F4HFE6131

NEF SERIES TIER
4B/STAGE IV
Industrial application
TIER 4B
F4HFE6131*B003
F4HFE613K*B004
F4HFE613N*B002
STAGE IV
F4HFE6131*B005
F4HFE613K*B005
F4HFE613N*B003
Technical and Repair manual

This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and

specialised personnel.
Before performing any operation check that the part relevant

to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles,
helmet, gloves, shoes, etc. and hoisting and transporting
equipment.
Operations are to be performed by following the indications

included here, using the special equipment indicated and
assuring proper repair, compliance with schedule and
operators safety requirements.
Each repair must aim to restore operating efficiency and safety

in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other

interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the

interventions and all the instructions that are not included on
this publication.
Data included in this publication may not be up-to-date

therefore subject to Manufacturers modifications that can be
added at any time for technical or commercial purposes and
also to meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed

on the unit, please get in touch with the FPT network before
starting any intervention.
It is forbidden to copy this text or any of its parts and all

illustrations included.
Publication edited by:

FPT Industrial S.p.A.
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P2D32N028 E - 1st Ed. 05.2014
NEF SERIES TIER 4B/STAGE IV INTRODUCTION 1
Introduction
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

PARTS INSTALLATIONS . . . . . . . . . . . . . . . . 9
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEY OF LECTURE OF THE HEADINGS

AND FOOTNOTES . . . . . . . . . . . . . . . . . . . 10
Print P2D32N028 E Base - May 2014

2 INTRODUCTION NEF SERIES TIER 4B/STAGE IV
Base - May 2014 Print P2D32N028 E

PREFACE
Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reat-
taching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assemblys elec-
tronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control
units peculiar to the electric system.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the fuel supply type and engine operation.
Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the
basis of their specific use.
Section 4 describes scheduled maintenance and specific overhauling.
Section 5 deals with removal and refitting of the main engine components.
Section 6 describes general mechanical servicing of the engine on the revolving stand.
Section 7 gives engine technical characteristics such as data, installation clearances and tightening torques.
Section 8 is about the tools necessary for performing these operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings
Danger for persons

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

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may some-
times cause the warranty to become null and void.
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Service operations
Example
1 1 = Seat of small end bush

Close applying the required torque + angular
2 = Seat of connecting rod bearings. value
2

Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than.
Machine finish
Maximum, peak
Undersized
Interference
Less than.
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 C
Damp Cold
Grease Winter
Temperature > 0 C
Sealant
Hot
Adhesive
Summer
Air bleeding Preload

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and mainten-
ance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from acci-
dentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dan-
gerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refilling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling.
Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is avail-
able to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energized.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarization of supply voltage in drive electronic central units (for instance, a wrong polarization of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body struc-
ture.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and star-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidations, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by FPT.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 CV
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1.014 CV
NOTE The unit CV is converted into hp for simplicity according to a 1:1 ratio
1 hp = 1 CV.
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
NOTE Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 273.15 K
0 F = 255.37 K
0 C = 32 F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

vehicle title number
Basic edition referred to When month - year update

Printout Language month - year editorial
number Publication is present (revi) to the basic
phase closing edition

F4HFE613 ENGINE 1
F4HFE613 ENGINE
Section
General specifications 1
Operational diagrams 2
Electrical equipment 3
Scheduled maintenance 4
Removal - refitting of main components 5
General mechanical overhauling 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix

2 F4HFE613 ENGINE

F4HFE613 ENGINE 3
UPDATING
Section Section name Description of change Page Date of revision

4 F4HFE613 ENGINE

F4HFE613 ENGINE SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . 3
HOMOLOGATION PLATE . . . . . . . . . . . . . . . . 3
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 4
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 5
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 6
ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE AND POWER TYPICAL CURVES . . . 8
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 20

2 SECTION 1 - GENERAL SPECIFICATIONS F4HFE613 ENGINE

IDENTIFICATION PLATE
Figure 1
209200
HOMOLOGATION PLATE
Figure 2
209172
TIER 4B (F4HFE6131*B003 - F4HFE613K*B004 - F4HFE613N*B002)

Figure 3
214980
STAGE IV (F4HFE6131*B005 - F4HFE613K*B005 - F4HFE613N*B003)
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code
F4HFE6131*B003
F4HFE613K*B004 N67 ENT Z W
F4HFE613N*B002
F4HFE6131*B005
F4HFE613K*B005 N67 ENT L W
F4HFE613N*B003

TECHNICAL CODE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize
its application and power output level. It is stamped on a side of crank-case, close to oil filter.
F4 H F E 6 1 3 1 * B 003
First number shows the injection system

0 = Common rail 4 valves
8 = Engine parts for lightweight
A...E = truck applications without derating
The other numbers show engine configuration
Emissions level:
A = TIER 4a
B = TIER 4full/STAGE IV
C = EURO 6
D = Not emissioned
E = STAGE 2
Performances:
1,2,3... A,B,C...= Engine power or torque level
Application:
0 = Other application 5 = Genset
1 = Trucks 6 = Marine
2 = Buses 7 = Industrial / Agricultural turbo eVGT
3 = Industrial / Agricultural 8 = Cars and derivatives
4 = Industrial / Agricultural 9 = Military
Engine main characteristics:

0 = Turbocharged CNG
1 = Turbocharged diesel i.d. aftercooled
2 = Naturally Aspirated diesel i.d
3 = Naturally Aspirated diesel i.i
4 = Naturally Aspirated petrol
5 = Naturally Aspirated CNG
6 = Turbocharged diesel i.d.
7 = Turbocharged diesel i.i.
8 = Turbocharged petrol
9 = Turbocharged diesel i.i. aftercooled
No. of cylinders
Cylinder configuration:
A = 4 stroke vertical E = 4 stroke vertical with post-treat
B = 4 stroke horizontal F = 4 stroke horizontal with post-treat
C = 4 stroke vertical with EGR G = 4 stroke horizontal with EGR + post treat
D = 4 stroke horizontal with EGR L = 4 stroke vertical with EGR + post treat
F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6
Code Type of base: Application

A Not structural ON-ROAD
D Structural OFF-ROAD
H Not structural OFF-ROAD
F4 = New Engine Family

COMMERCIAL CODE
The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical pur-
pose of recognizing the engines components, which is served by the ENGINE S/N.
N 67 E N T Z W
ENGINE CONTROL UNIT: W = EDC17CV41
EMISSION LEVEL: Z = Tier 4B / L = Stage IV
AIR INTAKE: T = INTERCOOLED TURBOCHARGED
ENGINE BLOCK: N = NOT STRUCTURAL
FUEL SUPPLY: E = ELECTRONIC INJECTION
DISPLACEMENT: 67 = 6.700 cc NOMINAL
ENGINE FAMILY IDENTIFIER: N = NEF

ISO VIEW
Figure 4
214981
F4HFE613 engine
The engine F4HFE613 is a 6-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the NEF series
and operates according to a four-stroke diesel cycle.
The engine supply system is electronically-controlled and its based on the direct injection of the fuel in the combustion chamber
by means of high pressure pump and common rail.
The intake and exhaust valves are timed with the camshaft tappets, the push rods and the rocker arm assembly.

TORQUE AND POWER TYPICAL CURVES

(F4HFE6131*B003 - F4HFE6131*B005)
Figure 5
Maximum Power
Maximum Torque 215037

(F4HFE613K*B004 - F4HFE613K*B005)
Figure 6
Maximum Power
Maximum Torque
214990

(F4HFE613N*B002 - F4HFE613N*B003)
Figure 7
Maximum Power
214991
Maximum Torque

ENGINE VIEWS
(F4HFE6131*B003 - F4HFE6131*B005)
Figure 8
214982
LEFT-HAND SIDE VIEW
Figure 9
214983
RIGHT-HAND SIDE VIEW

Figure 10
214984
FRONT VIEW
Figure 11
214985
REAR VIEW
Figure 12
214986
TOP VIEW

(F4HFE613K*B004 - F4HFE613K*B005)
Figure 13
214992
LEFT-HAND SIDE VIEW
Figure 14
214993

Figure 15
214994
FRONT VIEW
Figure 16
214500
REAR VIEW

Figure 17
214996
TOP VIEW

(F4HFE613N*B002 - F4HFE613N*B003)
Figure 18
214997
LEFT-HAND SIDE VIEW

Figure 19
214998

Figure 20
214999
FRONT VIEW
Figure 21
21500
REAR VIEW

Figure 22
214501
TOP VIEW

GENERAL CHARACTERISTICS
F4HFE613
Type
1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
Compression ratio 17 : 1 18 : 1
Maximum power kW 210 151 129

(hp) (286) (205) (175)
rpm 2,200 2,200 2,200
Maximum torque Nm 1,150 940 805

(kgm) (117.23) (95.82) (82.06)
rpm 1,500 1,500 1,500
Idle speed rpm 750 50
Maximum engine
speed rpm 2375 50
Bore x stroke 104 x 132
Total displacement cm3 6728

Turbocharged -
Turbocharged - with intercooler
with intercooler
TURBOCHARGING
BorgWarner
Turbocharger type BorgWarner Fixed geometry
Waste-gate turbocharger (WGT) turbocharger
(FGT)
Forced by gear pump,
LUBRICATION
pressure relief valve, oil filter
Oil pressure with engine hot:
bar
- at idle speed bar 0.6

- at maximum speed bar 3.5
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.
Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

F4HFE613
Type
1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
COOLING Liquid cooled
Coolant pump control Belt driven

Thermostat:
- start of opening C 79 2
- max. opening C 96
REFILLING
Cooling circuit (1)

litres 11
Lubrication circuit (2)
total capacity (3) litres (kg) 18 (16.2)
Periodic replacement:
- oil sump at min level

ACEA E9 litres (kg) 8 (7.2)
SAE10W-40 / API CJ-4
- oil sump at max level
litres (kg) 14 (12.6)
Fuel tank (4)
litres -
Urea tank (5) litres 43 / 65 / 80
(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and Actifull OT
even during the summer months. As an alternative to Actifull OT, use another product that complies with FPT norm
FPI9.COOL002 and / or ASTM D-6210 standard.
(2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9. Recommended oil is SAE 10W-40 that com-
plies with FPT norm FPI9.LUBR001. FPT suggest to use original AkcelA or AmbrA lubricants compliant with SAE 10W40 stan-
dard. The oil consumption is considered to be acceptable until a quantity equaling 0.5% of fuel consumption is reached.
(3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.
(4) Use STANDARD fuel compliant to the ASTM D975 or EN 590. Instructions connected to the fuel tank capacity are the re-
sponsibility of the vehicle/equipment manufacturer since these are subject to changes depending on the various vehicle/equip-
ment configurations.
(5) Only use AdBlue /DEF in accordance with ISO 22241 specification.
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.
Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.


F4HFE613 ENGINE SECTION 2 - OPERATIONAL DIAGRAMS 1
SECTION 2
Operational diagrams
Page
FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . 3
- General Specifications . . . . . . . . . . . . . . . . . . . 3
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- System functionality . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 5
- Fuel system layout . . . . . . . . . . . . . . . . . . . . . . 6
FUEL SUPPLY SYSTEM COMPONENTS . . . . . . 7
- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Mechanical supply pump . . . . . . . . . . . . . . . . . 8
- CP3 high-pressure pump . . . . . . . . . . . . . . . . . 9
- Pressure regulator description . . . . . . . . . . . . . 13
- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 14
- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . . 14
- Quick coupler for fuel return . . . . . . . . . . . . . . 15
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 17
- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 18
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 19
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Operation description . . . . . . . . . . . . . . . . . . . 23
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 24

2 SECTION 2 - OPERATIONAL DIAGRAMS F4HFE613 ENGINE
Page
- BorgWarner fixed geometry turbocharger

(FGT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Waste gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- BorgWarner fixed geometry turbocharger (FGT) 27
EXHAUST GAS AFTER-TREATMENT SYSTEM

(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Schematic diagram . . . . . . . . . . . . . . . . . . . . . . 28
- AdBlue specification . . . . . . . . . . . . . . . . . . . . . 32
- System of cooling/heating ATS system . . . . . . . 33
MAIN COMPONENTS OF THE ATS SYSTEM . 35
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Ad Blue fluid level gauge control . . . . . . . . . . . 36
- DeNOx 2.2 Supply Module (SM) . . . . . . . . . . . 37
- Filter disassembly . . . . . . . . . . . . . . . . . . . . . . . 39
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 40
- DeNOx 2.2 Dosing module (DM) . . . . . . . . . . 41
- Engine coolant 3 way valve . . . . . . . . . . . . . . . 41
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . . . . 43
- Exhaust gas temperature sensor . . . . . . . . . . . . 44
- Humidity and temperature detecting sensor . . 45
ATS SYSTEM MAINTENANCE PLANNING . . . 46

FUEL SUPPLY SYSTEM

General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
ELECTRIC SYSTEM
Figure 1
214987
1. Electro-injectors connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air
temperature sensor - 4. Rail pressure sensor - 5. Camshaft timing segment speed sensor - 6. Fuel temperature sensor -
7. Fuel high pressure pump metering unit - 8. Engine Control Unit ECU17CV41 - 9. Crankshaft rpm increment speed sensor
- 10. In line connector - 11. Engine oil pressure and temperature sensor - 12. Coolant temperature sensor
Sensors
Through the sensors, present on the engine, the ECU con- The outlet tension is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor

It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

Assembled on a rail end, it measures the fuel pressure in the The control unit, depending on information coming from
rail in order to determine the injection pressure. sensors, controls the flow rate regulator, and changes pre--
injection and main injection modes.
The injection pressure value is used to control the pressure
and to determine the electric injection control length. Closed-loop control for injection pressure
Fuel temperature sensor Depending on engine load, measured by processing signals
coming from various sensors, the control unit controls the
It is a sensor that is equal to the previous one.
regulator in order to always have the optimum pressure.
It measures fuel temperature to provide the control unit with
Pilot and main injection spark advance control
an index of the diesel fuel thermal state.
The control unit, depending on signals coming from various
Coolant temperature sensor sensors, computes the optimum injection point according to
It is a variable-resistance sensor suitable to measure the an internal mapping.
coolant temperature to provide the control unit with an Idle speed control
index of the engine thermal state.
The control unit processes signals coming from various
Crankshaft sensor sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
It is an inductive sensor placed on the front engine part. Sig- time of injectors.
nals generated through the magnetic flow that is closed on Within certain thresholds, it also takes into account the bat-
the phonic wheel, change their frequencies depending on
tery voltage.
output shaft rotation speed.
Maximum speed limiting
Timing sensor Approaching the peak rpm, the ECU limits the fuel flow by
It is an inductive sensor placed on the engine rear left part. reducing the opening time of the electro-injectors.
It generates signals obtained from magnetic flow lines that are The peak rpm of the engines is 2375 50 revs/min. Above
closed through holes obtained on the keyed gear on the cam- this rate the ECU deactivates the electro-injectors.
shaft. The signal generated by this sensor is used by the ECU
as injection phase signal. Cut Off
Fuel cut off upon release is controlled by the control unit per-
Though being equal to the flywheel sensor, it is NOT inter-
forming the following logics:
changeable since it has a different outside shape.
- it cuts off injectors supply;
System functionality - it re-activates the injectors shortly before idle speed is
reached;
Self-diagnosis - it controls fuel flow rate regulator.
The ECU self-diagnostic system checks signals coming from
sensors by comparing them with threshold data. Smoke control upon acceleration
With strong load requests, the control unit, depending on sig-
Engine pre-heating resistance check nals received by air inlet meter and engine speed sensor, con-
The pre-post heating is activated when even only one of the trols the flow rate regulator and changes the injectors actu-
water, air or fuel temperature sensors signals a temperature ation time, in order to avoid exhaust smokes.
that is less than 5 C.
Fuel temperature control
Timing recognition When the fuel temperature exceeds 78 C (measured by the
By means of signals coming from camshaft sensor and fly- sensor placed on fuel filter) the control unit intervenes by
wheel sensor, the cylinder on which fuel must be injected is reducing injection pressure.
recognised upon startup. If the temperature exceeds 90 C, the power is reduced to
60%.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the fol-
lowing startup.

HYDRAULIC SYSTEM
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energized by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
Figure 2
High Pressure
Low Pressure 214988
Fuel outlet
1. Electro-injector - 2. Common Rail - 3. Fuel mechanical pump - 4. Fuel high pressure pump - 5. Fuel filter -
6. Engine Control Unit ECU17CV41
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit.
The high pressure circuit is composed of the following pipings:
- piping connecting high pressure pump outlet to common rail;
- common rail;
- pipings supplying injectors from common rail.
The low pressure circuit is composed of the following pipings:
- fuel suction piping from tank to pre-filter with manual priming pump;
- pipings supplying the mechanical pump through the engine control unit heat exchanger;
- pipings supplying the high pressure pump through the fuel filter.
The fuel draining circuit from common rail, injectors and high pressure pump backflow complete the system.

Fuel system layout The quick coupler for fuel return (11) housed on the cylinder
The flow rate regulator (6), placed upstream of the high-pres- head, assembled on injector return, limits the fuel return flow
sure pump, adjusts the fuel flow that is necessary on the low-- from injectors.
pressure system. Afterwards, the high-pressure pump takes Two by-pass valves are placed in parallel with the mechanical
care of supplying the rail properly. This arrangement, by pres- supply pump.
surising the necessary fuel only, improves the energetic effi-
ciency and limits fuel heating in the system. The by-pass valve (17) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure
Function of the pressure relief valve (8), assembled on the exceeds the allowed threshold value.
high-pressure pump, is keeping the pressure, at the flow rate
regulator inlet, constant at 5 bars, independently from the The by-pass valve (18) allows filling the supply system
efficiency of the fuel filter and of the system set upstream. through the manual priming pump (3).
Figure 3
High pressure
Low pressure
Fuel outlet
213604
HYDRAULIC SYSTEM DIAGRAM
1. Fuel tank - 2. Prefilter - 3. Manual pump - 4. Control unit - 5. Fuel filter - 6. Flow rate modulator -
7. High pressure pump - 8. Limiting valve on high pressure pump, 5 bar - 9. Mechanical supply pump - 10. High pressure
pump reflux pipe - 11. Quick coupler for fuel return from the injectors - 12. Return pipe - 13. Common rail excess pressure
valve - 14. Common rail - 15. Pressure sensor - 16. Injector - 17. By-pass valve - 18. By-pass valve
Fuel filter connections:

A. Outlet connection to high-pressure pump
B. Outlet connection for fuel discharge to the tank
C. Inlet connection for fuel discharge from high pressure pump
D. Inlet connection for fuel discharge from common rail and injectors
E. Inlet connection from mechanical supply pump
FUEL SUPPLY SYSTEM COMPONENTS Fuel filter

Fuel prefilter It is located on engine block in the circuit between feed pump
and high pressure pump (CP3).
On the support there are located: fuel temperature sensor
Figure 4 and heater resistances.
Fuel temperature, signalled by relating sensor to
EDC17CV41 central unit, enables a very accurate calculation
of the flow rate of fuel to be injected into the cylinders.
The electric heater is activated when the fuel temperature is
less than 0 C and deactivated when the fuel temperature
exceeds 5 C.
Figure 5
70494
The fuel filter is of the high water separation type, is

assembled on the vehicle chassis, and has the sensor (4) for
detecting water in fuel placed on the cartridge (3) base.
Manual priming pump (5) and air bleeding screw (2) from sys-
tem are located on filter support.
The presence of condensate into filter is signalled by sensor
(4) when a warning light on the instrument panel is lit. 99231
1. Fuel filter support - 2. Fuel temperature sensor -

3. Electric fuel heater - 4. Fuel filter - 5. Adapter -
6. Heater connector - 7. Gasket
If the warning light is on, it is necessary to im-
mediately operate to remove its cause; the com- Fuel filter connections:
mon rail system components are quickly damaged
A. Outlet connection to high-pressure pump
by the presence of water or impurities in the fuel.
B. Outlet connection for fuel discharge to the tank
C. Inlet connection for fuel discharge from high pressure
pump
D. Inlet connection for fuel discharge from common rail and
injectors
E. Inlet connection from mechanical supply pump

Mechanical supply pump Bleeding conditions

Feed mechanical pump is a gear pump, mounted on high
Figure 8
pressure pump rear side, having the task of feeding high pres-
sure pump. It is driven by high pressure pump shaft.
Normal operating conditions
Figure 6
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this situ-
72592 ation the by-pass valve (1) stays closed whereas by-pass valve
(2) opens due to inlet pressure, and fuel is drained out
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass through B.
valves in close position
Overpressure condition at outlet

NOTE The mechanical supply pump cannot be replaced
individually, therefore it cannot be removed from
Figure 7 the high pressure pump.
72593
The by-pass valve (1) cuts in when overpressure is generated

at outlet B. The existing pressure, overcoming valve spring (1)
elastic strength, makes inlet and outlet communicating
through duct (2).

