUL

29

Selection of main half-bearings (nominal diameter pins) After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in compliance with the following table:

Figure 62

STD.

114048

1

2

3

green

green

yellow

green

yellow

yellow

red

green

green

green

green

yellow

red

red

green

red

green

green

1

2

3 114055

Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Selection of main half-bearings (rectified pins) If the journals have been rectified, the procedure described cannot be applied.

In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type required for this undersizing.

Figure 63

red/black = mm 3.031 to 3.041 green/black = mm 3.041 to 3.051

-0.127 114048

yellow/black = mm 3.051 to 3.061

1

3

92.843 1 92.853

green/black

green/black

yellow/black

green/black

yellow/black

yellow/black

92.853 2 92.863

red/black

green/black

green/black

green/black

green/black

yellow/black

red/black

red/black

green/black

red/black

green/black

green/black

92.863 3 92.872

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SECTION 6 - ENGINE OVERHAUL

31

Figure 64

red = mm 3.092 to 3.102

-0.254 114048

92.726 1 92.746

Print P2D32C010 E

99.000 99.010

99.010 99.020

99.020 99.030

1

2

3

red

red

red

red

red

red

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 65

red = mm 3.219 to 3.229

-0.508 114048

92.472 1 92.492

Base - June 2014

99.000 99.010

99.010 99.020

99.020 99.030

1

2

3

red

red

red

red

red

red

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

SELECTING THE BIG END BEARING SHELLS (JOURNALS WITH NOMINAL DIAMETER) There are 4 references on the connecting rod casing in the positions illustrated: 1.

Coloured mark for identifying the weight

2.

Coloured mark for identifying the diameter grade

3.

Positioning stud visible from the front of the engine

4.

Progressive number for identifying the connecting rod

33

Figure 66

NOTE The identification colours of the marks are given in the table on CONNECTING ROD paragraph..

Determine the type of big end bearing to fit on each journal by following the indications in the table (Figure below).

193968

Figure 67

STD.

Class

1 yellow

2 green

3 blue

green

green

yellow

green

yellow

yellow

red

green

green

green

green

yellow

red

red

green

red

green

green

1

2

3

Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Selection of connecting rod half-bearings (rectified pins) If pins have been rectified, the procedure described must be applied.

In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings identified according to the relative table.

Figure 68

red/black = mm 2.057 to 2.065 green/black = mm 2.065 to 2.073

-0.127

yellow/black = mm 2.073 to 2.081

1

3

81.789 1 81.799

green/black

green/black

yellow/black

green/black

yellow/black

yellow/black

81.799 2 81.809

red/black

green/black

green/black

green/black

green/black

yellow/black

red/black

red/black

green/black

red/black

green/black

green/black

81.809 3 81.819

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SECTION 6 - ENGINE OVERHAUL

35

Figure 69

red = mm 2.120 to 2.129 green = mm 2.129 to 2.138

Print P2D32C010 E

-0.254 85.987 85.996

85.997 86.005

86.006 86.013

1

2

3

81.661 1 81.670

red

green

green

red

green

green

81.671 2 81.681

red

red

green

red

red

green

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 70

red = mm 2.247 to 2.256 green = mm 2.256 to 2.265

Base - June 2014

-0.508 85.987 85.996

85.997 86.005

86.006 86.013

1

2

3

81.407 1 81.416

red

green

green

red

green

green

81.417 2 81.427

red

red

green

red

red

green

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Replacing the timing control gear and the oil pump

37

Figure 73

Check that the teeth of the gears are not damaged or worn, otherwise remove them using the appropriate extractor.

Figure 71

114034

Using the hoist and hook 99360500 (1) mount the driving shaft (2).

144834

NOTE Before fitting the gear, spread Loctite type 603 on approx. 5 mm wide band on crankshaft, at 30 mm from contact surface.

Figure 74

After fitting the gear (1) on the crankshaft (2), heat it for ~15 minutes in an oven at temperature not higher than 180C. Let them cool down after the installation.

Checking main journal installation clearance Figure 72

114050

Place bearing halves (1) on main journals (2).

Check the installation clearance between the main journals and the relative bearings as follows.

114049

Fit the oil jets (2) aligning the dowel with the opening (3) in the crankcase.

Position the half-bearings (1) and the thrust bearing half rings on bearing journals as shown in the figure.

Ref (2)

No. 6

Print P2D32C010 E

Description M8

Tightening torques 50 ± 5 Nm

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Checking crankshaft end float

Figure 76

Figure 75

145839

Clean accurately the parts and remove any trace of oil; Fit caps (1), including the half bearings (2) on the relevant supports.

47588

End float is checked by placing a magnetic dial gauge (1) on the crankshaft (2), as shown in the figure.

If the value obtained is higher than specified, replace the rear thrust half-bearings and repeat this check.

Figure 77

α

191584

Position the main journal caps (4) and fit the strengthening plate (2) following the procedure described: Tighten the inner bolts and then the outer bolts by hand starting from main journal ”7” and continuing until main journal ”1”.

Tightening the bolts using torque wrench always starting from main journal ”7” and continuing until main journal ”1”

Ref

No.

(3)

14

(1)

8

Base - June 2014

Description M16x2x168 1st phase 2nd phase 3rd phase M10x1.5x20

Tightening torques 140 ± 7 Nm 60˚ 60˚ 49 ± 3 Nm Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

39

PISTON-CONNECTING ROD ASSEMBLY Figure 78

193957

PISTON CONNECTING ROD ASSEMBLY 1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston Make sure the piston does show any trace of seizing, scoring, cracking; replace as necessary.

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Removal

Figure 81

Figure 79

126311

Removal of the piston split rings (2) using the pliers 99360184 (1).

49026

Remove the piston pin (1).

If removal is difficult use the appropriate beater.

Pistons are equipped with three elastic rings: a sealing ring, a trapezoidal ring and a scraper ring.

Pistons are grouped into classes A and B for diameter.

Figure 80

Figure 82

126312

Remove the piston pin split rings (2) using the round tipped pliers (1).

Base - June 2014

32618

Measuring the gudgeon pin diameter (1) with a micrometer (2).

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SECTION 6 - ENGINE OVERHAUL

41

Figure 83

191256

MAIN DATA OF PISTON, SNAP RINGS AND PIN X = 0,6  0,1

Figure 86

Piston rings Figure 84

3513

The sealing ring (2) of the 1º cavity is trapezoidal. Clearance “X” between the sealing ring and its housing is measured by placing the piston (1) with its ring in the cylinder barrel (3), so that the sealing ring is half-projected out of the cylinder barrel.

16552

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

Figure 87

Figure 85

36134

16552

Check the clearance between the sealing rings (2) and the relative piston housings (1) using a thickness gauge (3).

Print P2D32C010 E

Check the opening between the ends of the sealing rings (1), using a thickness gauge (2), entered in the cylinder barrel (3).

If the distance between ends is lower or higher than the value required, replace split rings.

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

CONNECTING ROD Figure 88

209171

MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

NOTE

All dimensions indicated in figure, must be controlled with bush assembled and finished.

1 On the external breaking line, gap area allowed must be < 5 mm2.

2 No cracks are allowed in the threaded area.

NOTE

Make sure that the values of small end bush are between values listed in the Section 8:Technical Specification ­ Cylinder unit and crankshaft components; otherwise, replace the connecting rod.

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SECTION 6 - ENGINE OVERHAUL

43

Figure 89

193969

1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from the front of the engine - 4. Progressive number for identifying connecting rod

WEIGHT GRADE A Yellow

3308 g - 3338 g

GRADE B Green (*)

3339 g - 3368 g

GRADE C Blue

3369 g - 3398 g

DIAMETER  85.987-85.996  85.997-86.005  86.006-86.013  85.987-85.996  85.997-86.005  86.006-86.013  85.987-85.996  85.997-86.005  86.006-86.013

Yellow Green Blue Yellow Green Blue Yellow Green Blue

(*) As spares, only Grade B connecting rod are provided and can replace Grade A and C.

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SECTION 6 - ENGINE OVERHAUL

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Conditions for correct gudgeon pin-piston coupling

Fitting the connecting rod-piston assembly into the piston liners

Figure 90 Figure 93

49026

Lubricate the pin (1) and the relevant housing on the piston hubs with engine oil; piston must be inserted with a slight finger pressure and it should not come out by gravity.

115885

Mounting the connecting rod - piston assembly

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

Figure 92 If the cap (1) is fitted upsidedown, the connecting rod should be discarded.

NOTE As spares, class A pistons are provided and can be fitted also to cylinder barrels belonging to class B. 117694

NOTE The connecting rod screws can be reused as long as the diameter of the thread is not less than 11.4 mm.

Fit the connecting rod-piston assemblies (1) into the piston liners (2) using band 99360605 (1, following Figure). Check the following: - the openings of the split rings are offset by 120;

Mounting the piston rings Figure 91

Figure 94

47593

49029

To fit the piston rings (1) on the piston (2) use the pliers 99360184 (3).

The rings need to be mounted with the word ”TOP” (4) facing upwards. Direct the ring openings so they are staggered 120 apart.

