Motor Iveco F5C PDF

F5AE5484A / F5AE9454A /
F5AE9454D / F5AE9454J /
F5AE9454L / F5AE9484A /
F5AE9484B / F5AE9484G /
F5AE9484K / F5CE5454B*A005 /
F5CE5454B / F5CE5454C*A003 /
F5CE5454G*A001 / F5CE9454C /
F5CE9454E / F5CE9454G /
F5CE9484C / F5CE9484E
Engine
SERVICE MANUAL
Printed in U.S.A. Part number 84465357

English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. March 2011
Racine Wisconsin 53404 U.S.A. Replaces part number 84283922
Contents
INTRODUCTION
ENGINE AND PTO IN ................................................................... B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
84465357 28/02/2011
INTRODUCTION
84465357 28/02/2011
1
Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
84465357 28/02/2011
2
INTRODUCTION
Foreword
This publication contains data, features instructions and methods for performing repair operations on the assembly
and its components and is addressed to qualified, specialized personnel.
Check to make sure you have the right publication related to the component you are about to work on before you start.
Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check
that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.
Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to
ensure correct repair procedures and safety of operators.
NOTE: This manual applies to multiple applications, therefore images may not all be accurate.
84465357 28/02/2011
3
INTRODUCTION
Safety rules
Standard safety precautions
Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for
consultation.
• Keep working areas as clean as possible.
• Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain
adequate sanitary equipment.
• Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked
on a regular basis and personnel must be trained on proper interventions and priorities.
• Keep all emergency exits free of obstructions and clearly marked.
• Smoking in working areas subject to fire danger must be strictly prohibited.
Prevention of injury
• Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to
engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• Topping off or changing lubrication oils.
• Using compressed air or liquids at a pressure greater than 2 bar (29 psi).
• Wear a safety helmet when working close to hanging loads or equipment working at head level.
• Always wear safety shoes and fitting clothes.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections.
Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with
electricity.
• Do not smoke or start an open flame close to batteries and any fuel material.
• Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.
• Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may
occur.
• If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.
During maintenance
• Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating
pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122
°F).
• Never add coolant to an overheated engine and use only appropriate liquids.
• Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be
aware of all the risks involved with such an operation.
• Always use adequate and safe containers for engine fluids and used oil.
• Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.
• Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.
Wear a safety mask if necessary.
• Do not leave soiled rags that may contain any flammable substances close to the engine.
• Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air
in case of engine runaway.
• Never disconnect the batteries while the engine is running.
84465357 28/02/2011
4
INTRODUCTION
• Disconnect the batteries prior to performing any work on the equipment.

• Disconnect the batteries to place a load on them with a load tester.
• After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
• Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been re-
leased. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety
equipment.
• Do not alter the lengths of any wires.
• Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by Iveco.
• Do not modify the fuel system or hydraulic system unless approved by Iveco, Any unauthorized modification will
compromise warranty assistance and may affect engine operation and life span.
For engine equipped with an electronic control unit

• Do not weld on any part of the equipment without removing the control unit.
• Remove the in case of work requiring heating over 80 °C (176 °F).
• Do not paint the components and the electronic connections.
• Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of elec-
tronic components will void engine warranty assistance and may affect the correct working order and life span of
the engine.
Respect of the Environment

• Respect of the environment should be of primary importance. Take all necessary precautions to ensure person-
nel’s safety and health.
• Inform the personnel of the laws regarding the dispensing of used engine fluids.
• Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.
84465357 28/02/2011
5
INTRODUCTION
Torque
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
DESCRIPTION SIZE TORQUE
Oil Pan
Threaded cap with O-ring 45 - 55 N·m (33 - 41 lb ft)
Oil pan spacer M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
- Angle torque 85 - 95 °
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Conical thread cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
Cylinder head M15x1.5
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Exhaust Manifold
Exhaust manifold 10 - 20 N·m (7 - 15 lb ft)
84465357 28/02/2011
6
INTRODUCTION
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)

EGR Unit
Heat exchanger fastening to valve 20 - 30 N·m (15 - 22 lb ft)
unit
Heat exchanger fastening to throw 20 - 30 N·m (15 - 22 lb ft)
EGR fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Valve 5 - 15 N·m (4 - 11 lb ft)
Manifold fastening nuts 20 - 30 N·m (15 - 22 lb ft)
Manifold fastening rings 5 - 15 N·m (4 - 11 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
- Pre-torque 45 - 55 N·m (33 - 41 lb ft)
Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
84465357 28/02/2011
7
INTRODUCTION
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)

Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
84465357 28/02/2011
8
INTRODUCTION
Torque
DESCRIPTION SIZE TORQUE
Oil Pan
Side cap M6 35 - 45 N·m (26 - 33 lb ft)
Side caps M22 45 - 55 N·m (33 - 41 lb ft)
Front cap M35 35 - 45 N·m (26 - 33 lb ft)
Fixing of sump 65 - 75 N·m (48 - 55 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
84465357 28/02/2011
9
INTRODUCTION
Exhaust Manifold
Exhaust manifold 30 - 40 N·m (22 - 30 lb ft)
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)
Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
84465357 28/02/2011
10
INTRODUCTION
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
84465357 28/02/2011
11
INTRODUCTION
Special tools
380000134 Valve guide gasket assembly tool
380000134 1
380000150 Tool for engine T.D.C. positioning
380000150 2
380000219 Valve guide disassembly and reassembly tool
380000219 3
380000220 Piston ring compressor - 60 - 125 mm, procure

locally
380000220 4
84465357 28/02/2011
12
INTRODUCTION
380000221 Piston ring expander tool for removing and

installing piston rings - 60 - 125 mm, procure
locally
380000221 5
380000222 Valve guide reemer
380000222 6
380000228 Dial gauge - 0 - 5 mm
380000228 7
380000229 Dial gauge holding tool for rotatory injection

pump phasing (use with 380000228)
380000229 8
84465357 28/02/2011
13
INTRODUCTION
380000302 Tool for engine valve disassembly and

reassembly, procure locally
380000302_3A 9
380000304 Measuring device for angular torque, procure

locally
380000304 10
380000364 Dial gauge holding base for miscellaneous

measures (use with 380000228)
380000364_3A 11
380000667 Camshaft bushing removal and installation tool
380000667 12
84465357 28/02/2011
14
INTRODUCTION
380000670 Oil filter removal tool
380000670 13
380000978 Rotary stand for overhauling units, use OEM

4135 or a 2000 lb capacity engine stand
380000301 14
380000999 Handle for interchangeable bushing tools, use

appropriate tool
380000999_3-2 15
380001006 Diesel engine cylinder compression tester,

procure locally
380001006_3 16
84465357 28/02/2011
15
INTRODUCTION
380000732 Tool for rotating the engine flywheel, barring tool
380002385_3A 17
380100072 Injection pump gear puller
380100072_3A 18
380100074 Compression test adapter
380100074_3-2 19
380100075 Front main seal installation tool
380100075_3-2 20
84465357 28/02/2011
16
INTRODUCTION
380100076 Rear main seal installation tool
380100076_3-2 21
84465357 28/02/2011
17
INTRODUCTION
Special tools
380000134 Valve guide gasket assembly tool
380000134 1
380000150 Tool for engine T.D.C. positioning
380000150 2
380000219 Valve guide disassembly and reassembly tool
380000219 3
380000220 Piston ring compressor - 60 - 125 mm, procure

locally
380000220 4
84465357 28/02/2011
18
INTRODUCTION
380000221 Piston ring tool for disassembly and reassembly

of piston rings - 60 - 125 mm, procure locally
380000221 5
380000222 Valve guide reemer
380000222 6
380000228 Dial gauge - 0 - 5 mm
380000228 7
380000229 Dial gauge holding tool for rotatory injection

pump phasing (use with 380000228)
380000229 8
84465357 28/02/2011
19
INTRODUCTION
380000302 Tool for engine valve disassembly and

reassembly, procure locally
380000302_3A 9
380000304 Measuring device for angular torque, procure

locally
380000304 10
380000364 Dial gauge holding base for miscellaneous

measures (use with 380000228)
380000364_3A 11
380000667 Camshaft bushing removal and installation tool,

use with suitable tool
380000667 12
84465357 28/02/2011
20
INTRODUCTION
380000670 Oil filter removal tool
380000670 13
380000978 Rotary stand for overhauling units, use OEM

4135 or 2000 lb capacity engine stand
380000301 14
380000732 Rotate the engine flywheel, engine barring tool
380002385_3A 15
380000999 Handle for interchangeable bushing tools, use

appropriate tool
380000999_3-2 16
84465357 28/02/2011
21
INTRODUCTION
380001006 Diesel engine cylinder compression tester,

procure locally
380001006_3 17
380100072 Injection pump gear puller
380100072_3A 18
380100073 Front crankshaft seal installation tool
380100073 19
380100074 Compression test adapter
380100074_3-2 20
84465357 28/02/2011
22
INTRODUCTION
380100076 Rear main seal installation tool
380100076_3-2 21
84465357 28/02/2011
23
INTRODUCTION
84465357 28/02/2011
24
SERVICE MANUAL
ENGINE AND PTO IN
F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A

, F5AE9484B , F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B ,
F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G
, F5CE9484C , F5CE9484E
84465357 28/02/2011
B
Contents
ENGINE AND PTO IN - B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K ,
F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C
, F5CE9484E
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A

, F5CE9484E
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A

, F5CE9484E
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A

, F5CE9484E
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A

, F5CE9484E
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A

, F5CE9484E
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

, F5CE9484E
84465357 28/02/2011
B
ENGINE - 10.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.10.A / 1
Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
F5CE9454G
F5CE9454E
F5CE9484E
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
F5CE5454G*A001
F5CE5454B*A005
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
F5AE5484A
F5AE9454J
F5AE9454L
F5AE9484K
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUNCTIONAL DATA
84465357 28/02/2011
B.10.A / 2
ENGINE
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Connecting rod and piston

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Balancer
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wiring harness
Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B,
F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K
Electronic control
Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Sensing system
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SERVICE
ENGINE
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A,
F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Valve drive
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
84465357 28/02/2011
B.10.A / 3
Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Crankshaft
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
F5CE5454C*A003
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

F5CE5454C*A003
Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
F5CE5454C*A003
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F5CE5454C*A003
Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Timing gear
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Timing gear housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
84465357 28/02/2011
B.10.A / 4
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cylinder block
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Front cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Wiring harness
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
84465357 28/02/2011
B.10.A / 5
ENGINE AND PTO IN - ENGINE
ENGINE - General specification

F5CE9454C
Cycle Diesel 4 strokes

Aspiration Turbocharged
Injection Direct
N. of cylinders 4 In-line
Bore 99 mm (3.898 in)
Stroke 104 mm (4.094 in)
Total displacement 3202 cm³
Compression ratio 17 : 1
Max. power 40 kW (54 Hp) @ 2300 RPM
Max. torque 220 N·m (162 lb ft) @ 1400 RPM
Loadless engine idling 1100 - 1200 RPM
Loadless engine peak 2700 - 2800 RPM

F5CE9454G

Injection Direct
Bore 99 mm (3.898 in)

F5CE9454E

Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 6

F5CE9484E

Injection Direct
Bore 99 mm (3.898 in)

F5CE9484C

Injection Direct
Bore 99 mm (3.898 in)

F5AE9454A

Aspiration Turbocharged with intercooler
Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 7

F5AE9484A

Injection Direct
Bore 99 mm (3.898 in)

F5AE9454D

Injection Direct
Bore 99 mm (3.898 in)

F5AE9484B

Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 8

F5AE9484G

Injection Direct
Bore 99 mm (3.898 in)

F5CE5454G*A001

Injection Direct
Bore 99 mm (3.898 in)
Loadless engine idling 1150 RPM +/- 25 RPM
Loadless engine peak 2750 RPM +/- 25 RPM

F5CE5454B*A005

Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 9

F5CE5454C*A003

Injection Direct
Bore 99 mm (3.898 in)

F5AE5484A

Injection Direct
Bore 99 mm (3.898 in)
Max. power 70 kW (95.2 Hp) @ 2300 RPM
Max. torque 380 N·m (280.3 lb ft) @ 1400 RPM

F5AE9454J

Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 10

F5AE9454L

Injection Direct
Bore 99 mm (3.898 in)