CP3 high-pressure pump

CP3 high pressure pump is a pump with 3 radial plungers which is driven through a timing system gear. High pressure pump
does not require timing. On high pressure pump rear side, feed mechanical pump is mounted, driven by high pressure pump
shaft.
NOTE The high pressure pump cannot be serviced and should not therefore be removed and the fastening bolts should not
be tampered with.The only possible service operation is the replacement of the drive gear.
Figure 9
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Fuel flow rate regulator - 4. Control gear - 5. Fuel inlet fitting from fil-
ter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from
supply pump to filter - 9. Mechanical supply pump

High-pressure pump - inside structure

Figure 10
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft -
7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts.
Each plunger is made up of:

- one piston (5) driven by a three-lobe element (2) floating on pump shaft (6). Element (2) is floating on a misaligned side
of shaft (6). Therefore, during shaft rotation, the element is not turning together with the shaft, but is just translated, according
to a circular movement, to a wider radius. It results that the three pumping assemblies are driven alternatively;
- one cap intake valve (3);
- one delivery ball valve (4).

Operating principle
Figure 11
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply duct
- 6. Pressure regulator supply duct - 7. Flow rate regulator.
Plunger (3) is oriented towards the cam that is present on pump shaft (4). During suction stroke, the plunger is fed through feed
duct (5). The quantity of fuel to be sent to the plunger is set by flow rate regulator (7). Flow rate regulator, on the basis of PWM
command received by control unit, partialises fuel inflow to the plunger. During plunger compression stroke, fuel reaches such
a pressure that valve delivering the fuel to common rail (2) is opened and common rail is fed by the plunger through outlet (1).

Figure 12 Figure 13
72601
72598
Sec. C C Sec. A A
1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
inlet - 4. Main plunger supply duct - 5. Flow rate from pump with high pressure pipe fitting for common rail.
regulator - 6. Plunger inlet - 7. Regulator exhaust duct -
8. 5 bar pressure relief valve - 9. Fuel drain from regulator
inlet.
Figure 12 shows low pressure fuel paths inside the path and Figure 13 shows high pressure fuel flow through plunger out-
highlights: main plunger supply duct (4), plunger supply ducts let ducts.
(1 3 6), pump lubrication ducts (2), flow rate regulator
(5), 5 bar pressure relief valve (8) and fuel drain duct (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
Flow rate regulator (5) establishes the fuel amount to send
to plungers; excess fuel is drained out through duct (9).
5 bar pressure relief valve acts as fuel return regulator and
keeps 5 bar constant pressure at regulator inlet.

Pressure regulator description Figure 15

The fuel pressure regulator is fitted on the low pressure
circuit of pump CP.3. The pressure regulator modulates the
amount of fuel sent to the high-pressure circuit according to
the commands received directly from the engine control unit.
The pressure regulator is mainly composed of the following
components:
- connector,
- casing,
- solenoid,
- pre-load spring,
- shutter cylinder. 185437
When there is no signal, the pressure regulator is normally 1. Solenoid - 2. Magnetic core - 3. Preload spring -
open, therefore with the pump providing maximum delivery. 4. Shutter cylinder.
The engine control unit, via the PWM (Pulse Width When the solenoid (1) is not energized, the magnetic core
Modulation) signal, modulates the change in fuel flow rate in is pushed into the rest position by the pre-load spring (3). In
the high-pressure circuit by partially closing or opening the this position the shutter cylinder (4) allows the greatest
sections of passage of the fuel in the low-pressure circuit. section of passage for the fuel flow.
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the plungers (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the flow rate regulator, placed on the low-pres-
sure system; the flow rate regulator is controlled by the
EDC17CV41 control unit through a PWM signal.
When fuel is sent to a plunger, the related piston is moving
Operation downwards (suction stroke). When the piston stroke is
reversed, the intake valve closes and the remaining fuel in the
Figure 14 plunger chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure cir-
cuit.
The plunger compresses the fuel till the top dead center
(delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The plunger piston goes back towards the bottom dead cen-
ter and the remaining fuel is decompressed.
When the plunger chamber pressure becomes less than the
supply pressure, the intake valve is again opened and the
cycle is repeated.
185436
The delivery valves must always be free in their movements,
free from impurities and oxidation.
1. Solenoid - 2. Magnetic core - 3. Shutter cylinder - The pressure of fuel delivered to rail is modulated by elec-
4. Fuel inlet - 5. Fuel outlet. tronic control unit through flow rate regulator solenoid valve.
When the engine control unit operates the pressure The pump is lubricated and cooled by the fuel.
regulator (via PWM signal), the solenoid (1) is energized, The radialjet pump removal refitting time on the engine is
which in turn generates the movement of the magnetic core highly reduced in comparison with traditional injection
(2). The shift of the core causes the shutter cylinder (3) to pumps, because it does not require setting.
move axially, choking the flow of fuel.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.

Rail Electro-injector
Figure 16 The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position

Figure 17
209187
1. Rail - 2. Pressure sensor - 3. Fuel inlet from high pres-

sure pump - 4. Overpressure valve - 5. Adjustment valves -
6. Fuel outlet
The rail volume is of reduced sizes to allow a quick pressurisa-
tion at startup, at idle and in case of high flow-rates. It anyway
has enough volume as to minimise use of plenum chambers
caused by injectors openings and closings and by the high--
pressure pump operation. This function is further enabled by
a calibrated hole being set downstream of the high-pressure
pump. 15
The throttle valves or control bushes (5) have been fitted to
the fuel delivery couplings, which control the fuel pressure
waves generated by the high pressure pump.
A fuel pressure sensor (2) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a feed--
back information, depending on which the rail pressure value
is checked and, if necessary, corrected.
Overpressure valve
Overpressure valve is mounted at one rail end. Overpressure
valve task is to protect system components should rail pres-
sure sensor or CP3 pump pressure regulator malfunctioning
cause a pressure excessive increase in high pressure system.
When pressure in rail is reaching 1750 bar, the valve at start
operates in order to make fuel flow and consequently 70505
decrease pressure to safety values, then mechanically regu-
lates pressure in rail. The valve enables to operate engine for
long times with limited performance and prevents fuel 1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot
excessive overheating, so preserving pipes for fuel return to valve - 6. Ball shutter - 7. Control area - 8. Pressure
tank.. chamber - 9. Control volume - 10. Control duct -
11. Supply duct - 12. Control fuel outlet - 13. Electric
connection - 14. Spring - 15. High-pressure fuel inlet.
Rail nominal pressure 1600 bar

Overpressure valve opening start 1750 bar
Overpressure valve full opening 1950 - 100 bar

Injection start Quick coupler for fuel return

Figure 18 It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors.
Figure 19
15
186859
A. To tank
B. From injectors
70506
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot

valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control duct -
11. Supply duct - 12. Control fuel outlet - 13. Electric
connection - 14. Spring - 15. High-pressure fuel inlet.
When coil (4) is energised, it makes shutter (6) move

upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore

it must not be disassembled.

LUBRICATION Lubrication involves the heat exchanger as well, the turbo--

blower and the eventual compressor for any eventual com-
Lubrication by forced circulation is achieved through oil
pressed air system.
rotary expansion pump, placed in the front part of the base-
ment, driven by the straight-tooth gear splined to the shafts All these components may often vary according to the spe-
bar hold. cific duty and will therefore be examined in the specific sec-
tion.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Figure 20
Routing of oil under pressure
Routing of oil return by gravity to sump
Introduction of oil
215007
1. Turbocharger lubrication oil delivery pipe - 2. Lubricant oil filler cap - 3. Rocker arm shaft hole - 4. Camshaft bush -
5. Main half-bearings - 6. Connecting rod half-bearings - 7. Oil sump - 8. Oil suction - 9. Crankshaft transverse channels -
10. Piston cooling nozzles - 11. Rotary oil pump - 12. Turbocharger lubrication oil discharge pipe - 13. Oil filter -
14. Heat exchanger lubricant oil / coolant

Oil pump
Figure 21
70576
Housed in the front of the crankcase, the oil pump is a rotary

pump commanded by a spur gear fitted to the stub of the
crankshaft.
NOTE Since the oil pump cannot be overhauled. It shall

be replaced when damaged.
Heat exchanger
Figure 22
200097
1. Oil filter support - 2. Lubricant pressure control valve - 3. By-pass valve to cut off clogged oil filter - 4. Internal heat
exchanger gasket - 5. Heat exchanger lubricant oil / coolant - 6. Gasket between heat exchanger and crankcase

Oil pressure relief valve

Figure 23
Loosen the plug (1), withdraw the spring (2) and the relief
valve (3) from the support (4).
Check whether the valve (3) is not scored and is sliding
smoothly into its seat. The spring (2) shall not be broken or
yielded.
Pressure regulation at 100 C oil temperature: 107418
- 1.2 bar min pressure; By-pass valve (5) to cut out clogged oil filter.
- 3.8 bar max. pressure
Figure 24 Figure 25
Flow
70482
107419 Max blow-by:
MAIN DATA TO CHECK OIL PRESSURE RELIEF 20 cm3/1 at 0.83 bar pressure and at 26.7 C oil temperature.
VALVE SPRING

OIL VAPOUR RECYCLING

Figure 26
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

COOLING SYSTEM
The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:
- Expansion tank; placement, shape and dimensions are subject to change according to the engines equipment.
- Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will
have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
- Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be
specifically equipped based on the engines development.
- Heat exchanger to cool the lubrication oil: even this component is part of the engines specific equipment.
- Centrifugal water pump, placed in the front part of the engine block.
- Thermostat regulating the circulation of the cooling liquid.
- The circuit may eventually be extended to the compressor, if this is included in the equipment.
Figure 27
Water recirculating in engine A
Water coming out from

thermostat
1
Water cooling motorised throttle valve
actuator
Water coming into pump
2
3
8
6
4
209190
A = Engine coolant outlet pipe

(to radiator)
B = Engine coolant inlet pipe
B (from radiator)
COOLING SYSTEM LAYOUT

1. Thermostat to regulate temperature - 2. Cylinder head cooling channels - 3. Cylinder head gasket - 4. Water pump -
5. Heat exchanger lubricant oil / coolant - 6. Coolant chamber around the cylinder liners - 7. Motorised throttle valve
actuator water return pipe - 8. Motorised throttle valve actuator water delivery pipe

Water Pump
Figure 28
70486
Sec. A-A
The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt.
An automatic tensioner keeps the belt tension.
Pump performances
Coolant fluid temperature: 100 5 C
Anti-freeze concentration: 50%
Pump speed [rpm] Flow [L/min] Pressure [bar]

5,000 210 2.00 : 2.45
2,500 110 0.50 : 0.65

Thermostat
The thermostat, located in the cylinder head, is of the by-pass type and doesnt need regulations.
If there are doubts as to its proper functioning, replace it.
The basic parts of a thermostat are: heat motor, which includes a valve attached to a piston that is embedded in a special wax,
flange, spring and frame.
The thermostat has a jiggle pin that allows trapped air in the cooling system to pass through the thermostat and be released
from the system.
The thermostat has two important jobs:
- Accelerate engine warm-up by blocking the circulation of coolant between the engine and radiator until the engine has
reached its predetermined temperature.
- Regulate the engines operating temperature by opening and closing in response to specific changes in coolant temperature
to keep the engines temperature within the desired operating range.
Figure 29
209191
1. Flange - 2. Stem (piston) - 3. Frame - 4. Min. stroke at full opening temperature - 5. Jiggle pin - 6. Flange seal -
7. Main spring - 8. Wax slug - 9. By-pass valve
Thermostat performances
Min. allowed working temperature: -40 C
Max. allowed working temperature: 135 C
Max. allowed peak temperature (5 minutes): 150 C
Max. working differential pressure: 3 bar
Opening start: 79 2 C
Full opening temperature: 96 C
Min. stroke at full opening temperature: 7.5 mm

Operation description
- When the engine is cold, the thermostat is normally closed; restricting flow to the radiator allowing the engine to warm-up;
- As the engine warms, the increase in heat causes the wax to melt and expand, pushing against a piston inside a rubber boot;
- This forces the piston outward, opening the thermostat so coolant can start to circulate between the engine and radiator;
- As heat increases, the thermostat continues to open until engine cooling requirements are satisfied;
- If the temperature of the circulating coolant begins to drop, the wax element contracts; allowing spring tension to close
the thermostat, which decreases coolant flow through the radiator.
Figure 30
209198
A. Thermostat closed (coolant to water pump through by-pass port)

B. Thermostat open (coolant to radiator)

TURBOCHARGING
The adoption of turbocharging makes it possible to increase the power developed by the engine by emitting, at each cycle, a
quantity of combustive air greater than what the engine would have been able to intake naturally through the alternatingmotion
of the pistons.
A greater quantity of air emitted into the combustion chamber makes it possible to completely burn a higher quantity of fuel,
so as to respect the optimal stoichiometric ratio.
The turbocharging system is composed of: air filter, turbocharger and intercooler.
The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable.
The function of the turbocharger is to use the energy of the engines exhaust gas to deliver pressurized air to the cylinders.
The intercooler is composed of a radiator applied to the engine coolant radiator, with the function of lowering the turbocharger
output air temperature before it is sent to the cylinders.
Figure 31
AIR FILTER TURBOCHARGER
EXHAUST
INTERCOOLER
74195
The turbocharger consists of a rotating turbine, set in rotation by the exhaust gases during operation of the engine, and a rotating
compressor keyed by a shaft connecting the turbine. The compressor, driven by the turbine, compresses the air sucked through
the filter.
The air is then cooled by the intercooler and sent to the cylinders via the intake manifold.

BorgWarner waste-gate turbocharger (WGT)

(F4HFE6131*B003 - F4HFE6131*B005 - F4HFE613K*B004 - F4HFE613K*B005)
The turbocharger is fitted onto the exhaust manifold.
Figure 32
1
2
intake air
3
compressed air
exhaust gas
209192
1. Waste-gate valve - 2. Air compressor - 3. Gasket on exhaust manifold - 4. Exhaust gas turbine
The turbocharger mainly consists of:

- a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor
impellers;
- a turbine casing and a compressor casing mounted on the end of the central body;
- an overpressure relief valve (waste-gate) fitted to the turbine body. The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the exhaust pipe, when the boosting pressure downstream the
turbocharger reaches the calibration value.
Figure 33
Closed throttle valve Throttle valve open 75532
DEMONSTRATIVE CROSS-SECTION OF A TURBOCHARGER

WITH WASTE-GATE VALVE
Apply the magnetic-base dial gauge (2) on the exhaust gas

NOTE Verifying an anomalous operation of the engine, inlet flange in the turbine.
due to the booster system, it is recommended,
Position the tracer point of the gauge (2) on the tie rod (3)
before performing controls on the turbocharger, to
end and set to zero the gauge (2).
check the efficiency of the sealing gaskets and the
fixing of the connection sleeves, making sure of Through the pump (1) let in compressed air, in the actuator
clogging absence inside intake sleeves, air cleaner (6), at the prescribed pressure and make sure that such value
or inside radiators. is kept constant for the whole check time, otherwise replace
If the turbocharger damage is due to a lack of lubric- the actuator (6).
ation, check that the oil circulation pipes are not
broken or obstructed, in such case replace them or In the above-mentioned conditions, the tie rod must have
eliminate the trouble. carried out the prescribe stroke.
Bearing end play check NOTE During the operation, beat slightly the actuator (6)
in order to eliminate possible sticking of the actu-
Position the tracer point of the magnetic-base dial gauge on ator internal spring.
the turbocharger shaft end and set to zero the dial gauge.
Move the turbocharger shaft axially and check that the clear-
ance is not higher than the prescribed value. If a different value is found, loosen the nut (5) and operate
properly the knurled ring nut (4).
Replace the turbocharger if a different value is found.
Waste gate
The turbocharger is fitted with a pressure regulation valve,
mounted on the exhaust manifold before the turbine and
controlled by a pneumatic actuator, connected via a pipe to
the intake manifold.
Actuator replacement
Its job is to limit the quantity of exhaust gas acting on the tur-
bine by sending part of it directly into the exhaust pipe when Figure 35
the boost pressure downstream of the compressor reaches
the maximum value set.
Check and adjustment

Figure 34 5
3 2 1
166070
Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
Remove the nuts (2) and remove the actuator (1) from the
62873 supporting bracket. Fit the new actuator following the
Cover the air, exhaust gas and lubrication oil inlets and out- removal operations in reverse order and fitting a new clip (4),
lets. tighten the nuts (2) to 5.6 6.8 Nm torque.
Carry out an accurate external cleaning of the turbocharger, Check and adjust the actuator (1), if required, as described
using the anticorrosive and antioxidant solution and perform in the relevant chapter.
the check on the actuator (6). Then, paint the nut (6) with safety paint.
Clamp the turbocharger in a vice. Before refitting the turbocharger on engine, fill the central
Disconnect the pipe of the actuator (6) and apply to the actu- body with engine oil.
ator union, the pipe of pump 99367121 (1).

BorgWarner fixed geometry turbocharger (FGT)

(F4HFE613N*B002 - F4HFE613N*B003)
The turbocharger is fitted onto the exhaust manifold.
Figure 36
215002
intake air
compressed air
exhaust gas
1. Air compressor - 2. Gasket on exhaust manifold - 3. Exhaust gas turbine
The turbocharger mainly consists of:

- a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor
impellers;
- a turbine casing and a compressor casing mounted on the end of the central body;

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
Figure 37
Exhaust gas
Compressed air
Intake air
Coolant engine
Electric line
AdBlue
CAN
CAN
CAN
C
U SCR DOC
C
185019
1. Intake manifold - 2. Exhaust manifold - 3. Air Intercooler - 4. Air Filter - 5. Intake air humidity & temperature sensor -
6. T/C compressor - 7. T/C turbine - 8. Exhaust flap module - 9. NOx sensor - 10. Exhaust gas temperature sensor -
11. Dosing module - 12. Temperature sensor - 13. Exhaust gas temperature sensor - 14. Exhaust gas temperature sensor -
15. NOx sensor - 16. NH3 sensor - 17. NH3 sensor ECU - 18. Supply module Denox 2.2 - 19. AdBlue tank - 20. AdBlue
tank level sensor - 21. Urea Quality sensor - 22. Engine coolant 3 way valve - 23. Engine Control Module (EDC17CV41).
In order to reduce exhaust gas emissions to within the limits required by current standards, it has proved necessary to adopt
the exhaust gas after-treatment system (ATS) which combines two devices:
- two catalytic converters for the treatment of HC (unburned hydrocarbons) and CO (carbon monoxide);
- the device DeNOx 2.2 for the treatment of NOx (nitrogen oxides).
The ATS system is electronically managed by the ECU EDC17CV41 which, based on the number of engine revs, delivered
torque, exhaust gas temperature, amount of nitrogen oxides and air humidity intake, regulates the flow rate of the AdBlue
solution to be introduced into the system.
The pump module draws the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.

