Professional Documents
Culture Documents
Software Euro 3
NOTE for ASTRA
engines hardware and software Euro 3
Type of engine: F3BEE681_*B
IVECO Unetversity
Lungo Stura Lazio 15 / 19
10156 – Torino
Tel. 011.00.76279 – Fax 011.00.76237
1st Edition – 10 / 10
CONTENTS
Page
ON ROAD VEHICLES
TYPE SERIAL
NUMBER
F 3 B E 0 6 8 1 A ** B 0 0 1 -
Number of
li d
Number of stroke and cylinder position (0 = 4 stroke, vertical without SCR post-treatment)
Engine
A 540 hp / 2400 Nm
Engine range description
F3B
E 480 hp / 2200 Nm
B 430 hp / 2100 Nm
F3A
D 400 hp / 1900 Nm
TYPE SERIAL
NUMBER
F 3 B E 0 6 8 1 V ** B 0 0 1 -
Number of
li d
Number of stroke and cylinder position ((0 = 4 stroke, vertical without SCR post-treatment)
Engine
G 380 hp / 1800 Nm
Engine range description
V 420 hp / 1900 Nm
F3B
C 440 hp / 2100 Nm
E 480 hp / 2200 Nm
Type F2B
Bore mm 115
Stroke mm 125
Compression ratio 16 : 1
Maximum power kW 259
(352)
(BHP)
2400
rpm
Maximum torque Nm 1280
(kgm) (131)
Minimum speed of
engine with no load 525 50
rpm
Maximum speed of
engine with no load 2760 20
rpm
F2B
Type
TIMING GEAR
Begins before T.D.C. A 17°
Ends after B.D.C. B 31°
Operation
mm 0,35 0,45
X mm 0,35 0,45
Type F2B
TURBOCHARGING
Turbocharger type:
HOLSET variable geometry
HE 431 V
CAPACITIES
Capacity:
- engine sump at min level.
litres 12,5
kg 11,2
Lubricants – engine sump at max. level
litres 23
kg 21
– circulating quantity that does not
return to sump
litres 5
kg 4,5
– quantity contained in cartridge filter (to be
added when cartridge filter is
changed).
litres
kg 2,5
2,3
Injection Direct
Bore mm 125
Stroke mm 140
Minimum speed of
engine with no load
rpm. 550 50
Maximum speed of
engine with no load
rpm. 2550 20
Type F3A
TURBOCHARGING
Turbocharger type: HOLSET HE 531 V variable geometry
CAPACITIES
Capacity:
- engine sump at min level.
litres 17
Urania FE 5W30 kg 15,3
Urania LD 7 – engine sump at max. level
litres 25
kg 22,5
– circulating quantity that does not
return to sump
litres 7
kg 6,3
– quantity contained in cartridge filter (to be
added when cartridge filter is
changed).
litres
2,5
kg
2,3
F3BE0681G
F3BE0681C
F3BE0681A
F3BE0681V
F3BE0681E
Type
Bore mm 135
Stroke mm 150
Minimum speed of
engine with no load 525 25
rpm
Maximum speed of
engine with no load 2250 20
rpm
Type F3B
TURBOCHARGING
Turbocharger type: HOLSET variable geometry HE 551 V
CAPACITIES
Capacity:
- engine sump at min level. 20
litres 18
Urania FE 5W30 kg
Urania LD 5 – engine sump at max. level 28
litres 25,2
Urania Turbo LD
kg
– circulating quantity that does not
return to sump 7
litres 6,3
kg
– quantity contained in cartridge filter (to be
added when cartridge filter is
cartridge).
litres 3
kg 2,7
000551t
000552t
0052128t
000554t
A Turbocharger
B Blow – by valve
C Blow – by filter
D Flywheel
E Hole for inspecting flywheel positioning during adjustments
F Window for applying flywheel rotation tool
000555t
0053209t
1. PWM valve air filter – 2. Alternator – 3. Automatic belt tensioner – 4. Air conditioner
compressor – 5. Air conditioner compressor drive belt – 6. Viscostatic damping flywheel –
7. Fixed pulley – 8. Water pump – 9. VGT actuator – 10. Fan pulley – 11. Thermostat casing
0052131t
1. Compressed air outlet – 2. Oil filters – 3. Oil return pipe from turbocharger – 4. Water oil heat
exchanger – 5. Oil pressure adjustment valve – 6. Exhaust gas outlet – 7. Cam cover –
8. Exhaust manifold – 9. Turbocharger –
10. VGT actuator
0052132t
0053210t
1. Timing cover with blow-by filter and valve– 2. Compressor – 3. Starter motor – 4. Power
steering pump– 5. Feed pump – 6. Control unit EDC7 UC 31 – 7. Dipstick – 8. air conditioner
compressor – 9. Intake manifold – 10.PWM valve air cleaner – 11. Power steering fluid reservoir
– 12. Fuel filter with temperature sensor
0052134t
1. Exhaust manifold – 2. Fuel filler fitting – 3. Intake manifold – 4. Compressed air outlet –
5. Turbocharger – 6. Exhaust gas outlet
0053211t
1. PWM valve air filter – 2. Alternator – 3. Dipstick – 4. Automatic belt tensioner – 5. Air
conditioner compressor – 6. Air conditioner compressor drive belt – 7. Viscostatic damping
flywheel – 8. Fixed pulley – 9. Water pump – 10. Fan pulley - 11. VGT actuator –
12. Thermostat casing
0052136t
1. Compressed air outlet – 2. Oil filters – 3. Oil return pipe from turbocharger – 4. Water oil heat
exchanger – 5. Oil pressure adjustment valve – 6. Exhaust gas outlet – 7. Cam cover –
8. Exhaust manifold – 9. Turbocharger – 10. VGT actuator
0052137t
0053210t
1. Timing cover with blow-by filter and valve– 2. Compressor – 3. Starter motor – 4. Power
steering pump– 5. Feed pump – 6. Control unit EDC7 UC 31 – 7. Dipstick – 8. Air conditioner
compressor – 9. Intake manifold – 10.PWM valve air cleaner – 11. Power steering fluid reservoir
– 12. Fuel filter with temperature sensor
0052138t
1. Exhaust manifold – 2. Fuel filler fitting – 3. Intake manifold – 4. Compressed air outlet –
5. Turbocharger – 6. Exhaust gas outlet
000556t
The interchangeable, removable cylinder liners are wet-fitted in the engine block.
