SM F4GE-IVECO Backhoe EN PDF

Copyright © New Holland
PROVEN PERFORMANCE PROVEN PERFORMANCE

REPAIR MANUAL FOR CNH U.K. ENGINES

F4GE0454C -- F4GE0484G
The following models are to integrate repair manuals:
NEW HOLLAND LB90.B -- LB95.B -- LB110.B -- LB115.B
F4GE0454C
F4GE0484G
Every information, illustration and specification contained in the present manual is based on the most recent informa--
tion available at the time of printing.
NEW HOLLAND reserves the right, to modify the text at any time without prior communication.
NEW HOLLAND
PRINT NO. 604.13.612
Edition – April 2006
2 WE
MOTORI
2
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no--
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example:: T 1 -- 2 -- 3
Progressive page number for each group
Group number (if any)
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
This symbol regards safety.

! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min--1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
Section 1 -- Diagnostics EW--1--1
Section 2 -- Engines overhaul: EW--2--1

-- F4GE0454C
-- F4GE0484G
Section 3 -- Recharging and start--up EW--3--1

4 WE
MOTORI
SECTION 1
DIAGNOSTICS
INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
Main engine operating anomalies . . . EW--1--3
INDICE
EW--1--3
DIAGNOSTICS
MAIN ENGINE OPERATING ANOMALIES
1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

2 -- Engine overheats; 7 -- Engine knocks irregularly;
3 -- Engine lacks power and works erratically; 8 -- Engine stops;
4 -- Engine exhaust smoke black or dark grey; 9 -- Engine exceeds max. revs number;
5 -- Engine exhaust smoke grey (verging on 10 -- Excessive or insufficient oil pressure;
white); 11 -- Excessive fuel consumption;
12 -- Engine won’t stop.
1 ENGINE WON’T START
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Thermal starter in working order Replace.

NO
YES
Injection pump timed Verify correct timing as described in the relevant

NO chapter.
(to be continued)
EW--1--4
DIAGNOSTICS
Injectors in working order Check operation and adjust.

NO
YES
The feeding circuit or injection pump does not Check and blow off.
show air penetration NO
YES
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water NO tank).
YES
Prescribed compression ratio Overhaul the engine or make repairs only on

NO
concerned parts (valves, piston rings, etc.).
YES
Fuel filters in working order Replace.

NO
YES
Automatic advance variator and electric STOP Check and replace the concerned parts.
device both in working order NO
YES
Fuel pump fed correctly Check and replace (if necessary) the fuel pump.
NO
YES
Fuel tank supplied correctly Refuel.

NO
EW--1--5
DIAGNOSTICS
2 ENGINE OVERHEATS
Coolant level correct Check for leaks and restore the level.
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level.
NO
YES
Water pump in working order Overhaul or replace the unit.

NO
YES
Thermostat in working order Replace.

NO
YES
Radiator in working order Wash down thoroughly, check for fluid leaks, re--
NO place (if necessary) the part.
YES
Air filter and circuit piping both in working order Clean or replace faulty parts.
NO
YES
Openings for coolant flow to the head in working Wash down thoroughly.
order NO
EW--1--6
DIAGNOSTICS
Valve timing correct Check and perform correct timing.

NO
YES
Injection pump timed Check correct timing as described in the relevant

NO paragraph.
YES
Cylinder head gasket in working order Replace.

NO
YES
Fan in working order Replace.

NO
3 ENGINE LACKS POWER AND WORKS

ERRATICALLY
Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.
YES
Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.
YES
Feeding circuit in working order Check and make (if necessary) the required re--
NO pairs.
(to be continued)
EW--1--7
DIAGNOSTICS
The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.
YES
Thermostat in working order Replace.

NO
YES
Fuel pump in working order Replace.

NO
YES
Injectors in working order Check operation and adjust them.

NO
YES

NO paragraph.
YES
Automatic advance variator (in injection pump) in Check and bench--adjust the injection pump.
working order NO
YES
Distributing plunger (in injection pump) in work-- Check and bench--adjust the injection pump.
ing order NO
(to be continued)
EW--1--8
DIAGNOSTICS
Injection pump rate correct Check and bench--adjust the injection pump.
NO
YES
Speed governor (in injection pump) in working Check and bench--adjust the injection pump.
order at all speeds NO
YES
Circuit and L.D.A. device both in working order Check.

NO
YES
Injection pump with peak adjusting--screw fine-- Fine--tune the peak adjusting--screw.
tuned NO
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.
YES
Prescribed compression ratio Check and bench--adjust the injection pump.

NO
YES
Turbocharger in working order Repair or replace the unit.

NO
YES
Correct tie rod length between the accelerator Adjust the tie rod length.
and injection pump NO
EW--1--9
DIAGNOSTICS
ENGINE EXHAUST SMOKE BLACK OR

4 DARK GREY
Air filter in working order Replace.

NO
YES
Thermal starter in working order Replace.

NO
YES
Automatic addition device comes into operation Check and replace (if necessary).
NO
YES
Injectors in working order Check operation and adjust them as described.

NO
YES

NO paragraph.
YES
L.D.A. device in working order Ad just the L.D.A. device.

NO
YES
Injection pump adjusted as prescribed Check and bench--adjust the injection pump.
NO
(to be continued)
EW--1--10
DIAGNOSTICS
Injection pipes intact Check the condition of pipes and replace them (if
NO necessary).
YES
Prescribed compression ratio Check by means of a Motometer 75301430 tool

NO and carry out the necessary operations.
YES
High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO
5 ENGINE EXHAUST SMOKE GREY

(VERGING ON WHITE)
The thermostat comes into operation correctly Replace.

NO
YES
Injectors in working order Check operation and adjust as described in S.I.

NO 1094.
YES

NO paragraph.
YES
Coolant level correct Possible flow of coolant into the combustion

NO
chamber; replace the cylinder head gasket or
overhaul the engine.
(to be continued)
EW--1--11
DIAGNOSTICS
High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO
6 ENGINE EXHAUST SMOKE LIGHT BLUE
Excessive oil consumption Check the oil vapour vent and cylinder compres--
YES sion. Overhaul, if necessary, the cylinder head or
engine.
7 ENGINE KNOCKS IRREGULARLY
Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine.
NO
Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect--
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.
NO
Knock detected in pistons Check the following items: play between the pis--
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.
(to be continued)
EW--1--12
DIAGNOSTICS
Knock detected in the cylinder head Check the following items: operation play be--
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for excess--
YES ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.
NO
Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace.
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.
NO
Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump.
8 ENGINE STOPS
Fuel tank filled Refuel and drain (if necessary).

NO
YES
Fuel filters in working order Replace.

NO
(to be continued)
EW--1--13
DIAGNOSTICS
Feeling circuit in working order Check the circuit and drain.

NO
YES
Regular idle speed Adjust.

NO
YES
Regular injection pump rates Bench--check the flow rates.

NO
YES
Injection pump controls in working order Replace worn parts and adjust.
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
arms.
NO
YES
Intact valves Replace the valves.

NO
9 ENGINE EXCEEDS MAX. REVS NUMBER
Speed governor in working order Check and replace (if necessary) the worn parts.
NO
EW--1--14
DIAGNOSTICS
10 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE
Pressure control valve in working order Check and replace (if necessary).
NO
YES
Oil pump and delivery pipes both in working or-- Check and replace (if necessary).
der NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.
YES
Engine oil SAE viscosity conforming to stan-- Replace the engine oil with equivalent of ad--
dards NO equate viscosity.
11 EXCESSIVE FUEL CONSUMPTION
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.
YES
Air filter in working order Replace.