Figure 38
AdBlue
Electric line
Coolant engine
185020
1. Can line - 2. AdBlue tank - 3. AdBlue tank level sensor - 4. Urea quality sensor - 5. AdBlue temperature sensor -
6. Engine Control Module (EDC17CV41) - 7. Umidity and temperature sensor - 8. NOx sensor ECU - 9. NH3 sensor ECU
- 10. Supply module Denox 2.2 - 12. NH3 sensor - 13. NOx sensor - 14. Temperature sensor - 15. Clean Up Catalyst
(CUC) - 16. Selective catalyst reduction (SCR) - 17. Temperature sensor - 18. Mixer - 19. Dosing module - 20. Exhaust gas
temperature sensor - 21. Diesel Oxidation Catalyst (DOC) - 22. Exhaust gas temperature sensor - 23. NOx sensor -
24. Engine coolant 3 way valve - 25. NOx sensor ECU.
The ATS system is essentially composed of:

- a DOC catalytic converter (Diesel Oxidation Catalyst);
- an SCR catalytic converter (Selective Catalyst Reduction);
- a CUC filter (Clean Up Catalyst)
- a tank of the reagent solution (water + urea: AdBlue) with level indicator, temperature sensor and Urea quality sensor;
- a H2O switch valve;
- a supply module;
- a dosing module;
- four exhaust gas temperature sensors;
- a humidity sensor mounted on the engine air suction pipe downstream of the air filter.
- two sensors to detect the amount of nitrogen oxides (NOx);
- a sensor to detect the presence of NH3 (ammonia) upon exit of exhaust gases.

Figure 39
185021
The catalytic converters perform two functions:

- the first is composed of a DOC (Diesel Oxidation Catalyst) which removes HC (unburned hydrocarbons) and CO (carbon
monoxide) from the exhaust gases;
- the second is composed of the SCR (Selective Catalyst Reduction) and the CUC (Clean Up Catalyst) upstream of which
are located the AdBlue dosing module and the mixer; this is where the reduction reactions of the NOx (nitrogen oxides)
take place.
In the first phase the exhaust gases exiting the turbine are conveyed into the DOC catalytic converter in which the hydrocarbons
(HC) and carbon monoxide (CO) added to oxygen O2 are converted into carbon dioxide (CO2) and water (H2O) through
oxidation reactions.
In the second phase the dosing module, located in the exhaust pipe upstream of the SCR catalytic converter, introduces a water
and urea solution (AdBlue) into the exhaust gases by means of a dosing injector.
The final phase of the process is realised in the SCR catalytic converter: the reagent solution, due to the temperature of the
exhaust gases, instantly evaporates and, by hydrolysis, is converted into ammonia (NH3) and carbon dioxide (CO2), at the same
time; the evaporation of the solution causes the lowering of the exhaust gas temperature, bringing it close to the optimum
temperature required for the process.
By reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).
The engine control unit, based on the number of engine revs, delivered torque, exhaust gas temperature, air humidity intake,
the amount of nitrogen oxides and urea present in the exhaust gases (detected by the respective sensors), regulates the flow
rate of the AdBlue solution to be introduced into the system.
The amount of AdBlue injected is controlled by the NH3 sensor located downstream of the SCR.
It detects the presence of ammonia in the exhaust gases and transmits a signal to the engine control unit, thus supplying a
feedback signal.

Figure 40
215036
1. DOC upstream NOx sensor - 2. Engine coolant 3 way valve - 3. Dosing module DeNOx 2.2 -
4. Intake air humidity and temperature sensor - 5. Supply module DeNOx 2.2 - 6. AdBlue tank -
7. AdBlue tank level sensor - 8. Urea quality sensor (UQS) - 9. Selective catalyst reduction (SCR) -
10. SCR upstream exhaust gas temperature sensor - 11. Exhaust flap module - 12. Diesel Oxidation Catalyst (DOC) -
13. DOC upstream exhaust gas temperature sensor - 14. SCR downstream exhaust gas temperature sensor -
15. NH3 sensor - 16. NH3 sensor ECU - 17. SCR downstream NOx sensor

AdBlue specification
ISO 22241 / AUS32 / DIN V 70070
Urea 32.5% - solution in water
Min. Max.
Urea content 31.8 33.2 % by weight
Density at 20C 1.087 1.093 g/cm3
Refracting index at 20C 1.3814 1.3843
Alkalinity as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chromium 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg

System of cooling/heating ATS system

The system performs two functions:
- continuous cooling of the dosing module;
- heating of the AdBlue tank, the supply module and AdBlue pipes and, at the same time, cooling of the dosing module.
Figure 41
Coolant engine
AdBlue
185019
COOLING CONDITION
1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.
The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures
reached by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously
cooled.

Figure 42
Coolant engine
AdBlue
185023
CONDITION OF SIMULTANEOUS HEATING AND COOLING

1. Dosing module - 2. Engine - 3. Engine coolant 3 way valve - 4. AdBlue tank - 5. Supply module.
Please note that AdBlue may freeze below temperatures of -11C.

When the temperature of AdBlue in the tank falls below the acceptable limit, the switch valve (3) is activated which enables
the flow of the engine coolant into the heating coil inside the tank (4) and hence into the supply module (5).
In this phase, the engine cooling temperature is such as to carry out the function of heating the components as described above.
Afterwards the engine coolant is conveyed towards the dosing module in order to cool its temperature.

MAIN COMPONENTS OF THE ATS SYSTEM

Tank
Figure 43
215387
The tank has a level indicator command (1) and contains the reducing substance, consisting of a 33% urea and water solution
called AdBlue. The inlet (4) is equipped with a mesh filter (3). A urea quality sensor (2) and a temperature sensor are
incorporated in the tank.
NOTE FPT recommends maintaining AdBlue temperature below 50 C in the tank during operating conditions.
Tank ventilation: the circuit must be protected from dust.

Ad Blue fluid level gauge control

Figure 44
215388
1. AdBlue suction - 2. AdBlue return - 3. Engine coolant outlet - 4. Engine coolant outlet pipe - 5. AdBlue heating coil -
6. Engine coolant inlet pipe - 7. Connector - 8. Engine coolant inlet - 9. Ad Blue suction pipe - 10. Filter - 11. Bottom plate
(AdBlue NTC temperature sensor) - 12. Float (AdBlue level sensor) - 13. Reed pipe - 14. AdBlue return pipe
The AdBlue fluid level gauge control consists of

- a float (level sensor);
- an NTC temperature sensor;
- a liquid heating coil in case of low temperatures.
It informs the control unit of changes in the current due to the resistance, caused by the position of the float in relation to the
level of the AdBlue liquid.
Frozen AdBlue can be melted by means of a coolant heater coil (5).
A solenoid which is actuated by the ECU controls the engine coolant flow through the AdBlue circuit / tank heater.
Urea quality sensor is integrated in the tank unit to fulfil rapid anti-tampering.
NOTE Ensure connectors are properly sealed with a moisture proof plug prior to AdBlue tank leak testing.
Temperature sensor: NTC type;

1k +/-5% @ 25C
Level sensor recommended characteristic: 70 at low level;
20k at high level

Electrical connections:
Figure 45
215389
Ref. Description
1 Level
2 Common ground
3 NTC signal (temperature)
DeNOx 2.2 Supply Module (SM)

Figure 46
185025
1. Main filter - 2. Electrical connector - 3. Pressure compensation membrane - 4. Supply pipe from tank - 5. Fluid input pipe
of pump module heating - 6. AdBlue return pipe to tank - 7. Fluid output pipe of pump module heating - 8. Delivery pipe
to dosing module
The AdBlue supply module is essentially composed of a diaphragm pump which draws the AdBlue from the tank and conveys
it to the dosing module.
It is equipped with a circuit connected to the engine cooling system which, in the event of low temperatures, prevents the AdBlue
from freezing. A pressure sensor is located inside it.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and
depend on the operating conditions of the engine and the signals sent from the sensors.
Electric power requirements of DeNOx 2.2 Supply Module (SM) for 7.2 kg/h:
24 Volt systems: max 2750 mA @ 28 Volt battery voltage

Figure 47
185029
1. Coolant connector - 2. AdBlue inlet from tank - 3. AdBlue back-flow to tank - 4. AdBlue outlet to DM - 5. Pressure
sensor - 6. Main filter - 7. Membrane pump - 8. 4/2 Way valve.
To prevent damage to the pump and dosing module, the supply module contains a filter which removes any impurities from
the AdBlue.
Please refer to the following procedure for replacement of the filter.

Filter disassembly Figure 51
Figure 48
185430
185435 - Insert the tool (1) in the correct direction in the filter,
based on the colour of the filter supplied
NOTE During installation of the supply module on the
vehicle, take into account the minimum aperture
for filter replacement. Figure 52
The minimum value is approx. 155 mm.
Figure 49
185431
- Insert the appropriate tool (1) until a click is felt which

indicates the complete engagement of the filter (2).
185428
- Unscrew and remove the filter cover (1).

Figure 53
Figure 50
185432
185429
- Remove the equalizing element (1). - Remove the filter (1).

Filter assembly Figure 57

Figure 54
185428
185433 - Carefully clean the filter cover (1).

- Carefully clean the contact surface with water (1). - Tighten the filter cover to a torque of 20 5 Nm.
Figure 55
Figure 58
185434
- Oil gaskets and assembly new filter (1).
185435
Figure 56
NOTE During installation of the supply module on the

vehicle, take into account the minimum aperture
for filter replacement.
The minimum value is approx. 155 mm.
185429
- Assembly a new equalizing element (1).
NOTE Check that the filter cover and the contact surface
of the supply module are not cracked or damaged.
If necessary, replace any damaged components.

DeNOx 2.2 Dosing module (DM)

Figure 59
185026
1. Electrical connector - 2. AdBlue inlet - 3. Coolant engine inlet/outlet
The dosing module is controlled by the engine control unit. Its function is to measure the AdBlue solution to be injected into
the exhaust pipe upstream of the SCR catalytic converter.
It is mounted on the catalytic converter and whilst operating is constantly subjected to high temperatures, hence it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
Hydraulic Capability of DeNOx 2.2 Dosing module (DM):
Normal circulation and no injection: ~ 8 kg/h
Maximum with the small urea injector: ~ 15 kg/h (8 kg/h + 7 kg/h)
Maximum with the large urea injector: ~ 20 kg/h (8 kg/h + 12 kg/h)
Engine coolant 3 way valve

Figure 60
180580
1. Electrical connector - 2. AdBlue tank heating fluid pipe - 3. Dosing module coolant pipe - 4. Engine coolant pipe.
The switch valve is of solenoid valve 2 position/3-way type. Depending on the temperatures detected by the NTC sensor, the
switch valve closes or opens the passage of the engine coolant into the AdBlue tank heating coil. The cooling circuit of the dosing
module instead always stays open.
The first position, in fact, allows the cooling of the dosing module (DM - Dosing Module) whereas the second position allows
the cooling of the AdBlue tank, the supply module (SM - Supply Module) and the relevant pipes, besides heating the DM.

NH3 sensor
Figure 61
185027
The NH3 sensor is connected to the engine control unit and, by detecting the presence of ammonia (NH3) in the exhaust gases
exiting the catalytic converter, enables a more accurate regulation of the amount of AdBlue to be injected.
Figure 62
185028
A. Vehicle connector - B. Sensor connector.

101. Supply - 102. Can H - 103. Can L - 104. Ground.
NH3 SENSOR CHARACTERISTICS NOMINAL

Normal operating voltage 10 to 32 V
Average current 1.2 A
Max current 4.0 A
Temperature / humidity rating -40 to 105 C

Nitric oxide sensor
Figure 63
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare

The NOx sensor detects the amount of nitrogen oxides in the exhaust gases entering and exiting the catalytic converters.
Based on this information the engine control unit regulates the amount of AdBlue to be injected and also measures the efficiency
of the catalytic converters.
CHARACTERISTICS OF NOx SENSOR VALUE

Ambient temperature electronics: - 40 to +105 C
(+105 to +115 C allowed for up to 10
min)
Wire temperature: 230 C allowed for up to 100 h

Exhaust gas temperature sensor
Figure 64
102303
Figure 65
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) -
5. Ground cable (white) - 6. Sensor.
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.
CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR VALUE

Power supply 5.00 V 0.1%
Output voltage @ Temperature -40 to 1000 C 0.727 to 2.297 V
Pull up resistance 1000 0.1%
Lead resistance 1

Humidity and temperature detecting sensor

Figure 66
125531
1. Supply - 2. Moisture indicator - 3. Ground connection - 4. Temperature

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to
the control unit. These data are used by the ECU to determine the level of nitrogen oxide emissions.
Figure 67
102312
ELECTRIC BLOCK DIAGRAM

1. Power supply - 2. Moisture percentage - 3. Ground - 4. Temperature - A. Sample frequency generator - B. Base oscillator -
C. NTC temperature sensor - D. Amplifier low pass filter
CHARACTERISTICS OF HUMIDITY SENSOR VALUE

Voltage supply 5.00 0.25 VDC
Current consumption 10 mA
Humidity operating range 0% RH 100% RH
Output impedance 70
Isolation resistance 1 M @ 500 V
CHARACTERISTICS OF TEMPERATURE SENSOR VALUE

Temperature operating range -40 125 C
Resistance at 25 C NTC 2.186 k 1%
Max power at 25 C 100 mW

ATS SYSTEM MAINTENANCE PLANNING

The general checking/inspection intervals which must be carried out on the ATS system components are as follows.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested
by common sense and by the specific conditions in which the engine is run.
In case of evident system malfunction immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Component Function Service-Requirement

Tank Neck Filter Protect tank during filling No regular service planned (Cleaning, if
(300 or 100* m) required)
SM Pre-Filter Protect SM from dirt coming from tank Cleaning @ every oil change interval
(100 or 70* m)
SM Inlet-Filter (100 m) Protect SM during 1st start-up No regular service planned (Replacement,
if required)
SM Main-Filter Protect DM Change every 3,600 hours or 2 years
(whichever occurs first)
SM Backflow-Filter Protect throttle in backflow connector from dirt No regular service planned (Replacement,
(100 m) coming from pressure line or dirt introduced during if required)
change of SM Main-Filter
Dosing Valve Filter Protect DM during 1st start-up Cannot be serviced
(36 m)
* for application working in dusty environment only.
Figure 68
185427
FILTER LOCATION
1. Dosing valve filter - 2. Dosing module - 3. SM Backflow-Filter - 4. SM Pre-Filter - 5. Tank pre-filter - 6. AdBlue tank -
7. SM Inlet-Filter - 8. Supply module - 9. SM main filter.

F4HFE613 ENGINE SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
ELECTRICAL COMPONET LAYOUT . . . . . . . . 3
- EDC17CV41 electronic control unit . . . . . . . . 4
EDC SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . 5
- Pin out EDC 17CV41 control unit -

Engine side connector 2 . . . . . . . . . . . . . . . 7

Vehicle side connector 1 (TwoBox layout) . 10

Vehicle side connector 1 (OneBox layout) . 13
- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Topographical wiring diagram - Engine side . . 17
- EDC 17CV41 control unit wiring diagram -

Vehicle side (part 1/2) . . . . . . . . . . . . . . . . . . . 18

Vehicle side (part 2/2) - TwoBox layout . . . . . 19

Vehicle side (part 2/2) - OneBox layout . . . . . 20
- Electroinjectors . . . . . . . . . . . . . . . . . . . . . . . . 21
- Camshaft timing segment speed sensor . . . . . 23
- Crankshaft rpm increment speed sensor . . . . . 24
- Boost pressure and air temperature sensor . . 25
- Engine oil pressure and temperature sensor . . 26
- Rail pressure sensor . . . . . . . . . . . . . . . . . . . . 27
- Coolant temperature sensor . . . . . . . . . . . . . . 28
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 29

2 SECTION 3 - ELECTRICAL EQUIPMENT F4HFE613 ENGINE
Page
- Fuel high pressure pump metering unit . . . . . . 30
- Pre-heating resistor (Grid-heater) . . . . . . . . . . 31
- Electric starter motor . . . . . . . . . . . . . . . . . . . 32
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Motorized throttle valve actuator connector

(Exhaust flap) . . . . . . . . . . . . . . . . . . . . . . . . . 34

ELECTRICAL COMPONET LAYOUT
Figure 1
215003
The electrical components available on the 6-cylinder NEF engines are listed here following.
1. Electro-injectors - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Rail pressure sensor -
4. Boost pressure and air temperature sensor - 5. Electric starter motor - 6. Camshaft timing segment speed sensor -
7. Fuel temperature sensor - 8. Fuel high pressure pump metering unit - 9. Engine Control Unit ECU17CV41 -
10. Crankshaft rpm increment speed sensor - 11. Engine oil pressure and temperature sensor - 12. Alternator -
13. Coolant temperature sensor

EDC17CV41 electronic control unit

The ECU processes the signals from the sensors by applying software algorithms and controls the actuators (especially the electro--
injectors and pressure regulator).It records, in the non-volatile memory area, the information on the engine parameters originally
set or acquired during engine operation.
The control unit is mounted on the left-hand side of the engine and two connectors are fitted, of which:
- a connector for the engine cable (injector and sensor connector);
- a connector for the chassis cable.
To reduce the number of connections, the length of the connection cables with the injectors and, as a result, disturbances in the
transmitted signal, the control unit is mounted directly on the engine by means of a heat exchanger that cools it, using elastic dowels
which reduce the vibrations transmitted by the engine.
Internally, there is an ambient pressure sensor that is used to further improve injection system management.
It is also equipped with a very advanced self-diagnosis system and it is capable of recognizing and memorizing, in function of the
environmental conditions, the possible anomalies, even of an intermittent type, that occurred on the system during operation,
ensuring a more correct and reliable repair action with the help of the FPT diagnostic instruments.
Figure 2
189003
1. Vehicle connector 1 - 2. Engine connector 2

EDC SYSTEM FUNCTIONS

The EDC 17CV41 electronic center manages the following main functions:
Fuel injection
Engine brake engagement
Self-diagnosis
Recovery
It also enables:
Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- fuel temperature (DIESEL DENSITY)
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating
Pressure can be adjusted in case of:
- engine brake actuation
- serious defects involving load reduction or engine stop.
- ANTI-POLLUTION devices cutting in: p sensor, NOx sensor, NH3 sensor
Once the control unit has determined the mass of the introduced air and measured its pressure and temperature, it calculates the
corresponding fuel load needed to inject into the cylinder (mg. per delivery). It also takes diesel temperature into account (density).
The fuel load calculated in this way is converted into crank degrees i.e. injection advance and duration.
Delivery correction based on water temperature
When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays
are not optimized yet.
Fuel injected also tends to condense on cold metal surfaces.
Fuel dosing with a cold engine is therefore greater than when hot.
Delivery correction to prevent noise, fumes or overloads
Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center
to prevent them.
De-rating
In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.
The control unit uses the oil temperature reading in the event of a coolant temperature sensor failure.
Injection lead electronic control
Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder
to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.
Lead is corrected as required:
- during acceleration
- according to water temperature
and to obtain:
- reduced emissions, noise abatement and no overload
- better vehicle acceleration
High injection lead is set at start, based on water temperature.
Delivery start feedback is given by injection electro valve impedance variation.
Engine speed limiter
The control unit controls the engine speed at all rev ranges and in particular:
- at idle;
- at top speed.