F5AE9484K

Injection Direct
Bore 99 mm (3.898 in)
84465357 28/02/2011
B.10.A / 11
ENGINE - Service limits

Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Outside diameter 98.908 - 98.918 mm (3.8940 - 3.8944 in)
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
84465357 28/02/2011
B.10.A / 12
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)

Clearance between Piston pin and small end bearing 0.011 - 0.024 mm (0.0004 - 0.0009 in)
Maximum allowable twist for connecting rod 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)
Crankshaft
- Main journal diameter (1-2-3-4) 76.182 - 76.208 mm (2.9993 - 3.0003 in)
- Main journal diameter (5) 83.182 - 83.208 mm (3.2749 - 3.2759 in)
- Rod journals 64.015 - 64.038 mm (2.5203 - 2.5212 in)
Main bearing thickness 2.165 - 2.174 mm (0.0852 - 0.0856 in)
Main bore diameter (1-2-3-4) 80.588 - 80.514 mm (3.1728 - 3.1698 in)
Main bore diameter (5) 87.588 - 87.614 mm (3.4483 - 3.4494 in)
Clearance between main bearings and journals (1-2-3-4) 0.064 - 0.095 mm (0.0025 - 0.0037 in)
Clearance between main bearings and journals (5) 0.059 - 0.100 mm (0.0023 - 0.0039 in)
Clearance between rod bearing and journals 0.033 - 0.041 mm (0.0013 - 0.0016 in)
Main journal width for thrust bearing on crankshaft 31.85 - 32.150 mm (1.2539 - 1.2657 in)
Main journal width for thrust bearing in cylinder block 32.50 - 32.55 mm (1.2795 - 1.2815 in)
Thrust bearing thickness 2.51 - 2.56 mm (0.0988 - 0.1008 in)
Clearance between the crankshaft and thrust bearing 0.095 - 0.270 mm (0.0037 - 0.0106 in)
Cylinder Head
Valve guide seats in cylinder head 12.960 - 12.995 mm (0.5102 - 0.5116 in)
Valve Guides
- Inside diameter 8.023 - 8.038 mm (0.3159 - 0.3165 in)
Valves (Intake)
- Valve stem diameter 7.985 - 8.000 mm (0.3144 - 0.3150 in)
- Valve face angle 60 °
Valves (Exhaust)
Clearance between Valve stem and Guide 0.040 - 0.053 mm (0.0016 - 0.0021 in)
Valve seat in the cylinder head
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
Valve seat (Exhaust)
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
- Free spring 44.6 mm (1.756 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
Under a load of 500 - 556 N (112 - 125 lb) 23.8 mm (0.937 in)
Injector protrusion 1.7 - 2.35 mm (0.0669 - 0.0925 in)
Camshaft bore inside diameter
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
84465357 28/02/2011
B.10.A / 13
Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
84465357 28/02/2011
B.10.A / 14
ENGINE - Service limits

Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
84465357 28/02/2011
B.10.A / 15
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)

Clearance between Piston pin and small end bearing 0.011 - 0.024 mm (0.0004 - 0.0009 in)
Maximum allowable twist for connecting rod 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)
Crankshaft
- Main journal diameter (1-2-3-4) 76.182 - 76.208 mm (2.9993 - 3.0003 in)
- Main journal diameter (5) 83.182 - 83.208 mm (3.2749 - 3.2759 in)
- Rod journals 64.015 - 64.038 mm (2.5203 - 2.5212 in)
Main bearing thickness 2.165 - 2.174 mm (0.0852 - 0.0856 in)
Main bore diameter (1-2-3-4) 80.588 - 80.514 mm (3.1728 - 3.1698 in)
Main bore diameter (5) 87.588 - 87.614 mm (3.4483 - 3.4494 in)
Clearance between main bearings and journals (1-2-3-4) 0.064 - 0.095 mm (0.0025 - 0.0037 in)
Clearance between main bearings and journals (5) 0.059 - 0.100 mm (0.0023 - 0.0039 in)
Clearance between rod bearing and journals 0.033 - 0.041 mm (0.0013 - 0.0016 in)
Main journal width for thrust bearing on crankshaft 31.85 - 32.150 mm (1.2539 - 1.2657 in)
Main journal width for thrust bearing in cylinder block 32.50 - 32.55 mm (1.2795 - 1.2815 in)
Thrust bearing thickness 2.51 - 2.56 mm (0.0988 - 0.1008 in)
Clearance between the crankshaft and thrust bearing 0.095 - 0.270 mm (0.0037 - 0.0106 in)
Cylinder Head
Valve guide seats in cylinder head 12.960 - 12.995 mm (0.5102 - 0.5116 in)
Valve Guides
- Inside diameter 8.023 - 8.038 mm (0.3159 - 0.3165 in)
Valves (Intake)
Valves (Exhaust)
Clearance between Valve stem and Guide 0.040 - 0.053 mm (0.0016 - 0.0021 in)
Valve seat in the cylinder head
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
Valve seat (Exhaust)
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
- Free spring 44.6 mm (1.756 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
Under a load of 500 - 556 N (112 - 125 lb) 23.8 mm (0.937 in)
Injector protrusion 1.7 - 2.35 mm (0.0669 - 0.0925 in)
Camshaft bore inside diameter
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
84465357 28/02/2011
B.10.A / 16
Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
84465357 28/02/2011
B.10.A / 17
ENGINE - Overview
73092733 1
ENGINE FRONT VIEW
84465357 28/02/2011
B.10.A / 18
73092734 2
ENGINE RIGHT SIDE VIEW
73092735 3
ENGINE LEFT SIDE VIEW
84465357 28/02/2011
B.10.A / 19
73092736 4
ENGINE REAR VIEW
73092737 5
ENGINE TOP VIEW
84465357 28/02/2011
B.10.A / 20
ENGINE - Overview
73092883 1
ENGINE FRONT VIEW
84465357 28/02/2011
B.10.A / 21
73092885 2
73092884 3
84465357 28/02/2011
B.10.A / 22
73092886 4
ENGINE REAR VIEW
73092887 5
ENGINE TOP VIEW
84465357 28/02/2011
B.10.A / 23
ENGINE - Overview
93111631 1
ENGINE FRONT VIEW
84465357 28/02/2011
B.10.A / 24
93111630 2
93111629 3
84465357 28/02/2011
B.10.A / 25
93111632 4
ENGINE REAR VIEW
93111628A 5
ENGINE TOP VIEW
84465357 28/02/2011
B.10.A / 26
Connecting rod and piston - Exploded view
73092848A 1
CONNECTING ROD AND PISTON UNIT COMPONENTS
(1) Snap ring (5) Screws

(2) Pin (6) Half bearings
(3) Piston (7) Connecting rod
(4) Piston rings (8) Bushing
84465357 28/02/2011
B.10.A / 27
Balancer - Overview
73092889 1
Dynamic Balancer
(1) Reference notches for alignment and timing (4) Balancing masses
(2) Thrust washers (5) Shaft
(3) Bushings (6) Case
84465357 28/02/2011
B.10.A / 28
Wiring harness - Overview EGR System

73092804 1
(1) Water temperature sensor (4) Crankshaft speed sensor

(2) Air temperature pressure sensor (5) Sectioning
(3) EGR Valve
84465357 28/02/2011
B.10.A / 29
Wiring harness - Overview KSB

F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE9454J,
F5AE9454L, F5AE9484K
73092807 1
ELECTRIC CABLE TO CONNECT KSB WITH CERA
(1) Interface (3) Air sensor

(2) KSB signal (4) STOP
84465357 28/02/2011
B.10.A / 30
Electronic control Control module - Electrical schema EGR System

73092805 1
Electrical Layout
20000 - Starter battery 58105 - Engine high water temperature warning light
25201 - Remote control for pre-heating switch 58484 - Diagnosis warning light
48035 - Engine rev. no. sensor 47034 - Engine water temperature sensor for EGR
52502 - Key commutator for services with start 78029 - EGR solenoid valve
61121 - Resistor for engine pre-heating 86020 - EGR E.C.U.
58101 - Pre--heating (on) warning light 85156 - Air pressure temperature sensor
84465357 28/02/2011
B.10.A / 31
Electronic control Control module - Overview EGR System

73092806 1
Technical specifications
Manufacturer Bitron
Rated Voltage 13.5 V
Actual Voltage 10 - 16 V
Working temperature -30 - 100 °C (-22 - 212 °F)
Maximum current input Less than 5 A
EGR valve control signal PWM 133 - 147 Hz
84465357 28/02/2011
B.10.A / 32
Ref. Description
1 PWM output signal for EGR solenoid valve
2 -
3 ECU Mass
4 Mass for pre--heating (on) warning light
5 ECU supply (+ 15)
6 K line signal
7 Intake manifold temperature and pressure sensor supply
8 EGR solenoid valve feed (potentiometer)
9 K line mass
10 EGR solenoid valve mass (potentiometer)
11 Cooling liquid temperature sensor mass, on thermostat unit
12 Air pressure and temperature sensor mass
13 Engine RPM Signal
14 E.C.U. supply (+30)
15 Pre--heating remote control switch
16 Engine high temperature warning light
17 Diagnosis warning light
18 Start
19 EGR solenoid valve position signal
20 Cooling liquid temperature sensor, on thermostat unit
21 Air temperature sensor signal
22 Pressure sensor signal, on intake manifold
23 Negative from engine drive shaft impulse transmitter
24 Engine drive shaft transmitter mass
25 Positive from engine drive shaft impulse transmitter
84465357 28/02/2011
B.10.A / 33
Sensing system Crankshaft sensor - Overview

It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic
flow lines closing up through the openings of a tone wheel splined on the engine crankshaft. The same signal is used
to pilot the tachometer fitted on the vehicle instrument panel. It is connected to the Electronic Control Unit pins 25C
(signal) and 24C (signal). The third pin is for shielding. The Sensor’s resistance value is nearly 900 Ω.
73092812 1
84465357 28/02/2011
B.10.A / 34
ENGINE - Service instruction - Finding Top Dead Center (TDC)

F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G,
F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
1. Fit the tool 380000150 (1) through the case and into
the port on the flywheel, as shown.
2. Using the tool 380000150 (1) rotate the flywheel un-
til the notch (2) is visible in the inspection hole and
cylinder one is at T.D.C..
73092764 1
84465357 28/02/2011
B.10.A / 35
ENGINE - Service instruction - Finding Top Dead Center (TDC)

1. Fit the tool 380000150 through the case and into the
port (1) on the flywheel.
93111650 1
2. Using the tool 380000150 rotate the flywheel until the

notch is visible in the inspection hole (2) and cylinder
one is at T.D.C..
93111626 2
84465357 28/02/2011
B.10.A / 36
Rocker assembly Housing - Remove

Prior operation:
Valve cover - Remove (B.10.A)
1. Loosen the fastening screws (1), remove the over-

head holding the whole rocker arm unit (2) and re-
cover the two gaskets (3).
73092771 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
84465357 28/02/2011
B.10.A / 37
Camshaft Push rod - Remove

Prior operation:
Rocker assembly Housing - Remove (B.10.A)
1. Remove the push rods (1).
73092775 1
Next operation:
Camshaft Push rod - Inspect (B.10.A)
84465357 28/02/2011
B.10.A / 38
Rocker assembly Rocker arm - Remove

Prior operation:
1. Loosen the rocker arm fastening screw (1) from the

disassembled rocker arm (2) holding unit and then
remove the rocker arm.
73092779 1
2. Withdraw the rocker arm (1) from one side recovering

the equalizers (2) from the other.
73092780 2
Next operation:
Rocker assembly Rocker arm - Install (B.10.A)
84465357 28/02/2011
B.10.A / 39
Camshaft Push rod - Inspect

Prior operation:
Camshaft Push rod - Remove (B.10.A)
1. Check that the rocker arm rods are not deformed;

there must be no trace of wear or seizure on the
spherical housings of the rocker arm adjusting
screws as well as on the tappets (pointers); oth-
erwise these parts must be replaced. The suction
valve rods are identical and therefore interchange-
able.
73092794 1
Next operation:
Camshaft Push rod - Install (B.10.A)
84465357 28/02/2011
B.10.A / 40
Camshaft Push rod - Install

Prior operation:
Camshaft Push rod - Inspect (B.10.A)
1. Fit the push rods (1) in their housing.
73092775 1
Next operation:
84465357 28/02/2011
B.10.A / 41
Rocker assembly Rocker arm - Install

Prior operation:
Rocker assembly Rocker arm - Remove (B.10.A)
1. Fit the rocker arms onto the shaft.