A water seal is achieved by means of 3 rubber rings fitted in the lower part of the cylinder
liners. Cylinder liner protrusion is adjustable by means of shims supplied as spares. The specific
method used to produce the liner internal finish and the undeformable structure of the means
that oil consumption is exceptionally low. The liner bore diameter is graded at source and falls
into one of two tolerance classes: class A and class B.
In the plant, each liner is matched with a piston of the corresponding class.
Only class A liners are available as spares.
45150
0051572t
0051573
1. Water/oil/diesel repellent black felt – 2. Low density porous layer reinforced with fibre glass
(thickness 10 mm) – 3. Carbon black felt
The main and connecting rod bearings on F3A and F3B engines are reinforced mechanically by
distributing ceramic dust throughout the antifriction material for greater durability
47557
Reinforcement bush
for pin
000441t
The range is lubricated by new sprays located inside the pistons. These incorporate a valve that
only allows oil through above a threshold pressure of 1.7 bars.
When the pressure in the lubrication system is below this threshold, the valve cuts the
lubrication (cooling) in this area to save oil for lubrication in more critical areas of the engine
(gears, roller bearings).
In F3A and F3B engines, the bushes have been fitted inside the piston hubs so that they can
withstand the higher mechanical stress (see drawing above).
The pistons have been modified to take reduced height piston rings that control fuel
consumption and oil vapours.
109080
109108
109045
X = 0.8 ± 0.15 mm
108837
60615
1. Connecting rod-piston assembly – 2. Area where installation position symbol stamped and
grading class – 3. Connecting rod stamp area
In addition to the matched class A piston-liner set, a single class A piston is also available. This
may also be matched to liners of different class on engines fitted to the in-service fleet.
47557
45150
000557t
000557t
000557t
002141t
CRANK
JOURN
000557t
CRANK
JOURN
000557t
STD.
1 2 3
- 0,127
000556t
CATEGORY
1 2 3 F2B
82,784
green/black green/black green/black 82,793
92,843
1 F3A
92,852
green/black green/black green/black
99,843
F3B
99,852
82,794
red/black green/black green/black F2B
82,803
92,853
2 red/black green/black green/black
F3A
92,862
99,853
F3B
99,862
82,804
F2B
82,814
red/black red/black green/black 92,863
F3A
3 92,873
red/black red/black green/black 99,863
F3B
99,873
CATEGORY 1 2 3
82,666
F2B
red red red 82,686
92,726
1 red red red
F3A
92,746
99,726
F3B
99,746
- 0,508
CATEGORY 1 2 3
82,412
F2B
82,432
red red red
92,472
F3A
1 red red red
92,492
99,472
F3B
99,492
Three markings are shown on the connecting rod body, in the position indicated “A”:
VIEW FROM
47557
- 0,127
CATEGORY
1 2 3 72,789
F2B
72,798
green/black green/black green/black 82,843
F3A
1 82,852
green/black green/black green/black 89,843
F3B
89,852
72,799
F2B
red/black green/black green/black 72,808
82,853
F3A
2 red/black green/black green/black
82,862
89,853
F3B
89,862
72,809
F2B
red/black red/black green/black 72,818
82,863
3 F3A
82,873
red/black red/black green/black
89,863
F3B
89,873
CATEGORY 1 2 3 72,671
F2B
72,680
82,726
F3A
82,735
red green green 89,726
F3B
89,735
1 red green green
72,681
F2B
72,691
82,736
F3A
red red green 82,746
89,736
2 red red green
F3B
89,746
- 0,508
CATEGORY 1 2 3
72,417
F2B
72,426
82,472
F3A
red green green 82,481
89,472
1 red green
F3B
89,481
green
72,427
F2B
72,437
82,482
F3A
red red green 82,492
89,482
2 red red
F3B
89,492
green
000558t
45254
0052129t
000561t
781
VALVE SPRINGS
F2B engine
109107
F3A engine
109060
F3B engine
108842
A I S A I S A I S A I S A I S A I S
44925
000562t
A Rocker shaft
B Rocker shaft bolt
C Intake valve rockers
D Rocker for pump injector
E Exhaust valve rockers
F Valve
G Adjustment screw
H Bridge
A CAMSHAFT gear
B Upper intermediate gear
C Lower intermediate gear
D Crankshaft gear
E Oil pump gear
000564t
1 Adjustable rod
2 Intermediate gear
3 Bolts
4 Oil pump
47597
000565t
60668
1-6
102650
108845
The Cursor engine lubrication circuit includes a system for lowering oil temperature by means of
a heat exchanger.
The oil is pressurised by a gear pump located behind the flywheel and is sent directly to the
heat exchanger that is washed by the engine coolant and adjusts its temperature to an optimum
level.
This adjustment is possible by reducing the oil temperature (directing it all through the heat
exchanger) or increasing the temperature (directing it through the by-pass thermostatic valve).
The fluid is directed from the heat exchanger output to two filters and then again to the engine
block to lubricate the anti-friction components.
The lubrication system is equipped with a oil vapour (blow-by) recovery system consisting of a
condenser, a filter and a safety valve. This system is located in the upper part of the timing
system cover.