NO
(to be continued)
EW--1--15
DIAGNOSTICS
Correct injector adjustment Check operation and adjust them.

NO
YES
Correct injection pump adjustment Check and bench--adjust.

NO
YES
L.D.A. device in working order Adjust the L.D.A. device.

NO
YES
Injection pump timed Check static force--fit of the injection pump.

NO
12 ENGINE WON’T STOP
Cut--off electromagnet in working order Replace the electromagnet.

NO
YES
Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16
DIAGNOSTICS
NOTES
SECTION 2
ENGINES F4GE0454C F4GE0484C

F4GE0484G OVERHAUL
INDEX
Engines F4GE0454C . . . . . . . . . . . . . . . . EW--2--3 Removing the injection pump . . . . . . . . . EW--2--45
Engines F4GE0484G . . . . . . . . . . . . . . . EW--2--3 Removing the rocker arm assembly . . . EW--2--47
Coding of source engines . . . . . . . . . . EW--2--4 Repair work on cylinder cluster . . . . . EW--2--50
Main engines features . . . . . . . . . . . . . . EW--2--5 Checks and measurements . . . . . . . . . . . EW--2--50
General engines features . . . . . . . . . . . EW--2--6 Checking the surface supporting
Assembling play -- specifications . . . EW--2--8 the head on the cylinder cluster . . . . . . . EW--2--51
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--14 Checking the eccentric lift and
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15 the pin alignment . . . . . . . . . . . . . . . . . . . . EW--2--52
Graphic indications and symbols . . . EW--2--16 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--52
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--52
General remarks . . . . . . . . . . . . . . . . . . . EW--2--17
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--53
F4GE0454C engine . . . . . . . . . . . . . . . . . EW--2--17
Replacing the bushings . . . . . . . . . . . . . . EW--2--54
F4GE0484G engine . . . . . . . . . . . . . . . . . EW--2--18
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--54
Description of main mechanic
engine components . . . . . . . . . . . . . . . . EW--2--19 Mounting the tappets – Distributing shaft EW--2--54
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--55
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--20 Measuring the journals and crankpins . . EW--2--55
Replacing the oil pump drive gears . . . . EW--2--58
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--21
Mounting the main bearings . . . . . . . . . . EW--2--58
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--22
Measuring the journal assembling play . EW--2--58
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--23
Checking the drive shaft shoulder play . EW--2--59
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--24
Connecting rod--piston assembly . . . . . . EW--2--60
Cylinder head (F4GE0454C engine) . . . EW--2--25
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Cylinder head
(F4GE0484G engines) . . . . . . . . . . . . . . . EW--2--26 Measuring the piston diameter . . . . . . . . EW--2--61
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Valves and valve seats . . . . . . . . . . . . . . . EW--2--27
Conditions for correct pin/piston
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--2--28
matching . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--29
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Auxiliary component drive . . . . . . . . . . . . EW--2--30
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--63
Additional masses . . . . . . . . . . . . . . . . . EW--2--31
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--64
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32
Checking the connecting rods . . . . . . . . . EW--2--64
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--33
Checking the torsion . . . . . . . . . . . . . . . . . EW--2--64
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Checking the flexion . . . . . . . . . . . . . . . . . EW--2--64
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--35 Mounting the connecting
Engines F4GE0454C*D660 -- F4GE0454C*D603 -- rod--piston assembly . . . . . . . . . . . . . . . . . EW--2--65
F4GE0484G*D660 -- F4GE0484G*D606 EW--2--35 Connecting rod--piston match . . . . . . . . . EW--2--65
Engine F4GE0484G*D655 -- Mounting the piston rings . . . . . . . . . . . . . EW--2--65
F4GE0484G*605 . . . . . . . . . . . . . . . . . . . . EW--2--35 Mounting the connecting rod/piston
Oil vapour recirculation . . . . . . . . . . . . . . . EW--2--36 assemblies in the cylinder liners . . . . . . . EW--2--66
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Measuring the crankpin assembling play EW--2--66
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--38 Checking piston protrusion . . . . . . . . . . . EW--2--67
Mechanic injection feeding system . . EW--2--39 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--67
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Distribution gearbox case . . . . . . . . . . . . EW--2--67
Mechanic fuel pump . . . . . . . . . . . . . . . . . EW--2--40 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--2--68
Injection assembly . . . . . . . . . . . . . . . . . EW--2--41 Injection pump – 1st phase . . . . . . . . . . . EW--2--69
Engine bench--overhaul . . . . . . . . . . . . EW--2--42 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Disassembling the engine . . . . . . . . . . . . EW--2--42 Assembling the additional masses . . . . . EW--2--69
O--ring replacement . . . . . . . . . . . . . . . . . EW--2--44 Flywheel cover case . . . . . . . . . . . . . . . . . EW--2--71
INDEX
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--72 Valve guide . . . . . . . . . . . . . . . . . . . . . . . . EW--2--78

Replacing the engine flywheel ring gear EW--2--72 Checking the play between the valve
Injection pump – 2nd phase . . . . . . . . . . EW--2--73 stem, valve guide and valve centring . . . EW--2--78
Mounting the injection pump – Valve springs . . . . . . . . . . . . . . . . . . . . . . EW--2--80
2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--73 Mounting the cylinder head . . . . . . . . . . . EW--2--80
Mounting the oil and water pumps . . . . . EW--2--73 Rocker arm assembly . . . . . . . . . . . . . . . . EW--2--81
Mounting the water / oil heat exchanger EW--2--75 Reattaching the cylinder head . . . . . . . . . EW--2--81
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--2--75 Mounting the injectors . . . . . . . . . . . . . . . EW--2--82
Removing the valves . . . . . . . . . . . . . . . . EW--2--75 Replacing the injectors . . . . . . . . . . . . . EW--2--85
Checking the cylinder head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--85
supporting surface . . . . . . . . . . . . . . . . . . . EW--2--76 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Checking the cylinder head water seal . EW--2--77 Rocker arm removal/reassembling . . EW--2--86
Valve descaling, check and grinding . . . EW--2--77 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--77 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Valve seats . . . . . . . . . . . . . . . . . . . . . . . . EW--2--78 Adjusting the tappets . . . . . . . . . . . . . . EW--2--87
Valve seat reconditioning -- replacement EW--2--78 Check priming of the injection pump . . . EW--2--88
EW--2--3
ENGINES F4GE0454C -- F4GE0484G OVERHAUL
Figure 1
86607
ENGINES F4GE0454C
Figure 2
86608
ENGINES F4GE0484G
EW--2--4
CODING OF SOURCE ENGINES
F 4 G E 0 4 8 4 G * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern:
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 4 = 4--cylinder
Group
Engines
8 = Direct injection turbo

diesel with intercooler
5 = Direct injection turbo
diesel
4 = Earthmovers
X Y Y Y Y Y Y Y Y
X = 6 rotary, 2--valve injection pump Manufacturing sequence number