Base - June 2014

- all pistons belong to the same class, A or B; - ideogram stamped on the piston crown is placed toward the engine flywheel, or the cavity, on the piston cover, corresponds to the position of the oil spray nozzles.

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SECTION 6 - ENGINE OVERHAUL

45

Piston protrusion check Once assembly is complete, check piston protrusion from cylinder barrels: it must be 0.873 to 1.177 mm.

Figure 95

1

Connecting rod-piston assembly

2

Marking area on the piston crown of ideogram specifying the assembly position and the selection class

3

Connecting rod marking area.

188462

Checking assembly clearance of big end pins To check the clearance proceed as follows: connect the connecting rods to the relative main journals, place a length of calibrated wire on the latter.

Figure 96

Ref

No.

(2)

12

Description M12x1.25x69 1st phase 2nd phase

Tightening torques 50 ± 2.5 Nm 60˚

Remove the caps and check the clearance by comparing the width of the calibrated wire with the scale calibration on the envelope containing the wire.

α

115886

Fit the connecting rod caps (1) together with half-bearings and tighten the screws (2) to the torque indicated in the table using tool 99395216 (3).

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

CYLINDER HEAD Before dismounting cylinder head, check cylinder head for hydraulic seal by proper tooling; in case of leaks not caused by cup plugs or threaded plugs, replace cylinder head.

NOTE

Checking the planarity of the head on the cylinder block Figure 98

In case of plugs dismounting/replacement, on mounting, apply sealant Loctite 121078 on plugs.

Dismounting the valves NOTE

Before dismounting cylinder head valves, number them in view of their remounting in the position observed on dismounting should they not have to be overhauled or replaced.

Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.

198334

The planarity (1) is checked using a ruler (2) and a thikness gauge (3). If deformations exist, surface the head using proper surface grinder; the maximum amount of material to be removed is 0.2 mm.

Figure 97 NOTE After leveling, make sure that valve sinking and injector protrusion are as described in the relative paragraph.

47583

Install and fix tool 99360264 (2) with bracket (4); tighten by lever (1) until cotters are removed (3); remove the tool (2) and the upper plate (5), the spring (6) and the lower plate (7).

Repeat the operation on all the valves.

Turn the cylinder head upside down and remove the valves (8).

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SECTION 6 - ENGINE OVERHAUL

VALVE Removing deposits and checking the valves

47

Figure 100

Figure 99

92841

MAIN DATA - VALVES AND VALVE GUIDES 48625

Remove carbon deposits using the metal brush supplied.

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

Check the diameter of the valve stem using a micrometer (see following Figure) and replace if necessary.

* Values to be obtained after installing the valve guides Check, by means of a micrometer, that valve stem diameters are as specified; if necessary, grind the valves seat with a grinder, removing the minimum quantity of material.

VALVE GUIDES Figure 101

*

INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES

191585

* Values to be obtained after installing the guide valves Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Replacing of valve guides

Checking protrusion of injectors

Remove valve guides by means of tool 99360288.

Install by means of tool 99360288 equipped with part 99360294, which determines the exact installation position of valve guides into the cylinder heads; if they are not available, install the valve guides in the cylinder head so that they project out by mm 16.3 to 16.7 (Previous Figure).

Figure 103

After installing the valve guides, smooth their holes with sleeker 99390310.

Replacing - Reaming the valve seats To replace the valve seats, remove them using the appropriate tool.

47585

Figure 102

Using dial gauge (1), check the protrusion of the injector (2) which must be 1.53 mm.

41032

Ream the valve seats (2) on cylinder head using tool (1).

NOTE Valve seats must be reamed whenever valves or valve guides are replaced or ground.

After reaming the valve seats, use tool 99370415, to make sure that the valve position, with respect to the cylinder head surface, is the following: - -0.5 to -0.8 mm (recessing) of exhaust valves; - -1.65 to 1.95 mm (recessing) of discharge valves.

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

TIMING GEAR Camshaft drive

49

Idler gear

Figure 104

Figure 106

193958

TIMING CONTROL COMPONENT PARTS 1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod 5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear 8. Drive shaft driving gear.

Intermediate gear pin

193970

Twin idler gear

Figure 105

Figure 107

86926

Rated assembling play between idler gear bushings and pins: 0.040  0.080 mm.

193971

Replacing the bushings Bushings (1) can be replaced when they are worn. Put up the bushing, then grind it so as to bring it to a dimension of  65.010  0.10 mm.

NOTE Bushing fitting in gears (2, previous Figures) must be performed in arrow direction, placing them as shown in figures.

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Camshaft Checking cam lift and pin alignment Figure 108

47506

Place the camshaft (4) on the live centre (1) and using a centesimal dial gauge (2) check the lift value of the cams (3) indicated in the DATA -ASSEMBLY CLEARANCE table.

Figure 109

47507

When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed 0.030 mm.

If misalignment exceeds this value, replace the shaft.

Figure 110 1

47505

In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained by their difference.

If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.

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51

Figure 111

191586

191586

MAIN DATA - CAMSHAFT AND TOLERANCES The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the shaft and the relative bushes.

TOLERANCES ORIENTATION POSITION

TOLERANCE CHARACTERISTIC Perpendicularity

SYMBOL ⊥

Concentricity or coaxial alignment

OSCILLATION Circular oscillation IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS CRITICAL IMPORTANT SECONDARY

↗ SYMBOL  ⊕ ⊝

Bushes Figure 112

114214

MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS * Bush inner diameter after installation The bush surfaces must not show any sign of seizing or scoring; if they do replace them.

Print P2D32C010 E

Measure the bush inner diameters with a baremeter and replace them, if the value measured exceeds the tolerance value.

To take down and fit back the bushes, use the proper tool 99360505.

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Use beater 99360505 to change bushings

Fitting the valves and oil seal ring

Removal

Figure 115 Figure 113

114280

Use tool 99360505 (3) fitted as shown in fig. to remove bushings (2).

Accurately position beater during removal phase.

Fitting For fitting, reverse operations performed for removal, with care to make lube hole (1), drilled on bushing, coincide with corresponding hole in housing.

87051

Lubricate the valve stem and insert the valves in the respective valve guides; fit the lower caps (1). Use tool 99360292 to fit the oil seal (2) on the valve guides (3) of the exhaust valves; then, to fit the valves, proceed as follows.

VALVE SPRINGS Figure 114

Valve closed

NOTE

Should valves not have been overhauled or replaced, remount them according to numbering performed on dismounting.

Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.

Valve open Figure 116 114215

MAIN DATA TO CONTROL EXHAUST AND DISCHARGE VALVE SPRING

86290

- fit springs (6) and the upper plate (5); - apply tool 99360264 (2) and block it with bracket (4); tighten the lever (1) until cotters are installed (3), remove tool (2).

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SECTION 6 - ENGINE OVERHAUL

53

ROCKER SHAFT Figure 117

114216

The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker a rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.

Shaft Figure 118

114217

MAIN DATA OF THE ROCKER ARM SHAFT Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.

Rocker Figure 119

114219

DISCHARGE VALVE ROCKER Figure 120

114218

EXHAUST VALVES ROCKER The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.

Print P2D32C010 E

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 123

ASSEMBLY Figure 121

117690 218502

Clean the surface of the parts to be joined removing impurities and oil residuals. Apply silicon LOCTITE 5970 (1) to the cover (2) as shown in the picture.

The diameter of the sealing string must be 1.5  0.5/0.2.

- Fit part (4) of the tool 99346265 on the front tang (3) of the crankshaft; fasten it with the screws (5) and spline the new tight ring (6) on it.

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

Fit the front cover within 10 minutes after applying the sealer.

Figure 122

Figure 124

218501

Install front cover (1) on crankcase (5) and tighten fastening screws (3) to the prescribed torque after having interposed washers (2).

NOTE

Ref (3)

218503

Fit the oil pump (4) on crankcase (2) and tighten fastening screws (1 and 3) to the prescribed torque.

Crankcase (5) has two reference studs (4) that must match with related housings on the front cover (1).

No. 9

Base - June 2014

Description M8x1.25x20

Tightening torques 19 ± 3 Nm

Ref (1) (3)

No. 3 5

Description M8x1.25x45 M8x1.25x60

Tightening torques 24 ± 3 Nm 24 ± 3 Nm Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 125

55

Figure 127

218028

Clean surfaces to be coupled to remove dirt and oil residuals.

218504

Install the clearance adjusting rod (2) on crankcase (3) and tighten fastening screw (1) to the prescribed torque.

Ref (1)

No. 1

Description M8x1.25x16

Tightening torques 24.5 ± 2.5 Nm

Figure 126

Apply LOCTITE 5970 (2) silicone on gear casing (1) as shown in the figure.

The sealant seam diameter must be 1.5 ± 0.5/0.2 mm.

!

Install gear casing within 10 min. from sealant application.

Figure 128

α

218505

Fit gear pin (2) in position into clearance adjusting rod (1) and install double gear (5) complete with shoulder plate (4).

Tighten fastening screws (3) in two phases to prescribed torque.

218506

Use two suitable lifting hooks (2) in order to lift and fit flywheel box (1) to engine block (3) by using a hoist.