2. The intake arms (short) (2) goes on first, and then
the exhaust arms (long) (1).
73092780 1
Next operation:
84465357 28/02/2011
B.10.A / 42
Rocker assembly Housing - Install

Prior operation:
1. Replace the gaskets (3), reassemble the rocker arm

holding case (2) and tighten the fastening screws (1)
to the prescribed torque setting.
2. After having completed the assembly, check that the
rocker arms are correctly positioned on the valves
and the tappet push rods.
73092771 1
Next operation:
Valve cover - Install (B.10.A)
84465357 28/02/2011
B.10.A / 43
Valve drive Camshaft - Remove

Prior operation:
Timing gear housing - Remove (B.10.A)
1. Loosen the fastening screws (1) and disassemble

the camshaft (3) holding plate (2).
73092822A 1
2. Carefully withdraw the camshaft (1) from the engine

bock.
73092823A 2
Next operation:
Valve drive Camshaft - Install (B.10.A)
84465357 28/02/2011
B.10.A / 44
Camshaft Tappet - Remove

Prior operation:
Valve drive Camshaft - Remove (B.10.A)
1. Withdraw the tappets (1) from the engine block.
73092824A 1
84465357 28/02/2011
B.10.A / 45
Valve drive Camshaft - Measure

Prior operation:
1. Place the camshaft on footstocks and, using a dial

gauge placed on the central support, check that the
radial oscillation does not exceed 0.015 mm (0.0006
in) otherwise, replace the shaft.
NOTICE: The surface of the camshaft pins and of cams
must be extremely smooth. In case any trace of meshing or
scratches are detected, replace the shaft and the relevant 73092828 1
bushings.
2. Using a micrometer (1), check the diameter of the
camshaft (2) supporting pins on the two perpendicu-
lar axles.
73092829 2
Next operation:
84465357 28/02/2011
B.10.A / 46
Camshaft Bushing - Measure

1. The front camshaft bushing (2) must be driven into
the respective seat.
2. There must be no trace of meshing or wear in the
inner surface.
3. Using a bore meter (1) measure the front diameter of
the camshaft bushing (2).
4. Measurements must be made on two perpendicular
axles.
73092830 1
73092831 2
MAIN DATA OF THE CAMSHAFT BUSHING AND RELEVANT SEAT
84465357 28/02/2011
B.10.A / 47
Camshaft Bushing - Replace

1. Use the beater 380000667 (2) and hand grip
380000999 (3) to disassemble and replace the
bushings (1).
NOTICE: In phase of assembly, the bushing (1) must be
oriented making the lubrication ports coincide with those
on the crankcase.
73092832 1
84465357 28/02/2011
B.10.A / 48
Camshaft Tappet - Install

Prior operation:
Camshaft Tappet - Remove (B.10.A)
1. Lubricate the tappets (1) and fit them into the relevant
seats within the crankcase.
73092834 1
Next operation:
84465357 28/02/2011
B.10.A / 49
Valve drive Camshaft - Install

Prior operation:
1. Lubricate the camshaft supporting bushing and as-

semble the camshaft (1) paying attention not to dam-
age the bushing or the shaft’s seats.
73092823A 1
2. Position the camshaft (3) holding plate (2) with the

slot towards the upper side of the crankcase and the
marking towards the operator; tighten the fastening
screws (1) to the prescribed torque setting.
73092835 2
Next operation:
Valve drive Camshaft - End play (B.10.A)
84465357 28/02/2011
B.10.A / 50
Valve drive Camshaft - End play

Prior operation:
1. Check the end play of the camshaft. The measure-

ment should be 0.10 - 0.36 mm (0.004 - 0.014 in).
73092836 1
84465357 28/02/2011
B.10.A / 51
Valve assembly Valve - Cleaning

Prior operation:
Cylinder head - Disassemble (B.10.A)
1. Remove carbon deposits from the valves using a

wire wheel.
2. Check that the valves show no signs of seizure or
cracking. Replace if any defects are found.
73092876 1
Next operation:
Valve assembly Valve - Measure (B.10.A)
84465357 28/02/2011
B.10.A / 52
Valve assembly Valve - Measure

Prior operation:
Valve assembly Valve - Cleaning (B.10.A)
1. Using a micrometer (2) measure the valve stem (1).

The prescribed value is 7.985 - 8.000 mm (0.314 -
0.315 in).
73092877 1
Next operation:
Cylinder head - Assemble (B.10.A)
84465357 28/02/2011
B.10.A / 53
Valve assembly Spring - Measure

Prior operation:
1. Before assembly, test the valve spring flexibility using

specific tool. Compare the load and elastic strain test
results with the technical specifications of the new
springs, reported in the table below.
73092880 1
Height Load
(H) 44.6 mm (1.756 in) 0 N (0 lb)
(H1) 34 mm (1.339 in) 256 - 284 N (58 - 64 lb)
(H2) 23.8 mm (0.937 in) 502 - 554 N (113 - 125 lb)
Next operation:
84465357 28/02/2011
B.10.A / 54
Crankshaft Rear seal - Install

1. Fit the specific tool 380100076 (5) to the rear shank

(6) of the engine drive shaft, fix it with the screws (4)
and install the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092782 1
Next operation:
Flywheel - Install (B.10.A)
84465357 28/02/2011
B.10.A / 55
Crankshaft Front seal - Install

1. Fit the inner part of tool to the front crankshaft. Make

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092788A 1
84465357 28/02/2011
B.10.A / 56
Crankshaft Main bearing - Remove

Prior operation:
Oil pan - Remove (B.60.A)
1. Loosen the screws (1) and disassemble the crank-

shaft bearing caps . (2).
73092818 1
2. The third (central) main bearing cap (1) and asso-

ciated support have a bearing-half equipped with
thrust bearing.
NOTE: Note down the assembly position of the upper and
lower half bearings since, in case of reuse after the over-
haul, they will have to be reassembled in the same position.
73092819 2
3. Remove the crankshaft. Refer to Crankshaft - Re-

move (B.10.A) for the proper procedure.
4. Remove the crankshaft upper half bearings (1).
73092821 3
Next operation:
Crankshaft Main bearing - Install (B.10.A)
84465357 28/02/2011
B.10.A / 57
Crankshaft - Remove
Prior operation:
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092820 1
Next operation:
Crankshaft - Install (B.10.A)
84465357 28/02/2011
B.10.A / 58
Crankshaft - Measure
Prior operation:
Crankshaft - Remove (B.10.A)
1. In case meshing, scratches or excessive oval shap-

ing is detected on the main journals and crankshaft
bearing pins, it is necessary to grind the pins. Before
proceeding with pin (2) grinding, measure the shaft
pins by means of a micrometer (1) in order to estab-
lish to which diameter the pins must be reduced.
73092838 1
73092839 2
PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND
CRANKSHAFT BEARING PINS
84465357 28/02/2011
B.10.A / 59
73092840 3
ENGINE DRIVE SHAFT MAIN TOLERANCES
73092841 4
Next operation:
84465357 28/02/2011
B.10.A / 60
Crankshaft Main bearing - Install

1. Carefully clean the crankshaft half bearings (1) hav-
ing lubrication port and fit them in their respective
seats.
NOTICE: If using the old bearings, be sure to place them
back into their original position.
2. Install the bearing with the thrust shoulders in the
correct position.
73092842 1
Next operation:
84465357 28/02/2011
B.10.A / 61
Crankshaft - Install
Prior operation:
Crankshaft Main bearing - Install (B.10.A)
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092820 1
Next operation:
Crankshaft - End play (B.10.A)
84465357 28/02/2011
B.10.A / 62
Crankshaft Journal - Measure

Prior operation:
1. Check the clearance between the engine crankshaft

main journals and the respective crankshaft bearings
proceeding as follows:
• Carefully clean the parts and eliminate any oil
residue.
• Place a calibrated wire (3) onto the journal (4),
lengthwise, as shown in the figure.
• Fit the caps (1) and the half bearings (2) on the
relevant supports.
NOTE: Always use new screws in the assembly phase.
73092843 1
2. Tighten the pre-lubricated screws (1) and tighten

them in three subsequent phases:
• Stage 1 - 45 - 55 N·m (33 - 41 lb ft).
• Stage 2 - 74 - 86 N·m (55 - 63 lb ft).
73092844A 2
3. • Stage 3 - Using tool 380000304 (1) fitted as

shown in the figure and further tighten the
screws (2) by 85 - 95 °.
73092845A 3
84465357 28/02/2011
B.10.A / 63
4. Remove the caps from their support. The clearance

between the crankshaft bearings and the relevant
pins should be detected comparing the width mea-
sured by the gauge wire (2) at the point of maximum
width with the scale graduation reported on the pack-
age (1) of the gauge wire.
5. The numbers reported on the scale indicate the
clearance in millimeters. If the clearance detected
differs from the prescribed value, replace the half
bearings and repeat the measurement; once achiev-
ing the slack prescribed, lubricate the crankshaft
bearings and finally assemble the supports tighten-
ing the fastening screws as described previously.
73092846A 4
Next operation:
84465357 28/02/2011
B.10.A / 64
Crankshaft - End play

Prior operation:
1. The check of the shoulder clearance is performed

with a magnetic based dial gauge (2) placed on the
engine shaft (3) as indicated in the figure.
2. If the clearance is out of spec, remove the cap (1)
and replace the thrust bearing.
73092847A 1
84465357 28/02/2011
B.10.A / 65
Crankshaft Rear seal - Install

1. Fit the specific tool (5) to the rear shank (6) of the
engine drive shaft, fix it with the screws (4) and install
the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092904 1
84465357 28/02/2011
B.10.A / 66
Crankshaft Front seal - Install

1. Fit the inner part of tool to the front crankshaft. Make

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092909 1
84465357 28/02/2011
B.10.A / 67
Crankshaft - Remove
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092920 1
Next operation:
84465357 28/02/2011
B.10.A / 68
Crankshaft - Install
Prior operation:
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092920 1
84465357 28/02/2011
B.10.A / 69
Timing gear - Install

1. Align the tooth on the crankshaft gear (1) that has

the 45 ° bevel, with the timing gear (2) that has two
reference marks as shown in the figure.
2. Rotate the camshaft keeping the timing gear in place
until the camshaft’s pin fits into the relevant housing
within the timing gear.
3. Install the screws of the transmission gear without
fully tightening them.
4. With a magnetic base dial gauge, check the clear-
ance among the engine crankshaft gear and the
camshaft gear: it must be 0.068 - 0.168 mm (0.003
- 0.007 in).
5. Tighten the fastening screws of the transmission
gear.
73092907 1
84465357 28/02/2011
B.10.A / 70
Timing gear - Install

1. Align the tooth on the crankshaft gear (1) that has

the 45 ° bevel, with the timing gear (2) that has two
reference marks as shown in the figure.
2. Rotate the camshaft keeping the timing gear in place
until the camshaft’s pin fits into the relevant housing
within the timing gear.
3. Install the screws of the transmission gear without
fully tightening them.
4. With a magnetic base dial gauge, check the clear-
ance among the engine crankshaft gear and the
camshaft gear: it must be 0.068 - 0.168 mm (0.003
- 0.007 in).
5. Tighten the fastening screws of the transmission
gear.
73092907 1
84465357 28/02/2011
B.10.A / 71
Timing gear housing - Remove

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

cover.
73092774 1
Next operation:
Timing gear housing - Install (B.10.A)
84465357 28/02/2011
B.10.A / 72
Timing gear housing - Install

Prior operation:
1. Assemble the front case (1) and tighten the fastening

screws to the prescribed torque.
NOTE: It is absolutely necessary to clean the surface to be
sealed in order to obtain perfect tightness. Apply LOCTITE®
5970 sealer on the gearcase in order to form a sealing bead
of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must
be homogeneous (no lumps), free of air bubbles, thinner
areas and gaps. Any imperfection must be corrected as
soon as possible. Avoid the excess of sealer: too much
sealing material would leak and pour out on both sides of
the joint parts and, as a consequence, obstruct the pas-
sage of the lubricant. After having applied the sealer, the
parts must be joined within 10 minutes.
73092785 1
84465357 28/02/2011
B.10.A / 73
Timing gear housing - Remove