Y = Engine model
EW--2--5
MAIN ENGINES FEATURES
Applications
LB90.B LB90.B
A LB110.B LB110.B LB115.B LB115.B
LB95.B LB95.B
B F4GE0454C F4GE0454C F4GE0484G F4GE0484G F4GE0484G F4GE0484G
C *D660 *D603 *D660 *D606 *D655 *D605
E 4485
71 kW 71 kW 82 kW 82 kW 82 kW 82 kW
F
2200 min--1 2200 min--1 2200 min--1 2200 min--1 2200 min--1 2200 min--1
Net power at flywheel (ISO 14396)
G Direct injection
H Rotary injection pump
T.C. T.A.A.
I
(Boosted) (Boosted by intercooler)
Up to From chassis
Up to chassis From chassis Up to chassis From chassis
chassis no. no.
no. 031056821 no. 031056822 no. 031056893 no. 031056894
N5GH04353 N5GH04354
A Backhoe--loaders
B Type of engine
C g
Engine model
D Number of cylinders
E Total displacement
F Max. ppower currentlyy available
G Type of injection
H Injection system
I Air supply system
EW--2--6
GENERAL ENGINES FEATURES
F4GE0484G F4GE0484G F4GE0454C

Type
*D660 *D655 *D606 *D605 *D660 *D603
Cycle 4--stroke diesel engine

Feeding Boosted by intercooler Boosted
Injection Direct
Number of cylinders 4 in--line
Bore mm 104
Stroke mm 132
Total displacement cm3 4485
Compression ratio 17.5 : 1
Max. rating kW 82 82 71
min --1 2200 2200 2000
Max. torque Nm 480 (48) 398 (39.8)

--
min --1 1400 1400
No--load idle rpm min --1 --
No--load peak rpm min --1 --
BOOSTING
With intercooler HOLSET
Type of turbocompres- HX25W
HOLSET HX25W
sor:
Forced by means of gear pump, pressure relief

LUBRICATION
valve, oil filter
Oil pressure with hot en-
gine: --
at idle rpm bar
at peak rpm bar --
EW--2--7

Type
*D660 *D655 *D606 *D605 *D660 *D603
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
FILLING
Total capacity
Ambra Mastergold HSP 1st filling: litres --
15W40 kg
-- engine sump litres --

kg
-- engine sump + filter litr

--
es
kg
VE4 / 12 F
FEEDING
Bosch--type injection 1100 L 954 1100 L 956--2 1100 L 954
Pump setting 0° ± 0.5°
Start of delivery mm 1
Type of nozzle DSLA 145 1174
Injection sequence 1 -- 3 -- 4 -- 2
Injection pressure (bar) 245 bar

EW--2--8
ASSEMBLING PLAY -- SPECIFICATIONS

Type
*D660 *D655 *D606 *D605 *D660 *D603
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners ∅1 104.000 to 104.024
Pistons: supplied with

standard
spares
Measurement dimension 8
X 103.714 to 103.732
Outer diameter ∅1 38.010 to 38.016
Pin seat ∅2
Piston -- cylinder liners 0.268 to 0.310
Piston diameter ∅1 0.4
Position of pistons from

0.28 to 0.52
crankcase X
Gudgeon pin ∅3 37.994 to 38.000
Gudgeon pin -- Pin seat 0.010 to 0.022

X1*
2.705 to 2.735
Piston ring slots X2
2.44 to 2.46
X3
4.03 to 4.05
* measured on ∅ of 101
mm
S1*
Piston rings S2 2.602 to 2.606
S3 2.35 to 2.38
* measured 1,5 mm 3.97 to 3.99
away from the external
∅
1 0.100 to 0.175
Piston rings – Slots 2 0.060 to 0.110
3 0.040 to 0.080
Piston rings 0.4

EW--2--9

Type
*D660 *D655 *D606 *D605 *D660 *D603
Piston ring end opening
in cylinder liner:
X1 0.3 to 0.45
X2 0.6 to 0.8
X3 0.3 to 0.55
Connecting rod small--

end
40.987 to 41.013
bushing seat ∅1
Connecting rod bearing
72.987 to 73.013
seat ∅2

end bushing diameter
Outer ∅4 41.279 to 41.553
Inner ∅3 38.019 to 38.033

end bushing – seat 0.266 to 0.566
Gudgeon pin – Bushing 0.019 to 0.039
Measurement dimension
X --
Max. error on connecting

rod axis --
parallelism =
Journals ∅1
82.99 to 83.01
Crankpins ∅2
68.987 to 69.013
Main half bearings S1*
2.456 to 2.464
Connecting rod half bea-
1.955 to 1.968
rings S2*
* supplied with spares
Bed supports no.:

no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
EW--2--10

Type
*D660 *D655 *D606 *D605 *D660 *D603
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
Connecting rod half bea- + 0.250; + 0.500
rings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.095 to 0.265

EW--2--11

Type
*D660 *D655 *D606 *D605 *D660 *D603
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
Valve stem and respect-

0.039 to 0.079
ive guide
Seat on head for valve

seat:
46.987 to 47.013
∅1
43.637 to 43.663
∅1
Valve seat outer diam-

eter;
inclination of valve seats
on cylinder head:
47.063 to 47.089
∅2
60°
α
43.713 to 43.739
∅2
45°
α
Hollow X 1.00 to 1.42
X 1.00 to 1.42
Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102
Valve seats --
EW--2--12

Type
*D660 *D655 *D606 *D605 *D660 *D603
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for distributing

shaft bushings no. 5 59.222 to 59.248
Distributing shaft seats
no. 1--2--3--4 54.089 to 54.139
Distributing shaft support

pins:
53.995 to 54.045
1⇒5 ∅
Bushing outer diameter

for
59.222 to 59.248
distributing shaft: ∅
under a load of 3.3 kN
Bushing inner diameter ∅ 54.083 to 54.147
Bushings and seats in

0.113 to 0.165
crankcase
Bushings and support
0.038 to 0.162
pins
Eccentric working lift:
6.045
7.239
EW--2--13

Type
*D660 *D655 *D606 *D605 *D660 *D603
∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030
∅2
Outer diameter of tappet
collar:
∅3 15.929 to 15.959
∅2
∅2 15.965 to 15.980
∅3
Between the tappets and

0.020 to 0.065
the seats
Tappets --
∅1
Rocker arm shaft ∅1 18.963 to 18.975
Rocker arms ∅2 19.000 to 19.026

∅2
Between the rocker arm
0.025 to 0.063
and the shaft
EW--2--14
TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st phase
p 50 ± 6 (5 ± 0.6)
2nd p
phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90°
Connecting g rod cap
p fastening
g screws 1st p
phase 50 ± 5 (5 ± 0.5)
2nd phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
-- Lubrication with oil

EW--2--15
TOOLS
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Joint for pressure control in the cylinders (use with 380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and depression measuring
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Diesel engine cylinder compression control device
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380001004)
380002730 Engine PMS positioning tool
EW--2--16
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

α
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
EW--2--17
GENERAL REMARKS
F4GE0454C ENGINE
Figure 3
86552
1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
EW--2--18
F4GE0484G ENGINE
Figure 4
86553
1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
EW--2--19
DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water pump (2) and oil pump (4).
Figure 5
86554
EW--2--20
Drive shaft
It is made of steel and rests on five induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft (2) drive gear and engine
Inside the drive shaft are the lubricating oil ducts. flywheel (5) mounting hub.
The following items are force--fitted on the front The main half bearings are made of steel with anti--
shank: oil pump (1) drive gear, phonic wheel, friction alloy coating.
damper flywheel and auxiliary component drive pul- The second main half bearing is equipped with a
ley. shoulder to restrain the drive shaft end play.
Parts (2) and (5) cannot be replaced.
Figure 6
84207
1. Oil pump control gear -- 2. Camshaft control gear --