Ref (3)

No. 3

Description M12x1.75x90 1st phase 2nd

Print P2D32C010 E

Tightening torques 30 Nm

phase 90˚ Base - June 2014

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 129

Figure 131

218508

Check that pistons 1-6 are exactly at T.D.C.

218507

Use torque wrench to lock fastening screws (1, 2, 3, 4, 6 and 7) at prescribed torque on flywheel box (5) following the scheme shown in the figure below.

Ref (1) (2) (3) (4) (6) (7)

No. 1 3 1 1 7 2

Description M10x1.5x110 M10x1.5x35 M12X1.75X120 M10x1.5x180 M12x1.75x80 M12x1.75x193

Use suitable lifting hooks (1 and 3) in order to lift and fit the cylinder head (2) on the engine block (4) after having interposed a new gasket (5) by using a hoist with engine lifting sling 99360585.

NOTE

Tightening torques 41.5 ± 3.5 Nm 41.5 ± 3.5 Nm 63 ± 7 Nm 41.5 ± 3.5 Nm 63 ± 7 Nm 63 ± 7 Nm

Figure 130

If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.

Removed screws must not be used again. Employ new screws only.

Figure 132

α

218509

The fastening screws (1) must be lubricated with MOLYKOTE treatment before being mounted on the cylinder head (2).

Tighten the screws (1) fixing cylinder head (2) to engine block in four phases to prescribed torque following order and mode shown in the figures below.

Ref 218029

Tightening order layout for flywheel box fastening screws

Base - June 2014

(1)

No.

26

Description M16x2x170 1st phase 2nd phase 3rd phase 4th phase

Tightening torques 50 Nm 100 Nm 90˚ 75˚ Print P2D32C010 E

F2CFE613E ENGINES

NOTE

SECTION 6 - ENGINE OVERHAUL

The screws (1) must be tightened following a ”spiral” pattern starting in the middle and going outwards.

57

Figure 135

α NOTE

The angle tightening is carried out through tool 99395216.

NOTE

Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

45268

- Angle locking by means of tool 99395216 (1): 3rd phase: 90˚ angle 4th phase: 75˚ angle.

Figure 133

Figure 136 198348

Cylinder head retaining screw locking sequence diagram.

Figure 134

114263

Clean surfaces to be coupled to remove dirt and oil residuals.

Apply LOCTITE 5970 silicone on gear casing (1) as shown in the figure. + 0,5

The sealant seam diameter must be 1.5 - 0,2

mm.

45267

- Pre-lock by torque wrench (1): 1st phase: 50 Nm (5 kgm); 2nd phase: 100 Nm (10 kgm).

Print P2D32C010 E

!

Install gear casing within 10 min. from sealant application.

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F2CFE613E ENGINES

ENGINE FLYWHEEL

Figure 137

NOTE If toothing on engine flywheel for engine start-up is very damaged, change crown wheel.

Refit crown wheel after heating up at approx.

200C.

Figure 139

218510

Apply gauge 99395221 (1) on flywheel box (4) to check and adjust centre-to-centre distance between camshaft and fuel high-pressure pump.

Fit connection flange (2) in position on the tool (1) and tighten fastening screws (3) to prescribed torque by allen wrench.

Remove tool 99395221 (1) from flywheel box (4).

High pressure pump installation Figure 138 218514

- Fit part (6) of the tool 99346260 on the rear tang (3) of the crankshaft; fasten it with the screws (1) and spline the new tight ring (2) on it.

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

192060

Install high-pressure pump (1) on flange (2).

Tighten the screws (1) to the prescribed torque.

Ref (1)

No. 3

Base - June 2014

Description M8x1.25x40

Tightening torques 33 ± 3 Nm

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

59

Engine flywheel installation NOTE Crankshaft has a reference pin that must match with related housing on engine flywheel.

Figure 140

114265

A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2 notches, position corresponding to 54.

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Figure 141

Figure 143

α

145832

192078

Position flywheel (1) on crankshaft, lubricate screws (2) threading with engine oil and lock them.

Install rail on cylinder head and lock retaining screws by hand.

Ref

Ref (-)

No.

(2)

8

Description Tightening torques M18x1.5x72 1st phase 120 Nm 2nd phase 90˚

Install injectors in correct position and lock to required torque.

No. 6

Description M10x1.5x45

Tightening torques 46 ± 3 Nm

Stop rotation using specific tool (99360351).

1st phase: pre-lock with torque wrench (3) at 120 Nm torque.

Figure 142

α

49036

2nd

phase: 90 angle locking using tool 99395216 (1).

Base - June 2014

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F2CFE613E ENGINES

61

SECTION 6 - ENGINE OVERHAUL

Figure 144

193973

Fit pipes on injectors and head locking fittings by hand.

The previously removed pipes ca no longer be refit and must be replaced.

Lock fittings on injectors and head (B) at required torque.

Lock rail to cylinder head retaining screws at required torque.

Lock fittings on rail (A, C) at required torque.

Lubricate the injector fastening O-Rings using the following lubricants: PDE SILIKONFETT 22, NLG 12, PDE LUBRICOMET GR 220 NLG12.

!

TYPE A B C

Check that the injectors (2) are equidistant from the springs (1). Distance ”X” which separates them should always be the same.

DESCRIPTION M18 x 1.5 M14 x 1.5 M16 x 1.5

LOCK TORQUE 40  2 Nm 35  2 Nm 35  2 Nm

Install pipes on rail and lock fittings by hand.

!

Print P2D32C010 E

After fitting the high-pressure pipelines, during the following 20 hours of work, frequently check engine oil level (IT MUST NOT INCREASE).

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Camshaft installation

Figure 146

Figure 145

114267

193964

Position crankshaft with pistons 1 and 6 at TDC. This condition is obtained when: 1.

the opening with one reference (5) for the engine flywheel (4) is visible from the inspection window;

2.

tool 99360612 (1), through housing (2) of engine rpm sensor, inserts in hole (3) drilled on engine flywheel (4).

Install camshaft (3) and orient it with references () positioned as in the figure.

Clean the matching surfaces of the plate (1) to remove impurities and oil residues.

Apply silicon LOCTITE 5970 (6) on the plate (1) as shown in the picture.

NOTE Take care NOT to get sealant on the inner groove (5).

Otherwise, adjust engine flywheel orientation (4).

Remove too 99360612 (1).

The diameter of the sealant bead should be 1.5

+ 0,5 - 0,2

mm.

Fit the plate (1) within 10 mins of applying the sealant with the gasket (2) and tighten the screws (4) to the prescribed torque.

Ref (4)

Base - June 2014

No. 5

Description M8x1.25x20

Tightening torques 20 ± 2 Nm

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

TIMING CAMSHAFT AND USING TOOL 99395223

Figure 147

63

FLYWHEEL

Timing camshaft

Figure 149

198353

Apply gage 99395222 (1), check and adjust position of connecting rod (3) for relay gear, lock screw (2) at required torque.

Figure 148

193960

Rotate the crankshaft with the tool 99360341 so that the opening marked with two references (5) is visible from the lower inspection window in the flywheel cover casing.

In this condition, insert the tool 99360612 (1) via the housing (2) for the engine rpm sensor in the opening (3) in the engine flywheel (4).

Figure 150

1 114270

Refit relay gear (2) and lock screws (1) using six-splined spanner at required torque.

Ref (1)

No. 3

Description M12x1.5

Tightening torques 25 ± 5 Nm

NOTE The relay gear (2) bushing can be replaced when worn out. After securing bushing, grind it to reach dia. 58.010  0.10 mm.

Print P2D32C010 E

2 192072

Fit the tool 99395223 (1) at the front of the camshaft.

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Figure 151

Figure 153

1

2 3 192074 192073

Rotate the tool (1) 99395223 in order to insert the pin (3) in the opening (2, previous Figure) in the head. Fasten the tool (1) 99395223 using two M8x1.25 bolts (2).

Figure 152

Install crosspieces (1) on valve rod.

NOTE Before refitting rocker arm shaft assembly, check that all adjustment screws have been fully unlocked.

Figure 154

3 α

3

117691

Fit the camshaft drive gear (1) so that the fastening openings in the shaft are aligned with the slots (2) in the drive gear.

Position the gear (1) taking care to position the spokes (4) as illustrated.

201437

Apply tool 99360558 (1) and related lock block (4) to rocker arm shaft (2) and install shaft on cylinder head.

Remove lock block (4) and lock retaining screws at required torque.

Tighten the fixing bolts (3).

Ref (3)

No. 4

Base - June 2014

Description Tightening torques M10x1.5x45 1st phase 25 ± 5 Nm 2nd phase 45˚

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Timing flywheel

TIMING CAMSHAFT AND WITHOUT TOOL 99395223

Figure 155

65

FLYWHEEL

Timing camshaft Figure 156

145834

Fit the high pressure pump gear (5) tightening the nut (4) to torque.

Use the flat washer in conjunction with the nut (4) replacing the one supplied with the Bosch CP3 pump.

Fit the flywheel (6) so that the tooth marked with the arrow () is in line with the sensor housing (2).

To check that the position is correct, insert tool (1) 99360613 in the timing sensor (2) housing.

Proceed with tightening the bolts (3).