Engine start
Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator
pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables
the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn
by the starter motor.
Cold starting
Pre-post heating is activated when just one of the three sensors (water, air or fuel) registers a temperature lower than 10 C.
Upon activation of the key contact, the pre-heating warning light turns on the electronic dashboard (cluster display) and remains
on for a variable amount of time depending on the temperature (while the heating element at the intake manifold heats the air),
then it flashes. It is now possible to start up the engine.
When the engine is running, the warning lamp goes out but the heater element continues working for a certain (variable) period
of time for post-heating.
If, with the warning lamp blinking, the engine is not started within 2025 seconds (absence time) the operation is cancelled in order
not to discharge the batteries.
The pre-heating curve is also variable in relation to the battery voltage.
Warm starting
When the ignition key is inserted and the reference temperature exceeds 10 C, a warning light turns on for approximately 2
seconds as a short test, then goes out. It is now possible to start up the engine.
Run Up
When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),
and diagnoses the system.
After Run
At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the micropro-
cessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom) memory to
make tem available for the next start (Cf. Run Up).
These data essentially consists of:
- miscellaneous settings, such as engine idling and the like
- settings of some components
- breakdown memory
The process lasts for some seconds, typically from 2 to 60 according to the amount of data to be stored, after which the ECU sends
a command to the main relay and makes it disconnect from the battery.
NOTE This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter
before 60 seconds at least after engine cutout.
In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown
memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Repeated procedure interruptions could in fact lead to center damage.
Cut-off
It refers to the supply cut-off function during deceleration.
Cylinder Balancing
Individual cylinder balancing contributes to increasing comfort and operability.
This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each
cylinder, to compensate for injector hydraulic tolerances.
The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information
is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.
Synchronisation Search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with
the sequence already synchronized.
If this occurs when the engine is off, the control unit energises a single solenoid valve. At the latest by the 2nd engine shaft revolution,
an injection will occur in that cylinder, for which the central unit only has to synchronise itself on the combustion sequence and
start the engine.

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

Figure 3
Colour legend
C ORANGE
A SKY BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN 189005
S PINK
R RED
V GREEN
Z PURPLE
Pin Cable colour Signal Component
01 C O_P_SVL21 Injector 1 low, Bank 2, Cylinder 5
02 GN O_P_SVL22 Injector 2 low, Bank 2, Cylinder 6
03 N O_P_SVL23 Injector 3 low, Bank 2, Cylinder 4
04 - - Free
05 - - Free
Engine oil pressure and temperature sensor: ground for frequency input
06 Z G_R_DF03
3
07 BN V_V_5VSS1A Boost pressure and air temperature sensor: supply +5V
08 - - Free
09 - - Free
10 - - Free
11 HB V_V_5VSS3B Rail pressure sensor: supply +5V
12 C I_A_AN18 Fuel temperature sensor: NTC temperature signal
13 BC I_A_AN15 Engine oil pressure and temperature sensor: NTC temperature signal
14 - - Free
15 - - Free
16 - - Free
Motorised throttle valve actuator connector (Exhaust flap): Controller
17 LV B_D_CANH2
Area Network 2 high (CAN H)
Motorised throttle valve actuator connector (Exhaust flap): Controller
18 BV B_D_CANL2
Area Network 2 low (CAN L)
19 - - Free
20 - - Free
21 - - Free
22 - - Free
23 - - Free
24 - - Free
25 Z O_P_SVH21 Injector 1 high, Bank 2, Cylinder 5
26 GR O_P_SVH22 Injector 2 high, Bank 2, Cylinder 6
27 M O_P_SVH23 Injector 3 high, Bank 2, Cylinder 4
28 - - Free
29 - - Free
30 - - Free


31 R V_V_5VSS1F Engine oil pressure and temperature sensor: supply +5V
32 - - Free
33 - - Free
34 - - Free
35 V I_A_AN01 Engine oil pressure and temperature sensor: pressure signal
36 HR I_A_RAILPS Rail pressure sensor: pressure signal
37 LG I_A_AN16 Boost pressure and air temperature sensor: NTC temperature signal
38 - - Free
39 G I_A_AN17 Coolant temperature sensor: NTC temperature signal
40 - - Free
41 - - Free
42 - - Free
43 - - Free
44 - - Free
45 - - Free
46 - - Free
47 - - Free
48 - - Free
49 L O_P_SVH11 Injector 1 high, Bank 1, Cylinder 1
50 V O_P_SVH12 Injector 2 high, Bank 1, Cylinder 3
51 H O_P_SVH13 Injector 3 high, Bank 1, Cylinder 2
52 - - Free
53 - - Free
54 - - Free
55 - - Free
56 - - Free
57 - - Free
58 GV O_V_MEU Fuel high pressure pump metering unit: supply
59 H-B G_R_AN18 Fuel/coolant temperature sensor: common ground analog input 18
60 HV G_R_RAILPS Rail pressure sensor: ground
61 - - Free
62 - - Free
63 - - Free
64 - - Free
65 N G_R_CRS Crankshaft rpm increment speed sensor: signal negative
66 B I_F_CRS Crankshaft rpm increment speed sensor: signal positive
67 N G_R_CAS Camshaft timing segment speed sensor: signal negative
68 B I_F_CAS Camshaft timing segment speed sensor: signal positive
69 H G_R_GN-- -
70 - - Free
71 - - Free
72 - - Free
73 B O_P_SVL11 Injector 1 low, Bank 1, Cylinder 1
74 R O_P_SVL12 Injector 2 low, Bank 1, Cylinder 3
75 G O_P_SVL13 Injector 3 low, Bank 1, Cylinder 2
76 - - Free
77 - - Free
78 - - Free
79 - - Free
80 - - Free


81 - - Free
82 - - Free
83 GN O_T_MEU Fuel high pressure pump metering unit:
84 - - Free
85 - - Free
86 RG I_A_AN05 Boost pressure and air temperature sensor: pressure signal
87 - - Free
88 - - Free
89 - - Free
90 BV G_R_AN05 Boost pressure and air temperature sensor: ground analog input 5
91 - - Free
92 - - Free
93 - - Free
94 - - Free
95 - - Free
96 - - Free

Pin out EDC 17CV41 control unit - Vehicle side connector 1 (TwoBox layout)
Figure 4
189004
Pin Signal Component

01 V_V_BAT +4 Battery plus 4
02 O_T_RL 11 SCR heater
03 G_G_BAT -1 Battery minus 1
04 O_T_RL 14 SCR hose suction line heater
06 - Free
07 I_A_AN 23 SCR pressure sensor
08 I_A_AN 25 SCR temperature sensor
09 I_A_AN 22 Catalyst downstream temperature sensor
10 G_R_AN 10 Common ground
11 - Free
12 - Free
13 I_S_DIG 01 Water in fuel switch
14 - Free
15 I_A_AN 04 Humidity sensor
16 I_A_AN 13 Exhaust gas temperature upstream sensor
17 - Free
18 - Free
19 O_S_RH 04 Starter relay
20 O_T_RH 03 ATS intelligent sensors Auxiliary Relay (H)
21 - Free
22 - Free
23 O_T_RH 01 DEF Dosing Module
24 - Free
27 O_V_RH 31 Common battery plus
29 G_G_RL 11 Ground for low side power stage 11
30 - Free
31 I_A_AN 12 SCR level sensor
32 I_A_AN 24 Catalyst upstream temperature sensor
33 - Free
34 O_F_ENGN Engine speed output
35 - Free
36 - Free


37 - Free
38 - Free
40 I_A_AN 14 Air temperature sensor
41 - Free
42 - Free
44 O_S_RL 24 OBD led
45 O_T_RL 18 ATS intelligent sensors Auxiliary Relay (L)
46 B_D_CANH0 CAN high
47 B_D_CANL0 CAN low
48 - Free
51 G_G_RL 07 Diagnostic LED ground
53 - Free
54 - Free
55 - Free
56 - Free
57 - Free
58 - Free
59 - Free
60 - Free
61 O_S_RL 20 Fuel filter / pre-filter heating relay
62 - Free
63 I_S_T 50 Start switch term. 50 input signal
64 - Free
65 - Free
66 - Free
67 - Free
68 V_V_5VSS1D Common supply
69 I_S_T 15 KL15
70 B_D_ISOK ISO-K interface
71 B_D_CANH1 Controller area network 1 (high)
72 O_S_RL 12 SCR Tank Heating Valve
77 O_S_RH 07 Diagnostic LED plus
78 - Free
79 - Free
80 - Free
81 - Free
82 - Free
83 O_S_RL 22 Grid heater relay
84 O_T_RL 13 SCR pump motor


85 O_T_RL 16 SCR reverting valve
86 - Free
87 - Free
88 O_S_RL 21 Low side source driver 21
89 G_G_RL 13 SCR pump motor
90 V_V_5VSS3A Common supply
91 - Free
92 - Free
93 O_S_RL 27 Auxiliary relay / SCR heater relay
94 - Free
95 B_D_CANL1 Controller area network 1 (low)
96 0_T_RL 10 DEF Dosing Module

Pin out EDC 17CV41 control unit - Vehicle side connector 1 (OneBox layout)
Figure 5
189004

02 O_T_RL 11 SCR heater
04 O_T_RL 14 SCR hose suction line heater
06 - Free
07 I_A_AN 23 SCR pressure sensor
08 I_A_AN 25 SCR temperature sensor
09 I_A_AN 22 Catalyst downstream temperature sensor
11 - Free
12 I_S_DIG 05 Redundant brake switch
13 I_S_DIG 01 Water in fuel switch
14 I_S_CRCNEG Cruise Control/PTO Control (Set -)
15 I_A_AN 04 Humidity sensor
16 I_A_AN 13 Exhaust gas temperature upstream sensor
17 - Free
18 - Free
19 O_S_RH 04 Starter relay
20 O_T_RH 03 ATS intelligent sensors Auxiliary Relay (H)
21 - Free
22 - Free
23 O_T_RH 01 DEF Dosing Module
24 - Free
30 - Free
31 I_A_AN 12 SCR level sensor
32 I_A_AN 24 Catalyst upstream temperature sensor
33 - Free
34 O_F_ENGN Engine speed output
35 I_S_CRCRES Cruise Control/PTO Control (Resume)
36 I_S_CRCOFF Cruise Control/PTO Control (Off)


37 I_S_DIG 04 2nd speed limiter switch
38 - Free
40 I_A_AN 14 Air temperature sensor
41 I_A_AN 26 Multiple state switch
42 - Free
44 O_S_RL 24 OBD led
45 O_T_RL 18 ATS intelligent sensors Auxiliary Relay (L)
46 B_D_CANH0 CAN high
47 B_D_CANL0 CAN low
48 - Free
51 G_G_RL 07 Diagnostic LED ground
53 I_F_VSS Vehicle speed sensor signal
54 G_R_VSS Vehicle speed sensor ground
55 - Free
56 - Free
57 - Free
58 - Free
59 - Free
60 I_S_DIG02 Low idle position switch
61 O_S_RL 20 Fuel filter / pre-filter heating relay
62 - Free
63 I_S_T 50 Start switch term. 50 input signal
64 - Free
65 - Free
66 V_V_5VSS2D 5V sensor supply 2D
67 - Free
68 V_V_5VSS1D Common supply
69 I_S_T 15 KL15
70 B_D_ISOK ISO-K interface
71 B_D_CANH1 Controller area network 1 (high)
72 O_S_RL 12 SCR Tank Heating Valve
77 O_S_RH 07 Diagnostic LED plus
78 - Free
79 I_A_APP1 Accelerator pedal position sensor 1 signal
80 G_R_APP1 Accelerator pedal position sensor 1 ground
81 I_S_DIG04 Cruise Control/PTO Control (Set +)
82 I_S_DIG012 Brake main switch
83 O_S_RL 22 Grid heater relay
84 O_T_RL 13 SCR pump motor


85 O_T_RL 16 SCR reverting valve
86 - Free
87 - Free
88 O_S_RL 21 Low side source driver 21
89 G_G_RL 13 SCR pump motor
90 V_V_5VSS3A Common supply
91 - Free
92 - Free
93 O_S_RL 27 Auxiliary relay / SCR heater relay
94 - Free
95 B_D_CANL1 Controller area network 1 (low)
96 0_T_RL 10 DEF Dosing Module

16
Base - May 2014

Figure 6
Engine cable
SECTION 3 - ELECTRICAL EQUIPMENT
209182
1. Engine oil pressure and temperature sensor - 2. Crankshaft rpm increment speed sensor - 3. Electro-injectors connections (cylinders 1-2) -
4. Electro-injectors connections (cylinders 3-4) - 5. Motorised throttle valve actuator connector (Exhaust flap) - 6. Electro-injectors connections (cylinders 5-6) -
7. Rail pressure sensor - 8. Boost pressure and air temperature sensor - 9. Camshaft timing segment speed sensor - 10. Fuel temperature sensor -
11. Fuel high pressure pump metering unit - 12. In line connector - 13. Engine Control Unit ECU17CV41 - 14. Coolant temperature sensor
F4HFE613 ENGINE
Print P2D32N028 E
Print P2D32N028 E
Figure 7
F4HFE613 ENGINE
Topographical wiring diagram - Engine side
1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Engine oil pressure and temperature sensor - 5. Boost pressure
and air temperature sensor - 6. Motorised throttle valve actuator connector (Exhaust flap) - 7. In line connector - 8. Camshaft timing segment speed sensor - 9.
209183
Crankshaft rpm increment speed sensor - 10. Fuel high pressure pump metering unit - 11. Rail pressure sensor - 12. Electro-injector (cylinder 6) - 13. Electro-injector
(cylinder 5) - 14. Electro-injector (cylinder 4) - 15. Electro-injector (cylinder 3) - 16. Electro-injector (cylinder 2) - 17. Electro-injector (cylinder 1)
E1. Electro-injector connector (cylinder 1-2) - E2. Electro-injector connector (cylinder 3-4) - E3. Electro-injector connector (cylinder 5-6)
17
Base - May 2014

18
Base - May 2014

Figure 8
EDC 17CV41 control unit wiring diagram - Vehicle side (part 1/2)
215038
1. Vehicle connector EDC 96 pin - 2. CAN BUS to Customers application computer - 3. Diagnostic connector - 4. Controller Area Network C - 5. SCR downstream NOx
ECU - 6. SCR downstream NOx sensor - 7. DOC upstream NOx ECU - 8. DOC upstream NOx sensor - 9. NH3 ECU - 10. NH3 sensor - 11. Urea Quality sensor -
12. In line connector - 13. Battery Disconnection Switch (BDS) - 14. Alternator - 15. Alternator connector kit (J1) - 16. Starter electric motor - 17. Battery -
18. Battery charge warning lamp - 19. SCR hose suction line heater - 20. Fuel pre-filter heater relay - 21. Fuel pre-filter heater - 22. SCR electrical heater -
23. SCR heater relay - 24. Fuel filter/pre-filter heater relay - 25. Fuel filter heater - 26. Grid-heater relay - 27. Water in fuel switch - 28. ATS intelligent sensors auxiliary relay -
29. Grid-heater - 30. Starter control relay - 31. Starter relay - 32. Body controller starter interlock (Vehicle safety) - 33. Body controller starter interlock relay - 34. Key switch -
35. Alternative connections (A. ECU under time relay - B. ECU under BDS - C. ECU not under BDS)
F4HFE613 ENGINE
Print P2D32N028 E
Figure 9
Print P2D32N028 E
F4HFE613 ENGINE
218027
1. Vehicle connector EDC 96 pin - 2. Controller Area Network B - 3. SCR tank level and temperature sensor - 4. Diagnostic LED - 5. DEF dosing module -
EDC 17CV41 control unit wiring diagram - Vehicle side (part 2/2) - TwoBox layout
6. SCR downstream exhaust gas temperature sensor - 7. SCR upstream exhaust gas temperature sensor - 8. DOC upstream exhaust gas temperature sensor -
9. Humidity and ambient temperature sensor - 10. SCR tank heating valve - 11. SCR Pump module
(A. SCR pressure sensor - B. SCR reverting valve - C. SCR pump motor)
19
Base - May 2014

20
Base - May 2014

Figure 10
215039
EDC 17CV41 control unit wiring diagram - Vehicle side (part 2/2) - OneBox layout
1. Vehicle connector EDC 96 pin - 2. Controller Area Network B - 3. SCR tank level and temperature sensor - 4. Diagnostic LED - 5. DEF dosing module -
6. SCR downstream exhaust gas temperature sensor - 7. SCR upstream exhaust gas temperature sensor - 8. DOC upstream exhaust gas temperature sensor -
9. Brake main switch - 10. Redundant brake switch - 11. Accelerator pedal position sensor - 12. Vehicle speed signal - 13. 2nd speed limiter switch -
14. Cruise Control / PTO Control - 15. Multiple state switch (Resistor module) - 16. Humidity and ambient temperature sensor - 17. SCR tank heating valve -
18. SCR Pump module (A. SCR pressure sensor - B. SCR reverting valve - C. SCR pump motor)
F4HFE613 ENGINE
Print P2D32N028 E
Electroinjectors
Figure 11
182250
1. Coils for connection to engine cable - 2. Head anchorage bracket - 3. Fuel intake manifold - 4. High pressure fuel input -
5. Low pressure residual fuel output - 6. Gasket - 7. Injector.
It is a N.O. solenoid valve.

They are connected to the EDC ECU on connector A.
The electroinjector can be considered as consisting of 2 parts:
- actuator - atomizer including pressure rod, needle and nozzle;
- control solenoid valve including coil and pilot valve.
The solenoid valve controls atomizer needle lift.
INJECTION START
When coil is energized, lock pin moves upward.
The control volume fuel flows to return duct causing control volume pressure drop.
At the same time, fuel pressure in pressure chamber causes needle uplift and therefore fuel injection in cylinder.
END OF INJECTION
When coil is de-energized, lock pin returns to lock position to look for a force balance such to return to needle close position and
stop injection.