Pressurised oil
Gravity-fed oil
DETAIL A
Pressurised oil
Gravity-fed oil
44918
Pressurised oil
Gravity-fed oil
DETAIL A
Pressurised oil
Gravity-fed oil
60672
0051579t
0051580t
001340t
1. Delivery to turbocharger – 1a. Return from turbocharger- 2. Oil filter by-pass valve (2 bar) –
3. Thermostat – 4. Pressure relief valve (5 bar) – 5. Safety valve (10 bars) on oil pump – 6. Oil
pump – 7. Crankshaft– 8. Lubrication fittings for gear bearings – 9. Piston sprays – 10. Cylinder
head - 11. Engine brake solenoid
0051581t
47573 60665
47447 87205
DEMONSTRATION FIGURE
78950
1. Oil temperature sensor- 2. Oil pressure sensor for pressure gauge - 3. Sending unit for low
pressure warning light bulb - 4. By-pass valve - 5. Thermostat valve.
92843
44915
60631
ENGINE COLD
45357
ENGINE WARM
ENGINE COLD
0052139t
ENGINE WARM
0052306t
The fan offers two possible effective rotation speeds controlled by the Front Frame Computer by
exciting the air solenoid for the slow speed and coil (11) for the second speed. When neither the
first nor second speed is engaged, the fan turns slowly due to the friction (neutral position).
The following parameters/systems may require fan activation via the B.C. control unit:
coolant temperature
climate control system coolant temperature
Intarder
8.5 bar
0052307t
When fan activation is not required for efficient engine operation, the Front Frame Computer
control unit drives the air solenoid to move piston (8). Piston (8) is displaced to move permanent
magnets (3) away from fan hub (2). The magnetic field generated by magnets (3) is insufficient
to drive fan hub (2).
The fan may turn slowly due to the friction present.
0052308t
When first speed operation is required, the Front Frame Computer discharges air from duct (10)
through the air solenoid.
Piston (8) is displaced to move permanent magnets (3) away from fan hub (2). Piston
movement is generated by return spring (7) and blades (4).
Shaft rotation speed is equal to the speed of pulley (1) and the effect of the magnetic field
generated by magnets (3) causes fan hub (2) to turn to a top speed of 650 rpm.
For F2B engines, the first speed is always engaged because the air solenoid and the air
discharge system inside the unit are not present.
0052309t
When the first speed is insufficient to cool the engine effectively, the Front Frame Computer
control unit governs activation of the second fan by exciting coil (11).
The magnetic field generated by the coil attracts floating ring (9) of fan hub (2) to pulley (1) until
both units are joined together.
In this situation, fan speed is equal to pulley speed.
Steering
Wheel
Interface
Solenoid
fan
Front Body
Frame Computer
Computer
Fan coil
Pressure
switch Climate control
climate control system
Sensor
EDC Temperature
Water
0052256t
Troubleshooting
Defect Cause
The fan always turns at first speed Air supply pipe blocked
Air supply pipe blocked
The fan does not turn faster than 650 rpm The control unit outlet does not drive the
(first speed) coil
Break in control unit/coil wiring
Coil short-circuited
Incorrect sliding of mechanical parts
The fan always turns at second speed Control unit outlet always drives the coil
Incorrect sliding of mechanical parts
77469
In rest condition, gap X between pulley (1) and floating ring (2) (subject to wear) must be
between 0.5 and 1.2 mm.
Wear up to a maximum gap thickness of 2.5 mm is permitted.
60675
Principle of operation
Irrespective of the turbocharger type, the basic concept is to use exhaust gas pressure (turbine)
to compress combustion air (compressor) entering the chambers. This solution increases the
engine's volumetric efficiency.
The operating principle of the variable geometry turbocharger is described below because it is
more complex and used on all ranges.
80 Course ME22 ETH – Ed.1 – 10/10
Turbocharger with wastegate
HOLSET HX 50W
The following diagram shows the principle of operation.
002863t
001228t
1. Air intake – 2. Gasket – 3. Piston – 4. Outer spring – 5. Inner spring control disc – 6. Inner
spring – 7. O – Ring – 8. Spring holder– 9. End stop – 10. Dust seal - 11. Control rod
0052917t
1. Service reservoir
2. Shut off solenoid
3. Air filter
4. VGT solenoid
5. Turbocharging pressure sensor (located upstream of compressor)
6. Turbine actuator
7. Turbine rpm sensor
8. EDC control unit
9. Body Computer
10. Switch
001412t
001413t
C Exhaust cam
0053204t
A Normal engine operation: the roller slides the line and only meets the main valve
riser.
A2 is normal operating clearance (0.40 ± 0.05 mm when cold for Cursor 8, 0.50 0.05
Cursor 10, 0.60 0.05 Cursor 13), measured exactly at the engine brake riser, i.e. at
TDC. The graph also clearly shows the reason why the clearance is not as set when it
is checked with the cam in other positions.
For example, the value at A1 is:
about 1.7 mm when cold (Cursor 8);
about 1.8 mm when cold (Cursor 10);
about 1.9 mm when cold (Cursor 13).
000593t
p= (2 ÷ 5) bar
The features on the Cursor EURO 3 range are the same of the Euro 4 range:
Addition of a pressure damper to reduce pressure peaks in the delivery pipe to the
injectors;
filter element volume increase;
changes in the control unit intake, pump intake and cylinder head intake pipes.
Take particular care that the fuel emerging from the bleed screw on the cylinder head
does not contaminate the fan, water pump and the alternator and air conditioner drive
belts. Risk of damage.
F2B engines
The Cursor 8 Euro 3 range pump-injector is the same of that used in the Euro 4/5 range.
000578t
The Cursor ETH Euro 3 range injector is the same of that used in the Euro 4/5 range.
108843
Because the injection pressure of the new UIN 3.1 pump injectors is higher, they spray the fuel
more finely into the exhaust chamber to improve combustion and thus reduce polluting exhaust
emissions.
OLD
102935
Use tool 99342155 to remove the pump - injector from the cylinder head as follows:
attach part (3) of tool 99342155 to the pump-injector (4);
fit part (2) to part (3), resting part (2) on the cylinder head;
tighten nut (1) and remove pump-injector (4) from the cylinder head.