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

cover.
73092900 1
Next operation:
Timing gear housing - Install (B.10.A)
84465357 28/02/2011
B.10.A / 74
Timing gear housing - Install

Prior operation:
1. Assemble the front case (1) and tighten the fastening

NOTE: It is absolutely necessary to clean the surface to be
sealed in order to obtain perfect tightness. Apply LOCTITE®
5970 sealer on the gearcase in order to form a sealing bead
of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must
73092906 1
84465357 28/02/2011
B.10.A / 75
Connecting rod and piston - Remove

Prior operation:
1. Loosen the screws (1) fastening the connecting rod

caps (2) and remove the connecting rod caps.
2. Withdraw the pistons with the connecting rods from
the upper part of the crankcase.
NOTE: Keep the half bearings in their respective housings
since, in case of reuse after the overhaul, they will have to
be reassembled in the same position.
73092817 1
Next operation:
Connecting rod and piston - Install (B.10.A)
84465357 28/02/2011
B.10.A / 76
Connecting rod and piston - Disassemble

Prior operation:
Connecting rod and piston - Remove (B.10.A)
1. Make sure that the piston does not show any signs
of seizing, scoring or cracking. Replace if necessary.
2. Remove the piston rings (2) using the tool
380000324 (1).
73092849 1
3. Remove the snap rings (1) that hold the piston pin in
place using round tipped pliers.
73092863 2
4. Remove the piston pin (1). It may be necessary to

use hammer and wooden dowel to remove the pin.
73092862 3
Next operation:
Connecting rod and piston - Assemble (B.10.A)
84465357 28/02/2011
B.10.A / 77
Connecting rod and piston Piston - Measure

Prior operation:
Connecting rod and piston - Disassemble (B.10.A)
1. Using a micrometer (2), measure the diameter of the

piston (1) to determine the assembly clearance.
NOTE: The diameter of the piston must be measured at
the point shown in the figure for accurate measurement.
73092850 1
73092852 2
MAIN DATA OF THE PISTON, PINS AND SNAP RINGS
Next operation:
84465357 28/02/2011
B.10.A / 78
Piston Pin - Measure

Prior operation:
1. Measure the diameter of the piston pin (1) with a

micrometer (2).
73092853 1
2. Lubricate the pin (1) and the pin housing in the piston
with engine oil.
3. Insert the pin into the piston. It must be inserted with
slight finger pressure and it should not come out by
gravity.
73092854 2
Next operation:
84465357 28/02/2011
B.10.A / 79
Piston Ring - Measure

Prior operation:
1. Check the thickness of the piston ring (2) with a mi-

crometer (1).
73092855 1
2. Check the clearance between the rings (3) and their

landings on the piston (2) with a feeler gauge (1).
73092856 2
3. The ring (2) of the first landing has a "V" shape. The
clearance (X) between the ring and landing is mea-
sured by setting the piston (1) with the ring in the
cylinder liner (3) so that the ring is exposed half way
out of the cylinder liner.
73092857 3
84465357 28/02/2011
B.10.A / 80
4. Using a feeler gauge (1), check the opening between

the ends of the rings (2).
5. The ring must be inserted in the cylinder liner for an
accurate measurement. If the gap is less than or
greater than as required, replace the rings.
73092858 4
Next operation:
84465357 28/02/2011
B.10.A / 81
Connecting rod and piston - Assemble

Prior operation:
1. Throughout the pin (3), connect the piston (2) to the

connecting rod (4) following the indication of the ref-
erence arrow (1) to correctly fix the piston (2) into
the cylinder barrel, also taking into consideration the
numbers printed on the connecting rod (4).
73092862 1
2. Install the snap rings (1) using the round tipped pliers
to hold to the assembly together.
73092863 2
3. Install the piston rings (1) on the piston (2) by using

the pliers 380000221 (3).
4. Direct the ring openings so they are staggered 120 °
apart.
73092849 3
Next operation:
Connecting rod and piston - Install (B.10.A)
84465357 28/02/2011
B.10.A / 82
Connecting rod and piston - Install

Prior operation:
1. Fit the half bearings (1) on the connecting rod and

cap.
2. Lubricate the pistons, the snap pins and the cylinder
barrel interior.
73092864 1
3. Using the band 380000220 (2), fit the connecting rod

and piston unit (1) into the cylinder barrel, checking
that:
• The number of each connecting rod corre-
sponds to the coupling cap number.
• The snap rings’ openings must be misaligned
by 120 °.
• All the connecting rod/piston units must have
the same weight.
• The notch on the piston shield must match the
oil nozzles’ position.
73092865 2
84465357 28/02/2011
B.10.A / 83
73092866 3
Journal Clearance
4. Carefully clean the parts eliminating any oil residuals.
5. Place a piece of calibrated wire (2) on the engine
crankshaft pins (1).
6. Fit the connecting rod caps (3) and the relevant half
bearings (4).
NOTICE: Always use new screws in phase of assembly.
73092867 4
7. Lubricate the fastening screws (1) with engine oil and

tighten them to 45 - 55 N·m (33 - 41 lb ft) using a
torque wrench (2).
73092868 5
84465357 28/02/2011
B.10.A / 84
8. Fit the tool 380000304 (1) to the socket wrench and

then further tighten the screws (2) by 65 - 75 °.
73092869 6
9. Remove the cap and measure the clearance by com-

paring the width measured by the calibrated wire (1)
with the scale graduation reported on the calibrated
wire package (2).
10. In case the clearance measured differs from the pre-
scribed value, replace the half bearings and measure
the clearance again.
73092870 7
Next operation:
Oil pan - Install (B.60.A)
84465357 28/02/2011
B.10.A / 85
Flywheel - Remove
1. Fit tool (1) 380002385 to the flywheel housing and,

using a wrench, lock the flywheel rotation.
2. Loosen the screws fastening the flywheel to the en-
gine drive shaft.
73092772 1
3. Screw two medium length screws in the ports (4), in

order to secure the flywheel (1) with a sling.
4. By means of two guide pins (2) previously screwed
in the engine drive shaft ports (3), guide the flywheel
withdrawal throughout a hoist.
5. Withdraw the flywheel casing grommet.
6. Withdraw the grommet of the timing gearcase.
73092773 2
Next operation:
84465357 28/02/2011
B.10.A / 86
Flywheel - Install
Prior operation:
Flywheel - Remove (B.10.A)
1. Screw two hooks or eyebolts on the flywheel (1)

through the ports (4).
2. By means of a hoister, draw the flywheel up to its
housing inside the casing.
NOTE: The flywheel has a reference dowel that couples
with the relevant seat on the box.
3. Screw two pins (2) of appropriate length into the
shaft’s ports (3) and, using them as a guide, duly fit
the engine flywheel (1) into its casing.
4. Fit the tool 380002385 to the flywheel casing in order
to lock the engine flywheel rotation.
73092773 1
5. Tighten the engine flywheel (3) fastening screws (2)

in the following sequence.
• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
NOTE: Angular fastening must be executed using tool
380000304. Before assembly, always check that the port
threads and the screws show no trace of wear and dirt.
73092783 2
84465357 28/02/2011
B.10.A / 87
Flywheel - Remove

gine drive shaft.
73092772 1

73092899 2
Next operation:
84465357 28/02/2011
B.10.A / 88
Flywheel - Install
Prior operation:

through the ports .
73092899 1

• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
73092905 2
84465357 28/02/2011
B.10.A / 89
Flywheel - Remove

gine drive shaft.
73092772 1

93111650 2
Next operation:
84465357 28/02/2011
B.10.A / 90
Flywheel - Install
Prior operation:

through the ports (4).
93111650 1

• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
93111650 2
84465357 28/02/2011
B.10.A / 91
Balancer - Remove
Prior operation:
1. Unscrew the screws (2) which fasten the dynamic

balancer (1) and remove it.
73092902 1
Next operation:
Balancer - Install (B.10.A)
84465357 28/02/2011
B.10.A / 92
Balancer - Install
Prior operation:
Balancer - Remove (B.10.A)
1. Mount the dynamic balancer (1) taking care that the

reference notches (2) coincide as shown in figure.
76092914 1
Next operation:
84465357 28/02/2011
B.10.A / 93
Cylinder block Bore - Check

Prior operation:
Once engine is disassembled, clean accurately the cylinder

block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder bore surfaces; they shall be free from seiz-
ing, scores, ovalization, taper, or excessive wear.
Inspection of cylinder bore to check ovalization, taper, and
wear shall be performed using the bore dial gauge (1) fitted
with the dial gauge previously set to zero on the ring gauge
(2) of the cylinder bore diameter.
NOTE: Should a ring gauge not be available, use a mi-
crometer for zero-setting. 73092825A 1
Measurements shall be performed on each cylinder at

three different heights in the barrel and on two planes per-
pendicular with each other: one parallel to the longitudinal
axis of the engine (A), and the other perpendicular (B).
Maximum wear is usually found on plane (B) in correspon-
dence with the first measurement.
Should ovalization, taper, or wear be found, bore and grind
the cylinder bores. Cylinder bore regrinding shall be per-
formed according to the spare piston diameter oversized by
0.4 mm (0.016 in) and to the specified assembling clear-
ance.
73092826A 2
84465357 28/02/2011
B.10.A / 94
NOTE: In case of regrinding, all bores shall have the same

oversize 0.4 mm (0.016 in).
73092827 3
84465357 28/02/2011
B.10.A / 95
Cylinder head - Remove

Prior operation:
1. Disassemble the cylinder head; loosen the cylinder

head (1) fastening screws (2); hook the brackets with
metal ropes and, throughout a hoister, detach the
cylinder head with valves from the basement.
2. Remove the cylinder head gasket.
73092775 1
Next operation:
Cylinder head - Install (B.10.A)
84465357 28/02/2011
B.10.A / 96
Cylinder head - Install

Prior operation:
Cylinder head - Remove (B.10.A)
1. Measure the piston projection and refer to the table

to select the appropriate thickness of the gasket.
73092790 1
Piston protrusion (A) Gasket thickness (B)

0.07 - -0.07 mm (0.0028 - -0.0028 in) 0.80 mm (0.031 in)
-0.08 - -0.22 mm (-0.0031 - -0.0087 in) 0.70 mm (0.028 in)
2. Fit the gasket (1) on the block centering it on the pins

(2) as a reference.
73092791 2
84465357 28/02/2011
B.10.A / 97
3. Place the head (1) on the block while aligning the

centering pins.
NOTE: Always use new screws for assembly.
4. Lubricate the head fastening screws (2) and tighten
them to the prescribed torque.
73092775 3
Next operation:
84465357 28/02/2011
B.10.A / 98
Cylinder head - Disassemble

Prior operation:
Cylinder head - Remove (B.10.A)
1. The intake valves (1) and exhaust valves (2) have

different head diameter.
2. Number the valves before removing them from the
cylinder head in order to be able to reassemble them
in the same order in case replacement is not neces-
sary.
73092871 1
3. Valve disassembly must be executed using tool

380000302 (1) to slightly press the plate (3) so that,
compressing the spring (4), it is possible to remove
the keepers (2). Then remove the plate (3) and the
spring (4).
4. Repeat the operation in correspondence of each
valve.
5. Turn the cylinder head upside down and withdraw the
valves (5).
73092872 2
6. Remove the seals (1) and (2) from their valve guides.
73092873 3
Next operation:
84465357 28/02/2011
B.10.A / 99
Cylinder head - Check

Prior operation:
1. Any deformation detected on the whole length of the

cylinder head must not exceed 0.20 mm (0.008 in).
In case higher value is detected, grind the cylinder
head in order to obtain the prescribed value.
73092874 1
Next operation:
84465357 28/02/2011
B.10.A / 100
Cylinder head Valve guide - Measure

Prior operation:
1. Using a bore meter, measure the valve guide inner

diameter.
73092878 1
Next operation:
84465357 28/02/2011
B.10.A / 101
Cylinder head Valve seat - Replace

Prior operation:
1. If the valve seat are damaged replace them.