3. Main half bearings -- 4. Shoulder half bearings -- 5. Engine flywheel hub
EW--2--21
Connecting rods
They are steel--stamped, of the oblique cut type,
with separation of the cap obtained by an advanced
technology (fracture split) instead of mechanic ma-
chining.
The connecting rod half bearings are made of steel,
with anti--friction alloy coating.
Figure 7
84038
EW--2--22
Pistons
The combustion chamber is found on the piston 1. Part no., spare no, and design modification no.
crown. The crown is cooled by the engine oil deliv-
ered by the nozzle fitted to the crankcase. 2. Arrow showing piston assembly mark into cylin-
der barrel, it shall be directed towards the front
The slots housing the piston rings are three; the 1st side of the cylinder block.
slot is obtained by a cast iron insert with trapezoidal
section. 3. Date of manufacture.
The following references are marked on the piston
crown: 4. Marking showing 1st slot insert testing.
Figure 8
86549
EW--2--23
Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
B. Exhaust valve control
The supports (front and rear) are equipped with steel
bushings mounted in an interfering manner and The camshaft is directly controlled by the output
coated with anti--friction material; two control eccen- shaft through the gear (C).
trics are provided for each cylinder. Gear (D) transmits motion to the injection pump.
Figure 9
86556
EW--2--24
Valve control
Figure 10
86557
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--25
Cylinder head (F4GE0454C engine)

The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);
Figure 11
86558
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--26
Cylinder head (F4GE0484G engines)
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);
Figure 12
86559
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--27
Valves and valve seats
Figure 13
S 1
84241
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 14
84242
Figure 14 shows the oil seals mounted on valve

stems.
EW--2--28
Valve guides
Figure 15
INTAKE EXHAUST
84046
DETAIL OF VALVE GUIDES AND SEATS

EW--2--29
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 16
86560
EW--2--30
Auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft
(5) to water pump (1), alternator (2) and fan (6).
The belt is stretched by means of automatic belt
stretcher (3).
Figure 17
86561
1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
EW--2--31
ADDITIONAL MASSES
Inside the oil sump, secured to the cylinder block are Make coincide marks (A) on gears for timed
located the additional masses. masses, insert hole pin (B) on the balancing mass
The additional masses shall be timed with each oth- to stop rotation temporarily.
er as shown below.
Figure 18
80354
1. Fastening screws -- 2. Support -- 3. Fastening screws -- 4. Gear -- 5. Balancing mass --

6. O--Ring -- 7. Ring -- 8. Gear -- 9. Counter--rotating shaft -- 10. Half bearings
EW--2--32
LUBRICATION
Forced circulation lubrication is performed by the fol- - water / oil cooler, housed in cylinder block;
lowing components: - oil pressure relief valve built into the cooler unit;
- rotor--equipped oil pump housed in the crank- - by–pass valve to cut out clogged oil filter, built
case front part, controlled by the straight--tooth into the cooler unit;
gear force--fitted on the drive shaft shank; - cartridge oil filter.
Figure 19
Oil return drop--type path
Pressure oil path
Oil supply
86562
EW--2--33
Heat exchanger
Figure 20
86458
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger --

4. Gasket between exchanger unit and engine block
EW--2--34
Oil pump
Figure 21
84052
Figure 22
70150
1. Drive shaft with oil pump drive gear

EW--2--35
Oil sump
The oil sump (1) is bolted to the cylinder block by
means of a plate (2).
The plate (2), fitted on the oil sump outline reduces
noise in addition to improve tightness.
Engines F4GE0454C*D660 -- F4GE0454C*D603 -- F4GE0484G*D660 -- F4GE0484G*D606
Figure 23
86563
Engine F4GE0484G*D655 -- F4GE0484G*605

Figure 24
86564
EW--2--36
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
Figure 25
114063
EW--2--37
COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.
Figure 26
86565
Water flowing out of the thermostat Water flowing into the pump
Water recirculating in the engine

EW--2--38
Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 27
84058
Figure 28
84059
EW--2--39
MECHANIC INJECTION FEEDING SYSTEM

Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.
Figure 29
86566
EW--2--40
Mechanic fuel pump

Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.
Figure 30
84249
1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank
Figure 31
84250
1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--41
INJECTION ASSEMBLY
Figure 32
84251
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--42
ENGINE BENCH--OVERHAUL Figure 35

Disassembling the engine
Figure 33
86568
86567
Drain the engine oil by taking the cap off the sump F4GE0484G versions
and the oil filling cap off the head cover. - take off intake manifold (3);
Remove the fan unit from the fan pulley. - disconnect the engine oil vapour recovery pipe
In order to be able to fit bracket 380000995 (which from blow--by (1);
fastens the engine to the overhaul stand) to the - take off tappet covers (4);
crankcase, it is necessary to:
- disconnect electric wiring (8);
- remove electric wiring (1).
- take off fuel filter (9);
- take off container (2);
- take off container control unit (5);
Figure 34
- disconnect the piping from L.D.A. system (13);
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 36;
- take off fuel filter support (6).
5
Figure 36
4
86463
In order to be able to fit bracket 380000995 to the

crankcase on the right side, it is necessary to re-
move:
- fastening bracket (2) from electric wiring (1);
- electric wiring (1);
- the starter motor (3).
Secure the engine to rotary stand 380000978.
70126
- take off turbine lubrication delivery pipe (7);
- remove the oil filter (4). Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--43
Figure 37 Figure 39
84255 86570
- Remove injector (5) feed pipes (5) from injection - Remove the screws (3) and then remove the tur-
pump (6); remove the rackets fastening the pipe bine (1).
unit (1), (2) and (3) on the cylinder head. - Remove the exhaust manifold (2).
- Remove the priming pump (4).
Figure 40
Figure 38
86571
- Remove the belt tightener (2).

- Remove the auxiliary component belt (4) operat-
ing the alternator fastening bracket (1).
86569 - Remove the alternator (3), the water pump (6),
the fan pulley (5) and the guide pulleys (7).
- Remove the feed pipe unit from injectors (1). - Remove the pulley support (8).
- Remove fuel drain pipe (2) from injectors by re- - Remove the engine cooling system connection
moving the screw (4) and the seal (3). from the cylinder block.
EW--2--44
Figure 41 Figure 43
84259 78257
Lock the flywheel properly to prevent rotation, loosen Apply the proper tension rod (3) of tool 380000996 to
the fastening screws (1) from pulley (2). outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
O--ring replacement
Figure 42
Figure 44
78256
Apply tool 380000980 (4) on drive shaft front shank

(2).
84237
Drill inner seal ring (1), through tool 380000980 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth Remove gear oil pump (1).
of 5 mm.
Secure tool 380000980 (4) to ring (1) by screwing the IMPORTANT -- Oil pump (1) cannot be recondi-
6 screws (5) provided. tioned.
Take off ring (1) by fastening screw (3).
EW--2--45
Removing the injection pump Figure 47

Figure 45
84071 86573
Unlock the engine flywheel. - Remove cover (1) from gear covering case (2).
Rotate the drive shaft until it reaches the condition of - Lock the engine flywheel.
1° cylinder at top dead centre. - Loosen nut (3) securing the injection pump drive
Such condition is obtained when (after removing the gear (4).
closing plug), by pushing pin 380002730 (1) shown
by the arrow, it is housed in its own seat obtained on
distributing shaft drive gear (2).
Figure 46
Figure 48
84260
To correctly preset the injection pump prior to remov-

ing it, loosen screw (2) and remove L--shaped spacer
(1). 84261
Fasten again screw (2) to its abutting end.