0051576t
60520
001339t
0053205t 45376
C D
45269 45264
E1 E2
45260 73533
F G
45261 60575
106535
D) The camshaft timing is correct if the specified cam lift values (see table, point C)
correspond to the following conditions:
1. The hole with one notch (5) is visible from the inspection window.
2. Tool 99360612 (1) fits into hole (3) on flywheel (4) through engine rpm sensor seat
(2).
77259
60575 77259
(FIGURE A) (FIGURE B)
77260
44,936A
The figure represents the option chosen for Cursor 8 engines (pump-injector with non-coaxial
coil). The procedure described below applies to all Cursor engines.
Adjust the piston of the cylinder for which the clearance is to be adjusted to TDC at the end of
the compression stroke. The valves of this cylinder are closed while both valves of the
symmetrically opposite cylinder are open.
The symmetrical cylinder pairs are 1 – 6, 4 – 3 e 2 – 5.
To carry out these operations correctly, proceed as described below, using the information
given in the table overleaf.
FIRING ORDER 1 – 4 – 2 – 6 – 3 – 5
To carry out the above adjustment correctly, it is essential to carry out the sequence
shown in the table on the page alongside. At each rotation phase, check the accuracy
of the position by inserting pin 99360612 in the 11th hole of each of the three 18-hole
sectors.
mm
Cylinder liners:
outer diameter:
upper 130,161 130,186 141,961 141,986 153,461 153,486
2
lower 128,475 128,500 139,890 139,915 151,890 151,915
length - - -
Cylinder liners–
engine block seats
upper 0,014 0,064 0,014 0,064 0,014 0,039
lower 0,010 0,060 0,085 0,135 0,085 0,135
Outer diameter 2 - - -
Cylinder liners:
A* 115,000 115,012 125,000 125,013 135,000 135,013
outer diameter 3
B* 115,010 115,022 125,011 125,024 135,011 135,024
Protrusion X 0,035 0,065 0,045 0,075 0,045 0,075
* Selection class
Pistons:
measurement height X 18 18 18
outer diameter 1 A* 114,871 114,883 124,861 124,873 134,861 134,873
outer diameter 1 B* 114,881 114,893 124,872 124,884 134,872 134,884
pin seat
*Supplied as spares 46,010 46,018 50,010 50,016 54,010 54,018
** Only production.
Piston diameter 1 - - -
Piston pin – piston seat 0,010 0,024 0,010 0,022 0,010 0,024
FEDERAL MAHLE
MOGUL■ PISTON▲
1,583 1,583
X1* 2,098 2,128* 2,427*
1,613
PISTONpin grooves X2 1,554 1,550 1,550 1,570 1,550 1,570
1,574 1,570
X3 4,020 4,040 5,020 5,040
4,02 4,04
* measured on diameter of 111 * measured on * measured on
mm (F2B) 120mm 130mm
Piston rings:
trapezoid seal S1* 1,429 1,473 1,929 1,973 2,296 2,340
sealing lip S2 1,470 1,500 1,470 1,500 1,470 1,500
milled oil scraper with
slots and internal
spring S3
3,970 3,990 3,970 3,990 4,970 4,990
*meas. 2 mm from ext. (F2B-
F3A)
*meas. 2.5 mm from ext. (F3B)
1 0,247 0,311■ 0,125 0,199 0,087 0,131
1 0,111 0,175▲
Piston rings - grooves 0,054 0,104■ 0,050 0,100 0,050 0,100
2
0,050 0,100▲
2 0,030 0,070 0,030 0,070
0,030 0,065
3
APiston ring end opening
in cylinder liner:
X1 0,30 0,40 0,35 0,45 0,40 0,50
X2
X3 0,55 0,70 0,60 0,75 0,65 0,80
0,35 0,65 0,35 0,65 0,40 0,75
Small end bush seat
1 49,975 50,000 54,000 54,030 59,000 59,030
Connecting rod bearing
seat 2 Nominal 77,000 77,030 87,000 87,030 94,000 94,030
value
1 77,000 77,010 87,000 87,010 94,000 94,010
Selection categories 2 77,011 77,020 87,011 87,020 94,011 94,020
3 77,021 77,030 87,021 87,030 94,021 94,030
Connecting rod small end
bush diameter
outer 4 50,055 50,080 54,085 54,110 59,085 59,110
mm
Main journals 1 Nominal value 82,910 82,940 92,970 93,000 99,970 100,000
1 82,910 82,919 92,970 92,979 99,970 99,979
Selection category 2 82,920 82,929 92,980 92,989 99,980 99,989
3 82,930 82,940 92,990 93,000 99,990 100,000
Main journals 3 Nominal value 89,000 89,030 99,000 99,030 106,300 106,330
1 89,000 89,009 99,000 99,009 106,300 106,309
Selection category 2 89,010 89,019 99,010 99,019 106,310 106,319
3 89,020 89,030 99,020 99,030 106,320 106,330
STD, 0,040 0,098 0,060 0,108
Half-bearings - - 0,127 0,040 0,098 0,050 0,090 0,061 0,119
main journals -0,254, -0,508 0,040 0,110 0,060 0,130
STD, 0,035 0,093 0,050 0,108
Half-bearings – - 0.127 0,035 0,093 0,040 0,080 0,051 0,109
crankpins -0,254, -0,508 0,035 0,083 0,050 0,098
Main bearing halves 0,127 – 0,254 – 0,508 0,127 – 0,254 – 0,508 0,127 – 0,254 – 0,508
Connecting rod bearing half 0,127 – 0,254 – 0,508 0,127 – 0,254 – 0,508 0,127 – 0,254 – 0,508
Thrust half-rings
(thickness) X3 3,38 3,43 3,38 3,43 3,380 3,430
Parallelism 1–2 0,010 0,025 0,025
Concentricity 1–2 0,040 0,040 0,040
mm
Valve guides and seats on head 0,015 0,045 0,015 0,045 0,015 0,045
Valves:
4 7,970 7,985 8,960 8,975 9,960 9,975
60° 30’ 7’ 30” 60° 30’ 7’ 30” 60° 30’ 7’ 30”
4 7,970 7,985 8,960 8,975 9,960 9,975
45015' 45° 30’ 7’ 30” 45° 30’ 7’ 30”
Valve stem and associated guide 0,038 0,068 0,040 0,070 0,040 0,070
mm
Valve spring
height:
free spring H 80
66 76
under load of:
H1 62 (600N 33N)
H2 49.5 (540N 27N) 59 (775N 39N)
48.8 (1140N
37.5 (966N 48N) 46 (1366N 68N)
57N)
Camshaft mounting
journals:
17 75,924 75,940 82,950 82,968 82,950 82,968
Outer diameter of
camshaft bushes:
Rocker shaft
37,984 38,000 41,984 42,000 41,984 42,000
1
mm
Seats for bushes in
rockers:
Stage one:
outer bolt
FRONT
pretightening
SIDE (25 Nm)
44897
Stage two:
FRONT inner bolt
SIDE pretightening
(140 Nm)
44898
Stage three:
tightening of
FRONT inner bolts
SIDE through
60°