2. With the tools and being careful not to indent the
cylinder heads, remove as much material as possible
from the valve seats until removal from cylinder head
is possible by means of a punch.
3. Heat cylinder head up to 80 - 100 °C (176 - 212 °F) 73092879 1
and with the beater assemble the new valve seats
previously cooled into the cylinder head.
Next operation:
84465357 28/02/2011
B.10.A / 102
Cylinder head - Assemble

Prior operation:
1. Lubricate the valve stems (1) and fit them in the rel-
evant valve guides in the same position they were
before disassembly.
2. Fit the grommets (2)and (3) to the valve guide using
tool 380000134.
73092881 1
3. Place the spring (4) and the upper plate (3) on the
cylinder head.
4. Using tool 380000302 (1), compress the spring (4)
and constrain the parts to the valve (5) using the
keepers (2).
73092872 2
Next operation:
84465357 28/02/2011
B.10.A / 103
Valve cover - Remove

1. Loosen the screws (1) and remove the tappet covers
(2).
73092766 1
84465357 28/02/2011
B.10.A / 104
Valve cover - Install

1. Replace the gaskets (2) and install the valve covers
(1).
73092797 1
84465357 28/02/2011
B.10.A / 105
Front cover - Install

1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
73092787A 1
84465357 28/02/2011
B.10.A / 106
Front cover - Install

1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
73092908 1
84465357 28/02/2011
B.10.A / 107
Rear cover - Install

1. Accurately clean the timing gearcase and the engine

block.
NOTICE: It is absolutely necessary to clean the surface
to be sealed in order to obtain perfect tightness. Apply
LOCTITE® 5970 sealer on the gearcase in order to form a
sealing bead of 1.5 mm (0.059 in). The sealing bead must
73092781 1
84465357 28/02/2011
B.10.A / 108


block.
73092903 1
84465357 28/02/2011
B.10.A / 109


block.
93111626 1
84465357 28/02/2011
B.10.A / 110
Wiring harness - Remove

1. Remove the wiring harness from all electrical equip-

ment.
84465357 28/02/2011
B.10.A / 111
Index
ENGINE - 10.A
Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Balancer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F5CE5454C*A003
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
F5CE5454C*A003
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
F5CE5454C*A003
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Crankshaft Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
F5CE5454C*A003
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
84465357 28/02/2011
B.10.A / 112
Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cylinder head Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Cylinder head Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electronic control Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electronic control Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
F5CE9454G
F5CE9454E
F5CE9484E
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
F5CE5454G*A001
F5CE5454B*A005
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
F5AE5484A
F5AE9454J
F5AE9454L
F5AE9484K
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A,
F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
F5CE5454C*A003
84465357 28/02/2011
B.10.A / 113
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
F5CE5454C*A003
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F5CE5454C*A003
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
F5CE5454C*A003
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring harness - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wiring harness - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B,
F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K
Wiring harness - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
84465357 28/02/2011
B.10.A / 114
FUEL AND INJECTION SYSTEM - 20.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.20.A / 1
Contents
FUNCTIONAL DATA
FUEL AND INJECTION SYSTEM

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injection pump
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel filter system
Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Priming pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sensing system
Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE
FUEL AND INJECTION SYSTEM

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel injection pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel filter system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
84465357 28/02/2011
B.20.A / 2
Fuel injector
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Priming pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel line
Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454C*A003
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

F5CE5454C*A003
Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

84465357 28/02/2011
B.20.A / 3
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
FUEL AND INJECTION SYSTEM - Overview
73092749 1
SUPPLY SYSTEM DIAGRAM
(1) Injectors (2) Fuel filter (3) Tank (4) Supply pump (5) Ignition pump
The engine supply system consists of the following components:

• Fuel tank (aboard the vehicle)
• Fuel delivery and return pipes
• Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)
• Priming pump, fitted on the engine and driver by the engine camshaft
• Fuel filter (its position on the engine may vary depending on the outfit and use)
• Supply rotary pump
• Injector feed pipe (from the fuel supply pump to the fuel injectors)
• Injectors
NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift
pump, description will not be accurate.
84465357 28/02/2011
B.20.A / 4
73092750 2
PIPE LAYOUT
(1) Injector feed pipe (5) KSB thermal bulb

(2) Fuel exhaust pipe from injectors (6) Solenoid valve
(3) Supply rotary pump (7) Injector
(4) Union for pressure gauge pipe within LDA intake
manifold
84465357 28/02/2011
B.20.A / 5
Working system description

The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and
is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed
inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the
fuel pressure based on the increase of engine revolutions’ number. Then, the fuel reaches the valve controlling fuel
pressure within the supply pump. The distributor piston further increases such pressure and delivers the fuel to the
injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the
fuel tank.
NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift
pump, description will not be accurate.
73092751 3
84465357 28/02/2011
B.20.A / 6
Fuel injection pump - Dynamic description

Supply phase
The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the
compression chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).
73092753 1
(1) Fuel supply pipe (4) Compression chamber (7) End of delivery port
(2) Solenoid valve (5) Fuel delivery pipe from pump to (8) Cursor
injectors
(3) Axial groove (6) Distributor piston (9) Injector
84465357 28/02/2011
B.20.A / 7
Delivery phase
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The
combination of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within
the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to
the injectors (6).
73092754 2
(1) Fuel feed pipe (3) Distributor piston inner pipe (5) Distributor piston
(2) Compression chamber (4) Fuel delivery pipe from pump to (6) Injector
injector
84465357 28/02/2011
B.20.A / 8
End of delivery phase

The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby
establishing pressure balance between the distributor piston inner chamber, the injectors? delivery pipe and the pump
interior. Since such pressure is lower than the one required to start the injector, end of delivery will be determined.
73092755 3
(1) Fuel feed pipe (3) Fuel delivery pipe (5) Cursor
(2) Compression chamber (4) End of delivery pipe (6) Distributor piston
84465357 28/02/2011
B.20.A / 9
Engine stop
Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The
solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs
the fuel feed pipe (1).
73092756 4
(1) Fuel feed pipe (3) Spring (5) Compression chamber

(2) Mobile cap (4) Solenoid valve
84465357 28/02/2011
B.20.A / 10
Load Delivery Adjustment (LDA) device

The duty of the LDA device is to adjust the fuel delivery depending on the air pressure within the intake manifold. Air
pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there
is a conical housing (5) in which the feeling pin runs (6). The setting pin (4) axial motion drives the feeling pin (6) shift
and the latter acts on the stop lever (7). The stop lever rotates on its own axle (8) and acts on the control plate in
order to adjust the fuel delivery depending on the air quantity within the cylinders.
73092757 5
Section of the LDA device
84465357 28/02/2011
B.20.A / 11
Fuel injection pump - Sectional view

Identification coding example
V rotary distributor piston pump
E pump dimensions
4 four cylinder engines
12 distributor piston size in mm
1150 no. of pump rev/min.
RV right direction rotation
73092752 1
Ref. Description
(1) Membrane
(2) Setting ring
(3) Feeler pin
(4) Drive lever
(5) Speed regulator
(6) Transfer pump
(7) Drive shaft
(8) Cam disk
(9) Spark lead adjuster
(10) Distributor piston
(11) Supply pipe fitting
(12) Hydraulic head
(13) Control plate
(14) Adjusting pin
(15) Counter spring
84465357 28/02/2011
B.20.A / 12
Fuel filter system Fuel filter - Overview

The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water
from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device;
depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and
a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge
filter.
84465357 28/02/2011
B.20.A / 13
73092759 1
(1) Fuel filter support (2) Cartridge filter (3) Water drainage device (not
available on all versions)
84465357 28/02/2011
B.20.A / 14
Priming pump - Overview

The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the
engine block and driven by the engine camshaft.
73092758 1
(1) Pump (2) Control lever (3) Camshaft
84465357 28/02/2011
B.20.A / 15
Sensing system Air temperature-pressure sensor - Overview

It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device.
73092811 1
84465357 28/02/2011
B.20.A / 16
FUEL AND INJECTION SYSTEM - Bleed

1. Disconnect the fuel filter pipe (1) and act on the prim-
ing pump (2) drainage lever.
2. Continue drainage until fuel discharge is completed.
3. Connect the pipe (1) to the filter.
73092801 1
84465357 28/02/2011
B.20.A / 17
Fuel injection pump - Remove

1. Unscrew the pump fastening screws on the rear part
of the gear cover. To disassemble the pump, fit tool to
the pump wheel and fix it with the three screws (1).
Using the specially provided wrench, slowly tighten
the screw (2) holding the rear part of the pump re-
moving the pump completely.
NOTE: Before pump disassembly, check whether a drive
shaft locking system is available for that model. In such
case, using the specially provided tool 380000150, lock the
engine into the position corresponding to T.D.C. for cylinder
1. Then, throughout the specific locking system available,
lock the pump drive shaft. At this point, the pump should
be in phase and therefore no timing will be requested in
phase of reassembly (unless any maintenance operation 73092763 1
is necessary).
Next operation:
Fuel injection pump - Install (B.20.A)
84465357 28/02/2011
B.20.A / 18
Fuel injection pump - Install

Prior operation:
Fuel injection pump - Remove (B.20.A)
1. Fit the ignition pump gear (1) into its housing.

2. Fit the pre-set ignition pump into its housing on the
engine, inserting the shaft into the gear hole.
3. Tighten the three screw nuts on the rear part of the
timing gearcase and the front cover fixing the shaft
to the gear.
4. With magnetic base dial gauge, check the clearance
among the engine shaft gear and the oil pump gear:
it must be 0.068 - 0.168 mm (0.003 - 0.007 in).
73092787A 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
84465357 28/02/2011
B.20.A / 19
Fuel injection pump - Install

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

2. Fit the pre-set ignition pump into its housing on the
engine, inserting the shaft into the gear hole.
3. Tighten the three screw nuts on the rear part of the
timing gearcase and the front cover fixing the shaft
to the gear.
among the engine shaft gear and the oil pump gear:
it must be 0.068 - 0.168 mm (0.003 - 0.007 in).
73092908 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
84465357 28/02/2011
B.20.A / 20
Fuel injection pump - Timing adjust
Prior operation:
Cold KSB timing

1. Place the pump in vice.
2. Remove the plug on the backside of the pump.
3. Install the dial gauge 380000228 (1) and dial gauge
holder into the pump.
4. Turn the pump shaft (2) until tension is relieved and
the pump cam plate is not loading the plunger.
NOTE: Double nut the end of the pump shaft, this will aid
in rotating the pump shaft.
5. Pre load the dial gauge by 3 mm (0.118 in) and zero
the gauge.
6. Turn the pump shaft so that the key way is aligned
closely to the 11 O’clock position while watching the
dial gauge and stop when the correct specification 93101557 1
(below) is reached.
• Specification is 1.60 mm (0.063 in)
• Timing between 1.55 - 1.65 mm (0.061 - 0.065
in)
7. Lock pump in position by removing the spacer plate
(3) and snugging the bolt (4).
NOTE: Do not loosen the locking bolt until the pump is
installed and torqued on the engine.
8. Set the engine to Cylinder 1 top dead center. Refer
to ENGINE - Service instruction (B.10.A) for the
proper procedure.
9. Install the pump and gear on the engine. Refer to
Fuel injection pump - Install (B.20.A) for the proper
procedure.
10. Remove the lock screw.
NOTE: Leave the dial gauge in the back of the pump.
11. Rotate the engine one full rotation to #1 TDC while
monitoring the pump pre-travel.
12. Pin the flywheel at #1 TDC and make note of the
reading on the dial gauge. If the reading is within
10 mm (0.394 in), timing is correct.
13. Remove the dial gauge.
14. Install the plug.
15. Install the spacer plate and tighten the lock bolt.
Hot KSB timing

16. Set the engine to T.D.C. refer to ENGINE - Service
instruction (B.10.A).
17. Remove the spin-on fuel filter. Do not discard.
84465357 28/02/2011
B.20.A / 21
18. Apply 12 volts to the KSB for a minimum of 5 minutes.