Ref. Description ECU pin

1 Injector 3 high, Bank 1, Cylinder 2 51A
2 Injector 3 low, Bank 1, Cylinder 2 75A
CONNECTOR E1
CONNECTOR E2
CONNECTOR E3
Figure 12
1 2
209193
1. Screws fastening wiring support - 2. Electro-injector wiring - 3. Wiring support - 4. Electro-injectors -

5. Nuts fastening wiring on each electro-injector

Camshaft timing segment speed sensor

The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft.
The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 67A - 68A. The sensor impedance is 900 .
Figure 13
209186
Figure 14
183652 50288
Connector Wiring diagram
Ref. Description ECU Pin

1 Ground 67A
2 NTC 68A
3 Shield 69A

Crankshaft rpm increment speed sensor

The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted
on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 65A - 66A. The sensor impedance is 900 .
Figure 15
50319
Figure 16 Figure 17
183652 50288
Connector Wiring diagram

1 Ground 65A
2 NTC 66A
3 Shield 69A

Boost pressure and air temperature sensor

This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 90A - 37A - 07A - 86A.
The power supply is 5 Volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 37A Temperature signal
Pin 86A Pressure signal
Figure 18
209195
Figure 19 Figure 20
213601 190518
Wiring diagram

1 Ground 90A
2 NTC signal (temperature) 37A
3 +5 V power input 07A
4 Signal (pressure) 86A

Engine oil pressure and temperature sensor

The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 06A - 13A - 31A - 35A.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 13A Temperature signal
Pin 35A Pressure signal
Figure 21
209196
Figure 22 Figure 23
213602 190518
Wiring diagram

1 Ground 06A
3 +5 V power input 31A
4 Signal (pressure) 35A

Rail pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 60A - 36A - 11A.
The power supply is 5 Volt.
Figure 24
183654
Fuel pressure sensor connector
Ref. Description ECU pin

1 Ground 60A
2 Signal 36A
3 Power supply 11A

Coolant temperature sensor

It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies
the need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
This sensor is connected to the control unit on pins 39A - 59A.
The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 25
215014
Figure 26 Figure 27
213603 107798

1 Ground 39A

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.
The fuel temperature sensor is connected to the control unit on pins 12A - 59A.
The sensor impedance at 20 C is approximately 2.50 .
Figure 28
209197
The ECU drives the filter heater contactor at fuel temperature 5 C.
Figure 29
107798
213603
Connector

1 Ground 12A

Fuel high pressure pump metering unit
Figure 30
183657
The flow rate regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate
the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit.
It basically consists of the following parts:
- trapezoidal section shutter;
- valve control pin;
- pre-charging spring;
- coils.
In the absence of the control signal, the flow rate regulator is normally open, and hence the high pressure pump is in its maximum
delivery conditions.
The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the
high pressure pump.
This component cannot be replaced individually and hence it cannot be taken down.
The quantity of fuel supplied to the high pressure pump is metered by the flow rate regulator on the low pressure system; the
flow rate regulator is managed by the control unit.
Delivery pressure to the rail is modulated between 250 and 1600 bar by the electronic control unit by controlling the flow rate
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pin 58A - 83A.
- The solenoid valve impedance is approximately 3.2 .
1 Ground 58A
2 Signal 83A

Pre-heating resistor (Grid-heater)

The pre-post heating resistance is located on the intake manifold.
The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor.
The resistance impedance is approximately 0.5 .
Figure 31
201031
A. - B. Connection terminals
Grid-heater performances
2,4 kW @ 24 V
isolated ground
controlled by the Engine Control Unit ECU17CV41
installed into the intake manifold
Figure 32
002371t
A. Control contactor
The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 C.
The contactor impedance is approximately 15 .
Do not use flammable gases or liquids to provoke the engine ignition.

These substances in contact with the resistance could easily become inflamed creating situations of serious danger.

Electric starter motor

Figure 33
215011
Figure 34 Figure 35
215012 165899
The starter motor runs the engine, gaining its inertia and friction, and bringing it to a certain number of revolutions such as to initiate
the formation of the mixture required for combustion and then the autonomous movement of the engine.
The movement is transmitted by a DC electric motor, powered by the battery, via an engagement pinion which rotates the sprocket
formed on the engine flywheel.
Due to a free wheel engagement, the pinion turns off when the main engine rotates faster than the starter motor.
A relay energized by the current of the starter motor engages the pinion by means of a fork.
The starter motor included is a translation type and starts by means of the pinion, with relay housed directly above the starter motor.
Ignition is usually controlled via the ignition switch on the control panel and provides a positive voltage to the relay located on the
starter motor.
Specifications:
Type: BOSCH HX87-M
Nominal voltage: 24 V
Nominal rated power: 4 kW
Number of poles: 4
Direction of rotation: clockwise (seen from flywheel side)
Battery capacity: min. 44 Ah - Max. 110 Ah
Discharge current (EN 50342): min. 357 A - Max. 765 A

Alternator
Figure 36
215009
Figure 37
215010
Figure 38
215008
It is frontally located on the right-hand side of the engine and is controlled by the auxiliary assembly belt.
Specifications:
Type: BOSCH NCB1
Nominal voltage: 28 V
Nominal rated current: 70 A @ 6,000 rpm
35 A @ 1,800 rpm
Stand-by current consumption: 1mA
Maximum continuous rotation velocity: 12,000 min-1
Operating temperature range: -40 C +110 C
Weight: 6.5 kg
Direction of rotation: clockwise

Motorized throttle valve actuator connector (Exhaust flap)

Figure 39
215013

1 V Bat -
2 Ground -
3 - -
4 Can L 18A
5 Can H 17A

F4HFE613 ENGINE SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Regular maintenance and inspection planning . 3
- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE PROCEDURES . . . . . . . . . . . . 4
- Checks and inspections . . . . . . . . . . . . . . . . . . 4
- Planned maintenance . . . . . . . . . . . . . . . . . . . 6
- Unscheduled maintenance . . . . . . . . . . . . . . . 8

2 SECTION 4 - SCHEDULED MAINTENANCE F4HFE613 ENGINE

SCHEDULED MAINTENANCE
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure,
immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Regular maintenance and inspection planning
Checks (in periods of use) Frequency

Check the engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check the engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Engine visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 hours
Drain the water from the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 hours (1)
Check tension and condition of ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hours
Check the condition of the exhaust duct(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six-months
Check using ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In the case of a fault
Planned maintenance Frequency
Change engine lubricant oil (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours (2) (3)
Change oil filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours (2) (3) (4)
Change fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours (5) (1)
Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours (2) (1) (4)
Change ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,200 hours
Turbocharger visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,200 hours
Change blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,500 hours (2)
Special maintenance Frequency
Adjust valves/rocker arms clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,400 hours
Replacement of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 hours (5)
*) Frequency for construction equipment application: -100 hours versus standard application.
1) Maximum period relative to the use of high quality fuel, (specification ASTM D975 or EN 590); this is reduced based on fuel
contamination and the alarm signals due to filter clogging and/or the presence of water in the pre-filter. The filter clogging signal
indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off after drainage, the filter
must be replaced.
2) To be performed every year even if the specified operating hours interval has not been reached.
3) The frequencies are applicable for lubricants which meet the international standards API CJ-4 / ACEA E9 as specified in the
REFILLING table.
4) Only use filters with the following specifications:
- degree of filtering < 12 m
- filtering efficiency 99.5% ( > 200).
5) To be performed every two years even if the specified operating hours interval has not been reached.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveni-
ences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES
Checks and inspections
Engine oil level check
The check must be executed when the engine is disconnected and possibly cool.
The check can be made using the specially provided flexible rod.
Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put
it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.
Always ensure the oil added has the same characteristics of the oil contained in the sump.
Mixing is not allowed as this would not guarantee correct lubrication of the internal parts of the engine.
Figure 1
214989
If the level is insufficient, it is necessary to top up with lubricant oil which meets the international specifications ACEA E9, as indicated
in the REFILLING table.
Remove the lubricant oil cap (1) and pour engine lubricant oil through the hole.
Use the oil dipstick to check that the lubricant oil level does not exceed the Max limit.
Make sure that the oil dipstick is fully inserted and that the oil filler cap is fully tightened in a clockwise direction.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water and detergent.
Adequately protect the skin and the eyes, operate in full compliance with safety regulations.
Disposal must be carried out properly, and in full compliance with the law and regulations in force.

Combustion system inspection Lubricating system inspection

The check must be executed both when the engine discon- The check must be executed both when the engine discon-
nected and when it is running. nected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the spe- Verify the presence of any oil leakage or blow-by from the
cific equipment), to the filter, to the high pressure pump and head, from the engine pan of from the heat exchanger.
to the rail diffuser and from this last one to the head.
Special attention must be paid to the connections on the high

pressure pipelines.
Due to the high pressure within the pipelines running The engine oil is highly polluting and harmful.
from the high-pressure pump to the rail diffuser and In case of contact with the skin, rinse well with water
from this last one to the electro-injectors, special and detergent.
attention must be aid also in checking presence of any
leakage or blow-by. Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the Disposal must be carried out properly, and in full
skin surface provoking serious poisoning. compliance with the law and regulations in force.
Cooling system inspection Inspection of water presence within fuel filter or pre-filter
The check must be executed both when the engine discon-
nected and when it is running.
Check the pipelines from the engine to the radiator, from the
expansion tank and vice-versa. Find out any blow-by, verify the NOTE The components of the common rail system can be
status of the pipes specially close to the holding strips. damaged very quickly in presence of water or
impurity within the fuel.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors, Timely proceed operating on the pre-filter (not
from the manifold and from the radiating unit. available on the engine block) to carry out the drain-
age of the water within the feed circuit.
Due to the high temperatures achieved by the sys- Inspection of drive belt tensioning
tem, do not operate immediately after the engines
disconnection, but wait for the time deemed neces- The drive belt tensioning control is made using an automatic
sary for the cooling. tensioning device therefore no intervention is required apart
Protect the eyes and the skin from any eventual high from checking the wear status of the belt itself.
pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how Check of belts tear and wear status
every year before winter season and be replaced in any case Carefully verify the belts surface in order to detect any sign of
every two year. incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
NOTE In case of new filling, proceed bleeding system, Danger: if the engine is switched off but is still hot,
through the bleeds on the engine. unexpected motion of the belt may occur.
Wait for engine temperature cooling as a precaution
If bleeding of the system is not carried out, serious in order to avoid serious danger injury.
inconvenience might be caused to the engine due
to the presence of air pockets in the engines head.

Planned maintenance Whereas you replace the lubrication oil, it is necessary to

replace the filter.
Oil motor and oil filter replacement
According to the application the filter can be located in differ-
ent positions: the following procedure is a valid guide for all
applications.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature. - The filter is composed by a support and a filtering cart-
ridge. For the cartridge replacement use the
The motor oil reaches very high temperature: you 9936076-tool.
must always wear protection gloves.
Warning: the oil filter contains inside a quantity of oil

Due to the several applications, the pan shape and the oil of about 1 kg.
quantity can change slightly. However, the following opera-
tions are valid for all applications. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor Warning: avoid the contact of skin with the motor oil:
is hot. in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the The motor oil is very pollutant: it must be disposed
pan connected with the drain plug. of according to the rules.
- Unscrew the plug and then take out the control dipstick
and the inserting plug to ease the downflow of the lubrica-
tion oil. - Replace the filtering cartridge with a new one and screw
manually until when the gasket is in contact with the sup-
port.
The oil motor is very pollutant and harmful. - Tighten further using tool 99360076 to a torque of
20 2 Nm.
In case of contact with the skin, wash with much water
and detergent. - Operate the motor for some minutes and check the level
through the dipstick again. If it is necessary, carry out a top-
Protect properly skin and eyes: operate according to ping up to compensate the quantity of oil used for the
safety rules. filling of the filtering cartridge.
Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
Use only the recommended oil or oil having the

! requested features for the correct motor functioning.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service war-
ranty is no more valid.
- Check the level through the dipstick until when the filling
is next to the maximum level notch indicated on the dip-
sick.

Fuel filter replacement Change ancillary belt
During this operation dont smoke and dont use free Figure 3
flames.
Avoid to breathe the vapors coming from filter.
Figure 2
215006
- Remove the belt (2) by acting on the automatic belt ten-

sioner (8) with the appropriate tool (6) from the altern-
ator (7), water pump (5), fan control pulley (1), crankshaft
215005 pulley with damper (4) and fixed guide roller (3).
- Place a container for collecting the diesel under the filter - Replace the worn belt (2) with new one.
support (1).
- Fit the Poly V belt (2) on the pulleys and guide roller.
- Remove the filter (3) by unscrewing it from its relative
support by using the 99360076-tool. - Use the appropriate tool (6) on the automatic belt ten-
sioner (8) in order to fit the new belt (2) in the operating
- Replace the filter element and the O-ring seal (2) contai- position.
ned inside the filter (3).
- Additional adjustments are not required. The belt (2) ten-
- Carefully clean the surfaces of the support (1) in contact sion is adjusted automatically by the calibrated spring in
with the O-ring seal (2). the automatic belt tensioner (8).
- Moisten the sealing gasket (2) of the fuel filter (3) with a - Operate the engine for a few hours and check that the
thin layer of oil. belt (2) is properly fit.
- Manually tighten the fuel filter (3) on the support (1) until
it comes into contact with the gasket (2).
Additionally tighten the fuel filter (3) to the prescribed
torque using a specific tool.
Ref No. Description Tightening torques

(3) 1 M20x1.5 20 2 Nm
Do not smoke or use open flames during this opera- Warning: with switched off motor (but still hot) the
tion. Do not inhale the vapours that exit the filter. belt can operate without advance notice.
Pay attention to the electric fuel pre-heater (if instal- Wait for the motor temperature lowering to avoid
led) and the relative electrical connection. very serious accidents.
Do not fill the new fuel filter before placing it on the

support in order to prevent harmful impurities from
entering the fuel circuit and the injection system.
Eliminate the consumables and any materials in con-

tact with them (for example, filters) in accordance
with current regulations.
The FPT Technical Service Network workshops are
equipped for this purpose.

Inspection/replacement of blow-by filter Unscheduled maintenance

The filter in subject has been developed and equipped for the Adjustment of valve/rocker arm clearance
collection, filtering and condense of the lubricating oil vapours.
Within the filter unit (2) two cartridge filters are included (3).
Figure 5
Figure 4
182221
The adjustment of the clearance between the rocker arms and

the intake and exhaust valve control rods must be strictly car-
209217
ried out using an Allen wrench (1), box-end wrench (3) and
The check of the filtering element is carried out by removing a feeler gauge (2).
the cover and drawing off the cartridges (3). Clearance shall be as follows:
- intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.
Turbocharger visual inspection
Only proceed when the engine is not turning over. Visually
check that the turbine and compressor impellers and the relat-
ive inlet and outlet ducts are not obstructed or damaged, oth-
erwise replace them.
NOTE In order to perform the rocker arm - valve clearance

adjustment more quickly, proceed as follows:
- Rotate the crankshaft, balance the valves of cylinder

no. 1 and adjust the valves marked by the asterisk as
shown in the tables below:
cylinder no. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
- Rotate the crankshaft, balance the valves of cylinder

no. 6 and adjust the valves marked by the asterisk as
shown in the tables below:
intake * * - * - -
exhaust * - * - * -

Change engine coolant

- Only proceed when the engine is not turning, and is at low
temperature, so as not to run the risk of burns.
- Place a container for collecting coolant under the heat
exchanger (radiator).
- Remove the pressurization cap from the expansion tank.
- Loosen the retaining elements and remove the sleeves
connecting the engine cooling circuit to the heat
exchanger.
- Drain the coolant from the heat exchanger (radiator) and
wait until it is completely empty.
- Once emptied, refit the cooling circuit making sure the
sleeves are perfectly sealed.
- Refill the engine and the heat exchanger until the cooling
circuit has been completely refilled using a mixture of 50%
water and Actifull OT, as contained in the section FLUIDS.
Do not fill the expansion tank to the brim.
- With the coolant cap open, start the engine and let it idle
for approx. one minute. This helps to completely bleed
the air contained in the cooling circuit.
- Stop the engine and top up with more coolant, if neces-
sary.
- When the engine is cold, make sure that the coolant in the
expansion tank is a few centimetres below the filling hole.
- In the event of an externally located level indicator as
regards the heat exchangers, proceed with the top up
operation by making sure that the coolant does not over-
fill the internal volume of the exchanger in order to allow
the expansion of coolant volume during increases in tem-
perature.
The failure to observe the aforesaid procedure does

not guarantee the presence of the correct quantity of
coolant in the engine.
When the engine is hot, pressure builds up in the coo-

! ling circuits which may eject hot liquid violently, resul-
ting in a risk of burns. Open the filler cap of the coolant
tank only if necessary and only when the engine is
cold.


F4HFE613 ENGINE SECTION 5 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS 1
SECTION 5
Removal and installation of main
components
Page
REMOVAL AND INSTALLATION AUXILIARY

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL AND INSTALLATION 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT PUMP REMOVAL AND INSTALLATION 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT REMOVAL AND INSTALLATION 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION STARTER MOTOR 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CABLE REMOVAL AND INSTALLATION 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL PIPES REMOVAL AND INSTALLATION . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE CONTROL UNIT REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 SECTION 5 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS F4HFE613 ENGINE
Page Page
FUEL FILTER REMOVAL AND INSTALLATION 9 TURBOCHARGER REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL FILTER SUPPORT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9 EXHAUST MANIFOLD REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INJECTION PUMP REMOVAL AND INSTALLATION 10
INTAKE MANIFOLD REMOVAL AND
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL AND INSTALLATION COMMON RAIL 10 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CYLINDER HEAD REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . . 24
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OIL VAPOUR RECIRCULATION (BLOW- BY)
SYSTEM REMOVAL AND INSTALLATION . . 11 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL AND INSTALLATION ENGINE
OIL HEAT EXCHANGER . . . . . . . . . . . . . . . . 26
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TAPPET COVER REMOVAL AND INSTALLATION 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OIL SUMP REMOVAL AND INSTALLATION . . 27
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INJECTOR WIRING SUPPORT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 13 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION ROCKER ARM
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INJECTOR REMOVAL AND INSTALLATION . . 16
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE OIL FILTER REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . . 18
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

REMOVAL AND INSTALLATION AUXILIA- ALTERNATOR REMOVAL AND INSTALLA-

RY DRIVE BELT TION
Removal Removal
Disconnect the electrical connections of the alternator.
Figure 1 Remove the auxiliary components drive belt as described in
the relative procedure.
Figure 2
215006
166099
- Remove the belt (2) by acting on the automatic belt Undo the screws (1) and disconnect the alternator (2).
tensioner (8) with the appropriate tool (6) from the
alternator (7), water pump (5), fan control pulley (1),
crankshaft pulley with damper (4) and fixed guide roller Ref No. Description
(3). (1) 1 M10x1.5x110
(1) 1 M10x1.5x30
Installation Installation
- Fit the Poly V belt (2) on the pulleys and guide roller. Place the alternator (2) in position, fasten the screws (1) and
tighten them to the specified torque.
- Use the appropriate tool (6) on the automatic belt
tensioner (8) in order to fit the new belt (2) in the
operating position. Ref No. Description Tightening torques
- Additional adjustments are not required. The belt (2) (1) 1 M10x1.5x110 43 6 Nm
tension is adjusted automatically by the calibrated spring (1) 1 M10x1.5x30 43 6 Nm
in the automatic belt tensioner (8).
- Operate the engine for a few hours and check that the Install the auxiliary components drive belt as described in the
belt (2) is properly fit. relative procedure.
Connect the alternator electrical connections.

COOLANT PUMP REMOVAL AND INSTAL- Installation

LATION
Figure 4
Removal
Remove the auxiliary components drive belt as described in
Position a suitable container to catch any coolant.
Figure 3
70221
Apply a new seal ring (2) to the coolant pump (1).
166100
Figure 5
Undo the screws (1) and remove the water pump (2).
Ref No. Description

(1) 2 M8x1.25x35
166100
Place the coolant pump (2) in position, fasten the screws (1)
and tighten them to the specified torque.

(1) 2 M8x1.25x35 24 4 Nm
Install the auxiliary components drive belt as described in the

relative procedure.