44898
Stage four:
tightening of
FRONT inner bolts
SIDE through
60°
44898
Stage five:
FRONT tightening of
SIDE outer bolts
through
90°
44899
44900
45359
45360
SEQUENCE: Pretightening 4 – 3 – 1 –2
Tightening 1 – 4 – 2 –3
45361
45362
45363
PART TORQUE
Nm kgm
Bolts securing engine block base to engine block (see fig. 8)
Outer bolts M12 x 1.75 Stage one: pretightening; 30 3
Inner bolts M 18 x 2 Stage two: pretightening; 120 12,2
Inner bolts M 18 x 2 Stage three: angle tightening 60°
Inner bolts M 18 x 2 Stage four: angle tightening 55°
Outer bolts M12 x 1.75 Stage five: angle tightening 60°
Piston cooling nozzle fitting 35 2 3,5 0,2
Bolts securing heat exchanger to engine block (see fig. 12)
Pretightening 11,5 3,5 1,15 0,35
Tightening torque 19 3 1,9 0,3
Bolts securing suction head to engine 24,5 2,5 2,5 0,25
block base
Bolts securing spacer and oil sump (see fig. 13)
Pretightening 38 3,9
Tightening torque 45 4,6
Bolts securing gear casing to engine block M 12 x 1.75 63 6,4
Bolts securing control unit to engine block base 24 2,5 2,4 2,5
Cylinder head bolt: (see Figure 9)
First stage Pretightening 60 6,1
Second stage Pretightening 120 12,2
Stage three Angle tightening 90°
Stage four Angle tightening 65°
Rocker shaft bolt
First stage Pretightening 80 80,2
Second stage Angle tightening 60°
Lock-nut for rocker adjustment screw 39 0,5 3,9 0,5
Bolts for injector brackets 26 2,6
Bolts securing thrust plates to head 19 3 1,9 0,3
Bolt securing engine mounting bracket to cylinder head
First stage Pretightening 120 12,2
Second stage Angle tightening 45°
PART TORQUE
Nm kgm
Bolt securing engine mounting bracket to flywheel casing
First stage Pretightening 100 10,2
Second stage Angle tightening 60°
Bolt for camshaft gear:
First stage Pretightening 60 6
Second stage Angle tightening 60°
Bolts securing phonic wheel to camshaft gear 8,5 1,5 0,85 0,15
Exhaust manifold bolts (see fig. 10)
Pretightening 40 5 40,1 0,5
Tightening torque 70 5 7,1 0,5
Engine brake actuator cylinder bolts 19 1,9
Connecting rod cap bolts:
First stage Pretightening 60 6,1
Second stage Angle tightening 60°
Flywheel bolts:
First stage Pretightening 120 12,2
Second stage Angle tightening 90°
Damping flywheel bolts:
First stage Pretightening 70 7,1
Second stage Angle tightening 50°
Intermediate gear pin bolts:
First stage Pretightening 30 3
Second stage Angle tightening 90°
Bolts securing idler gear adjustment connecting rod 24,5 2,5 2,5 0,25
Oil pump bolts 24,5 2,5 2,5 0,25
Crankshaft seal cover bolts 24,5 2,5 2,5 0,25
Fuel filter/pump bolts 19 1,9
Bolts and nuts securing turbocharger (see fig. 11)
pretightening 35 3,6
tightening 46 4,7
Water pump bolts 25 2,5
Bolts securing fan hub to spacer 30 3
Bolts securing fan spacer to pulley 30 3
Bolts securing fan mount to engine block 100 10,2
Fixed tensioner bolt 10,5 0,5 1 0,05
Automatic belt tensioner bolt 50 5 5,1 0,5
Bolts securing fixed pulley for auxiliary drivebelt to engine block 105 5 10,5 0,5
Starter motor bolts 74 4 7,4 0,4
Air heater bolts 30 3 3 0,3
Air compressor bolts 74 4 7,5 0,4
Injector wiring nuts 1,64 0,28 0,164 0,028
PART TORQUE
Nm kgm
Air compressor drive gear nut 170 10 17 1,7
Alternator bolt: M10 1.5 L = 35 mm 44 4 4,5 0,4
M10 1.5 L = 60 mm 44 4 4,5 0,4
Power steering pump bolts 46,5 4,5 4,65 0,45
Air conditioner compressor/mount bolts 24,5 2,5 2,45 0,25
Guard bolts 24,5 2,5 2,45 0,25
Filter blocked sensor fastening 55 5 5,5 0,5
Fuel/water temperature sensor fastening 35 3,5
Thermometric sending unit/switch fastening 25 2,5
Air temperature sending unit fastening 35 3,5
Pulse sending unit fastening 82 0,8 0,2
Engine brake solenoid fastening 32 3,2
Stage one:
FRONT SIDE external bolt
pretightening
60592
Stage two:
FRONT SIDE inner bolt
pretightening
:
60593
Stage three:
FRONT SIDE tightening of
inner bolts
through angle
60593
60593
Stage five:
FRONT SIDE tightening of
outer bolts
through angle
60594
60580
60581
60581
60582
SEQUENCE: Pretightening 4 – 3 – 1 –2
Tightening 1 – 4 – 2 –3
60666
60583
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99340051 X
Tool for removing front
crankshaft seal
99340053 X X
99340052 X
Tool for removing rear crankshaft
seal
99340054 X X
99346245 X
Tool for fitting front crankshaft
seal
99346250 X X
99346246 X
Tool for fitting rear crankshaft
seal
993462260 X X
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99360177 X
Plugs (6) protecting injector
seats
99360180 X X
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99360262 X
Plate for removing and refitting
engine valves (use with
99360261)
99360263 X
99360288 X
Drift for removing valve guides
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99360328 X
Installing tool for fitting seal to
valve guide
99360329 X
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99360337 X
Plate for compressing cylinder
liners (use with 99360334 -
99360336)
99360338 X
99360487 X
Drift for removing and refitting
camshaft bushes
99360499 X X
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99365054 X
99365056 X X
99378101
99378102
Drifts for stamping engine
99378103
identification plates (use with X X X
99378104
99378100)
99378105
99378106
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99390310 X
99390330 X
99394014 X
Guide bush (use with 99394041
or 99394043)
99394015 X X
DESCRIPTION MODEL
TOOL NO.