12 volts is required to remove the cold-start advance
on the pump in order to check the static (hot) timing.
19. Use a mirror to ensure that the KSB timing is retarded
with the KSB lever (arm) moved forward (toward the
front of the pump) almost against the angle stop (1).
20. Use a 12 mm socket or wrench to remove the plunger
access plug. The access plug is in the center of the
rear end cap of the injection pump.
20111651A 2
21. Install the timing adaptor (2) and the dial indicator (3)
into the hole where you removed the plunger access
plug.
22. If needed, loosen and reposition the bottom two in-
jector lines to allow room for the dial indicator.
23. Tighten the timing adapter.
24. Preload the dial indicator needle to 2.5 mm (0.10 in).
25. Pull outward on the end of the dial indicator stem and
release it to ensure the stem moves freely and does
not bind. If the stem does not move freely, reposition
the dial indicator until the stem moves freely.
20111652 3
26. Slide out the TDC timing pin from the flywheel to un-
lock the flywheel.
27. Rotate the engine counter-clockwise until the dial in-
dicator needle drops to a minimum reading and stops
moving. You are now positioned between cam lobes
of the injection pump.
28. Position the dial indicator needle at the zero position.
29. Rotate the engine clockwise until the TDC timing pin
reengages the flywheel and locks it at TDC.
30. Check the injection pump timing.
• Specification is 0.75 mm (0.030 in)
• Timing between 0.65 - 0.85 mm (0.026 - 0.033
in)
31. If only a slight timing adjustment is required, loosen
the pump mounting bolts and rotate the injection
pump.
NOTE: The holes for the mounting bolts are not elongated. Only a slight adjustment can be made by rotating the
injection pump.
84465357 28/02/2011
B.20.A / 22
Fuel filter system - Remove

1. Place a container under the diesel fuel filter and un-

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
73092765 1
84465357 28/02/2011
B.20.A / 23
Fuel filter system - Install

1. Install the fuel filter support (1) and the fuel filter (2).
73092765 1
84465357 28/02/2011
B.20.A / 24

1. Place a container under the diesel fuel filter and un-

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
73092894 1
84465357 28/02/2011
B.20.A / 25

1. Install the fuel filter support (1) and the fuel filter (2).
73092894 1
84465357 28/02/2011
B.20.A / 26

1. Refer to your product service manual.
84465357 28/02/2011
B.20.A / 27

1. Refer to your product service manual.
84465357 28/02/2011
B.20.A / 28
Fuel injector - Remove

1. Unscrew the injector support fastening screws (1),
disassemble the injector supports and remove the
injectors (2).
73092766 1
84465357 28/02/2011
B.20.A / 29
Fuel injector - Install

1. Install new seals on the injectors.
2. Make the holes (1) for fuel return all face the same
direction.
73092796 1
3. Install the injectors (1) and tighten the fastening

screws (2) to the prescribed torque setting.
73092795 2
84465357 28/02/2011
B.20.A / 30
Priming pump - Remove

1. Remove the priming pump (1).
73092765 1
84465357 28/02/2011
B.20.A / 31
Priming pump - Install

1. Install the priming pump (1).
73092765 1
84465357 28/02/2011
B.20.A / 32
Priming pump - Remove

1. Remove the priming pump (1).
73092894 1
84465357 28/02/2011
B.20.A / 33
Priming pump - Install

1. Install the priming pump (1).
73092894 1
84465357 28/02/2011
B.20.A / 34
Fuel line Low pressure - Remove

1. Remove the Load Delivery Adjustment (LDA) pipe.

Remove the fuel pipes from the priming pump (1)
to the filter and from the filter to the ignition pump
(2), then fit the specially provided caps to the pipes,
the pumps and the filter. Unscrew the screws (3),
fastening the fuel ignition pipes and remove them.
73092762 1
84465357 28/02/2011
B.20.A / 35
Fuel line Low pressure - Install

1. Reassemble the pipe from the pump to the injector

and tighten the bracket’s fastening screws (3).
2. Reassemble the pipe from the pump to the fuel filter
(2) and from the fuel filter to the priming pump (1).
3. Reassemble the Load Delivery Adjustment (LDA)
pipe.
73092762 1
84465357 28/02/2011
B.20.A / 36
Fuel line Low pressure - Remove

1. Remove the Load Delivery Adjustment (LDA) pipe.

Remove the fuel pipes from the priming pump (1)
to the filter and from the filter to the ignition pump
(2), then fit the specially provided caps to the pipes,
the pumps and the filter. Unscrew the screws (3),
fastening the fuel ignition pipes and remove them.
73092893A 1
84465357 28/02/2011
B.20.A / 37
Fuel line Low pressure - Install

1. Reassemble the pipe from the pump to the injector

and tighten the bracket’s fastening screws (3).
2. Reassemble the pipe from the pump to the fuel filter
(2) and from the fuel filter to the priming pump (1).
3. Reassemble the Load Delivery Adjustment (LDA)
pipe.
73092762 1
84465357 28/02/2011
B.20.A / 38
Index

FUEL AND INJECTION SYSTEM - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL AND INJECTION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel filter system Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injection pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5CE5454C*A003
Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F5CE5454C*A003
Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454C*A003
Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5CE5454C*A003
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454C*A003
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
84465357 28/02/2011
B.20.A / 39
84465357 28/02/2011
B.20.A / 40
AIR INTAKE SYSTEM - 30.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.30.A / 1
Contents
FUNCTIONAL DATA
AIR INTAKE SYSTEM

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air intake manifold

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84465357 28/02/2011
B.30.A / 2
ENGINE AND PTO IN - AIR INTAKE SYSTEM
AIR INTAKE SYSTEM - Overview

The boosting system is composed of the following parts:

• Air filter
• Turbocharger
73092748 1
BOOSTING
84465357 28/02/2011
B.30.A / 3
AIR INTAKE SYSTEM - Overview

The boosting system is composed of the following parts:

• Air filter
• Turbocharger
73092891 1
BOOSTING
84465357 28/02/2011
B.30.A / 4
Turbocharger - Remove
1. Disconnect the oil delivery pipe (2) from the tur-

bocharger.
2. Disconnect the oil drain pipe (3).
3. Remove the turbocharger to intake hose (4).
4. Remove the turbocharger unit (1).
73092760 1
84465357 28/02/2011
B.30.A / 5
Turbocharger - Install
1. Reassemble the turbocharger (1) unit.

2. Connect the oil delivery pipe (2) to the turbocharger.
3. Connect the oil drain pipe (3).
4. Install the turbocharger to intake hose (4).
73092760 1
84465357 28/02/2011
B.30.A / 6

bocharger.
73092892 1
84465357 28/02/2011
B.30.A / 7

73092892 1
84465357 28/02/2011
B.30.A / 8

bocharger.
93111630 1
84465357 28/02/2011
B.30.A / 9

93111630 1
84465357 28/02/2011
B.30.A / 10
Air intake manifold - Remove

1. Remove the intake manifold (1).
73092766 1
84465357 28/02/2011
B.30.A / 11
Air intake manifold - Install

1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
73092799 1
84465357 28/02/2011
B.30.A / 12
Air intake manifold - Install

1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
73092912 1
84465357 28/02/2011
B.30.A / 13
Index

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84465357 28/02/2011
B.30.A / 14
EXHAUST SYSTEM - 40.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.40.A / 1
Contents
FUNCTIONAL DATA
EXHAUST SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sensing system
Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
EXHAUST SYSTEM
Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84465357 28/02/2011
B.40.A / 2
ENGINE AND PTO IN - EXHAUST SYSTEM
EXHAUST SYSTEM - Overview

EGR (EXHAUST GAS RECIRCULATION)
The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that
produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and
therefore is an efficient NOx emission control system.
INTERNAL EGR
The specific design of intake cams of the internal EGR system allows part of exhaust gas to be recycled to engine
cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always
active. Its configuration requires no additional parts such as control valves, pipelines or heat exchangers therefore
engine profile remains unchanged. Besides main lobe, intake cam has an additional lobe as to configuration without
EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this
way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled
to cylinder inlet for combustion phase.
73092746 1
Aspiration cam profile
(X) Cam rotation angle (Y) Cam lift
84465357 28/02/2011
B.40.A / 3
EXHAUST SYSTEM - Overview

EGR (EXHAUST GAS RECIRCULATION)
The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that
produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and
therefore is an efficient NOx emission control system.
EXTERNAL E.G.R.
The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial
exhaust gas recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the
combustion temperature maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced.
Hence, reducing the aforesaid temperatures by decreasing the concentration of oxygen in the combustion chamber,
the EGR system efficiently controls NOx emissions. The exhaust gases through the conduit (4) and only after re-
ceiving the consent by the electronic control unit EGR, cross the valve (1) and reach the heat exchanger (2) where,
thanks to the engine coolant recycle, are cooled to be then entered into the intake manifold (5).
73092747 1
EXTERNAL E.G.R.
(1) Valve unit (5) Intake manifold

(2) Heat exchanger (6) Exhaust manifold
(3) Water delivery pipe (7) Engine head
(4) Exhaust gas pipe
84465357 28/02/2011
B.40.A / 4
Sensing system - Overview EGR valve

73092813 1
(A) Exhaust gas input - (B) Exhaust gas output
Coil characteristic Potentiometer characteristic

Resistance 7.5 - 8.5 Ω Total resistance 4000 Ω
Frequency 100 - 150 Hz Maximum voltage 15 V
Voltage 12 - 16 V Supply current 10 mA
Circuit configuration Voltage divider
84465357 28/02/2011
B.40.A / 5
EXHAUST SYSTEM - Remove EGR System

1. Using pliers, remove the clips (1) and the water deliv-
ery pipe connected to the valve support and the ex-
changer (2). Loosen the clip (3) and detach the pipe
(4), from the EGR valve housing. Unscrew the EGR
fastening screws on the front side (5), and those on
the valve support side (6), then remove the EGR unit.
73092761 1
84465357 28/02/2011
B.40.A / 6
EXHAUST SYSTEM - Install EGR System

1. Place the whole E.G.R. on the intake manifold,

tighten the front side (5) and valve support (6) fas-
tening screws to the prescribed torque.
2. Connect the pipe (4) to the E.G.R. valve housing and
then tighten the clip (3).
3. Reassemble the pipe (2) and, using pliers, fit the rel-
evant clip (1).
73092761 1
84465357 28/02/2011
B.40.A / 7
Exhaust manifold - Remove

1. Remove the exhaust manifold (1).
73092766 1
84465357 28/02/2011
B.40.A / 8
Exhaust manifold - Install

1. Fit the exhaust manifold (3) with new seal (2) and
tighten the nuts (1) with studs tightening them to the
required torque.
73092793 1
84465357 28/02/2011
B.40.A / 9
Index

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST SYSTEM - Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST SYSTEM - Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sensing system - Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84465357 28/02/2011
B.40.A / 10
ENGINE COOLANT SYSTEM - 50.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.50.A / 1
Contents
FUNCTIONAL DATA
ENGINE COOLANT SYSTEM

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermostat
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sensing system
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coolant line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fan and drive

Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454C*A003
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454C*A003
84465357 28/02/2011
B.50.A / 2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5CE5454C*A003
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
84465357 28/02/2011
B.50.A / 3
ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Overview

The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092742 1
ENGINE COOLING SYSTEM DIAGRAM
84465357 28/02/2011
B.50.A / 4
ENGINE COOLANT SYSTEM - Overview

The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092890 1
ENGINE COOLING SYSTEM DIAGRAM
84465357 28/02/2011
B.50.A / 5
Thermostat - Overview
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermo-
stat, which cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine
circuit, allowing engine heat up quickly. The thermostat valve starts opening at nearly 80 °C (176 °F), allowing water
circulation into the radiator and also obstructing direct return towards the engine. Check the thermostat efficiency and
replace it in case of doubtful functioning.
73092744 1
THERMOSTAT DIAGRAM
(1) Stroke starts at 77 - 81 °C (171 - 178 °F). (2) 7 mm (0.28 in) stroke at 92 - 96 °C (198 - 205 °F).
84465357 28/02/2011
B.50.A / 6
Water pump - Overview

The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft
as a whole. Water tight between the pump unit (3) and the shaft (2) is ensured by the sheath (4).
73092743 1
WATER PUMP SECTION
(1) Hub (4) Sheath

(2) Shaft with bearing (5) Impeller
(3) Pump unit
84465357 28/02/2011
B.50.A / 7
Sensing system Coolant temperature - Overview

The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores.
73092808 1
Characteristics
Working temperature range
- Connector’s side -40 - 130 °C (-40 - 266 °F) ; 150 °C (302 °F) for less
than 10 min.
- Bulb’s side on engine -40 - 140 °C (-40 - 284 °F)
Voltage 6 - 28 V
84465357 28/02/2011
B.50.A / 8
Sensing system Coolant temperature - Overview KSB
73092810 1
Characteristics
Contact closing temperature 60 - 70 °C (140 - 158 °F)
Maximum load on contacts 15 A
84465357 28/02/2011
B.50.A / 9
Thermostat - Remove
1. Remove the thermostat unit (1).
73092766 1
84465357 28/02/2011
B.50.A / 10
Water pump - Remove

Prior operation:
Fan and drive Belt - Remove (B.50.A)
1. Remove the water pump (1).
73092770 1
Next operation:
Water pump - Install (B.50.A)
84465357 28/02/2011
B.50.A / 11
Water pump - Install

Prior operation:
Water pump - Remove (B.50.A)
1. Fit a new seal (2) on the water pump (1).