192079

Secure special tool 99360341 to gear casing.

Remove the tools 99395223, 99360612 and 99360613.

Ref (4) (6)

No. 1 3

Description M18x1.5 M8x1.25

Tightening torques 105 ± 5 Nm 23 ± 2 Nm

NOTE The arrow indicated engine rotation direction.

With the aforementioned tool, turn the flywheel (1) in the direction of the engine rotation so as to bring cylinder piston 1 to 54˚ before the T.D.S. during compression (cylinder 6 in discharge phase).

This condition occurs when the hole with two notches (3) on the engine flywheel (1), can be seen through the small inspection window (2).

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F2CFE613E ENGINES

Figure 157

Figure 159

71774

The exact position of piston 1 at 54˚ before T.D.C. is obtained when, under the conditions described above, the specific tool (1) is inserted into the hole (3) on the engine flywheel (4) through the engine rpm sensor seat (2).

Otherwise, rotate engine flywheel (4) to adjust its orientation.

117691

Install gear (1) controlling camshaft so that fastening holes on shaft coincide with slots (2) on control gear.

NOTE

Remove the specific tool (1).

Position the gear (1) taking care to position the spokes (4) as illustrated.

This operation is necessary in order to be able to fit the flywheel correctly which can only be fitted in one position in relation to the gear.

Figure 158 Lock retaining screws (3).

Ref (3)

No. 4

Description Tightening torques M10x1.5x45 1st phase 25 ± 5 Nm 2nd phase 45˚

Figure 160

115063

Rotate the camshaft so that the openings at the rear of the engine are arranged in the configuration illustrated in the diagram.

192076

Install crosspieces (1) on valve rod.

NOTE Before refitting rocker arm shaft assembly, check that all adjustment screws have been fully unlocked.

Base - June 2014

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 161

67

Figure 163

192075

Apply tool 99360558 (1) to rocker arm shaft (2) and install shaft on cylinder head.

Lock retaining screws at required torque.

177714

Using the appropriate tool, turn the flywheel in a clockwise direction until the needle of the dial gauge reaches the minimum value possible.

Remove tool 99360612.

NOTE Figure 162

The measurement is to be taken keeping the rocker arm roller in contact with the profile of the exhaust cam on the camshaft.

The dial gauge is to be zeroed with the rocker arm roller in contact with the base radius of the cam profile.

Reset the dial gauge.

Turn the flywheel in an anticlockwise direction, until the dial gauge shows the timing system cam lift value of 4.70 ± 0.05 mm.

Figure 164 185253

As shown in the figure, position the dial gauge (1) with the flat based rod (3) on the roller (4) of the rocker arm controlling the discharge valve of cylinder 3 and preload it to at least 7 mm.

NOTE

Position the flat based dial gauge rod (see detailed part) so that its axis passes through the centre of the roller on which it is resting.

During the CHECK phase, not during the engine overhaul phase, the allowed tolerance of the measurement is between -0.05 - +0.12 mm.

During OVERHAUL, the allowed tolerance is ± 0.05 mm.

115064

Camshaft is timed if conditions below are found at cam lift values 4.70  0.05: 1) hole identified with two notches (5) is visible through manhole; 2) fixture 99360612 (1) through housing (2) of engine rpm sensor inserts in hole (3) on engine flywheel (4).

Print P2D32C010 E

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F2CFE613E ENGINES

Figure 165

Figure 166

114281

In case conditions shown in previous Figure and shown at paras 1 and 2 are not found, operate as follows: - turn the engine flywheel until the required cam lift value appears on the dial gauge; - release screws (2) securing gear (1) of camshaft to as to make control gear and camshaft independent; - conveniently operate on engine flywheel so as to obtain conditions indicated at paras 1 and 2, previous Figure, considering that cam lift value must remain unchanged; - use the slots on the gear (1); lock screws (2) and repeat control as already described; - lock screws (2) at required torque.

Ref (2)

No. 4

Description Tightening torques M10x1.5x45 1st phase 25 ± 5 Nm 2nd phase 45˚

185523

Turn the flywheel (4) again until it reaches the following conditions: - the hole marked with two notches (5) can be seen from the small inspection window; - the specific tool (1) is inserted into the hole (3) on the engine flywheel (4) through the engine rpm sensor seat (2).

Figure 167

NOTE While performing this operation recover the clearance between the camshaft gears.

When adjustment via the slots is not sufficient for recovering the offset, proceed as follows: Lock the screws (2) and turn the flywheel 1/2 turn in a clockwise direction.

114281

Turn the flywheel in an anticlockwise direction, until the dial gauge shows the timing system cam lift value of 4.70 ± 0.05 mm.

Mount the gear (1) with the four slots centred in relation to the camshaft fastening holes locking the relevant screws (2) to the prescribed tightening torque.

Remove the screws (2) and disassemble the camshaft gear (1).

Ref

Description Tightening torques M10x1.5x45 1st phase 25 ± 5 Nm (2) 4 2nd phase 45˚ Recover the clearance between the timing gears by turning the flywheel in a clockwise direction and then in an anticlockwise direction until the dial gauge shows the value of 4.70 ± 0.05 mm. Check the conditions described above.

Base - June 2014

No.

Print P2D32C010 E

F2CFE613E ENGINES

69

SECTION 6 - ENGINE OVERHAUL

Timing flywheel

Intake and exhaust rocker arm clearance adjustment

Figure 168

Figure 169

114287

Adjustment of clearance between rocker arms and intake/exhaust valve control crosspieces must be performed with utmost care. Bring to blast phase cylinder to be adjusted; the valves of this cylinder are closed while the symmetric cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5 and 3-4.

In order to perform these operations correctly, refer to procedure and table below.

114284

Install gear (7) of high pressure pump and lock nut (8) at required torque.

Ref (8) NOTE

No. 1

Description M18x1.5

Tightening torques 105 ± 5 Nm

When refitting, use the flat washer in conjunction with the nut replacing the one supplied with BOSCH pump CP3.

Turn the flywheel in an anticlockwise direction until the inspection window (3) corresponds with the hole marked with 2 notches (2) (cylinder 1 compressing).

Insert the specific tool through the flywheel sensor seat.

Mount the phonic wheel (4) so that the tooth marked with the arrow () corresponds with the sensor seat (6).

In order to check the correct positioning, insert the specific tool into the timing sensor seat (6).

Tighten the screws (5).

-

Use a polygonal spanner to release lock nut (1) of rocker arm adjustment screw (2).

-

Insert filler gage (3) having same value of operating clearance shown in “Characteristic and data“ tables.

-

Use special spanner to lock/unlock adjustment screw.

-

Check that filler gage (3) slides with a low friction.

-

Lock nut (1) retaining the adjustment screw.

Ref (1)

No. 12

Description M10x1.25

Tightening torques 39 ± 5 Nm

IGNITION ORDER 1-4-2-6-3-5 START AND ROTATION CLOCKWISE 1 and 6 at TDC 120 120 120 120 120

BALANCE VALVES OF CYLINDER No.

ADJUST CLEARANCE OF VALVES CYLINDER No.

6 3 5 1 4 2

1 4 2 6 3 5

Remove the specific tools.

NOTE

Ref (5)

No. 3

Print P2D32C010 E

Description M8x1.25

Tightening torques 23 ± 2 Nm

In order to correctly carry out adjustments above, it is mandatory to perform the sequence indicated in the table, checking exact positioning at each phase by means of pin 99360612.

Base - June 2014

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F2CFE613E ENGINES

Figure 170

Figure 172

E00033

Fit the crankcase venƟlaƟon valve body (2) together with a new gasket and Ɵghten the fastening screws (1) to the prescribed torque.

E00034

Install cylinder head cover (1) and lock screws (2) at required torque following order shown in Figure below diagram.

Ref No. DescripƟon

Tightening torques

Ref No. DescripƟon

Tightening torques

(1)

9±1Nm

(2)

8.5 ± 1.5 Nm

3

M6x1

Figure 171

20

M6x1x50

Figure 173

E00035

E00036

Fit the head internal electric wire (injectors+pressure sensor) passing it through the opening and securing it using bands as illustrated in the diagram (↓).

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

71

Figure 174

219644

Install the centrifugal filter element (1) on the timing gear (5) and tighten the fastening screws (2).

Fit the timing cover (3) and tighten the fastening screws (4) Ref (2) (4)

No. 3 6

Description M6x1x16

Tightening torques 9 ± 1 Nm

Figure 175

117695

Rotate the engine Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel casing and front cover with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing impurities and oil residuals.

Apply silicon LOCTITE 5970 (1) as shown in the picture. The diameter of the sealing string must be 1.5  0.5/0.2 mm.

Print P2D32C010 E

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72

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE ASSEMBLY AT BENCH (LEFT HAND SIDE COMPONENTS)

Figure 176

Figure 179

192063

Install suction rose (1).

218050

Fit the exhaust manifold (1) in position with new gaskets (3) to the cylinder head (2) and tighten the fastening screws (4) to the prescribed torque following order and mode shown in the figure below.

Figure 177

Ref (4)

NOTE

No. 24

Description Tightening torques M10x1.5x38 1st phase 30 ± 5 Nm 2nd phase 60 ± 5 Nm

Always replace the gaskets (3) using new ones.

Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit.

218530

Figure 180

Install gasket (5) onto the oil sump (3) and fit the oil sump (3) together with spacer (2) on the crankcase (4).

Tighten fastening screws (1) to prescribed torque following order and mode shown in the figure below.

Ref (1)

No. 26

Description M10x1.5x45

Tightening torques 41.5 ± 3.5 Nm 171168

Figure 178

Tightening order layout for exhaust manifold fastening screws The central section of the exhaust manifold (1) must be tightened first.

218524

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F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 181

73

Figure 183

218049

Screw the studs (3 and 5) on the exhaust manifold (1); Hold the turbocharger (6) together with the waste-gate valve and place it on the exhaust manifold (1) after having interposed a new gasket (2);

218047

Install the turbocharger air outlet duct (10) to intercooler onto the turbocharger.

Screw fastening screw (9) to tighten V-clamping collar (8) to prescribed torque

Tighten the fastening nuts (4 and 7) to the prescribed torque.

Fit the bracket (4) together with the exhaust gas absolute pressure sensor (5) and tighten fastening screws (3 and 7) to prescribed torque.

Ref No. (3,5) 4

Install exhaust gas pipe (2) onto exhaust manifold and tighten hose couplings (1 and 6) to prescribed torque.

(4,7)

4

Description Tightening torques M10x1.5x30 M10x1.25 1st phase 35 ± 5 Nm 2nd phase 46 ± 2 Nm

Figure 182

Ref No. (1,6) 2 (3,7) 2 (9) 1

Description M14x1.5 M6x1x14 M6x1x50

Tightening torques 30 ± 2 Nm 10 ± 2 Nm 7 ± 1 Nm

Figure 184

218048

218046

Install the oil pressure relief valve (3) into the crankcase and tighten the fastening screws (4) to prescribed torque.

Install lubrication oil delivery pipe (2) from crankcase to turbocharger and tighten hose couplings (1 and 5) to prescribed torque.

Fit new gasket (2) on the crankcase and install the oil filter (5) with its support and bracket (1).

Tighten the fastening screws (6 and 7) to prescribed torque.

Ref (4) (6) (7)

No. 2 2 2

Print P2D32C010 E

Description M8x1.25x20 M8x1.25x90 M8x1.25x60

Tightening torques 23.5 ± 2.5 Nm 24.5 ± 2.5 Nm 24.5 ± 2.5 Nm

Tighten the screw (3) fixing lubrication oil delivery pipe (2) to oil filter bracket (4).

Ref No. (1,5) 2 (3) 1

Description M18x1.5 M8x1.25x20

Tightening torques 50 ± 5 Nm 24 ± 3 Nm

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SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE ASSEMBLY AT BENCH (RIGHT HAND SIDE COMPONENTS)

Figure 187

Figure 185

218043

218045

Install the intake manifold (1) together with boost pressure and air temperature sensor (4) on the cylinder head, after having interposed new gaskets (5) and the grid-heater resistance (6).

Install backflow fuel pipe (6) from high-pressure pump to fuel tank. Connect fittings (2 and 7) and tighten fastening screw (5) to prescribed torque.

Install low pressure fuel pipe (3) from ECU to mechanical pump. Connect fittings (4 and 8) and tighten fastening screw (1) to prescribed torque.

Tighten fastening screws (2 and 3) to prescribed torque.

Ref (2) (3) (3)

No. 2 3 1

Description M10x1.5x110 M10x1.5x100 M10x1.5x150

Tightening torques 43 ± 3 Nm 43 ± 3 Nm 43 ± 3 Nm

Ref No. (4,8) 2 (2,7) 2 (1) 1 (5) 1

Description M16x1.5 M16x1.5 M8x1.25x25 M8x1.25x16

Tightening torques 30 ± 5 Nm 45 ± 5 Nm 24.5 ± 2.5 Nm 24.5 ± 2.5 Nm

Figure 186

218044

Install air intake duct (1) and tighten fastening screw (4) to prescribed torque.

Fit crankcase pressure sensor (2) and tighten fastening screw (3) to prescribed torque.

Install the bracket (5) and tighten fastening screws (6 and 7) to prescribed torque.

Ref (3) (4) (6) (7)

No. 1 1 1 1

Base - June 2014

Description M12x1.5 M10x1.5x16 M8x1.25x16

Tightening torques 44 ± 4 Nm 8 ± 2 Nm 43 ± 3 Nm 24 ± 3 Nm Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

Figure 188

75

Figure 189

218017

Fit the fuel filter bracket (1) and tighten the fastening screws (2 and 4) to the prescribed torque.

Connect the high-pressure fuel pipe (5) from high-pressure pump to cylinder head and tighten the hose couplings (3 and 10) and the screw (6) to the prescribed torque.

Connect the low pressure fuel pipe (11) from fuel filter to high-pressure pump and the pipe (12) from mechanical pump to fuel filter and tighten the fittings (7 and 9) to the prescribed torque.

218016

Fit the fuel filter support (2) together with the fuel filter clogging (pressure drop) sensor (5) and NTC temperature sensor (4) on the engine cable supporting bracket (1) and tighten the fastening screws (3) to the prescribed torque.

Ref (3)

No. 4

Description M8x1.25x30

Tightening torques 24 ± 3 Nm

Fasten the engine cable to the retainers and connect the electrical connection to the fuel high-pressure pump metering unit (8), as described in the relative procedure.

Figure 190 Ref No. (7,9) 2 (3,10) 2 (6) 1 (2) 3 (4) 1 (4) 1

Description M16x1.5 M14x1.5 M6x16 M8x1.25x35 M8x25 M10x25

Tightening torques 30 ± 5 Nm 35 ± 2 Nm 10 ± 1 Nm 24 ± 3 Nm 24 ± 3 Nm 37.5 ± 7.5 Nm

218042

Screw the spacers (4). Install the ECU (2) including the heat exchanger and tighten fastening nuts (3) to prescribed torque.

Connect the fitting (5) of low pressure fuel pipe from engine control unit heat exchanger to mechanical pump.

Fit engine oil pressure and temperature sensor (1) on the crankcase and tighten fastening screws (6) to prescribed torque.

Ref (3) (4) (5) Print P2D32C010 E

No. 3 3 1

Description M8x1.25 M8x1.25x47 M16x1.5

Tightening torques 24 ± 3 Nm 30 ± 5 Nm Base - June 2014

76

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

ENGINE ASSEMBLY AT BENCH (FRONT HAND SIDE COMPONENTS)

Figure 193

Figure 191

α

218041

Apply a new seal ring (1) to the coolant pump (2).

Assemble the water pump (2) complete with its sealing gasket (1) and tighten the fastening screws (3) to the prescribed torque.

218039

Install crankshaft pulley (8) on crankshaft (3) and tighten fastening screws (7) to prescribed torque.

Install idler guide pulley (1) and tighten fastening screw (2) to prescribed torque.

Fit damper pulley (4) on crankshaft pulley (8) and tighten fastening screws (6) together with washers (5).

Ref (3)

No. 4

Description M8x1.25x25

Tightening torques 24.5 ± 2.5 Nm

Fit alternator support (13) and tighten fastening screws (11 and 12) to prescribed torque.

Install automatic belt tensioner (10) and tighten fastening screw (9) to prescribed torque.

Figure 192 Ref (2) (6) (7) (9) (11) (11) (12)

No. 1 6

Tightening torques 60 ± 8 Nm 115 ± 5 Nm

6

Description M12x1.75x70 M12x1.75x30 M14x2x60 1st phase

1 1 1 1

2nd phase M10x1.5x70 M10x1.5x140 M10x1.5x120 M10x1.5x100

50˚ 45 ± 5 Nm

70 Nm

218040

Apply a new sealing ring (4) and fit engine coolant inlet pipe (5) to the crankcase.

Tighten fastening screws (6) to prescribed torque.

NOTE

The flywheel blocking device can aid the installation of the damper pulley (4) fitted onto the crankshaft pulley (8).

Assemble thermostat unit: install gasket (1), thermostat (9) and sealing ring (8) into cylinder head; fit coolant outlet pipe (7) together with coolant temperature sensor (2) and tighten the fastening screws (3) to the prescribed torque.

Ref (3) (6)

No. 5 2

Base - June 2014

Description M8x1.25x70 M8x1.25x50

Tightening torques 24.5 ± 2.5 Nm 23.5 ± 2.5 Nm Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

REMOVING THE ENGINE ROTATING STAND

FROM

THE

77

Figure 195

Support the engine appropriately with a hoist, disconnect it from the rotating stand, remove brackets 99361046 and place it on a suitable support to complete engine assembly.

COMPLETING ENGINE ASSEMBLY Figure 194

218036

Install lubricant oil heat exchanger (4) complete with relevant gasket (1) into crankcase (5). Tighten fastening screws (2) together with spacers (3) to prescribed torque.

Ref 218037

(2)

No. 16

Description M8x1.25x50 1st phase 2nd

Screw the studs (4) into flywheel housing (5) and fit starter electric motor (3).

phase

Tightening torques 11.5 ± 3.5 Nm 24.5 ± 2.5 Nm

Tighten fastening nuts (2) to prescribed torque.