F2B F3A F3B
99395215
X
99395219 X
99396033 X
Crankshaft front seal cover
locating ring
99396035 X X
Page
A B
73652/A
The wiring used for the various CAN lines present on the vehicle comes in the form of twisted
wires. This configuration has been chosen to eliminate electrical signal interference.
BLACK VDB/SB
YELLOW ECB
GREEN ICB
GREY BCB
WHITE FMB
BLUE IDB
Body Computer
7 12
J2
1 6
74206
0Ω ~ 60 Ω ~ 120 Ω O.L.
CAN line short-circuited CAN line OK Heater coil line interrupted CAN line interrupted
BM
OBD II
Connector
VCM FMS
FMB Connector
E
C B
ECM MTCO/DTCO C CLIMATE
B
Diagnostic B
Connector EM ACC
AHT_A
VDB
FFC
ALLISON RFC
EUROTRONIC II
AHT_W
0056331t
KEY:
BC Body Computer
DDM Driver Door Module
PDM Passenger Door Module
BM Bed Module
CLIMATE Climate control system
FFC Front Frame Computer control unit
RFC Rear Frame Computer
AHT-A Air heater, located to the right rear of the cab
AHT-W Water heater, located in the right front wheel arch, near the FFC
MTCO/DTCO Tachograph/Digital tachograph
VCM Vehicle Control Module
IC Cluster
ABS ABS control unit
INTARDER Intarder control unit
ECAS Air suspension control unit
EUROTRONIC II Eurotronic II automatic transmission control unit
ACC ACC (Adaptive Cruise Control) radar control unit
ECM Engine control unit (EDC7 UCI31)
OBD II Connector 16 pin coupling for OBD (on board diagnosis)
SWI Steering Wheel Interface control unit
EM Expansion Module
RADIO Radio
FMS Connector FMS connector (bodybuilders)
MTCO/DTCO
BC
Diagnostic
IC Connector
VDB
VCM
EUROTRONIC II
0056332t
Specifications:
Data transmission speed 250,000 ( BITS/SEC)
Wiring colour black
Number of ECUs connected 3-8
BCB (Body Control Bus) communication line
Allows communication between the engine control units and sensors. It is connected to the
following control units: EDC , VCM, and OBD connector.
VCM
ECB
OBD II
Connector
EDC7
0056333t
Specifications:
Data transmission rate 250,000 (BITS/SEC)
Wiring colour Yellow
Number of ECUs connected 3÷8
Course ME22 ETH – Ed.1 – 10/10 142
MAIN ELECTRICAL COMPONENTS
116829
It also allows:
interfacing with other on-board electronic systems;
EOL programming;
diagnostics.
Fuel metering
Fuel metering is calculated on the basis of:
accelerator pedal position or user request;
engine rpm;
intake air quantity.
The result may be corrected on the basis of
coolant temperature
or to prevent:
noise;
fumes;
overloads;
overheating;
turbine over-revving.
Delivery may be altered in the case of:
engine brake operation;
action of external devices (ASR, speed limiter etc.);
serious faults that involve a reduction in load or stalling of the engine.
After calculating the intake air mass by measuring volume and temperature, the control unit
calculates the corresponding mass of fuel to be injected in the relevant cylinder (mg. per
delivery stroke) taking into account also diesel temperature.
The fuel mass calculated in the this way is first converted into a volume (mm3 per delivery
stroke) and then in crank degrees, i.e. injection duration This duration is dependent on engine
speed. Fuel metering is mapped in the EDC7 UC31 control unit on the basis of torque demand
associated with accelerator pedal position. To obtain this torque, the control unit monitors the
engine rpm and the amount of air taken into the cylinders.
Engine speed;
Turbo air pressure/flow.
De-rating
If the engine overheats, the injection is altered to reduce engine performance (torque). The four
graphs below shows the torque limitation trend plotted against coolant, oil, turbo air and fuel
temperature.
0054203t
0054204t
Engine starting
When the engine is first cranked, the timing signals and cylinder no. 1 recognition signals are
synchronised (flywheel sensor and camshaft sensor). The accelerator pedal signals is ignored
upon start-up. Start-up output is set exclusively on the basis of engine temperature by means of
a special map. When the control unit detects an rpm number and flywheel acceleration that
suggests the engine has not started and is no longer cranked by the starter motor, it re-enables
the accelerator pedal.
Cold starts
When even one of the three temperature sensors (coolant, air or diesel) records a temperature
lower than 10°C, pre-post heating is activated.
When the ignition contact is turned on, the preheating warning light comes on and remains on
for a variable period according to the temperature (as the coil at the intake manifold heats the
air) before starting to flash. At this point the engine may be started.