Loosen the three nuts (2) (4) (5) securing the injection
pump (1) to the flywheel covering case (3), then take
the pump out of its housing by means of tool
IMPORTANT -- Carefully store the L--shaped
380000979 through proper application to gear (4) in
spacer with the pump body.
NO TAG.
EW--2--46
Figure 49 Figure 51
86574 78258
Remove screws (1) securing engine flywheel (2) to the Apply tool 380000981 (3) on drive shaft rear shank
drive shaft. (5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2).
Figure 50 Figure 52
86575 78257
Screw two pins (2) of adequate length into drive shaft Apply the proper torsion bar (3) of tool 380000996 to
holes (3). outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever
Remove tool 380000990 (2).
(4).
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
EW--2--47
Figure 53 Figure 55
86608
86576
Remove screws (1) and disassemble gears (3) and
Remove screws (2) and then remove the flywheel (4) from camshaft (2).
housing (1).
Figure 56
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter.
86578
Use pin (1) to lock the additional masses (2) at T.D.C.

Loosen the fastening screws (3) and remove the addi-
Figure 54 tional masses (2).
Removing the rocker arm assembly

Figure 57
86577 84081
Turn the engine upside down, remove screws (2), For each cylinder, remove rocker arm assembly (1),
take off oil sump (1). loosen adjusting nuts (3), unscrew registers (2) and
remove screws (4).
EW--2--48
Figure 58 Figure 61
84082
Take out injectors (2) by means of tool (1) 380000982. 86609
Remove screws (2) and take off timing gear case (1).
Figure 59 IMPORTANT -- Take note of the mounting position

of screws (2), due to the different size of the latter.
Figure 62
86579
Remove screws (1) securing the head to the crank-

case.
Figure 60
70158
Remove connecting rod cap (2) fastening screws (1),

then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part.
86580
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep- again, they must be mounted in the same position
arate the cylinder head from the crankcase by means they had prior to being taken off.
of a hoist.
EW--2--49
Figure 63 Figure 66
70159
Remove screws (1) and take off bed caps (2). 70162
Take off main half bearings (1).

Figure 64
Remove screws (2) and take off oil nozzles (3).
Figure 67
70160
The penultimate bed cap (1) and its respective sup-

port have half bearing (2) provided with shoulder.
70163
Remove screws (1) and take off distributing shaft (3)

IMPORTANT -- Take note of the mounting position retaining plate (2).
of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in IMPORTANT -- Take note of plate (2) mounting
the same position they had prior to being taken off. position.
Figure 65
Figure 68
70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000992 (1) and a hoist. crankcase.
EW--2--50
Figure 69 Figure 70
70165 70166
Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
NOTE – If no ring gauge is available, use a micro-

meter to perform reset.
REPAIR WORK ON CYLINDER CLUSTER Figure 71

Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
70167
Measurements must be taken for each single cylin-

der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
EW--2--51
Figure 72 Checking the surface supporting the head on

the cylinder cluster
Figure 73
70170
Verify that the head supporting plane on the cylinder

cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.
NOTE -- Crankcase flattening may be carried out

80585 only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
IMPORTANT -- In case of reconditioning, all the
liners must be machined to the same increase (0.5
mm). Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
Check the main bearing seats as follows:
After flattening, restore the cylinder liner countersink,
- mount the bed caps on the supports without bear- as shown in Figure 72.
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.
EW--2--52
VALVE GEAR
Distributing shaft
Figure 74
86581
MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins
The shaft support pin and eccentric surfaces must be Figure 75

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft.
70171
Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--2--53
BUSHINGS Figure 76
The distributing shaft bushing (2) must be force--fitted
into their respective seats.
The inner surface must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of rear
bushing (2) and of distributing shaft intermediate
seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.
70172
Figure 77
sec. A-A
107399
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHING AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushing
EW--2--54
Replacing the bushings Mounting the tappets – Distributing shaft

Figure 78 Figure 80
70174 70176
To replace rear bushing (1), use beater 380000991 Lubricate tappets (1) and fit them to their respective
(2) and handle 380000999 (3) to remove and reas- seats of the crankcase.
semble the bushing.
IMPORTANT -- Bushing (1) must, upon mounting,

be turned in such a way that the lubricating holes
match with the holes available on the crankcase
seats.
Tappets
Figure 79 Figure 81
84053 70164
MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushing and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushing or supporting seats during operation.
EW--2--55
Figure 82 Figure 84
70238 70180
Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.
DRIVE SHAFT
Measuring the journals and crankpins
Figure 85
Figure 83
70182
If traces of excessive seizing, scoring or out--of--

roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.
NOTE -- It is advisable to write down the measured

values on a table.
See Figure 86.
70179
Check the distributing shaft end play (1).

EW--2--56
Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crank-
pins must be marked with a special stamping
made on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
Figure 86
108487
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--57
Figure 87
70183
MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES
TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL ©
IMPORTANT
SECONDARY
EW--2--58
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 88 Figure 90
70184 70161
Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
Mounting the main bearings

Figure 89 Figure 91
70185 70186
Check the play between the drive shaft journals and

IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided

with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
EW--2--59
Figure 92 Figure 94
70187 70189
Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
Checking the drive shaft shoulder play

Figure 93 Figure 95
70188 70190
- 3rd phase with tool 380001001 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60° ± 5°. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--60
Connecting rod--piston assembly
Figure 96
70191
PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing
NOTE -- Pistons are supplied as spares increased by 0.4 mm.
Figure 97 Figure 98
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--2--61
Figure 99
86497
MAIN DATA ABOUT PISTON
Pistons
Measuring the piston diameter
Figure 100 Figure 101
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 8 mm far

from the piston skirt base.
EW--2--62
Gudgeon pins Figure 105

Figure 102
84097 84100
Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 103
Figure 106
84098
Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 104
84101
SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
EW--2--63
70194
Measuring the play between the ends of piston rings

(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).
Connecting rods
Figure 108
114314
Y Production year
D Production day
H Weight class
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
ment, it is therefore necessary to number the
new connecting rod with the same number as
the replaced one.
- By a letter (on the connecting rod body) which
86498 indicates the weight class of the factory--as-
sembled connecting rod:
MAIN DATA OF CONNECTING ROD, GUDGEON -- V, 1560 to 1600 (marked in yellow);
PIN BUSHING AND HALF BEARINGS -- W, 1601 to 1640 (marked in green);
* Dimension of inner diameter to be obtained after -- X, 1641 to 1680 (marked in blue);
driving into the connecting rod small--end and re- Replacement rods are supplied class W and
facing by means of a reamer. marked in green.
** This dimension cannot be measured in a free state. Material removal is not permitted.
IMPORTANT -- The connecting rod--connecting

rod cap matching surfaces are knurled to ensure
better match.
Therefore, it is recommended not to remove
knurls.
EW--2--64
Bushings Checking the torsion

Verify that the bushing in the connecting rod small-- Figure 111
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 110
61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ∼ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.
Checking the flexion

Figure 112
61696
Check parallelism of the axles of the connecting rods
(1) with a suitable device (5) as follows:
- assemble the connecting rod (1) on the proper
tool chuck (5) and lock it with the screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--65
Mounting the connecting rod--piston assembly Mounting the piston rings