THERMOSTAT REMOVAL AND INSTALLA- REMOVAL AND INSTALLATION STARTER

TION MOTOR
Removal Removal
Figure 6 Disconnect the starter motor electrical connections.
Figure 7
209202
215015
Unscrew the fastening screws (1) and disassemble the Ensure that the the electric starter motor (2) is suitably
thermostat unit: remove the engine coolant outlet pipe (2) supported.
and the thermostat (3) complete with its gasket. Unscrew the fastening nuts (3) and remove the electric
starter motor (2).
Unscrew the studs (4) from the flywheel housing (1).
Ref No. Description

Ref No. Description (3) 3 M10x1.5
(1) 3 M6x1x12 (4) 3 M10x1.5x50
Installation Installation
Assemble the thermostat unit: fit the thermostat (3) Screw the studs (4) and fit the electric starter motor (2) into
complete with its gasket and the engine coolant outlet pipe the internal part of the flywheel housing (1). Tighten the
(2); tighten the fastening screws (1) to the prescribed torque. fastening nuts (3) to the prescribed torque.
Connect the starter motor electrical connections.

Ref No. Description Tightening torques (3) 3 M10x1.5 43 6 Nm
(1) 3 M6x1x12 13.5 1.5 Nm (4) 3 M10x1.5x50 -

ENGINE CABLE REMOVAL AND INSTALLATION

Removal
Figure 8
214987
1. Electro-injectors connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air
temperature sensor - 4. Rail pressure sensor - 5. Camshaft timing segment speed sensor - 6. Fuel temperature sensor -
7. Fuel high pressure pump metering unit - 8. Engine Control Unit ECU17CV41 - 9. Crankshaft rpm increment speed
sensor - 10. In line connector - 11. Engine oil pressure and temperature sensor - 12. Coolant temperature sensor
Remove the engine cable by unplugging it from the ECU (8), Installation
from the motorized throttle valve actuator connector (2)
Place the engine cable in position and close the straps
and from all the sensors and transmitters to which it is
retaining the engine cable to the engine block. Connect the
connected. Open the straps holding the engine cable to the
engine cable to the ECU (8), to the motorized throttle valve
engine block and remove it completely.
actuator connector (2) and to all the sensors and
transmitters indicated in the electrical equipment section.

FUEL PIPES REMOVAL AND INSTALLATION

Figure 9
215016
Removal Figure 10
Remove the engine cable as described in the relative
procedure.
Position a suitable container to catch any fuel.
Disconnect the retainers (11 and 18) and remove low
pressure fuel pipe (20) from fuel filter to high pressure pump;
pressure fuel pipe (16) from engine control unit heat
exchanger to mechanical pump;
pressure fuel pipe (14) from mechanical pump to fuel filter.
Disconnect the retainers (10 and 15) and remove backflow
fuel pipe (8) from high pressure pump to fuel filter support;
Disconnect the retainers (3 and 6) and remove backflow fuel
pipes (4, 5 and 7) from common rail and electro-injectors to
the fuel filter support.
Unscrew the hose couplings (2 and 13) of the high pressure
fuel pipe (1) from high pressure pump to common rail;
Unscrew the screw fastening the pipe (1) to the engine block
and remove it. 179038
To disconnect low pressure/backflow fuel pipes from

relevant quick connecting joints, it is necessary to keep
pressed locking retainer (1) as shown in the picture.
Ref No. Description

(2,13) 3 M14x1.5

Installation ENGINE CONTROL UNIT REMOVAL AND

Fit the pipe (1) to the engine block and tighten the fastening INSTALLATION
screw to the prescribed torque. Removal
Connect the high pressure fuel pipe pipe (1) both to the high
pressure pump and to the common rail and tighten the hose Figure 12
couplings (2 and 13) to the prescribed torque.

(2,13) 2 M14x1.5 24 4 Nm
NOTE The high pressure fuel hose must always be

replaced with a new one whenever it is removed.
The hose couplings must be tightened to torque
using spanner 99317915 and torque wrench
99389829.
215017
Disconnect the engine cable (2) from the ECU (1), as

Fit backflow fuel pipes (4, 5 and 7) from common rail and described in the relative section.
electro-injectors to the fuel filter support and connect the Position a suitable container to catch any fuel.
retainers (3 and 6). Disconnect the retainer and remove the low pressure fuel
Fit backflow fuel pipe (8) from high pressure pump to fuel pipe from fuel pre-filter to the engine control unit heat
filter support and connect the retainers (10 and 15). exchanger.
Fit low pressure fuel pipe (14) from mechanical pump to fuel Disconnect the retainer (4) and remove the low pressure
filter and connect the retainers (12 and 19). fuel pipe from the engine control unit heat exchanger to to
Fit low pressure fuel pipe (16) from engine control unit heat mechanical pump, as described in the relative section.
exchanger to mechanical pump and connect the retainers (9 Unscrew the supporting screws (3), and remove the ECU (1),
and 17). including the heat exchanger.
Fit low pressure fuel pipe (20) from fuel filter to high pressure
pump and connect the retainers (11 and 18).
Install the engine cable as described in the relative procedure.
Ref No. Description

(3) 3 M8x1.25
Installation
Fit the ECU (1) including the heat exchanger on the
crankcase and tighten the supporting screws (3) to the
Figure 11
prescribed torque.
Connect the low pressure fuel pipe from the mechanical
pump to the engine control unit heat exchanger by means
of the retainer (4), as described in the relative procedure.
Connect the low pressure fuel pipe from fuel pre-filter to the
engine control unit heat exchanger by means of the retainer.
Connect the engine cable (2) to the ECU (1), as described
in the relative section.

116237 (3) 3 M8x1.25 24 4 Nm
To connect the low pressure fuel hose to the connection
fitting, insert the quick-fit coupling (2) in the connection NOTE Replacing the elastic support elements is
fitting and push it in until the catch (3) engages. recommended.

FUEL FILTER REMOVAL AND INSTALLA- FUEL FILTER SUPPORT REMOVAL AND
TION INSTALLATION
Removal Removal
Remove the engine cable as described in the relative
Figure 13 procedure.
Remove the fuel pipes as described in the relative procedure.
Remove the fuel filter as described in the relative procedure.
Figure 14
215005
Place a container for collecting the diesel under the filter

support (1).
Unscrew and remove the filter (3) from its relative support
(1) by tool 99360076.
215018
Ref No. Description Place a container for collecting diesel under the fuel filter
(3) 1 M20x.1.5 support (1).
Unscrew the fastening screws (4) and remove the fuel filter
Installation support (1) together with the electric fuel pre-heater (3) and
the fuel temperature sensor (2).
Moisten the sealing gasket (2) of the fuel filter (3) with a thin
layer of oil.
Manually tighten the fuel filter (3) on the support (1) until it
comes into contact with the gasket (2).
Additionally tighten the fuel filter (3) to the prescribed torque Ref No. Description
using a specific tool.
(4) 2 M12x1.75x30
NOTE Pay attention to the electric fuel pre-heater

(if installed) and the relative electrical connection.
Installation
Ref No. Description Tightening torques Place a container for collecting diesel under the fuel filter
(3) 1 M20x1.5 20 2 Nm support (1).
Fit the fuel filter support (1) together with the electric fuel
pre-heater (3) and the fuel temperature sensor (2) on the
crankcase and tighten the fastening screws (4).
NOTE Pay attention to the electric fuel pre-heater (if
installed) and the relative electrical connection.
(4) 2 M12x1.75x30 80 8 Nm
Install the fuel filter as described in the relative procedure.

Install the fuel pipes as described in the relative procedure.

INJECTION PUMP REMOVAL AND INSTAL- REMOVAL AND INSTALLATION COMMON

LATION RAIL
Removal Removal
Remove the engine cable as described in the relative Position a suitable container to catch any fuel.
procedure. Disconnect the fuel pressure sensor connector as described
Remove the fuel pipes as described in the relative procedure. in the procedure regarding the engine cable.
Disconnect the low pressure fuel return hose from the
Remove the fuel filter as described in the relative procedure. common rail, as described in the relative procedure.
Remove the fuel filter support as described in the relative Remove the fuel hose from the high pressure pump to the
procedure. common rail as described in the relative procedure.
Figure 15
Figure 16
209206
Ensure that the fuel high pressure pump (4) is suitably

supported.
Unscrew the fastening nuts (5) and remove the fuel high 209210
pressure pump (4) complete with the mechanical pump (6),
the flange (1) and the gear (3). Unscrew the hose couplings (1, 3, 8 and 9) from the common
Unscrew the studs (2). rail (6) and injector manifolds (7) and remove the high
pressure fuel delivery pipes (2 and 10).
Unscrew the threaded double-shank shoulder screws (4)
Ref No. Description and remove the common rail (6) from the intake manifold
(2) 3 M8x1.25x50 (5).
(5) 3 M8-8
Installation
Screw the studs (2) and fit the fuel high pressure pump (4) Ref No. Description
complete with the mechanical pump (6), the flange (1) and (1,8) 6 M14x1.5
the gear (3). (3,9) 6 M14x1.5
Tighten the fastening nuts (5) to the prescribed torque.
(4) 4 M8x1.25x125

(2) 3 M8x1.25x50 11 3 Nm
(5) 3 M8-8 24 4 Nm
Install the fuel filter support as described in the relative

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

Installation OIL VAPOUR RECIRCULATION (BLOW-

Install the common rail and high pressure fuel delivery pipes BY) SYSTEM REMOVAL AND INSTALLA-
by proceeding as follows: TION
Removal
- fit the common rail (6) on the intake manifold (5) and
manually tighten the threaded double-shank shoulder Figure 17
screws (4);
- tighten two central screws (4) to a torque of 0.1 Nm;
- fit the high pressure fuel delivery pipes (2 and 10) and
manually tighten the hose couplings (1, 3, 8 and 9) fist of
all from common rail side and then from cylinder head
side;
- tighten the hose couplings (1, 3, 8 and 9) to a torque of
5 Nm, fist of all from cylinder head side and then from
common rail side;
- tighten the threaded double-shank shoulder screws (4)
fixing the common rail (6) on the intake manifold (5) to
the prescribed torque;
- tighten the hose couplings (1, 3, 8 and 9) to the
prescribed torque, fist of all from common rail side and
then from cylinder head side.

212828
(1,8) 6 M14x1,5 1st phase 10 Nm
2nd phase 55 Position a suitable container to catch any oil.
(3,9) 6 M14x1.5 1st phase 10 Nm Unscrew the fastening screw (1), loosen the retaining clamps
2nd phase 55 (4) and remove the blow-by breather pipe (3).
(4) 4 M8x1.25x125 36 5 Nm Unscrew the hose connectors (2 and 6) and remove the oil
return pipe (5).
Unscrew the fastening screws (7) and remove the blow-by
filter (8).
NOTE The high pressure fuel delivery pipes must be

replaced every time they are removed. The hose
couplings must be tightened to torque using
spanner 99317915 and torque wrench 99389829. Ref No. Description
(1) 1 M6x1
(2,6) 2 M12x1.5
(7) 3 M6x1
Install the fuel hose from the high pressure pump to the Installation
common rail as described in the relative procedure.
Fit the blow-by filter (8) in position on the on the flywheel
Connect the low pressure fuel return hose to the common
housing and tighten the fastening screws (7) to the
rail, as described in the relative procedure.
prescribed torque.
Connect the fuel pressure sensor connector as described in
Install the oil return pipe (5) with new copper washers and
the procedure regarding the engine cable.
tighten the hose connectors (2 and 6) to the prescribed
torque.
Fit the blow-by breather pipe (3) into the coupling located
on the timing gear case and secure it with the retaining
clamps (4). Tighten the screw (1) fastening to the tappet
cover to the prescribed torque.

(1) 1 M6x1 10 2 Nm
(2,6) 2 M12x1.5 20 4 Nm
(7) 3 M6x1 10 2 Nm

TAPPET COVER REMOVAL AND INSTAL- Installation

LATION
Removal Figure 20
Figure 18
74757
Fit a new gasket (2) on the tappet cover (1).
166630
Undo the screw (1). Loosen the elastic strap (2) and remove
the blow-by pipe (3).
Unscrew the couplings (4) and remove the pipe (5).
Figure 19 Figure 21
212832 212832
Unscrew the fastening nuts (2 and 7) and remove the tappet Screw the threaded double-shank shoulder screws (4 and 6)
cover (1) from the wiring support (5) retrieving relative in the wiring support (5).
gasket (3). Install the tappet cover (1) on the wiring support (5) after
Unscrew the threaded double-shank shoulder screws (4 and having interposed a new gasket (3).
6) from the wiring support (5). Tighten the fastening nuts (2 and 7) to the prescribed torque.
Ref No. Description Ref No. Description Tightening torques

(2,7) 6 M8x1.25 (2,7) 6 M8x1.25 24 4 Nm

Figure 22 INJECTOR WIRING SUPPORT REMOVAL

AND INSTALLATION
Removal
Remove the tappet cover as described in the relative section.
Disconnect the engine cable from the injector wiring
connections, as described in the relative section.
Figure 23
166630
Place the pipe (5) in position with new copper washers in the
tappet cover and timing case couplings (4). Then tighten the
couplings (4) to the specified torque.
Place the blow-by pipe (3) into the coupling located on the
212833
timing case and secure it with the elastic strap (2).
Insert the upper coupling of the new blow-by pipe (5), with Remove the nuts (2) and disconnect the electrical cables (6)
a new seal ring, into the tappet cover and tighten the screw from the electro-injectors (5).
(1). Unscrew the screws (1, 7 and 8) and remove the
electro-injector wiring support (3) complete with gasket (4).
Ref No. Description

(1,7) 2 M8x1.25
(2) 12 M4
(8) 5 M8x1.25
Installation
Figure 24
74756
Check the condition of the electrical cables (5), if they are

damaged replace them by cutting the straps (2) securing
them to the bracket and removing the screws (4) securing
the connectors to this (3).
Fit a new gasket (1) on the bracket (2).

Figure 25 REMOVAL AND INSTALLATION ROCKER

ARM ASSEMBLY
Removal
Remove the injector wiring support as described in the
relative section.
Figure 26
212833
Fit the electro-injector wiring support (3) complete with a

new gasket (4) and tighten the screws (1, 7 and 8) to the
prescribed torque.
Connect the electrical cables (6) to the electro-injectors (5)
and use the torque wrench 99389834 to tighten the
fastening nuts (2) to the prescribed torque.

(1,7) 2 M8x1.25 24 4 Nm
(2) 12 M4 1.5 0.25 Nm
(8) 5 M8x1.25 24 4 Nm
212834
NOTE Always check that the threads on the screws and
their holes do not show any signs of wear or traces Loosen the tappet adjuster retaining nuts (3) and unscrew
of dirt before fitting. the tappet adjuster screws;
Unscrew the fastening screws (4) and disassemble the rocker
unit from the cylinder head, including support (2), rockers (1)
and shafts (5).
Connect the engine cable to the injector wiring connections,
as described in the relative procedure.
Install the tappet cover as described in the relative section. Ref No. Description
(4) 12 M8x1.25
Figure 27
70345
Remove the bridges (1) from valves and the pushrods (2)
from the cylinder head and crankcase.
Installation Figure 31
Figure 28
74765
Fit the rods (2).

70343
Position the bridges (1) on the valves with the marks ()
facing the exhaust manifold.
ROCKER ARM ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rocker arms
Figure 32
Figure 29
70344
SHAFT-ROCKER MAIN DATA

Check that shaft/rocker arm coupling surfaces are not
excessively worn or damaged.
Figure 30
212834
Check that tappet adjusters screws and retaining nuts (3) are
loose to prevent their balking on the rods when refitting the
rocker assembly.
Install the rocker unit consisting of bracket (2), rockers (1),
shafts (5) and secure them to the cylinder head by tightening
the fastening screws (4) to the prescribed torque.
122587
The control rods of the rocker arms must have no
deformations; the spherical seats for contact with the rocker (4) 12 M8x1.25 36 5 Nm
arm adjustment screw and with the tappets (arrows) must
show no trace of seizure or wear; if they do, replace them.
The intake and exhaust valve control rods are identical and
are therefore interchangeable.

Figure 33 INJECTOR REMOVAL AND INSTALLATION

Removal
Remove the injector wiring support as described in the
relative section.
Remove the rocker arm assembly as described in the relative
section.
Figure 34
182221
The adjustment of the clearance between the rocker arms

and the intake and exhaust valves must be strictly carried out
using an Allen wrench (1), box-end wrench (3) and a feeler
gauge (2).
Clearance shall be as follows:
- exhaust valves 0.50 0.05 mm.
NOTE In order to perform the rocker arm - valve 166638

clearance adjustment more quickly, proceed as
follows: Disconnect the high pressure hose couplings (1) from the
common rail (2) and injector manifolds (3), then remove
- Rotate the crankshaft, balance the valves of them.
cylinder no. 1 and adjust the valves marked by
the asterisk as shown in the tables below: Figure 35
intake - - * - * *
exhaust - * - * - *
- Rotate the crankshaft, balance the valves of

the asterisk as shown in the tables below:
intake * * - * - -
exhaust * - * - * - 212835
Undo the fastening nuts (2) and remove the fuel manifolds
(3).
Unscrew the electro-injector (4) fastening screws (1).
Install the injector wiring support as described in the relative
section.
Ref No. Description
Install the tappet cover as described in the relative section.
(1) 12 M6x1x35
(2) 6 M22x1.5x9.5
NOTE Disassembled fuel manifolds (2) must not be used

again, but replaced with new ones.

Figure 36 Figure 39
181861
181861
Remove the injector fastening screws and use tool 99342101 Use tool 99342101 (1) to fit the injector (2) into position.
(1) to remove the injectors (2) from the cylinder head. Screw in the injector fastening screws without tightening
them.
Installation
Figure 37 Figure 40
70338
Fit a new seal ring (2) lubricated with vaseline and a new
washer (3) on the injector (1).
91572
Figure 38
Fit a new seal ring (3), lubricated with Vaseline, onto a new
fuel manifold (2).
Position the fuel manifold in place on the cylinder head seat
so that the positioning balls (5) coincide with the relevant
housing (4).
NOTE Fuel manifolds (2) must not be reused after

removal but rather replaced with new ones.
203451
Place the injectors (1) in position on the cylinder head seats

so that the fuel inlet hole (2) is facing the fuel manifold seat
(3) side.

Figure 41
NOTE The hoses (1), as they are subject to high pressure,
must be replaced every time they are removed.
The hose couplings must be tightened to a torque
of 24 4 Nm, using spanner 99317915 (4) and
torque wrench 99389829 (5).
Install the rocker arm assemblies, the injector wiring support

and the tappet cover as described in the relative sections.
212835 ENGINE OIL FILTER REMOVAL AND

Screw the fastening nuts (2) without locking them; INSTALLATION
Tighten gradually and alternately the electro-injector (4) Removal
fastening screws (1) to the prescribed torque in four stages;
Tighten the fuel manifold (3) fastening nuts (2) to the Figure 43
prescribed torque.

M6x1x35 1st phase 3.5 0.35 Nm
2nd phase 25
(1) 12 3rd phase 25
4th phase 25
(2) 6 M22x1.5x9.5 55 5 Nm
NOTE During this operation, manoeuvre the injector (4)

so that the manifold (3) is properly inserted into
the injector fuel inlet hole.
215004
Tightening to angle is performed using tool
99395216. Place a container for collecting the spent oil under the filter
support (1).
Unscrew and remove the oil filter (3) from its relative support
Figure 42 (1) by tool 99360076.
Ref No. Description

(3) 1 M27x2
Installation
Moisten the sealing gasket (2) of the oil filter (3) with a thin
layer of oil.
Manually tighten the oill filter (3) on the support (1) until it
Additionally tighten the oil filter (3) to the prescribed torque
using a specific tool.
Operate the engine for a few minutes and then check the
level using the dipstick. If necessary, top up to compensate
for the quantity of oil used to fill up the filtering cartridge.
166640
Place the new high pressure fuel hoses (1) in position and (3) 1 M27x2 18 2 Nm
tighten the couplings to the electro-injector collectors (3)
and the common rail (2) to the specified torque.