If the power take-off (PTO) is present, install the power steering pump and service air/conditioning compressor with relative coolant pipes.

Figure 196

Apply a new sealing O-ring, fit the cover (6) and tighten fastening screws (1) to prescribed torque.

Ref (1) (2) (4)

No. 3 3 3

Description M12x1.75x25 M10x1.5 M10x1.5x30

Tightening torques 63 ± 5 Nm 43 ± 3 Nm 43 ± 3 Nm

218035

Install motorized throttle valve (2) together with actuator (4) onto turbocharger (5).

Screw fastening screw (3) to tighten V-clamping collar (1) to prescribed torque.

Ref (3)

Print P2D32C010 E

No. 1

Description M8x1.25x70

Tightening torques 14 ± 1 Nm

Base - June 2014

78

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

Figure 197

Figure 198

218034

218033

Install engine coolant delivery (4) and return (7) pipes of the motorized throttle valve actuator by proceeding as follows:

Install the lubrication oil filling pipe (7) by proceeding as follows:

- fit engine coolant return pipe (7) and tighten fittings (2 and 8) and retaining screws (5 and 6) to prescribed torque;

- fit the oil filling pipe (7) into the crankcase and tighten fastening screws (5) to prescribed torque;

- fit engine coolant delivery pipe (4) and tighten fittings (1 and 3) to prescribed torque.

- fit the bracket (8) retaining the oil filling pipe (7) to the crankcase and tighten the screw (9) to prescribed torque.

Fit the oil level dipstick pipe (6) on the crankcase and tighten fastening nut (3) to prescribed torque.

Ref (1) (3) (2,8) (5,6)

No. 1 1 2 2

Description M14x1.5 M16x1.5 M14x1.5 M8x1.25x18

Tightening torques 43 ± 3 Nm 43 ± 3 Nm 35 Nm 24 ± 3 Nm

Install the turbocharger lubrication oil discharge pipe (2) by proceeding as follows: - Tighten the coupling (4) on the crankcase to prescribed torque; - Tighten fastening screws (1) in the lower part of the turbocharger, after having interposed a new gasket.

Ref (1) (3) (4) (5) (9)

Base - June 2014

No. 2 1 1 2 1

Description M8x1.25x25 M18x1.5 M30x2 M8x1.25x60 M12x1.75x30

Tightening torques 24 ± 3 Nm 30 ± 3 Nm 110 ± 5 Nm 24 ± 3 Nm 63 ± 7 Nm

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 6 - ENGINE OVERHAUL

79

Engine cable refitting Figure 199

218032

1. Electro-injectors (CRIN3) - 2. Rail pressure sensor (RDS4) - 3. Coolant temperature sensor 4. Crankcase pressure sensor - 5. Fuel temperature and filter clogging (pressure drop) sensor 6. Boost pressure and air temperature sensor - 7. In line connector - 8. Engine Control Unit EDC17CV41 9. Engine oil pressure and temperature sensor - 10. Fuel high pressure pump metering unit 11. Flywheel increment speed sensor (crankshaft) - 12. Timing segment speed sensor (camshaft) 13. Motorized throttle valve actuator connector (Exhaust flap) - 14. Exhaust gas absolute pressure sensor After removing the engine from the rotating stand 99322230, place the engine cable in position and connect it to engine control unit (9), to motorized throttle valve actuator connector (13) and to all the sensors and transmitters indicated in the electrical equipment section.

Print P2D32C010 E

Close the straps holding the engine cable to the engine block.

Base - June 2014

80

SECTION 6 - ENGINE OVERHAUL

F2CFE613E ENGINES

CHECKS AND INSPECTIONS NOTE The following checking inspections must be carried out after the engine assembly on the vehicle .

Preventively check that the liquid levels have been correctly restored.

Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check:

- that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors; - that there are no oil leaks between the cover and the cylinder head, between oil sump and engine block, between heat exchanger oil filter and the relevant housings and between the different pipes in the lubricating circuit; - that there are no fuel leaks from the fuel pipes; - that there are no air leaks from pneumatic pipes; - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed.

- Carefully check and bleed the engine cooling equipment by repeated draining operations.

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

1

SECTION 7 Technical specifications Page

Print P2D32C010 E

GENERAL CHARACTERISTICS . . . . . . . . . . . . .

3

ASSEMBLY CLEARANCE DATA . . . . . . . . . . . .

5

TIGHTENING TORQUES . . . . . . . . . . . . . . . . .

11

Base - June 2014

2

SECTION 7 - TECHNICAL SPECIFICATIONS

Base - June 2014

F2CFE613E ENGINES

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

3

GENERAL CHARACTERISTICS F2CFE613 Type E*B009

E*B010

E*B011

A VALVE TIMING opens before T.D.C.

A

15˚

closes after B.D.C.

B

30

opens before B.D.C.

D

50

closes after T.D.C.

C

5

mm

-

mm

-

mm

0.4 ± 0,05

mm

0.4 ± 0,05

B C

D For timing check X X Running X

Bosch Common Rail with CRIN3 injectors and high pressure pump CP3.3 NH

FEED

Nozzle type

DLLA 145

Injection order

1-4-2-6-3-5

bar

Injection pressure

bar

Injector calibration

bar

1800

NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided

by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

Print P2D32C010 E

Base - June 2014

4

SECTION 7 - TECHNICAL SPECIFICATIONS

F2CFE613E ENGINES

ASSEMBLY CLEARANCE DATA F2CFE613 Type E*B009

E*B010

CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS

E*B011

mm

1 Bores for cylinder liners: upper

130.500 ÷ 130.525

lower

129.510 ÷ 129.535

upper

130.461 ÷ 130.486

lower

129.475 ÷ 129.500

1

Cylinder liners: external diameter: L

2

2

length

L

226.15

Cylinder liners crankcase bores upper lower

0.014 ÷ 0.064 0.010 ÷ 0.060

2

External diameter

-

Cylinder sleeve 3 X

inside diameter

3A*

117.000 ÷ 117.012

inside diameter

3B*

117.010 ÷ 117.022

Protrusion

X

0.035 ÷ 0.065

* Selection class 1 X 2 * Selection class

Pistons:

Federal Mogul

Mahle

measuring dimension external diameter

X 1A*

15 116.894 ÷ 116.906

18 116.871 ÷ 116.883

external diameter

1B*

116.904 ÷ 116.916

116.881 ÷ 116.893

2

52.016 ÷ 52.022

52.010 ÷ 52.018

A* B*

Federal Mogul 0.094 ÷ 0.118 0.094 ÷ 0.118

Mahle 0.117 ÷ 0.141 0.117 ÷ 0.141

pin bore Piston - cylinder sleeve

* Selection class Piston diameter

1

-

X Pistons protrusion

3

Gudgeon pin Gudgeon pin - pin housing

Base - June 2014

X

3

0.094 ÷ 0.118

51.994 ÷ 52.000 Federal Mogul 0.016 ÷ 0.028

Mahle 0.010 ÷ 0.024 Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

5

F2CFE613 Type

E*B009

E*B010

E*B011

mm X1 X2 X3

S1 S2 S3

Federal Mogul

Mahle

X1

2.582 ÷ 2.716

2.585 ÷ 2.615

X2

2.550 ÷ 2.570

2.550 ÷ 2.570

X3

4.020 ÷ 4.040

4.020 ÷ 4.040

Piston rings: trapezoidal seal

S1

lune seal

S2

Federal Mogul 2.429 ÷ 2.473 2.470 ÷ 2.500

Mahle -

milled scraper ring with slits and internal spring

S3

Piston ring grooves

1 Piston rings - grooves

2 3

Piston rings

Mahle -

Federal Mogul 0.109 ÷ 0.153 0.050 ÷ 0.100 0.030 ÷ 0.070

0,050  0,100

-

Piston ring end gap in cylinder liners

X1

-

3.970 ÷ 3.990

X2

X1

X3

X2

Mahle -

Federal Mogul 0.30 ÷ 0.40 0.60 ÷ 0.75 0.35 ÷ 0.65

-

X3 Small end bush housing Ø1

1 Big end bearing housing

2

Selection classes

3

Ø2 1 2 3

85.987 ÷ 85.996 85.996 ÷ 86.005 86.005 ÷ 86.013

3

52.015 ÷ 52.030

{

Small end bush diameter

inside Piston pin - bush

0.015 ÷ 0.036

Big end bearing

0.127* - 0.254 - 0.508

Connecting rod weight

Class *

55.690 ÷ 55.710

A

g

A

3308 ÷ 3338

B

3339 ÷ 3368

C

3369 ÷ 3398

Fitted in production only and not supplied as spares

Print P2D32C010 E

Base - June 2014

6

SECTION 7 - TECHNICAL SPECIFICATIONS

F2CFE613E ENGINES

F2CFE613 Type

E*B009

E*B010

E*B011

mm

1

2

S1

S 2

3

Main journals - nominal - class - class - class Crankpins - nominal - class - class - class