When the engine is running, the warning light goes off while the coil continues to be supplied for
a certain period (variable), to perform the post heating function.
If, with the warning light flashing, the engine is not started within 20 25 seconds (disattention
time), the operation is cancelled in order not to take charge from the battery without any reason.
The preheating curve also varies according to battery voltage.
Run up
When the ignition is turned on, the control unit transfers information stored when the engine was
shut down to its main memory (see: After run), and tests the system.
After Run
Whenever the engine is turned off by means of the ignition key, the control unit is supplied for a
few more seconds by the main relay.
This allows the microprocessor to transfer some data from the main menu (volatile) to a non-
volatile memory that can be deleted and rewritten (Eeprom) to make them available at the
subsequent start-up (see: Run up).
This data consists essentially of:
various settings (engine idle, etc.)
calibration of certain components
fault memory.
The procedure lasts several seconds, typically 2 to 7 (depends on the quantity of data to be
saved). After this the ECU sends a control to the main relay and causes disconnection from the
battery.
ATTENTION!
It is very important that this procedure should not be interrupted, e.g. by disconnecting the
engine using the battery disconnector or disconnecting the battery disconnector until at least 10
seconds have elapsed from engine shut down.
If this happens, the system remains in operation until the fifth incorrect shutdown (even if it is
not consecutive). After this, an error is stored in the fault memory and the engine operates in
recovery mode at the next start-up while the EDC warning light stays on.
Repeated breaks in the procedure could cause damage to the control unit.
Cut - off
This function stops fuel delivery during deceleration, during engine braking etc.
Synchronization Search
If the camshaft sensor signal is not present, the control unit can still
identify the cylinders into which fuel should be injected.
If this occurs when the engine is already running, the combustion sequence has already been
downloaded and the control unit therefore continues following the sequence for which it has
been synchronised.
If it occurs with the engine off, the control unit energises a single solenoid. Within no more than
2 crankshaft revolutions, an injection will take place in that cylinder and then all the control unit
has to do is synchronise with the firing order and start the engine.
Fuel metering
Because the ECU accurately monitors the fuel pressure in common rail systems (rail pressure),
a single map is required to determine injection duration.
The inputs are rail pressur (hPa) and injection output (mm³/injection).
The output is an injection time (µs) that may be obtained by means of a direct command from
the control unit.
Once the amount of fuel for injection and pre-injection has been defined, the control unit
recalculates the output for both at each cycle. This calculation is based on fuel density (set at
835mg/mm³)
0056334t
Key
1) 85150 EDC7 UC31 control unit
2) 72021 30-pin coupling for electrical connection to tester on ground
3) 25222 Relay enabling thermal starter activation
4) 48035 Engine rpm sensor
5) 78248 Variable geometry turbine control solenoid
6) 48042 Engine rpm sensor on timing system
7) 48043 Turbocharger speed sensor
8) 42030/47032 Oil temperature and pressure sensor
9) 85156 Turbo air temperature and air pressure sensor for EDC.
10) 85153 Coolant temperature sensor for EDC
11) 47042 Fuel temperature sensor
12) 78247 Solenoid for electronic injection
13) 78050 Solenoid controlling engine brake
Course ME22 ETH – Ed.1 – 10/10 150
EDC7 UC31 electronic control unit pin out
0051261t
N.B.: the EDC7 UC31 control unit is fitted directly on the engine via a heat exchange that allows
cooling. The control unit is fitted by means of flexible blocks to reduce vibrations from the
engine.
the EDC7 UC31 is protected by a fuse (30 A) located inside a supplementary fuse carrier box
(75000 - fuse n°3), located near the battery compartment.
The main relay normally used to supply the system is located inside the control unit.
N brown brown
Y yellow yellow
O orange orange
E grey grey
K pink pink
1 5
0050710t
Wiring
Wiring
ECU colour Function Function
colour
PIN F3A / F3A / B F2B
F2B
B
1 - Free B Cylinder 5 electronic injection solenoid
Free Cylinder 6 electronic injection
2 - B
solenoid
Cylinder 4-5-6 electronic injection B Cylinder 4 electronic injection solenoid
3 B
solenoid
4 - Free W Cylinder 1 electronic injection solenoid
5 - Free G Cylinder 3 electronic injection solenoid
6 Y Cylinder 2 electronic injection solenoid R Cylinder 2 electronic injection solenoid
7 O Engine brake control solenoid O Engine brake control solenoid
8 N Engine brake control solenoid N Engine brake control solenoid
9 - Free
10 - Free
Cylinder 1-2-3 electronic injection Y Cylinder 2 electronic injection solenoid
11 R
solenoid
12 G Cylinder 3 electronic injection solenoid R Cylinder 3 electronic injection solenoid
13 W Cylinder 1 electronic injection solenoid R Cylinder 1 electronic injection solenoid
Cylinder 4 electronic injection solenoid U Cylinder 4 electronic injection
U
14 solenoid
Cylinder 6 electronic injection solenoid Cylinder 6 electronic injection
15 E G
solenoid
16 P Cylinder 5 electronic injection solenoid P Cylinder 5 electronic injection solenoid
B black black
R red red
U blue blue
W white white
P purple purple
G green green 4
5
N brown brown
Y yellow yellow
O orange orange
E grey grey
K pink pink
1 3 23 30 36 29
0050712t
ECU Wiring
Function
PIN colour
1 N Variable geometry turbine control solenoid
2 - Free
3 B Variable geometry turbine control solenoid
4÷8 - Free
9 W Timing flywheel sensor
10 R Timing flywheel sensor
11 ÷ 14 - -
15 K Engine coolant temperature sensor
16 ÷ 17 - Free
Free
18 O/B Fuel temperature sensor
19 B Flywheel sensor
20 N Turbocharger speed sensor
21 ÷ 22 - Free
23 W Flywheel sensor
24 N Engine oil pressure/temperature sensor
25 W Air temperature/pressure sensor power supply
26 Y Engine coolant temperature sensor
27 O/B Oil temperature signal from engine oil pressure/temperature sensor
28 U Oil pressure signal from engine oil pressure/temperature sensor
29 - Free
30 W Turbocharger speed sensor
31 - Free
32 O Engine oil pressure/temperature sensor power supply
33 R Air temperature/pressure sensor power supply
34 G Air pressure signal from air pressure/temperature sensor
35 W/R Fuel temperature sensor
36 O Air temperature signal from air pressure/temperature sensor
71 89 72 54 6 11
1
7
12
53 35 18 36 17
0050711t
Pin
Wire Function
ECU
2 7151 Positive +30
3 7151 Positive +30
5 0150 Earth
6 0150 Earth
8 7151 Positive +30
9 7151 Positive +30
10 0150 Earth
11 0150 Earth
12 0094 Earth enabling preheating activation
29 5163 EDC system diagnosis request switch power supply (wiring)
34 Gn/Ve ECB CAN L line
35 WS/BI ECB CAN H line
40 8015 +15
75 9164 Preheating relay excitation signal for EDC
85 0163 EDC diagnostic switch power supply
89 2298 EDC control unit K line
0051662t
0051661t
0056335t
A: injector current
B: injection pressure
injector current/pressure
Camshaft position
During cold starting and heating (engine temperature less than 60ºC), the injection may be
carried out earlier, depending on water, oil and intake air temperature values.