2. Assemble the water pump (1).
3. Tighten the fastening screws to the prescribed
torque.
73092789 1
Next operation:
Fan and drive - Install (B.50.A)
84465357 28/02/2011
B.50.A / 12
Water pump - Remove

Prior operation:
1. Remove the water pump (1).
73092898A 1
Next operation:
Water pump - Install (B.50.A)
84465357 28/02/2011
B.50.A / 13
Coolant line - Remove

1. Remove the water delivery pipe (1) from the ex-

changer.
73092760 1
84465357 28/02/2011
B.50.A / 14
Coolant line - Remove

1. Remove the water delivery pipe (1) from the ex-

changer.
93111630 1
84465357 28/02/2011
B.50.A / 15
Fan and drive Belt - Remove

1. Loosen the screw (1) and the relevant screw nut on

the belt tensioning bracket (3).
2. Loosen the alternator through bolt in order to with-
draw the belt (2).
73092767 1
Next operation:
Fan and drive Belt - Install (B.50.A)
84465357 28/02/2011
B.50.A / 16
Fan and drive Belt tensioner - Remove

Prior operation:
1. Remove the belt tensioning bracket (1).
73092767 1
Next operation:
84465357 28/02/2011
B.50.A / 17
Fan and drive - Remove

Prior operation:
1. Remove the fan hub (1).

2. Loosen the screw (2) and remove the pulley (3).
73092770 1
Next operation:
84465357 28/02/2011
B.50.A / 18
Fan and drive - Install

Prior operation:
Fan and drive - Remove (B.50.A)
1. Install the fan hub (1).

2. Reassemble the pulley (3), tighten the fastening
screw (2) to the prescribed torque setting.
73092792 1
Next operation:
84465357 28/02/2011
B.50.A / 19
Fan and drive Belt tensioner - Install

Prior operation:
Fan and drive Belt tensioner - Remove (B.50.A)
1. Install the tensioner (1).
73092767 1
Next operation:
84465357 28/02/2011
B.50.A / 20
Fan and drive Belt - Install

Prior operation:
1. Fit the drive belt (1) on the pulley and the guide
rollers.
2. Tension the drive belt by tightening the screw (2).
73092767 1
84465357 28/02/2011
B.50.A / 21
Fan and drive Belt - Remove

1. Loosen the screw (1) and the relevant screw nut on
the belt tensioning bracket (3).
2. Loosen the alternator through bolt in order to with-
draw the belt (2).
73092896 1
Next operation:
84465357 28/02/2011
B.50.A / 22
Fan and drive Belt tensioner - Remove

Prior operation:
1. Remove the belt tensioning bracket (1).
73092896 1
Next operation:
84465357 28/02/2011
B.50.A / 23
Fan and drive - Remove

Prior operation:
1. Remove the fan hub (1).

2. Loosen the screw (2) and remove the pulley (3).
73092898A 1
Next operation:
84465357 28/02/2011
B.50.A / 24
Fan and drive - Install

Prior operation:
Fan and drive - Remove (B.50.A)
1. Install the fan hub (1).

2. Reassemble the pulley (3), tighten the fastening
screw (2) to the prescribed torque setting.
73092910 1
Next operation:
84465357 28/02/2011
B.50.A / 25
Index

Coolant line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003
Coolant line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5CE5454C*A003
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454C*A003
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454C*A003
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5CE5454C*A003
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensing system Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454C*A003
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84465357 28/02/2011
B.50.A / 26
LUBRICATION SYSTEM - 60.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.60.A / 1
Contents
TECHNICAL DATA
Oil pump
Oil filter
FUNCTIONAL DATA
LUBRICATION SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454C*A003
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5C, F5A
Oil filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5C, F5A
Blowby re-circulation system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil cooler
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sensing system
Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE
Oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454C*A003
84465357 28/02/2011
B.60.A / 2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil filter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Piston lubrication
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84465357 28/02/2011
B.60.A / 3
ENGINE AND PTO IN - LUBRICATION SYSTEM
Oil pump - General specification

Rotating speed 750 - 4200 RPM
Feed pressure 2 - 4 bar (29 - 58 psi)
Rated flow 12.2 - 75.9 l/min (3.2 - 20.1 US gpm)
Oil type SAE 20/30
Max. oil temperature 80 °C (176 °F)
84465357 28/02/2011
B.60.A / 4
Oil filter - General specification

Booster pressure 20 bar (290 psi)
Dynamic pressure 0 - 15 bar (0 - 218 psi) per 50,000 cycles
Operating temperature -40 - 140 °C (-40 - 284 °F)
Torque wrench setting 16 - 20 N·m (12 - 15 lb ft)
Maximum flow 50 l/min (13.2 US gpm)
Load loss at the end of life cycle 2.5 bar (36 psi)
84465357 28/02/2011
B.60.A / 5
LUBRICATION SYSTEM - Overview

Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092738 1
LUBRICATION SYSTEM DIAGRAM
84465357 28/02/2011
B.60.A / 6
LUBRICATION SYSTEM - Overview

Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092888 1
LUBRICATION SYSTEM LAYOUT
84465357 28/02/2011
B.60.A / 7
Oil pump - Overview

F5C, F5A
73092739 1
Oil pump
(1) Main gear (6) Cover

(2) Secondary gear (7) Internal rotor
(3) Pump unit (8) External rotor
(4) Drive shaft
(5) Secondary shaft
84465357 28/02/2011
B.60.A / 8
Oil filter - Overview

F5C, F5A
73092740 1
Engine oil filter
(1) Protective cover (2) Cartridge
84465357 28/02/2011
B.60.A / 9
Blowby re-circulation system - Overview

On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop
by gravity on the underlying tappet cover (3). The remaining non condensed vapours will be duly conveyed through
the breather (2), for instance by suction.
73092741 1
ENGINE OIL VAPOR RECIRCULATION
(1) Valve (2) Breather (3) Tappet cover
84465357 28/02/2011
B.60.A / 10
Oil cooler - Overview
73092745 1
OIL COOLER
The oil cooler within the engine cooling system has the duty to control the engine oil temperature, reducing it by
absorbing heat throughout the engine cooling liquid.
84465357 28/02/2011
B.60.A / 11
Sensing system Oil pressure - Overview

73092809 1
Characteristics
Voltage 12 - 24 V
Contact closure with decreasing pressure 0.2 bar (3 psi)
Contact opening with increasing pressure 0.9 bar (13 psi)
84465357 28/02/2011
B.60.A / 12
Sensing system Oil pressure - Overview

73092919 1
Characteristics
Voltage 12 - 24 V
Calibration 0.6 - 0.9 bar (9 - 13 psi)
Tightening torque 35 N·m (26 lb ft)
84465357 28/02/2011
B.60.A / 13
Oil pump - Remove

1. Loosen the screws (1) and remove the oil pump (2).
73092778 1
Next operation:
Oil pump - Install (B.60.A)
84465357 28/02/2011
B.60.A / 14
Oil pump - Install

Prior operation:
Oil pump - Remove (B.60.A)
1. Assemble the oil pump (2).

2. Screw the fastening screws (1) without fully locking
them.
among the engine crankshaft gear and the oil pump
gear: It must be between 0.068 - 0.168 mm (0.003 -
0.007 in).
4. Fully tighten the fastening screws (1).
73092784 1
84465357 28/02/2011
B.60.A / 15
Oil pan - Remove

1. Loosen the screws (2), disassemble the plate (3) and

remove the oil pan (1).
NOTE: The shape and dimensions of the oil pan and the
suction rose may vary depending on the engine appliance.
Hence, the figures provide a general indication of the op-
eration to be executed. Yet, the herein description of the
procedures is applicable.
73092776 1
2. Loosen the suction rose support fastening screws

(1).
3. Loosen the suction rose (3) fastening screws (2) and
then remove the suction rose.
73092777 2
84465357 28/02/2011
B.60.A / 16
Oil pan - Install

1. Reassemble the suction rose (3) tightening the sup-

port fastening screws (1) and the screw (2) fixing the
suction rose to the prescribed torque setting.
73092777 1
2. Fit the new gasket (1) to the oil pan (2).
73092800 2
3. Assemble the oil pan (1) and fit the plate thereon (3).
Tighten the fastening screws (2) to the prescribed
torque setting.
73092776 3
84465357 28/02/2011
B.60.A / 17
Oil pan - Remove

1. Turn the engine upside down.

2. Remove the screws (2) and detach the oil pan (1).
3. Remove the oil pick up tube.
73092901 1
84465357 28/02/2011
B.60.A / 18
Oil pan - Install

1. Instal the oil pick up tube.

2. Mount the oil pan (1) and tighten the screws (2) to
the required torque.
NOTE: Before installing the pan, verify that the threads of
the holes and the screws are not worn and dirty.
73092916 1
84465357 28/02/2011
B.60.A / 19
Oil filter - Remove

1. Remove the oil filter (1) and the oil filter base (2).
73092765 1
84465357 28/02/2011
B.60.A / 20
Oil filter - Install

1. Install the oil filter support (1) and the oil filter (2).
73092765 1
84465357 28/02/2011
B.60.A / 21
Oil filter - Remove

73092894 1
84465357 28/02/2011
B.60.A / 22

73092894 1
84465357 28/02/2011
B.60.A / 23
Oil filter - Remove

93111635 1
84465357 28/02/2011
B.60.A / 24

93111635 1
84465357 28/02/2011
B.60.A / 25
Piston lubrication Spray nozzle - Remove

Prior operation:
1. Loosen the fastening screws (1) and disassemble

the oil nozzles (2).
73092821 1
Next operation:
Piston lubrication Spray nozzle - Install (B.60.A)
84465357 28/02/2011
B.60.A / 26
Piston lubrication Spray nozzle - Install

Prior operation:
Piston lubrication Spray nozzle - Remove (B.60.A)
1. Fit the nozzles (2) and tighten the fastening screws

(1) to the prescribed torque setting.
73092837 1
Next operation:
84465357 28/02/2011
B.60.A / 27
Oil cooler - Remove

1. Place a container under the heat exchanger (2) to
collect the cooling liquid contained therein.
2. Loosen the screws (1)and disassemble the heat ex-
changer unit (2).
73092769 1
84465357 28/02/2011
B.60.A / 28
Oil cooler - Install

1. Reassemble the heat exchanger (1) remember to re-
place the old gasket with a new one; tighten the fas-
tening screws (2) to the prescribed torque setting.
73092769 1
84465357 28/02/2011
B.60.A / 29
Oil line - Remove

1. Loosen the clip and disconnect the pipe (1).

2. Remove oil delivery pipe connected to the tur-
bocharger (2) and then the oil return pipe (3).
73092760 1
84465357 28/02/2011
B.60.A / 30
Oil line - Install