TURBOCHARGER
REMOVAL AND INSTALLATION Ref No. Description
Removal (1,5) 2 11/16-16 (M16)
Remove the engine oil filter as described in the relative (3) 2 M8x1.25x25
procedure. Disconnect the engine cable from the motorized
(6) 1 M8x1.25x16
throttle valve, as described in the relative procedure.
(F4HFE6131*B003 - F4HFE6131*B005 -
(F4HFE6131*B003 - F4HFE6131*B005 - F4HFE613K*B004 - F4HFE613K*B005)
F4HFE613K*B004 - F4HFE613K*B005) Figure 46
Figure 44
215020
215021
(F4HFE613N*B002 - F4HFE613N*B003)
Figure 45
215023
Position a suitable container to catch any oil.

Unscrew the hose couplings (1 and 5) and remove the
lubrication oil delivery pipe (2) from the upper part of the
heat exchanger to the turbocharger.
Remove the lubrication oil discharge pipe (4) from the
turbocharger by proceeding as follows:
- unscrew the fastening screws (3) in the lower part of the
turbocharger, recovering the relevant gasket;
- unscrew the screw (6) that retain the piping (4) to the
block by means of the fastening collar;
- unscrew the coupling (7) from the crankcase.

(F4HFE613N*B002 - F4HFE613N*B003) (F4HFE613N*B002 - F4HFE613N*B003)

Figure 47 Figure 49
215026
Unscrew the fastening screws (3) and remove the bracket (2)
fixing the motorized throttle valve (4) to the exhaust
215024 manifold (1).
Position a suitable container to catch any coolant. Ref No. Description
Remove the motorized throttle valve water inlet and outlet (3) 4 M8x1.25x25
pipes by proceeding as follows:
(F4HFE6131*B003 - F4HFE6131*B005 -
- unscrew the fastening nut (2) and connector (1) and F4HFE613K*B004 - F4HFE613K*B005)
remove the upper-part water return pipe (9);
- unscrew the fastening nut (4), connector (5) and screw Figure 50
(6) and remove the lower-part water return pipe (7);
- unscrew the fastening screws (3) and remove the water
return pipe union (8);
- unscrew the fastening nut (10) and connector (12) and
remove the water delivery pipe (11).
Ref No. Description

(1,12) 2 M10x1
(2,4,10) 3 M12x1.5
(3) 2 M8x20 215022
(5) 1 M10x1
(F4HFE613N*B002 - F4HFE613N*B003)
(6) 1 M8x16
(F4HFE6131*B003 - F4HFE6131*B005 - Figure 51
F4HFE613K*B004 - F4HFE613K*B005)
Figure 48
215025
Unscrew the screw (3) and loosen the V-clamping collar (4)
to remove the motorized throttle valve (1) from the
214772 turbocharger (2).

Ref No. Description Installation

(3) 1 M6x1x50 (F4HFE6131*B003 - F4HFE6131*B005 -
F4HFE613K*B004 - F4HFE613K*B005)
(F4HFE6131*B003 - F4HFE6131*B005 -
F4HFE613K*B004 - F4HFE613K*B005) Figure 54
Figure 52
214768
Proceed assembling the turbocharger (3):
214768
- screw the studs (5) on the exhaust manifold (6);
Unscrew the fastening nuts (1) and remove the turbocharger - hold the turbocharger (3) together with the waste-gate
(3) together with the waste-gate valve (2), recovering the valve (2) and place it on the exhaust manifold (6) after
relevant gasket (4). having interposed a new gasket (4);
Unscrew the studs (5) from the exhaust manifold (6). - tighten the fastening nuts (1) to the prescribed torque.

(1) 4 M10 (1) 4 M10 43 6 Nm
(5) 4 M10x1.5x42 (5) 4 M10x1.5x42 25 5 Nm
Figure 53 Figure 55
215027 215027
Unscrew the fastening nuts (1) and remove the turbocharger Proceed assembling the turbocharger (5):
(5), recovering the relevant gasket (4). - screw the studs (3) on the exhaust manifold (2);
Unscrew the studs (3) from the exhaust manifold (2).
- hold the turbocharger (5) and place it on the exhaust
manifold (2) after having interposed a new gasket (4);
- tighten the fastening nuts (1) to the prescribed torque.

(1) 4 M10 (1) 4 M10 43 6 Nm
(3) 4 M10x1.5x42 (3) 4 M10x1.5x42 25 5 Nm

(F4HFE6131*B003 - F4HFE6131*B005 - (F4HFE6131*B003 - F4HFE6131*B005 -

F4HFE613K*B004 - F4HFE613K*B005) F4HFE613K*B004 - F4HFE613K*B005)
Figure 56 Figure 58
215022 214772

Figure 57 Figure 59
215025 215026
Install the motorized throttle valve (1) onto the turbocharger Assemble the bracket (2) fixing the motorized throttle valve
(2). (4) to the exhaust manifold (1) and tighten the fastening
Screw the screw (3) and tighten the V-clamping collar (4) to screws (3) to the prescribed torque.
the prescribed torque.
Ref No. Description Tightening torques Ref No. Description Tightening torques
(3) 1 M6x1x50 10 2 Nm (3) 4 M8x1.25x25 25 Nm


Figure 60 Figure 62
215021 215020
Figure 61 Figure 63
215024 215023
Install the motorized throttle valve water inlet and outlet Install the lubrication oil discharge pipe (4) onto the
pipes by proceeding as follows: turbocharger by proceeding as follows:
- fit the water delivery pipe (11) and tighten the fastening - screw the coupling (7) on the crankcase;
nut (10) and connector (12) to the prescribed torque; - screw the fastening screws (3) in the lower part of the
- fit the water return pipe union (8) and tighten the turbocharger, after fitting a new gasket;
fastening screws (3) to the prescribed torque; - screw the screw (6) that retain the piping (4) to the block
- fit the lower-part water return pipe (7) and tighten the by means of the fastening collar.
fastening nut (4), connector (5) and screw (6) to the Fit the lubrication oil delivery pipe (2) from the upper part of
prescribed torque; the heat exchanger to the turbocharger and tighten the hose
- fit the upper-part water return pipe (9) and tighten the couplings (1 and 5) to the prescribed torque.
fastening nut (2) and connector (1) to the prescribed
torque.
(1,5) 2 11/16-16 (M16) 36 5 Nm
(3) 2 M8x1.25x25 23 2 Nm
(6) 1 M8x1.25x16 23 2 Nm
(1,12) 2 M10x1 20 Nm
(2,4,10) 3 M12x1.5 45 Nm Connect the engine cable to the motorized throttle valve, as
described in the relative procedure.
(3) 2 M8x20 23 2.3 Nm Install the engine oil filter as described in the relative
(5) 1 M10x1 25 Nm procedure.
(6) 1 M8x16 23 2.3 Nm

EXHAUST MANIFOLD REMOVAL AND INTAKE MANIFOLD REMOVAL AND

INSTALLATION INSTALLATION
Removal Removal
Remove the turbocharger as described in the relative section. Remove the common rail as described in the relative section.
Disconnect the cold-start heater electrical connections (if
fitted).
Figure 64
Figure 66
214769 209212
Unscrew the screws (5) together with spacers (4) and Unscrew the fastening screws (1 and 6) and remove the
remove the exhaust manifold (3) complete with relevant gas- intake manifold (3) together with the boost pressure and air
kets (2) from the cylinder head (1). temperature sensor (2) from the cylinder head (4).
Ref No. Description

(5) 12 M10x1.5x65 Ref No. Description
(1) 7 M8x1.25x25
Installation (6) 3 M8x1.25x70
- Fit new gaskets (2) on the exhaust manifold (3);
- Assemble the exhaust manifold (3) on the cylinder head
(1) and tighten the fastening screws (5) together with
spacers (4) to the prescribed torque following order and
mode shown in the figure below.

(5) 12 M10x1.5x65 55 3 Nm
Install the turbocharger as described in the relative section.
Figure 65
209215
Tightening order layout for exhaust manifold fastening

screws.
A = Front side

Installation CYLINDER HEAD REMOVAL AND INSTAL-

Fit the intake manifold (3) together with the boost pressure LATION
and air temperature sensor (2) on the cylinder head (4) and Removal
tighten the fastening screws (1 and 6) to the prescribed
torque. Remove the engine cable as described in the relative section.
Remove the thermostat as described in the relative section.
Remove the common rail as described in the relative section.
Ref No. Description Tightening torques Remove the rocker arm assembly as described in the relative
(1) 7 M8x1.25x25 24 4 Nm section.
(6) 3 M8x1.25x70 24 4 Nm Remove the injectors as described in the relative section.
Remove the turbocharger as described in the relative section.
Remove the exhaust manifold as described in the relative
Figure 67 section.
Remove the intake manifold as described in the relative
section.
Figure 68
209211
Carefully clean the contact surfaces and apply a continuous

sealant bead of LOCTITE 5970 to the surface of the cylinder
head as shown in the figure below.
NOTE Perfect seal is only obtained by cleaning accurately

the surface to seal. Smear with LOCTITE 5970 to
obtain a bead of few mm diameter. It shall be
uniform (no clots), without air bubbles, thin areas
or discontinuities. Any imperfection shall be
corrected as soon as possible. Avoid to use excess
material to seal the joint. Excessive sealant could
74779
come out from joint sidesand cause lubricant
passage clogging. After applying the sealant, the Undo the retaining screws, hook metal cables onto the
joint shall be assembled immediately (10 - 20 brackets (1) and remove the cylinder head (2) from the
minutes). engine block using a hoist.
Remove the head gasket.
Install the common rail as described in the relative section.

Connect the cold-start heater electrical connections (if
fitted).

Installation Figure 70
Figure 69
75703
NOTE Before re-using retaining screws (1) measure

diameters D1 and D2 as shown in the figure:
- if D1-D2 < 0.1 mm the screw can be reused
- if D1-D2 > 0.1 mm the screw must be
replaced
Always check that the threads on the screws and
their holes do not show any signs of wear or traces
of dirt before fitting.
212839
Use suitable lifting hooks (1 and 2) in order to lift and fit the
cylinder head (5) on the engine block (4) after having Figure 71
interposed a new gasket (3) by using a hoist with tool
99360595.
NOTE Clean the cylinder head (5) and engine block (4)
contact surfaces.
There are two types of head gasket:
- Type A 1.25 mm thick
- Type B 1.15 mm thick
Check the average projection S of the pistons:
If S > 0.40 mm use gasket type A.
If S 0.40 mm use gasket type B.
Take care not to get the cylinder head gasket dirty.
Arrange a new cylinder head gasket (3) on the 212838
engine block with the marking TOP facing the
head. After having correctly positioned the gasket on the
The arrow shows the point where the gasket crankcase, assemble the cylinder head (2) and tighten the
thickness is marked. fastening screws (1 and 3) in three phases, following order
and mode shown in the figure below.

M12x1.75x130
1st phase 35 5 Nm
(1) 12 2nd phase 90
If the valves have been removed from the head, it is necessary 3rd phase 90
to assemble them before assembling the head itself on the M12x1.75x150
engine block. 1st phase 55 5 Nm
(3) 14 2nd phase 90
3rd phase 90
NOTE The screws (1 and 3) must be lubricated before

being mounted on the cylinder head (2).
The screws (1 and 3) must be tightened following
a spiral pattern starting in the middle and going
outwards.
Use tool 99395216 for angle tightening.

Figure 72 REMOVAL AND INSTALLATION ENGINE

OIL HEAT EXCHANGER
Removal
Remove the auxiliary components drive belt as described in
Remove the alternator as described in the relative section.
Position a suitable container to catch any engine oil.
A Remove the engine oil filter as described in the relative
70476 section.
Diagram of the tightening sequence for the cylinder head
fixing screws.
A = Front side Figure 73
Install the intake manifold as described in the relative section.

Install the exhaust manifold as described in the relative
section.
Install the turbocharger as described in the relative section.
Install the injectors as described in the relative section.
Install the rocker arm assemblies as described in the relative
chapter.
Install the common rail as described in the relative section.
Install the thermostat as described in the relative section.
Install the engine cable as described in the relative section.
166651
Unscrew the coupling (1) and remove the turbocharger oil
delivery pipe (2).
Remove the screws (3) and the oil pressure / temperature
sensor (4).
Remove the screws (5) and disassemble the oil filter / heat
exchanger bracket (6), intermediate plate (6) and relative
gaskets.
Installation
Figure 74
107275
Fit the following on the engine block: a new gasket (1), the
heat exchanger (2) a new gasket (3) and the oil filter bracket
(4).
Tighten the screws (5) to the specified torque.


Figure 75 Installation
Figure 77
166652
Place the oil temperature/pressure sensor (2) in position on

the bracket (1) with a new seal ring then screw in the 74770
retaining screws (3) and tighten them to the specified torque. Set the gasket (1) on the oil sump (2).
Install the oil delivery pipe (1), screwing on the coupling (2).
Install the engine oil filter as described in the relative section.
Install the alternator as described in the relative section. NOTE If it does not show any signs of damage the gasket
Install the auxiliary components drive belt as described in the can be reused.
relative procedure.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
If it is much below this level, top up with the necessary Figure 78
quantity.
OIL SUMP REMOVAL AND INSTALLATION

Removal
Place a suitable container under the oil sump drain plug to
catch the oil.
Open the oil filler on the cylinder head and remove the
dipstick to aid the flow of oil.
Unscrew the drain plug and let the oil in the sump drain 212841
completely.
Fit the oil sump (2) in position on the crankcase (5) and apply
the relevant plate (4) to it.
Tighten the fastening screws (1 and 3) to the prescribed
torque.
NOTE It is recommended to drain the oil when the engine Screw on the drain plug with a new washer and proceed to
is hot. fill with clean oil.
Figure 76 (1) 14 M8x1.25x40 25 Nm
(3) 4 M8x1.25x45 25 Nm
Use only recommended oils or those with the

required characteristics to ensure correct operation
of the engine.
Failure to observer these requirements shall void the
guarantees.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
74775 If it is much below this level, top up with the necessary
Undo the screws (2) then remove the plate (3) and oil sump quantity.
(1), retaining the gasket.
F4HFE613 ENGINE SECTION 6 - GENERAL MECHANICAL OVERHAULING 1
SECTION 6
General mechanical overhauling
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 3
FITTING THE ENGINE TO

THE ROTATING STAND . . . . . . . . . . . . . . . 3
REMOVAL OF MAIN COMPONENTS . . . . . . . 5
BENCH ENGINE BLOCK DISASSEMBLY . . . . . 17
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Controls and measurements . . . . . . . . . . . . . . 18
- Checking head supporting surface

on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . 19
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 20
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Checking cam lift and pin alignment . . . . . . . . 20
BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 21
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Fitting tappets camshaft . . . . . . . . . . . . . . . . 22
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Measuring journals and crankpins . . . . . . . . . . 23
CONNECTING ROD PISTON ASSEMBLY . . 25
- Connecting rod-piston assembly removal . . . . 25
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 27
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Fitting connecting rod-piston assembly . . . . . . 28
- Connecting rod-piston assembling . . . . . . . . . 28
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 29

2 SECTION 6 - GENERAL MECHANICAL OVERHAULING F4HFE613 ENGINE
Page
BENCH ENGINE BLOCK ASSEMBLY . . . . . . . . . 29

- Replacing oil pump control gear . . . . . . . . . . . 29
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 29

- Crankshaft installation . . . . . . . . . . . . . . . . . . . 30
- Checking crankshaft end float . . . . . . . . . . . . . 30
- Fitting connecting rod half bearings . . . . . . . . 31
- Fitting connecting rod-piston assembly
into cylinder barrels . . . . . . . . . . . . . . . . . . . . 31
- Checking piston protrusion . . . . . . . . . . . . . . . 32
CYLINDER HEAD DISMANTLING . . . . . . . . . . . 33

- Removing the valves . . . . . . . . . . . . . . . . . . . . 33
- Checking cylinder head wet seal . . . . . . . . . . . 33
- Checking cylinder head supporting surface . . . 34
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Removing carbon deposits, checking and
grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Checking clearance between valve stem
and valve guide and valve centering . . . . . . . . 35
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Regrinding replacing the valve seats . . . . . . . 35
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLING CYLINDER HEAD . . . . . . . . . . . . 38
REFITTING MAIN COMPONENTS . . . . . . . . . . 38
REMOVING THE ENGINE FROM
THE ROTATING STAND . . . . . . . . . . . . . . . . 57
COMPLETING ENGINE ASSEMBLY . . . . . . . . . . 57
CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 58

INTRODUCTION - Unplug the fuel temperature sensor and the camshaft

The following description covers general mechanical over- timing sensor electrical connections (2).
haul starting from the engine which has been removed from - Disconnect the low-pressure fuel hoses (3) from the
the vehicle. filter support.
- Unscrew the fastening screws and remove the fuel filter
support (4) complete with the bracket, if fitted, from the
NOTE Refer to the specific publication for removing the engine block.
engine from the vehicle.
Engine removal operations, as with overhauling,
must be carried out by specialised personnel with Figure 2
specific equipment.
This section contains:

- the operations to perform for mounting the engine on
the rotating stand,
- the sequence of removal operations for the main com-
ponents,
- overhaul of the engine block and the cylinder head,
- the sequence of refitting operations for the main compo-
nents, 116237
- operations required for completing engine assembly To disconnect the low pressure fuel hose from the relevant
after removal from the rotating stand, connecting joint, you need to keep the clasp (1) pressed, and
- final checks and tests. release the quick fitting joint (2).
Part of the operations covered in this section can be per-
formed directly on the engine still fitted in the vehicle, in rela- Figure 3
tion to their accessibility in the engine compartment and on
the vehicle version; these are listed in Section 5 - Removal-re-
fitting of main engine components.
FITTING THE ENGINE TO THE ROTATING

STAND
Figure 1
215015
Ensure that the electric starter motor (2) is suitably suppor-

ted.
Unscrew the fastening nuts (3) and remove the electric star-
ter motor (2).
Unscrew the studs (4) from the flywheel housing (1).
Ref No. Description

(3) 3 M10x1.5
(4) 3 M10x1.5x50
166072
To apply the brackets 99361037 to the engine block for

fastening the engine to the overhaul stand, proceed as fol-
lows, working from the left side of the engine:
- Position a suitable container to catch any fuel.
- Using tool 99360076, remove the fuel filter (1) from its
support.