0052247t 0052246t
Filling
000579t
Injection
000580
000581
N.B.:
The figures are an approximate guide to the principle of operation.
The component design and diesel flow pathway are different in reality.
Connector ST – E pinout
CURSOR 8 CURSOR 10 - 13
PIN WIRE FUNCTION PIN EDC PIN WIRE FUNCTION PIN EDC
0052248t
000688t
000689t
000690t
ST - E
000691t
000692t
System components
0052251t
1. Engine brake solenoid - 2. Engine brake switch - 3. Duplex control valve (main/secondary
brake switch) - Switch for engine brake provision -
5. Body Controller – 6. Engine brake engagement warning light – 7. Instrument Cluster
108401
Position 0 - off
Position 1 - on
Position 2 - on
Position 3 - on
Position 4 - on
Position 5 - on
Position 6 - on
The intarder activation percentage (if relevant) varies according to the type of gearbox fitted to
the vehicle (Eurotronic or manual).
upon release of the accelerator pedal with switch (1) on the right dashboard operated.
0052254t
000595t 000596t
0052913t
A. Actuator - B. Turbine rpm sensor - C. Turbocharger - D. Solenoid for VGT actuator control
0052914t
This NC proportional solenoid is located on the left side of the engine block beneath the turbine
(Cursor 8) or on the front of the engine (Cursor 10 and Cursor 13).
The electronic control unit governs this solenoid via a PWM signal to modulate the turbine
actuator supply pressure. The actuator position changes to alter the cross-section of the
exhaust gas flow to the impeller vanes and thus modulate
In the EURO 3 range, the correct actuator position is indirectly determined by measuring the
pressure in the intake duct.
The VGT solenoid is connected to the electronic control unit across pins C3/C1.
Coil resistance is ~ 20 - 30 Ohm.
Specifications:
Supplier BOSCH
Tightening torque 8 ± 2 Nm
Resistance 880 ÷ 920 Ω
000605t
Connector Function
1 To pin C 23 of the EDC control unit
2 To pin C 19 of the EDC control unit
3 Shielding
Specifications:
Supplier BOSCH
Tightening torque 8 ± 2 Nm
Resistance 880 ÷ 920 Ω
000606t
Connector Function
1 To pin C 10 of the EDC control unit
2 To pin C 9 of the EDC control unit
3 Shielding
0052257t
0051212t
1 Earth 25C
2 NTC signal (temperature) 36C
3 + +5 V power supply 33C
4 Signal (pressure) 34C
0052761t 0052762t
1 Earth 24C
2 NTC signal (temperature) 27C
3 + +5 V power supply 32C
4 Signal (pressure) 28C
104266
Connector Function
2 To pin C 15 of the EDC control unit
3 To pin C 26 of the EDC control unit
8530
Connector Function
2 To pin C 18 of the EDC control unit
3 To pin C 35 of the EDC control unit
Specifications:
Supplier BOSCH
Tightening torque max 35 Nm
104266
000600t
Activation times
Preheating before start-up [s]
Pre-heating
Ignition stage
heating
Post-heating
106990
16 1 2
15 3
26 17 18
14 4
25 27 28 19
13 5
24 30 29 20
12 23 21 6
22 7
11
10 9 8
106397
Wiring
Pin Function System
code
1 --
2 2298 K line ECM
3 --
4 2299 K line ABS – EBS – ECAS
5 --
6 2293 K line INTARDER – DMI - EM
7 --
8 2995 K line E.C.U. MUX *# I BC3 #
9 --
10 2295 K line Supplementary heater - Climate
control
11 8876 Ignition-operated positive (+15)
12 2292 K line VCM
13 --
14 2294 K line Instrument Cluster
Tachograph
15 --
16 --
17 --
18 2297 K line Eurotronic - Allison gearboxes
19
20 3397 Enable Intarder
21 6108 CAN (white) CAN_H VDB line
22 6109 CAN (green) CAN_L VDB line
23 --
24 --
25 8050 Remote Cranking VCM
26 Ground Cranking VCM
27 7772 Battery positive (+30)
28
29 5542 Speed segnal Tachograph (pin B7)
30 0050 Ground
181 Course ME22 ETH – Ed.1 – 10/10
72069 16 PIN COUPLING FOR OBD (On Board Diagnostic)
113249
Wiring
Pin Function System
code
1
2
3
4 0000 Earth
5 0050 Signal earth
6 White CAN (white) ECB CAN line H line
7
8
9
10
11
12
13
14 Green CAN (green) ECB CAN L line
15
16 7721 Direct positive from battery (+Batt)
0056336t
0056337t
0056338t