1 2 3 2 1 2 3

Main bearing shells Red Green Yellow

S1

Big end bearing shells Red Green Yellow

S2

Main bearing housings - nominal - class - class - class

3

92.970 ÷ 93.000 92.970 ÷ 92.980 92.980 ÷ 92.990 92.990 ÷ 93.000 81.915 ÷ 81.945 81.915 ÷ 81.924 81.925 ÷ 81.934 81.935 ÷ 81.945 2.968 ÷ 2.978 2.978 ÷ 2.988 2.988 ÷ 2.998 1.994 ÷ 2.002 2.002 ÷ 2.010 2.010 ÷ 2.018

1 2 3

99.000 ÷ 99.030 99.000 ÷ 99.009 99.010 ÷ 99.019 99.020 ÷ 99.030

Bearing shells main journals

0.050 ÷ 0.090

Bearing shells big ends

0.040 ÷ 0.080

Main bearing shells

0.127* - 0.254 - 0.508

Big end bearing shells

0.127* - 0.254 - 0.508

Main journal, thrust bearing X1

1

X1 39.900 ÷ 40.100 39.960 ÷ 40.040

1-2-3-4-5-6 7 Main bearing housing, thrust bearing

X2

32.94 ÷ 32.99

Thrust washer halves

X3

3.38 ÷ 3.43

X2 X3

Crankshaft end float 1

2

Concentricity

0.040

Ovalization

0.010

Taper *

0.11 ÷ 0.34

-

Fitted in production only and not supplied as spares

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

7

F2CFE613 Type E*B009

E*B010

E*B011

mm

CYLINDER HEAD - VALVE TRAIN  1 Valve guide housings in cylinder head 1

12.980 ÷ 12.997

2

8.023 ÷ 8.038

3

13.012 ÷ 13.025

 2

Valve guide  3 Valve guides - housings in the cylinder heads

0.015 ÷ 0.045

Valve guide

0.2 - 0.4

Valves:

 4



4 

7.970 ÷ 7.985 60 30  7 30

4 

7.970 ÷ 7.985 60˚ 30 ± 7 30

Valve stem and its guide

0,038 ÷ 0,068

Valve seat in head

 1

41.985 ÷ 42.020

1

40.985 ÷ 41.020

2 

42.060 ÷ 42.075 60˚ 30’

2 

41.060 ÷ 41.075 60˚ 30’

Outside diameter of valve seat; angle of valve seat in cylinder head:

 2



X

X Recessing of valve X

Between valve seat and head

Print P2D32C010 E

1

0.5 ÷ 0.8 1.65 ÷ 1.95

0.040 ÷ 0.090

Base - June 2014

8

SECTION 7 - TECHNICAL SPECIFICATIONS

F2CFE613E ENGINES

Table 1

F2CFE613 Type

E*B009

E*B010

E*B011

mm Valve spring height: free height

H

A*

B*

70.77

71.34

under a load of: H1

H2

N 460  23 N 460  22

H1A H1B

N 740  33 N 731,4  42

H2A H2B

{ {

H

51 39

Injector protrusion

X

1.53

Camshaft bushing housing in the cylinder head: 17

Ø

69.000 ÷ 69.030

Camshaft bearing journals: 17

Ø

64.924 ÷ 64.940



Outer diameter of camshaft bushings:





Inner diameter of camshaft bushings:



X







 2

 1

 3

69.090 ÷ 69.130

65.080 ÷ 65.116

Bushings and housings in the cylinder head

0.060 ÷ 0.130

Bushings and bearing journals

0.140 ÷ 0.192

Cam lift: H

7.404 8.211

 1 Rocker shaft

*

1

31.964 ÷ 31.980

Refereed to different supplies

Base - June 2014

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

9

F2CFE613 Type

E*B009

E*B010

E*B011

mm Seats for bushes in rocker arms 35.000 ÷ 35.016 35.000 ÷ 35.016

 Rocker arm bush outer diameter:

35.070 ÷ 35.110



35.070 ÷ 35.110 Rocker arm bush inner diameter: 32.025 ÷ 32.041



32.025 ÷ 32.041 Rocker arm bushings and housings: 0.054 ÷ 0.110 0.054 ÷ 0.110 Rocker arm bushings and shaft: 0.045 ÷ 0.077 0.045 ÷ 0.077

Print P2D32C010 E

Base - June 2014

10

SECTION 7 - TECHNICAL SPECIFICATIONS

F2CFE613E ENGINES

TIGHTENING TORQUES TORQUE

PART Nm 50 ± 5 20 ± 2 49 ± 3

Piston cooling spray nozzles (6 screws M8) Camshaft shoulder plate (5 screws) Crankcase stiffening plate (8 screws M10x1.5x20) Main bearing caps (14 screws M16x2x168) 1st phase 2nd phase 3rd phase

140 ± 7

1st phase 2nd phase

25 ± 5

kgm 5.0 ± 0.5 2.0 ± 0.2 4.9 ± 0.3 14.0 ± 0.7 60° 60°

Camshaft gear (4 screws M10x1.5x45)

25 ± 5

Transmission gear (3 screws M12x1,5) Connecting rod caps (12 screws M12x1.25x69) 1st phase 2nd phase High pressure pump (3 screws M8x1.25x40) High pressure pump gear (1 nut M18x1.5) Phonic wheel timing sensor (3 screws M8x1.25) Crankcase ventilation rotating filter (3 screws M6x1x16) Crankcase ventilation rotating filter cover (3 screws M6x1x16) Crankcase ventilation valve cover (3 screws M6x1) Fuel pipe from rail to electro-injectors ( 6 fittings M18x1.5) ( 6 fittings M14x1.5) Fuel pipe from high pressure pump to rail ( 1 fitting M18x1.5) ( 1 fitting M14x1.5) Fuel return pipe ( 1 fitting M16x1.5) ( 1 fitting M14x1.5) Fuel pipe from pressure pump to intermediate fitting (2 fittings M16x1.5) Fuel delivery and return pipe from pressure pump to fuel filter (4 fittings M16x1.5) Fuel pipe from injection control unit heater to pressure pump (2 fittings M18x1.5) Cylinder head (26 screws M16x2x170) 1st phase 2nd phase 3rd phase 4th phase

Base - June 2014

2.5 ± 0.5 45° 2.5 ± 0.5

50 ± 2.5

5.0 ± 0.25 90°

33 ± 3 105 ± 5 23 ± 2 9±1 9±1 9±1

3.3 ± 0.3 10.5 ± 0.5 2.3 ± 0.2 0.9 ± 0.1 0.9 ± 0.1 0.9 ± 0.1

40 ± 2 35 ± 2

4.0 ± 0.2 3.5 ± 0.2

40 ± 2 35 ± 2

4.0 ± 0.2 3.5 ± 0.2

35 ± 2 35 ± 2

3.5 ± 0.2 3.5 ± 0.2

35 ± 5

3.5 ± 0.5

35 ± 5

3.5 ± 0.5

40 ± 5

4.0 ± 0.5

50 ± 2.5 100 ± 2.5

5.0 ± 0.25 10.0 ± 0.25 90° 75°

Print P2D32C010 E

F2CFE613E ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

PART

TORQUE

Rocker arm shaft (7 screws M12x1.75) Tappet cover (20 screws M6x1x50) Engine oil pump (5 screws M8x1.25x60) (3 screws M8x1.25x45) Double gear (3 screws M8) 1st phase 2nd phase

Nm 105 ± 10 8.5 ± 1.5

kgm 10.5 ± 1.0 0.85 ± 0.15

24 ± 3 24 ± 3

2.4 ± 0.3 2.4 ± 0.3

30

3.0 90˚

19 ± 3

1.9 ± 0.3

41.5 ± 3.5 41.5 ± 3.5 41.5 ± 3.5 63 ± 7 63 ± 7 63 ± 7 42 ± 3 20 ± 2 40 ± 10 34 ± 4 60 ± 5 23 ± 2

4.15 ± 0.35 4.15 ± 0.35 4.15 ± 0.35 6.3 ± 0.7 6.3 ± 0.7 6.3 ± 0.7 4.2 ± 0.3 2.0 ± 0.2 4.0 ± 1.0 3.4 ± 0.4 6.0 ± 0.5 2.3 ± 0.2

1st phase 2nd phase

11.5 ± 3.5 24.5 ± 2.5 115 ± 5

1.15 ± 0.35 2.45 ± 0.25 11.5 ± 0.5

1st phase 2nd phase

70

Crankcase front cover (9 screws M10x1.25x20) Engine flywheel housing (3 screws M10x1.5x35) (1 screws M10x1.5x110) (1 screws M10x1.5x180) (2 screws M12x1.75x193) (1 screws M12x1.75x120) (7 screws M12x1.75x80) Engine oil sump (26 screws M10x1.5x45) Engine oil intake suction strainer (3 screws M8x1.25) Engine oil drain plug (1 M22x1.5) Engine oil filter housing (5 screws M8x1.25) Engine oil filter body Heat exchanger (4 screws M8x45) Heat exchanger body (16 screws M8x1.25x50)

Damper pulley (6 screws M12x1.75x30) Crankshaft pulley (6 screws M14x2x60)