1. Reassemble the oil delivery pipe (2) and the return

pipe (1).
73092760 1
84465357 28/02/2011
B.60.A / 31
Oil line - Remove


73092892 1
84465357 28/02/2011
B.60.A / 32
Oil line - Install


pipe (1).
73092892 1
84465357 28/02/2011
B.60.A / 33
Oil line - Remove

1. Loosen the clip and disconnect the pipe (1).

93111630 1
84465357 28/02/2011
B.60.A / 34
Oil line - Install


pipe (1).
93111630 1
84465357 28/02/2011
B.60.A / 35
Index

Blowby re-circulation system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454C*A003
LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil cooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil filter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5C, F5A
Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5CE5454C*A003
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454C*A003
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5C, F5A
Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
84465357 28/02/2011
B.60.A / 36
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84465357 28/02/2011
B.60.A / 37
84465357 28/02/2011
B.60.A / 38
STARTING SYSTEM - 80.A

, F5CE9484C , F5CE9484E
84465357 28/02/2011
B.80.A / 1
Contents
TECHNICAL DATA
Cold start aid

FUNCTIONAL DATA
Cold start aid

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5CE5454C*A003
SERVICE
Cold start aid

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
84465357 28/02/2011
B.80.A / 2
ENGINE AND PTO IN - STARTING SYSTEM
Cold start aid - General specification

Protrusion length 30.4 mm +/- 0.25 mm

Diameter of heating element 4 mm +/- 0.1 mm
Heat up time to 850 °C Less than 5 s
Temperature T60 950 - 1010 °C
Switch on current at 11 V Less than 19 A
Operating current at 11 V after 20 s 5 A +/- 1.0 A
Runout heating element 0.4 mm
84465357 28/02/2011
B.80.A / 3
Cold start aid - Overview

93111647 1
A glow plug typically comprises a heating coil in a metal tube closed at one end and filled with electrically insulating
ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head
into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface
temperature of more than 1000°C within a few seconds. The air-fuel spray generated by the injection ignites close to
the glow plug and initiates combustion.
84465357 28/02/2011
B.80.A / 4
Engine starter - Overview

73092815 1
Manufacturer BOSCH
Electrical system 12 V
Rated output 3 kW (4 Hp)
84465357 28/02/2011
B.80.A / 5
Cold start aid - Remove

NOTE: Three glow plugs (1) have direct access and are easily removed.
NOTE: The fourth glow plug (2) requires removal of the turbo intake (3).
1. Disconnect electrical connections (A) and (B) and
move out of the way.
93111637 1
2. Remove the adjustable pipe connector bolt (4).
93111637 2
3. Loosen the lower pipe connector bolt (5).
93111637 3
84465357 28/02/2011
B.80.A / 6
4. Rotate the pipe (6) away from the intake.
93111638 4
5. Remove the four bolts (7) from the heat exchanger

to rear intake flange.
93111638 5
6. Remove the four bolts (8) from the top of the intake.
93111638 6
7. Loosen the two hose clamps (C) from the elbow hose
(9) and remove hose.
93111639 7
84465357 28/02/2011
B.80.A / 7
8. Remove the intake (3) and the spacer (10).
93111639 8
93111640 9
NOTE: Now you have free access to remove the fourth glow plug.
84465357 28/02/2011
B.80.A / 8
Cold start aid - Install

1. Install the four new glow plugs and torque to 8 N·m

(70.8 lb in) before installing the air intake manifold.
2. Replace the gaskets and install the spacer (1) and
air intake manifold (2).
93111639 1
3. Install the four bolts (3) through the top of the air
intake.
93111638 2
4. Install the four bolts (4) securing heat exchanger to

the rear air intake flange.
93111638 3
84465357 28/02/2011
B.80.A / 9
5. Install the elbow hose (5) and tighten the two hose
clamps (A) securing it from the turbo to the air intake.
93111637 4
6. Rotate the pipe (6) in and secure it to the air intake

(2) with the adjustable pipe connector bolt (7).
93111637 5
7. Tighten the lower pipe connector bolt (8).
93111637 6
8. Connect the two electrical connections (9).
93111637 7
84465357 28/02/2011
B.80.A / 10
Engine starter - Remove

1. Hold the starter (1), unscrew the fastening screws

and remove the starter.
73092761 1
84465357 28/02/2011
B.80.A / 11
Engine starter - Install

1. Fit the starter (1) and tighten the fastening screws to

the prescribed torque setting.
73092761 1
84465357 28/02/2011
B.80.A / 12
Engine starter - Remove

1. Hold the starter (1), unscrew the fastening screws

and remove the starter.
73092892 1
84465357 28/02/2011
B.80.A / 13
Engine starter - Install

1. Fit the starter (1) and tighten the fastening screws to

the prescribed torque setting.
73092892 1
84465357 28/02/2011
B.80.A / 14
Index

Cold start aid - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cold start aid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cold start aid - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cold start aid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine starter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5CE5454C*A003
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454C*A003
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84465357 28/02/2011
B.80.A / 15
New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2011 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
84465357 28/02/2011
SPECIAL TOOL INDEX
Genuine IU PAGE
380000134 [Valve Guide Seal Special tools 12
Installer - for use with 7.8L &
9.0L Cursor Engines]
380000150 [Top Dead Center Special tools 12
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000219 [Valve Guide Special tools 12
Remover/Installer - used on
4.5L & 6.7L NEF Engines -
Same as 291046]
380000220 [Piston Ring Special tools 12
Clamp (60 - 125 mm)]
380000221 [Piston Ring Pliers Special tools 13
(65 - 110 mm)]
Reemer - used on 4.5L & 6.7L
NEF Engines]
380000228 [Dial Gauge (0 - 5 Special tools 13
mm)]
380000302 [Cylinder Head Special tools 14
Valve Spring Compressor]
380000304 [Torque Tightening Special tools 14
Angle Gauges (1/2 Inch And
3/4 Inch)]
380000364 [Piston Protrusion Special tools 14
Check, Gauge Base]
380000667 [Camshaft Special tools 14
Bushing Remover And
Installer]
380000670 [Oil Filter Removal Special tools 15
Tool (NH F5C)]
380000978 [Motore NEF - Special tools 15
Vedi Allegato]
380000999 [Adaptor 7/16 Special tools 15
UNF Male]
380001006 [Cylinder Special tools 15
Compression Tester]
380000732 [Engine Turning Special tools 16
Tool]
380100072 [Special Tool] Special tools 16
380000134 [Valve Guide Seal Special tools 18
380000150 [Top Dead Center Special tools 18
10.3L & 12.9L (13L) Cursor
Engines]
Remover/Installer - used on
4.5L & 6.7L NEF Engines -
Same as 291046]
380000220 [Piston Ring Special tools 18
Clamp (60 - 125 mm)]
28/02/2011
17
Genuine IU PAGE
380000221 [Piston Ring Pliers Special tools 19
(65 - 110 mm)]
Reemer - used on 4.5L & 6.7L
NEF Engines]
380000228 [Dial Gauge (0 - 5 Special tools 19
mm)]
380000302 [Cylinder Head Special tools 20
380000304 [Torque Tightening Special tools 20
3/4 Inch)]
380000364 [Piston Protrusion Special tools 20
Check, Gauge Base]
380000667 [Camshaft Special tools 20
Bushing Remover And
Installer]
380000670 [Oil Filter Removal Special tools 21
Tool (NH F5C)]
380000978 [Motore NEF - Special tools 21
Vedi Allegato]
380000732 [Engine Turning Special tools 21
Tool]
380000999 [Adaptor 7/16 Special tools 21
UNF Male]
380001006 [Cylinder Special tools 22
Compression Tester]
380000150 [Top Dead Center ENGINE - Service instruction - Finding Top Dead Center B.10.A / 35
10.3L & 12.9L (13L) Cursor
Engines]
10.3L & 12.9L (13L) Cursor
Engines]
10.3L & 12.9L (13L) Cursor
Engines]
10.3L & 12.9L (13L) Cursor
Engines]
380000667 [Camshaft Camshaft Bushing - Replace B.10.A / 48
Bushing Remover And
Installer]
380000999 [Adaptor 7/16 Camshaft Bushing - Replace B.10.A / 48
UNF Male]
380100076 [Special Tool] Crankshaft Rear seal - Install B.10.A / 55
380000362 [Crankshaft Lifting Crankshaft - Remove B.10.A / 58
Hook]
380000304 [Torque Tightening Crankshaft Journal - Measure B.10.A / 63
3/4 Inch)]
380000362 [Crankshaft Lifting Crankshaft - Remove B.10.A / 68
Hook]
28/02/2011
18
Genuine IU PAGE
380000324 [110-150 Diameter Connecting rod and piston - Disassemble B.10.A / 77
Piston Ring Pliers]
380000221 [Piston Ring Pliers Connecting rod and piston - Assemble B.10.A / 82
(65 - 110 mm)]
380000220 [Piston Ring Connecting rod and piston - Install B.10.A / 83
Clamp (60 - 125 mm)]
380000304 [Torque Tightening Connecting rod and piston - Install B.10.A / 85
3/4 Inch)]
380002385 [Flywheel Crank Flywheel - Remove B.10.A / 86
Handle]
380002385 [Flywheel Crank Flywheel - Install B.10.A / 87
Handle]
380000304 [Torque Tightening Flywheel - Install B.10.A / 87
3/4 Inch)]
Handle]
Handle]
3/4 Inch)]
Handle]
Handle]
3/4 Inch)]
380000302 [Cylinder Head Cylinder head - Disassemble B.10.A / 99
380000134 [Valve Guide Seal Cylinder head - Assemble B.10.A / 103
380000302 [Cylinder Head Cylinder head - Assemble B.10.A / 103
380000150 [Top Dead Center Fuel injection pump - Remove B.20.A / 18
10.3L & 12.9L (13L) Cursor
Engines]
380000228 [Dial Gauge (0 - 5 Fuel injection pump - Timing adjust B.20.A / 21
mm)]
Kit IU PAGE
380000229 [Measuring Special tools 13
Adapter used with 380000228]
380000229 [Measuring Special tools 19
Adapter used with 380000228]
28/02/2011
19
New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2011 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
84465357 28/02/2011

Motor Iveco F5C PDF

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Motor Iveco F5C PDF

Uploaded by

Copyright:

Available Formats

F5AE5484A / F5AE9454A /

Printed in U.S.A. Part number 84465357

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

For engine equipped with an electronic control unit

Respect of the Environment

DESCRIPTION SIZE TORQUE

Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)

Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)

DESCRIPTION SIZE TORQUE

380000134 Valve guide gasket assembly tool

380000150 Tool for engine T.D.C. positioning

380000219 Valve guide disassembly and reassembly tool

380000220 Piston ring compressor - 60 - 125 mm, procure

380000221 Piston ring expander tool for removing and

380000222 Valve guide reemer

380000228 Dial gauge - 0 - 5 mm

380000229 Dial gauge holding tool for rotatory injection

380000302 Tool for engine valve disassembly and

380000304 Measuring device for angular torque, procure

380000364 Dial gauge holding base for miscellaneous

380000667 Camshaft bushing removal and installation tool

380000670 Oil filter removal tool

380000978 Rotary stand for overhauling units, use OEM

380000999 Handle for interchangeable bushing tools, use

380001006 Diesel engine cylinder compression tester,

380000732 Tool for rotating the engine flywheel, barring tool

380100072 Injection pump gear puller

380100074 Compression test adapter

380100075 Front main seal installation tool

380100076 Rear main seal installation tool

380000134 Valve guide gasket assembly tool

380000150 Tool for engine T.D.C. positioning

380000219 Valve guide disassembly and reassembly tool

380000220 Piston ring compressor - 60 - 125 mm, procure

380000221 Piston ring tool for disassembly and reassembly

380000222 Valve guide reemer

380000228 Dial gauge - 0 - 5 mm

380000229 Dial gauge holding tool for rotatory injection

380000302 Tool for engine valve disassembly and

380000304 Measuring device for angular torque, procure

380000364 Dial gauge holding base for miscellaneous

380000667 Camshaft bushing removal and installation tool,

380000670 Oil filter removal tool

380000978 Rotary stand for overhauling units, use OEM

380000732 Rotate the engine flywheel, engine barring tool

380000999 Handle for interchangeable bushing tools, use

380001006 Diesel engine cylinder compression tester,

380100072 Injection pump gear puller

380100073 Front crankshaft seal installation tool

380100074 Compression test adapter

380100076 Rear main seal installation tool

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A

ENGINE AND PTO IN - B

FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A

ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A

ENGINE AND PTO IN - B

Connecting rod and piston

Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36