Connecting rod--piston match Figure 116
Figure 113
86550
The following reference data are engraved on the pis-
ton crown:
84093
1. Spare part number and design modification
number; Use pliers 380000986 (3) to fit piston rings (1) on pis-
2. Arrow showing piston assembly mark into cylinder ton (2).
barrel, it shall be directed towards the front side of
the cylinder block. IMPORTANT -- Spare piston rings are supplied in
3. Date of manufacture. the following dimensions:
4. Marking showing 1st slot insert testing.
-- standard, marked with yellow paint;
Figure 114
-- increased by 0.4 mm, marked with yellow/green
paint;
Figure 117
86551
Connect piston (2) to connecting rod (4) by means of

pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5)
stamped on connecting rod (4) cen be seen as shown
in the figure.
Figure 115
70200
Mount half bearings (1) both on the connecting rod
and the cap.
IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
EW--2--66
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 120
Figure 118
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners. of oil;
- place a piece of gauged wire (2) on drive shaft
pins (1);
- mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 121
Figure 119
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 122
80612
SCHEME FOR MOUNTING THE CONNECTING

ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the arrow (1) stamped on the piston crown faces 70205
the crankcase front side, or the notch obtained on - Apply tool 380001001 (1) on the compass
the piston skirt corresponds to the position of oil wrench, then tighten screws (2) further in a criss--
nozzles. cross sequence.
EW--2--67
Figure 123 Checking piston protrusion

Figure 125
70206 70208
- Take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Figure 124 Distribution gearbox case
Figure 126
70207
If the measured play is different from the specified

one, replace half bearings and repeat the check.
86582
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi- SCHEME FOR SEALANT LOCTITE 5205
nitely by tightening the connecting rod cap fastening APPLICATION AREA
screws as described. Clean thoroughly distribution gearbox case (1) and
the engine crankcase.
Cleaning the surface to be sealed is necessary and
IMPORTANT -- Prior to mounting the connecting unavoidable in order to ensure optimum seal.
rod cap fastening screws definitely, verify that the Apply sealant LOCTITE 5205 on the case so as to
diameter of the same (as measured at the middle make a bead with a diameter of a few millimetres.
of the thread length) is not smaller than 0.1 mm of The bead must be smooth (no lumps) and free from
the diameter measured at about 10 mm from the air bubbles, thin areas or gaps.
screw end. Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
Check manually that connecting rods (1) run axially both sides of the joint and obstruct lubricant flowing
on the drive shaft pins, and that the end play of the passages.
same (as measured by means of a thickness gauge After completing sealant application, the joints must
(2) is 0.10 to 0.33 mm. be mounted immediately (within 10 -- 20 minutes).
EW--2--68
86610 86611
SCHEME FOR REAR GEARBOX CASE Turn drive shaft (4) and distributing shaft (2) in such
FASTENING SCREW TIGHTENING SEQUENCE a direction that when mounting driven gear (1) on the
Reassemble case to the crankcase. distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.
Valve timing
70211 86612
Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--69
Injection pump – 1st phase Figure 133

Timing
Figure 131
86613
Force--fit gear (1) transmitting the motion to the pump,

84071
then fasten nut (2) by hand.
Bring cylinder 1 to the top dead centre. This condition
occurs when pin 380002730 (1) (shown by an arrow) Turn the engine and then assemble the additional
is housed in the seat available on the distributing shaft masses.
drive gear (2).
Assembling the additional masses

Figure 134
Figure 132
86578
Assemble the additional masses (2) and tighten the

screws (3) on the cylinder block.
84273
Mount the injection pump body (1) in the gearbox seat Remove the additional masses locking pin (1).
(2), then secure it by means of screws (3).
EW--2--70
Additional masses timing

Make the marks (A) on the timing gears coincide, in-
sert the pin into the hole (B) set on the balancing
mass.
Figure 135
86614
1. Injection pump gear -- 2. Camshaft control gear--

3. Injection pump control gear -- 4. Additional mass unit
EW--2--71
Flywheel cover case Figure 137

Figure 136
86576
86583
SCHEME FOR FLYWHEEL COVER CASE
FASTENING SCREW TIGHTENING SEQUENCE
SCHEME FOR SEALANT LOCTITE 5205 Fit case back to the crankcase, tighten the fastening
APPLICATION AREA screws (2) in the positions they had prior to being
taken off, then fasten them to the specified torque.
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox. Screws:
Cleaning the surface to be sealed is necessary and - M12 x 1.75 x 100 80 ± 10 Nm
unavoidable in order to ensure optimum seal. - M16 x 1.50 x 80 200 ± 20 Nm
Apply sealant LOCTITE 5205 on the case (1) so as - M16 x 1.50 x 100 200 ± 20 Nm
to make a bead with a diameter of a few millimetres. - M12 x 1.75 x 78 80 ± 10 Nm
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on Figure 138
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
70216
Apply part (5) of tool 380000984 on drive shaft rear

shank (6), secure it by means of screws (4) and
force--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--72
ENGINE FLYWHEEL Figure 141

Figure 139
2
1
86574
86584 Tighten screws (2) fastening engine flywheel (3) to

the drive shaft.
Check the clutch disc supporting surface and turn it
if scoring is detected.
NOTE -- The rated thickness of the engine flywheel

is 70.5 mm.
Replacing the engine flywheel ring gear

Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, NO TAG) by using a nor-
mal beater, then mount the new gear ring after previ-
ously heating it to 150 °C for 15’ to 20’; the countersink
made on the gear ring inner diameter must face the
engine flywheel. Figure 142
α
Figure 140
86585
Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
86575 - 2nd phase: tighten to an angle of 60° ± 5°.
Screw down two pins (2) of adequate length into the IMPORTANT -- Angle tightening is carried out by
shaft holes (3), then remove the engine flywheel (1) means of tool 380001001.
by means of suitable harnesses and a hoist.
EW--2--73
Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 146
Figure 143
86586
70220
Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 144
Figure 147
86587
Apply sealant (1) as shown in the figure, then put on 70221
small cover (2) and tighten screws to the specified tor-
que. Apply a new seal ring (2) onto water pump (1).
Figure 145
Figure 148
84260
Remove plug (1) from the distribution gear seat 70222

Figure 45.
Mount water pump (1).
Remove presetting screw (2) and insert L--shaped Fasten screws (2) and tighten them to the specified
spacer (1). Fasten again the screw to its abutting end. torque.
EW--2--74
70223
Take seal ring (2) off front cover (1), clean thoroughly 86577
the attaching surface and apply sealant LOCTITE
5205 onto the same. Mount oil sump (1).
Figure 150 Fasten screws (2) and tighten them to the specified
torque.
70224
Clean thoroughly the surface of front cover (2) attach-

ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
Figure 153
Figure 151
70225 86588
Apply part (5) of tool 380000983 on drive shaft front Force--fit pulley (1) complete with spacer (2) onto the
shank (6), secure it by means of screws (4) and force-- drive shaft, then torque--tighten and angle--tighten the
fit the new seal ring (3) on the same. screws by means of tool 380001001.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in front cover (7). Secure guide pulleys (4) to the front cover by means
of screws (3).
EW--2--75
Mounting the water / oil heat exchanger Figure 156

Figure 154
84175 86589
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support.
gasket (1), heat exchanger (2), a new gasket (3), and
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Applicare la nuova cartuccia filtro olio.
Cylinder head
Removing the valves
Figure 157
Figure 155
84179
Valves can be removed by means of tool 380000987

84177
(1) by pressing slightly on collar (3) so that lock cones
(2) can be removed by compressing springs (4). Then
Position alternator support (1) in such a way that pins
remove collar (3) and springs (4).
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified Repeat the procedure on all valves.
torque.
EW--2--76
84282 86590
Take off oil seals (1) fitted to the valve stems.