Electro-injector brackets (6 screws M10x1.5x40) Rail (3 screws M8) Intake manifold (3 screws M10x1.5x100) (2 screws M10x1.5x110) (1 screw M10x1.5x150) Air conditioning compressor / PTO cover (3 screws M12x1.75x25) Starter motor (3 nuts M10x1.5) Engine brake collar (1 nut M6x1) Engine coolant return and delivery pipes to engine brake control actuator (4 fittings M12x1.5) Turbocharger (4 nuts M10x1.5) Shoulder plate (5 screws M8x1.25x20)

Print P2D32C010 E

11

7.0 50˚

46 ± 3 23 ± 2

4.6 ± 0.3 2.3 ± 0.2

43 ± 3 43 ± 3 43 ± 3

4.3 ± 0.3 4.3 ± 0.3 4.3 ± 0.3

63 ± 5 43 ± 3 6±1

6.3 ± 0.5 4.3 ± 0.3 0.6 ± 0.1

25 ± 5 46 ± 2 20 ± 2

2.5 ± 0.5 4.6 ± 0.2 2.0 ± 0.2

Base - June 2014

12

SECTION 7 - TECHNICAL SPECIFICATIONS

F2CFE613E ENGINES

PART

TORQUE

Oil outlet pipe from turbocharger (2 screws M8x1.25x25) (1 fitting M27x1.5) (1 fitting M30x2) Oil delivery pipe to turbocharger (2 fittings M16x1.5) Bracket retaining oil delivery pipe to turbocharger (1 screw M8x1.25x16) Exhaust manifold (24 screws M10x1.5x38) Engine management control unit (3 nuts M8x1.25) Timing sensor (1 screw M6x1) Engine rpm sensor (1 screw M6x1) Air temperature and pressure sensor (1 screw) Engine oil temperature and pressure sensor (2 screws) Alternator drive belt fixed tensioner (1 screw M10x1.5) Water pump drive belt mobile tensioner (1 screw M10x1.5x80) Engine flywheel (8 screws M18x1.5x72) 1st phase 2nd phase Thermostat (5 screws M8x1.25x70) Coolant temperature sensor Water pump (4 screws M8x1.25x25) Engine coolant pipes (1 fitting M12x1.5) Degassing pipe (1 fitting M12x1.5) Fluid inlet pipe to water pump (2 screws M8x1.25) Engine coolant outlet pipe from cylinder head (5 screws M8x1.25) Fuel filter support (4 screws M8x1.25x30) Fuel filter bracket (3 screws M8x1.25x35) (1 screw M8x25) (1 screw M10x25)

Base - June 2014

Nm

kgm

24 ± 3 25 ± 5 110 ± 5 42± 2 23 ± 2 45 ± 5 24 ± 3 9±1 9±1 9±1 9±1 20 ± 2 45 ± 5

2.4 ± 0.3 2.5 ± 0.5 11.0 ± 0.5 4.2 ± 0.2 2.3 ± 0.2 4.5 ± 0.5 2.4 ± 0.3 0.9 ± 0.1 0.9 ± 0.1 0.9 ± 0.1 0.9 ± 0.1 2.0 ± 0.2 4.5 ± 0.5

120 ± 5

12.0 ± 0.5 90˚

24.5 ± 2.5 20 ± 5 24.5 ± 2.5 20 ± 2 20 ± 2 20 ± 2 20 ± 2 24 ± 3

2.45 ± 0.25 2.0 ± 0.5 2.45 ± 0.25 2.0 ± 0.2 2.0 ± 0.2 2.0 ± 0.2 2.0 ± 0.2 2.4 ± 0.3

24 ± 3 24 ± 3 37.5 ± 7.5

2.4 ± 0.3 2.4 ± 0.3 3.75 ± 0.75

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F2CFE613E ENGINES

SECTION 8 - TOOLS

1

SECTION 8 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Base - June 2014

2

SECTION 8 - TOOLS

Base - June 2014

F2CFE613E ENGINES

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F2CFE613E ENGINES

SECTION 8 - TOOLS

3

TOOLS TOOL NO.

DESCRIPTION

99322230

Telescopic revolving stand (bearing capacity 2000 daN, torque 375 daNm)

99342157

Tool to extract injectors

99346260

Crankshaft rear seal installer

99346265

Crankshaft front seal installer

99360184

Piston ring removal and refitting pliers (105 - 160 mm)

99360264

Tool for assembly and disassembly engine valves

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Base - June 2014

4

SECTION 8 - TOOLS

F2CFE613E ENGINES

TOOLS TOOL NO.

DESCRIPTION

99360288

Drift for removing valve guide

99360292

Installer for valve guide seal

99360294

Drift for fitting valve guide (to be used with 99360288)

99360334

Compression tool for checking the protrusion of cylinder liners (to be used with 99370415-99395603 and special plates)

99360335

Cylinder liner compression plate (to be used with 99360334)

99360341

Flywheel crank handle

Base - June 2014

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F2CFE613E ENGINES

SECTION 8 - TOOLS

5

TOOLS TOOL NO.

DESCRIPTION

99360351

Flywheel restrainer

99360500

Crankshaft lifting tackle

99360505

Camshaft bush assembly and disassembly punch

99360558

Tool for lifting and carrying shaft rockers

99360585

Rocking sling for removing/installing engine

99360605

Belt to insert piston in cylinder liner (60 - 125 mm)

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Base - June 2014

6

SECTION 8 - TOOLS

F2CFE613E ENGINES

TOOLS TOOL NO.

DESCRIPTION

99360612

Engine TDC positioning tool

99360613

Tool for timing adjustment of phonic disc on camshaft

99360703

Tool to stop cylinder liners

99360706

Tool to extract cylinder liners (use with special rings)

99360724

Ring (115 mm) (to be used with 99360706)

99361046

Brackets fixing engine to revolving stand 99322230

Base - June 2014

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F2CFE613E ENGINES

SECTION 8 - TOOLS

7

TOOLS TOOL NO.

DESCRIPTION

99367121

Hand pump to measure pressures and vacuums

99368542

Set of 9 insert box wrenches 14X18 (13 - 17 - 18 - 19 - 21 - 22 - 24 - 27 - 30 mm)

99370400

Timing control tool (use with 99395606)

99370415

Base supporting the dial gauge for checking cylinder liner protrusion (to be used with 99395603)

99389833

Snap coupling torque wrench 14X18 (20-120 Nm)

99389834

Dynamometric screwdriver (1-6 Nm) to set injector solenoid valve connector check-nut

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Base - June 2014

8

SECTION 8 - TOOLS

F2CFE613E ENGINES

TOOLS TOOL NO.

DESCRIPTION

99390310

Valve guide sleeker

99395216

Measuring pair for angular tightening with 1/2” and 3/4” square couplings

99395221

Gauge to determine centre-to centre distance between camshaft and fuel high-pressure pump

99395222

Gauge to determine centre-to-centre distance between camshaft and transmission gear

99395223

Gauge for camshaft phasing

99395603

Dial gauge (0 - 5 mm)

Base - June 2014

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F2CFE613E ENGINES

SECTION 8 - TOOLS

9

TOOLS TOOL NO.

DESCRIPTION

99395606

Dial gauge (0-30 mm)

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Base - June 2014

10

SECTION 8 - TOOLS

Base - June 2014

F2CFE613E ENGINES

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F2CFE613E ENGINES

APPENDIX

1

Appendix Page

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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . .

3

- Standard safety prescriptions . . . . . . . . . . . . . .

3

- Prevention of injury . . . . . . . . . . . . . . . . . . . . .

3

- During maintenance . . . . . . . . . . . . . . . . . . . .

3

- Respect of the Environment . . . . . . . . . . . . . .

4

Base - June 2014

2

APPENDIX

Base - June 2014

F2CFE613E ENGINES

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F2CFE613E ENGINES

APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

- Do not execute any intervention if not provided with necessary instructions.

Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.

Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation.

- Keep working areas as clean as possible, ensuring adequate aeration.

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

- Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities.

- Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines.

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

- Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.

- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.

- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids.

- Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation.

- Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

- Keep the engine clean from oil tangles, diesel fuel and or chemical solvents.

Prevention of injury

- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas aerated. Whenever necessary wear safety mask.

- Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.

- Do not leave rags impregnated with flammable substances close to the engine.

- Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed:  2 bar)

- Do not utilize fast screw-tightening tools.

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

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- Use protection cream for hands.

- Change wet cloths as soon as possible - In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections.

Ensure that hands and feet are dry and execute working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for.

- Do not smoke nor light up flames close to batteries and to any fuel material.

- Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

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- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on the electrical system.

- Disconnect batteries from system aboard to load them with the battery loader.

- After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

- Do not disconnect and connect electrical connections in presence of electrical feed.

- Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles.

Non fulfillment of these prescriptions may cause serious injury and poisoning.

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4

APPENDIX

- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration.

- Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters.

- Do not modify cable wires: their length shall not be changed.

- Do not connect any user to the engine electrical equipment unless specifically approved by FPT. - Do not modify fuel systems or hydraulic system unless FPT specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration.

For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox.

- Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.

F2CFE613E ENGINES

Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted.

- Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures.

- Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger.

- Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.

- Do not paint the components and the electronic connections.

- Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.

Base - June 2014

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