Remove the thermostat unit (2) and brackets (1) and
To remove the valves, properly turn the head upside (3).
down.
IMPORTANT -- Mark the exhaust and intake

valves prior to removing them.
Checking the cylinder head supporting surface
INTAKE EXHAUST
84181 84183
In addition to the head dimensions, the exhaust The plane of the supporting surface of head (1) to cyl-
valves differ from intake valves in that they are inder cluster is checked by means of a ruler (2) and
equipped with a supplementary notch (1) obtained on a thickness gauge (3).
the stem for intake valves. The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
EW--2--77
Checking the cylinder head water seal VALVES

Check the water seal by means of suitable equipment. Figure 163
Use a pump to feed water heated to ∼ 90 °C at a pres- EXHAUST INTAKE
sure of 2 to 3 bar. VALVE VALVE
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.
IMPORTANT -- Prior to mounting the caps, apply

water--repellent sealant on the sealing surface of
the same.
If leaks are detected from the cylinder head, the latter

must be replaced.
84185
MAIN DATA OF INTAKE AND EXHAUST VALVES
Figure 162 Valve descaling, check and grinding
Figure 164
84284
Nominal thickness A of the cylinder head is 95 ± 0.25

84186
mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm. Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
IMPORTANT -- After regrinding, check valve sink- crimping or burns.
ing and regrind valve seats if required, to obtain
the required value. Adjust, if required, the valve seats with the proper
grinder, removing the least amount of material pos-
sible.
EW--2--78
Figure 165 VALVE GUIDE

Figure 167
84187
Use a micrometer (2) to measure valve stem (1),

which must be equal to 7.96 to 7.98. INTAKE EXHAUST
84046
Use a bore gauge to measure the valve guide inner

diameter, which must be equal to the value shown in
the figure.
Checking the play between the valve stem, VALVE SEATS

valve guide and valve centring
Valve seat reconditioning -- replacement
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). Check by reading the scorings
parator (1) placed as shown. Assembling play must and burns, use the tool (1) over it again according to
be equal to 0.039 to 0.079 mm. the tilting values indicated on the Figure 169.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
EW--2--79
Figure 169
INTAKE EXHAUST
84190
VALVE SEAT DIMENSIONS
Figure 170
EXHAUST INTAKE
86591
VALVE SEAT HOUSING DIMENSIONS
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same proper tool (1, Figure 168) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of the proper tool, according to the values shown in Figure 169.
EW--2--80
Figure 171 MOUNTING THE CYLINDER HEAD

Figure 173
84192 84282
After the reconditioning operations, verify, by means Lubricate the valve stem and insert into the respective
of base 380001000 (2) and comparator 380001004 valve guide according to the position marked upon
(1), that valve hollow (3) corresponds to the specified disassembling.
value.
Mount seal rings (1) onto the valve guide.
VALVE SPRINGS
Figure 172
84193
Figure 174
MAIN DATA FOR INTAKE AND EXHAUST
VALVE SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of the proper tool. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.
Height Under a load of

mm N
84179
H(Free) 63.50 No load
Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000987 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).
EW--2--81
Reattaching the cylinder head Figure 177

Figure 175
84113 84209
Verify that the cylinder head attaching plane and the Prior to inserting the pushrods, verify their state of
crankcase attaching plane are both clean. preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
Do not spoil the cylinder head gasket.
not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
IMPORTANT -- Prior to reusing the cylinder head they are interchangeable.
fastening screws, verify that they do not show Rocker arm assembly
traces of wear or deformations; otherwise, replace
them. Figure 178
84195
PARTS MAKING UP THE ROCKER ARM

ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
84265 84196
Mount the cylinder head on the crankcase by fastening MAIN DATA OF ARBOUR--ROCKER ARM
screws (1) without torque--tightening them. Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--82
84197
Verify that the tappet adjusters are unscrewed to pre- 84200

vent the latter from crawling on the rods when the Ad just the play between the rocker arms and the
rocker arm assembly (1) is mounted. valves by means of an Allen wrench (2), box wrench
Mount the rocker arm assembly made up of the ar- (3) and thickness gauge (1).
bours and rocker arm support, then secure them to
the head without torque--tightening screws (2) and The operation play is:
(3). -- intake valves: 0.25 ± 0.05 mm
Figure 181 -- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
FIRING ORDER 1--3--4--2
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
of cylinder valve no.
Mounting the injectors

Figure 184
84198
Fasten the head screws according to the instructions
given in Figure 182.
Figure 182
84285
Scheme of cylinder head fastening screw tightening
sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201
screw M12 x 1.75 x 70 [ ]50 Nm ± 5 Nm;

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; Mount a new seal ring (2) lubricated with petrolatum
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; and a new seal washer (3) on injector (1).
- 2nd phase: angle tightening: 90° Mount the injectors on their seats on the cylinder
- 3rd phase: angle tightening only for screws 140 head, then tighten them by means of a torque wrench.
and 180 mm long: 90°.
EW--2--83
86615 86570
Mount the injector feeding pipe assembly (1). Mount - Mount exhaust manifold (2).
the pipes for fuel discharge (2) from injectors, by using - Mount turbine (1) by means of screws (3).
gaskets (3) and by tightening screws (4).
Figure 188
86592
APPLICATION ON F4GE0454C
Figure 186
86593
APPLICATION ON F4GE0484G
The intake manifold unit is made up of manifold (6) on

84255 the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Mount the injection pump (6) injector feeding pipes
(5), then secure brackets (1), (2) and (3) fastening the Apply sealant LOCTITE 5205 between cover (5) and
pipe assembly onto the cylinder head. manifold (6), then tighten the screws to the specified
torque.
Mount priming pump (4).
EW--2--84
84252
86568 - Assemble the wiring harness (1).

- Mount tappet covers (4).
- Assemble the heater (2).
- Assemble the intake manifold elbow (3).
- Mount container control unit (5).
- Mount fuel filter support (6).
- Mount fuel filter (9).
- Attach quick coupling pipes (7), (10), (11) and (12)
by following the indications given in Figure 190.
- Mount electric wiring (8).
- Mount L.D.A. system piping (13).
- Connect the engine oil vapour recovery pipe to
blow--by (1).
Figure 192
Figure 190
86463
- Mount the starter motor (3).

70126
- Mount turbine lubricating oil return piping with its
Press the clamp (1) in arrow direction (Figure B) and respective fastening bracket.
connect the pipe. - Mount turbine lubricating oil delivery pipe and en-
Reset the clamp to the initial locking position A. gine oil pipes and to water / oil heat exchanger
unit.
EW--2--85
Figure 193 REPLACING THE INJECTORS

Removal
Figure 196
86594
- Assemble the thermostat unit (1) to the cylinder

head (3) and tighten the screws (2) to torque.
- Assemble the water temperature sensor (5) and
tighten it using the torque wrench. 86596
- Assemble the fan pulley support (6) on the head

(3) by means of screws (4), tighten the screws to Place the vehicle in safe conditions.
torque. Lift the engine compartment cover, disconnect the
battery cables and proceed as follows:
Figure 194
- disconnect engine oil vapour recovery pipe (2)
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
86595
Mount fan pulley (2) on support (1) by torque--tighten-

ing screws (3) to the prescribed torque.
86571 84082
Mount Poli--V belt (4) on pulley (5), drive shaft pulley, Remove injectors (2) by means of tool 380000982 (1)
guide pulleys (2), water pump (6) and on alternator and take them off the cylinder head.
(3); then, stretch the belt by acting on automatic belt
stretcher (3).
EW--2--86
Reassembling ROCKER ARM REMOVAL/REASSEMBLING

Figure 198 Removal
Figure 200
84081
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2).
84201
Remove screws (4) and dismount rocker arm assem-
bly (1) made up of the rocker arm support and ar-
Mount a new seal ring (2) lubricated with petrolatum bours, then take off valves.
and a new seal washer (3) on injector (1). Reassembling
Mount the injectors on their seats on the cylinder Verify that the tappet adjusters are unscrewed to pre-
head, then tighten them by means of a torque wrench. vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
torque of 36 Nm.
Ad just the tappets as described above.
Figure 199
84290
Mount new seal rings (1) on fuel manifolds (2).

Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
blow--by.
EW--2--87
ADJUSTING THE TAPPETS

Figure 201
84200
Ad just the play between the rocker arms and the FIRING ORDER 1--3--4--2
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
Adjusting cylinder
1 3 4 2
The operation play is: valve no.
Adjusting clearance
-- ± 0.05 mm of cylinder valve no.
4 2 1 3
– intake valves: 0.25 ± 0.05 mm
-- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
EW--2--88
Check priming of the injection pump Turn the engine shaft counter clockwise of a few de-
grees and then turn again in the opposite direction un-
til the P.M.S. is determined.
Figure 202
In this position, on the comparator (2) you will read the
pumping element pre--lift value prescribed.
Turn the pump counter clockwise if the stroke is lower,
or clockwise if the stroke is higher until the stroke pre-
scribed is achieved.
Then lock the pump with the fixing nuts to the couple
prescribed.
88141
Turn the engine shaft unit the piston of the 1st cylinder
near the P.M.S. and close the relevant valves (com-
pression stage).
Assemble tool 380000977 (1) and with the compara-
tor (2) in the seat of the injector of the 1str cylinder,
preload the comparator (2).
Figure 203
87720
With the injection pump inserted in the relevant seat

and the fixing screws loosened, assemble the
comparator 380001004 (2) and its holder 380001084
(1), preloading the rod of 2.5 mm.
Turn the engine shaft properly in order to determine
the exact PMS of the piston of the 1st cylinder and of
the injection pump pumping element, zero the
comparators (2, Figure 202 and 2, Figure 203).
SECTION 3
RECHARGING AND START--UP
INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--3--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--5
Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--5
Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--3--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--3--6

INDEX
EW--3--3
STARTER MOTOR
BOSCH -- 24 V -- 4 kW
Quick diagnosis
Fault Possible causes Remedy
Dragging torque insufficient 1. Batteries run down Restore

2. Circuit connections oxidized or Replace the component
loose
3. Brushes not in working order Replace the component
4. Short--circuited field windings Replace the component
5. Interruptedor short circuited ar-- Replace the component
mature
6. Out--of--round collector Replace the component
Dragging torque sufficient, but 1. Free wheel or faulty electro--ma-- Replace the component
the engine won’t start. gnet
Pinion won’t engage. 1. Bevelled ring gear Restore
EW--3--4
Bosch 24 V -- 4 kW
6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
84262 84267
WIRING DIAGRAM 3/4 VIEW
84268 84269
CHARACTERISTIC CURVES PINION ADJUSTER

EW--3--5
ALTERNATOR
BOSCH NCBI 28 V 35--70 A
Quick diagnosis
Fault Possible causes Remedy
No recharge 1. Interruption of recharge circuit Check the recharge circuit con--

(warning light, fuse, connector, nections, clean and tighten the
etc.) cable terminals on the alterna--
tor and battery
2. Voltage regulator not in wor-- Replace the component
king order
3. Interrupted rotor winding Replace the component
4. Worn brushes Replace the component
Poor recharge 1. Loose belt Apply correct tension

2. Faulty voltage regulator Replace the component
3. Excessive wear of rotor rings Replace the component
or brushes
4. Short--circuited diodes Replace the component
5. Short--circuited rotor winding(s) Replace the component
Excessive recharge 1. Loose circuit connections Check the connections to ter--

minals and cable terminals of
batteries, starter motor and al--
ternator
2. Voltage regulator not in wor-- Replace the component
king order
3. Earth fault Check earth connections
EW--3--6
Bosch NCBI 28 V 35--70 A

Thrre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.
Direction of rotation (control side) clockwise
Current delivered at 6.000 min--1 ≥ 55A
Rated voltage 28,5V
84270 84271
WIRING DIAGRAM 3/4 VIEW
84272 84274
CHARACTERISTIC CURVES OF CURRENT CHARACTERISTIC CURVES OF VOLTAGE

DELIVERY REGULATOR

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Copyright © New Holland

PROVEN PERFORMANCE PROVEN PERFORMANCE

REPAIR MANUAL FOR CNH U.K. ENGINES

Progressive page number for each group

Group number (if any)

This symbol regards safety.

Section 1 -- Diagnostics EW--1--1

Section 2 -- Engines overhaul: EW--2--1

Section 3 -- Recharging and start--up EW--3--1

MAIN ENGINE OPERATING ANOMALIES

1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

1 ENGINE WON’T START

Thermal starter in working order Replace.

Injection pump timed Verify correct timing as described in the relevant

Injectors in working order Check operation and adjust.

Prescribed compression ratio Overhaul the engine or make repairs only on

Fuel filters in working order Replace.

Fuel tank supplied correctly Refuel.

Water pump in working order Overhaul or replace the unit.

Thermostat in working order Replace.

Valve timing correct Check and perform correct timing.

Injection pump timed Check correct timing as described in the relevant

Cylinder head gasket in working order Replace.

Fan in working order Replace.

3 ENGINE LACKS POWER AND WORKS

Thermostat in working order Replace.

Fuel pump in working order Replace.

Injectors in working order Check operation and adjust them.

Injection pump timed Check correct timing as described in the relevant

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

Prescribed compression ratio Check and bench--adjust the injection pump.

Turbocharger in working order Repair or replace the unit.

ENGINE EXHAUST SMOKE BLACK OR

Air filter in working order Replace.

Thermal starter in working order Replace.

Injectors in working order Check operation and adjust them as described.

Injection pump timed Check correct timing as described in the relevant

L.D.A. device in working order Ad just the L.D.A. device.

Prescribed compression ratio Check by means of a Motometer 75301430 tool

5 ENGINE EXHAUST SMOKE GREY

The thermostat comes into operation correctly Replace.

Injectors in working order Check operation and adjust as described in S.I.

Injection pump timed Check correct timing as described in the relevant

Coolant level correct Possible flow of coolant into the combustion

6 ENGINE EXHAUST SMOKE LIGHT BLUE

7 ENGINE KNOCKS IRREGULARLY

Fuel tank filled Refuel and drain (if necessary).

Fuel filters in working order Replace.

Feeling circuit in working order Check the circuit and drain.

Regular idle speed Adjust.

Regular injection pump rates Bench--check the flow rates.

Intact valves Replace the valves.

9 ENGINE EXCEEDS MAX. REVS NUMBER

10 EXCESSIVE OR INSUFFICIENT OIL

11 EXCESSIVE FUEL CONSUMPTION

Air filter in working order Replace.

Correct injector adjustment Check operation and adjust them.

Correct injection pump adjustment Check and bench--adjust.

L.D.A. device in working order Adjust the L.D.A. device.

C D660 D603 D660 D606 D655 D605