Fit brackets 99361037 to the engine block and use these to secure the engine to the rotating stand 99322205.
Drain the oil from the engine by removing the plug from the oil sump.
Dispose of the oil according to applicable laws.
Figure 4
215019

REMOVAL OF MAIN COMPONENTS

Figure 5
214987
1. Electro-injectors connections - 2. Motorized throttle valve actuator connector (Exhaust flap) -

3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Camshaft timing segment speed sensor -
6. Fuel temperature sensor - 7. Fuel high pressure pump metering unit - 8. Engine Control Unit ECU17CV41 -
9. Crankshaft rpm increment speed sensor - 10. In line connector - 11. Engine oil pressure and temperature sensor -
12. Coolant temperature sensor
Remove the engine cable by unplugging it from the ECU (8), nected. Open the straps holding the engine cable to the
from the motorized throttle valve actuator connector (2) engine block and remove it completely.
and from all the sensors and transmitters to which it is con-

Figure 6
215028
Position a suitable container to catch any fuel. (9) from high pressure pump to fuel filter support;
Disconnect the retainer (11) and remove low pressure fuel Disconnect the retainers (2 and 4) and remove backflow fuel
pipe (18) from fuel filter to high pressure pump; pipes (3, 5 and 8) from common rail and electro-injectors to
Disconnect the retainers (13 and 17), unscrew the screw the fuel filter support.
(15) and remove low pressure fuel pipe (16) from engine Unscrew the hose couplings (1) of the high pressure fuel
control unit heat exchanger to mechanical pump; pipe (19) from high pressure pump to common rail;
Disconnect the retainer (12) and remove low pressure fuel Unscrew the screws (6 and 7) fastening the pipe (19) to the
pipe (14) from mechanical pump to fuel filter. engine block and remove it.
Disconnect the retainer (10) and remove backflow fuel pipe
Ref No. Description

(1) 2 M14x1.5
(6) 1 M8x1.25x20
(7) 1 M8x1.25x16

Figure 7 Figure 9
215029 215031
Position a suitable container to catch any fuel. Unscrew the fastening screw (2) and remove the automatic
Disconnect the retainer and remove the low pressure fuel belt tensioner (1).
pipe from fuel pre-filter to the engine control unit heat Unscrew the fastening screws (3, 4 and 6) and remove the
exchanger. alternator (5) and its bracket (7).
Unscrew the supporting screws (2), and remove the ECU (1),
including the heat exchanger.
Ref No. Description Ref No. Description

(2) 3 M8x1.25 (2) 1 M10x1.5x70
(3) 1 M10x1.5x110
(4) 1 M10x1.5x20
(6) 1 M10x1.5x30
Figure 8 Figure 10
215030 209220
Remove the belt (2) by acting on the automatic belt tensio- Place a container for collecting the spent oil under the filter
ner (8) with the appropriate tool (6) from the alternator (7), support (1).
water pump (5), fan control pulley (1), crankshaft pulley with Unscrew and remove the oil filter (3) from its relative support
damper (4) and fixed guide roller (3). (1) by tool 99360076.
Ref No. Description

(3) 1 M27x2


Figure 11 Figure 13
215032 215033
Figure 12 Figure 14
215034 215035
Position a suitable container to catch any oil. Position a suitable container to catch any coolant.
Unscrew the hose couplings (1 and 5) and remove the lubri- Remove the motorized throttle valve water inlet and outlet
cation oil delivery pipe (2) from the upper part of the heat pipes by proceeding as follows:
exchanger to the turbocharger. - unscrew the fastening nut (2) and connector (1) and
Remove the lubrication oil discharge pipe (4) from the turbo- remove the upper-part water return pipe (9);
charger by proceeding as follows:
- unscrew the fastening nut (4), connector (5) and screw
- unscrew the fastening screws (3) in the lower part of the (6) and remove the lower-part water return pipe (7);
turbocharger, recovering the relevant gasket;
- unscrew the fastening screws (3) and remove the water
- unscrew the screw (6) that retain the piping (4) to the return pipe union (8);
block by means of the fastening collar;
- unscrew the fastening nut (10) and connector (12) and
- unscrew the coupling (7) from the crankcase. remove the water delivery pipe (11).

(1,5) 2 11/16-16 (M16) (1,12) 2 M10x1
(3) 2 M8x1.25x25 (2,4,10) 3 M12x1.5
(6) 1 M8x1.25x16 (3) 2 M8x20
(5) 1 M10x1
(6) 1 M8x16
(F4HFE6131*B003 - F4HFE6131*B005 - (F4HFE613N*B002 - F4HFE613N*B003)

F4HFE613K*B004 - F4HFE613K*B005)
Figure 15 Figure 18
214772 215025
(F4HFE613N*B002 - F4HFE613N*B003) Unscrew the screw (3) and loosen the V-clamping collar (4)
Figure 16 to remove the motorized throttle valve (1) from the turbo-
charger (2).
Ref No. Description
(3) 1 M6x1x50
(F4HFE6131*B003 - F4HFE6131*B005 -
F4HFE613K*B004 - F4HFE613K*B005)
Figure 19
215026
Unscrew the fastening screws (3) and remove the bracket (2)
fixing the motorized throttle valve (4) to the exhaust mani-
fold (1).
Ref No. Description

(3) 4 M8x1.25x25
(F4HFE6131*B003 - F4HFE6131*B005 -
F4HFE613K*B004 - F4HFE613K*B005)
Figure 17
214768
Unscrew the fastening nuts (1) and remove the turbocharger

(3) together with the waste-gate valve (2), recovering the
relevant gasket (4).
Unscrew the studs (5) from the exhaust manifold (6).
Ref No. Description

(1) 4 M10
(5) 4 M10x1.5x42
215022

(F4HFE613N*B002 - F4HFE613N*B003) Figure 22

Figure 20
212829
215027 Unscrew the fastening screws (1 and 3) and remove the

cover (2), retrieving relative gasket.
Unscrew the fastening nuts (1) and remove the turbocharger If present, remove the flange and the gear of the power take--
(5), recovering the relevant gasket (4). off (PTO).
Unscrew the studs (3) from the exhaust manifold (2). Unscrew the fixing nut (7) and remove the camshaft timing
segment speed sensor (6).
Ref No. Description Ensure that the fuel high pressure pump (4) is suitably sup-
(1) 4 M10 ported.
(3) 4 M10x1.5x42 Unscrew the fastening nuts (5) and remove the fuel high
pressure pump (4) complete with the mechanical pump, the
Figure 21 flange and the gear. Unscrew the studs (5).
Ref No. Description

(5) 3 M8x1.25x50
(5) 3 M8-8
(1,3) 2 M12x1.75x25
(7) 1 M6x1x5
Figure 23
212828
212830
Position a suitable container to catch any oil.
Unscrew the fastening screw (1), loosen the retaining clamps Unscrew the hose couplings (1, 3, 8 and 9) from the common
(4) and remove the blow-by breather pipe (3). rail (6) and injector manifolds (7) and remove the high pres-
Unscrew the hose connectors (2 and 6) and remove the oil sure fuel delivery pipes (2 and 10).
return pipe (5). Unscrew the threaded double-shank shoulder screws (4)
Unscrew the fastening screws (7) and remove the blow-by and remove the common rail (6) from the intake manifold
filter (8). (5).

(1) 1 M6x1 (1,8) 6 M14x1.5
(2,6) 2 M12x1.5 (3,9) 6 M14x1.5
(7) 3 M6x1 (4) 4 M8x1.25x125

Figure 24 Figure 26
212831 212832
Unscrew the fastening screws (1 and 5) and remove the Unscrew the fastening nuts (2 and 7) and remove the tappet
intake manifold (3) together with the boost pressure and air cover (1) from the wiring support (5) retrieving relative
temperature sensor (2). gasket (3).
Unscrew the threaded double-shank shoulder screws (4 and
6) from the wiring support (5).

(1) 7 M8x1.25x25 (2,7) 6 M8x1.25
(5) 3 M8x1.25x70
Figure 25 Figure 27
214769
212833
Unscrew the screws (5) together with spacers (4) and Remove the nuts (2) and disconnect the electrical cables (6)
remove the exhaust manifold (3) complete with relevant from the electro-injectors (5).
gaskets (2) from the cylinder head (1). Unscrew the screws (1, 7 and 8) and remove the electro--
injector wiring support (3) complete with gasket (4).

(5) 12 M10x1.5x65 (1,7) 2 M8x1.25
(2) 12 M4
(8) 5 M8x1.25

Figure 28 Figure 30
212835
Undo the fastening nuts (2) and remove the fuel manifolds
(3).
Unscrew the electro-injector (4) fastening screws (1).
212834
Loosen the tappet adjuster retaining nuts (3) and unscrew Ref No. Description
the tappet adjuster screws; (1) 12 M6x1x35
Unscrew the fastening screws (4) and disassemble the rocker (2) 6 M22x1.5x9.5
unit from the cylinder head, including support (2), rockers (1)
and shafts (5).
NOTE Disassembled fuel manifolds (2) must not be used

Ref No. Description again, but replaced with new ones.
(4) 12 M8x1.25
Figure 29 Figure 31
70345
Remove the bridges (1) from valves and the pushrods (2)
from the cylinder head and crankcase.
181861
Undo the injector fastening screws and use tool 99342101 (1)
to remove the injectors (2) from the cylinder head.

Figure 32
NOTE The flywheel blocking device can aid the removal
of the damper pulley (8) fitted onto the crankshaft
pulley (9).
Figure 34
212836
Unscrew the fastening screws (3 and 4) and remove the

engine coolant inlet (1), retrieving relative gasket (2).
Ref No. Description

(3) 2 M10x1.5x130
(4) 1 M10x1.5x70 212838
Unscrew the screws (1 and 3) fixing the cylinder head (2) to

Figure 33 the crankcase.
Ref No. Description

(1) 12 M12x1.75x130
(3) 14 M12x1.75x150
Figure 35
212837
Unscrew the fastening screws (4) and remove the fan control
pulley (3).
Unscrew the fastening screws (1) and remove the fan pulley
mounting (2).
Unscrew the fastening screws (13) and remove the automa-
tic belt tensioner mounting (12).
Unscrew the fastening screw (6) and remove the idler guide
pulley (5).
Unscrew the fastening screws (7) and remove the damper
pulley (8) together with the crankshaft pulley (9). 212839
Unscrew the fastening screws (10) and remove the water
pump (11). Use suitable lifting hooks (1 and 2) in order to lift and remove
the cylinder head (5) complete with gasket (3) from the
engine block (4) by using a hoist with tool 99360595.
Ref No. Description
(1) 4 M8x1.25x45
(4) 4 M10x25
(6) 1 M10x1.5
(7) 6 M12x1.25
(10) 2 M8x1.25x35
(13) 2 M8x1.25x30

Figure 37 Figure 38
212840 212842
Unscrew the fastening screws (4) and remove the oil filter / Unscrew the fastening screws (2 and 8) and remove the oil
heat exchanger together with oil pressure and temperature suction strainer pipe brackets (1).
sensor (5), including oil filter support (6), heat exchanger Unscrew the fastening screws (3) and remove the oil suction
plate (3) and relative gaskets (1 and 2). strainer pipe (5) recovering relevant gasket from the crank-
case (7).
Unscrew the fastening screws (6) and remove the stiffening
plate (4) from the crankcase (7).

(4) 15 M8x1.25x35 (2) 1 M10x1.5x20
(3) 2 M8x20
(6) 3 M10x1.5x25
(8) 1 M10x1.5x25
Figure 36 Figure 39
212841 00900t
Turn the engine upside-down. Extract the crankshaft front cover seal. Fit the tool 99340055
Unscrew the fastening screws (1 and 3) and remove the oil (4) onto the front shank (2) of the crankshaft. Through the
sump (2) from the crankcase (5), recovering relevant gasket guide holes in the tool, perforate the internal seal (1) with a
(4). drill bit ( 3.5 mm) to a depth of 5 mm.
Secure the tool to the ring (1) with the 6 screws provided.
Then extract the ring by screwing in the screw (3).
Ref No. Description

(1) 14 M8x1.25x40
(3) 4 M8x1.25x45

Figure 40 Figure 42
00904t 75811
Fit the appropriate tie-rod (3) of tool 99363204 onto the Undo the screws (1) and remove the oil pump (2).
external seal (2) as illustrated in the figure and, using the lever
(4), extract it from the front cover (1).
Ref No. Description

(1) 4 M8x1.25
Figure 41
Figure 43
212843 212844
Unscrew the fastening screws (1 and 3) and remove the front Apply tool 99360351 on the flywheel housing in order to
cover (2) together with the crankshaft rpm increment speed block the engine flywheel (3) rotation.
sensor. Screw out two opposite screws (2) fixing the engine flywheel
(3) to the crankshaft (4).
Introduce two withdrawal pins in the ports (see the following
picture).
Ref No. Description Loosen remaining screws (1) fixing the engine flywheel (3)
(1) 7 M8x1.25x30 to the crankshaft (4) and remove flywheel blocking tool
(3) 6 M8x1.25 99360351.
NOTE Take note of the screw (1 and 3) assembly posi-

tion, since the screws have different length. Ref No. Description
(1,2) 8 M12x1.25

Figure 44 Figure 46
212846
212845
Screw up two medium length screws in the ports (2) to sling Unscrew the fastening screws (1, 2, 3 and 4) and remove the
the engine flywheel (3). flywheel housing.
Throughout the two guide pins (4) previously screwed up
into the crankshaft ports (1) control the engine flywheel (3)
withdrawal by means of a hoist with tool 99360595. Ref No. Description
(1) 2 M12x1.75
(2) 2 M10x1.5
(3) 10 M10x1.5
(4) 6 M12x1.75
Figure 45
NOTE Note down the installation positions of the screws
since they are of different sizes.
Figure 47
00903t
Extract the flywheel housing seal ring by fitting tool

99340056 (3) on the rear shank (5) of the drive shaft.
Through the guide holes of the tool, perforate the internal 212847
seal ring with a drill bit ( 3.5 mm) to a depth of 5 mm. Unscrew the fastening screws (2) and remove the timing gear
Fix tool 99340056 (3) to the ring (1) by means of the 6 (1) from the camshaft.
screws (4) provided.
Proceed to remove the ring (1) by screwing in the screw (2).
Fit the appropriate tie-rod of tool 99363204 onto the fly-
wheel housing external seal and extract it using the lever. Ref No. Description
(2) 6 M8x1.25

Figure 48 Figure 50
70159
Remove the screws (1) and remove the main caps (2).
212849 Figure 51
Unscrew the fastening screws (2, 4, 5 and 6) and remove the
timing gear case (1) from the crankcase (3).
Ref No. Description
(2) 4 M8x1.25
(4) 3 M10x1.5
(5) 1 M12x1.75
(6) 2 M10x1.5
NOTE Note down the installation positions of the screws

since they are of different sizes.
70160
BENCH ENGINE BLOCK DISASSEMBLY
The second-last-main cap (1) and its relevant support have
the half-bearing (2) equipped with shoulder.
Figure 49
NOTE Write down the upper and lower half-bearing as-
sembling position, in the event of use, they should
be mounted in the position detected when disas-
sembling.
Figure 52
70158
Remove and remove the connecting rod cap (2) fixing

screws (1).
Extract the pistons together with the connecting rods from
the top of the crankcase.
NOTE Maintain the half-bearings in their relevant seats be-

cause, in the event of use, they should be mounted 74774
in the position detected when disassembling. Remove the crankshaft (2) from the block by means of tool
99360500 (1) and hoister.

Figure 53 Figure 56
70162 70165
Remove the main half-bearings (1). Withdraw the tappets (1) from crankcase.
Remove the screws (2) and remove the oil nozzles (3).
Ref No. Description CRANKCASE

(2) 6 M8x1.25x20 Controls and measurements
Figure 54 Figure 57
70163 75386
Remove the screws (1) and remove the camshaft (3) check Carefully clean the crankcase, when performed the engine
plate (2) disassembly.
Use the proper rings to transfer the crankcase.
Carefully check that the block does not present any cracks.
NOTE Write down the plate (2) assembling position. Check the plug conditions. Replace them if they are rusty or
in case of doubt about their conditions.
Examine the cylinder bore surfaces; they must not present
Figure 55 any seizing, scoring, ovalization, taper, and excessive wearing
traces.
The internal diameter check of the cylinder bore, to verify the
ovalization, taper and wearing entity, is performed by means
of bore meter (1) equipped with dial gauge previously set to
zero on the ring gauge (2) of the cylinder barrel diameter.
NOTE If you do not have at your disposal the ring gauge,

70164
use a micrometer for the zero setting operation.
Carefully withdraw the camshaft (1) from the crankcase.

Figure 58 Figure 59
70167
The measurements must be performed for each individual

cylinder at three different heights from the barrel and on two
perpendicular surfaces: one parallel to the longitudinal engine
axis (A) and the other one perpendicular (B); usually the max
wear is detected on this latter surface and in correspondence
with the first measurement.
If you detect any ovalization, taper or wear, ream and grind
the cylinders. The cylinder barrel regrinding must be per-
formed in relation to the diameter of the spare pistons over-
sized of 0.4 or 0.8 mm in respect of the nominal value and
prescribed assembling clearance.
107804
NOTE In the event of grinding operation, all the cylinders

must result of the same oversize (0.4 or 0.8 mm)
Check the main bearing seats, proceeding as follows:

- mount the main caps on the supports without bearings;
- tighten the fixing screws to the torque prescribed;
- by means of an adequate gauge, verify that the internal
diameter of the seats correspond to the value pre-
scribed.
If you detect a higher value, replace the crankcase.
Checking head supporting surface on cylinder

unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.

TIMING SYSTEM
Camshaft
Figure 60
MAIN DATA ABOUT CAMSHAFT PINS

84089
Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and
the bush.
Checking cam lift and pin alignment BUSH

Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error Figure 62
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 7.582 mm for exhaust
cams and 6.045 mm for intake cams, in case of different values
replace the camshaft.
Figure 61
70172
Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
70171
axes.
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.

Figure 63
Sec. A-A
107268
CAMSHAFT BUSH AND HOUSING MAIN DATA

* Value to be obtained after driving the bush.
Bush replacement TAPPETS
Figure 64 Figure 65
70174 112890
To replace rear bushing (1), use, for dismounting and mount- MAIN DATA CONCERNING THE TAPPETS AND THE
ing it, beater 99360362 (2) and handgrip 99370006 (3). RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE Bushing (1), on mounting, must be oriented in such

a way that lubrication holes match the holes pres-
ent on block seat.

Fitting tappets camshaft Figure 69

Figure 66
70179
Check camshaft end float (1).

70176
It shall be 0.23 0.13 mm.
Lubricate the tappets (1) and fit them into the relevant hous- Figure 70
ings on the engine block.
Figure 67
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
70164

Lubricate the bushing and other timing system shaft support
(1) 6 M8x1.25x20 15 3 Nm
seats and mount camshaft (1) taking care that, during the
operation, the bushing or support seats are not being dama-
ged.
Figure 68
70238
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.

CRANKSHAFT
Measuring journals and crankpins NOTE It is recommended to insert the found values in the
proper table. See next Figure.
Figure 71
Undersize classes are: 0.250 0.500 mm
NOTE Journals and crankpins shall always be ground to

the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the journals (2)
measure them with a micrometer (1) to decide the final di-
ameter to which the pins are to be ground.
Figure 72
196432
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value

Figure 73
* Measured on a radius greater than 45.5 mm 70577

** 0.500 between adjacent main journals
MAIN CRANKSHAFT TOLERANCES
Figure 74
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

CONNECTING ROD PISTON ASSEMBLY Figure 76

Connecting rod-piston assembly removal
Figure 75
32613
Remove split rings (1) from piston (2) using pliers 99360183
70191
(3).
CONNECTING ROD PISTON ASSEMBLY COMPO-
NENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws Figure 77
- 6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE Pistons are supplied spare with 0.4 or 0.8 mm

oversize.
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 78
196434
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter

Pistons Conditions for proper pin-piston coupling

Measuring piston diameter
Figure 79 Figure 82
32619
32615 Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
Using a micrometer (2), measure the diameter of the piston pressure and shall not be withdrawn by gravity.
(1) to determine the assembly clearance.
Figure 80
Piston rings
Figure 83
70192
The clearance between the piston and the cylinder barrel can 16552
be checked also with a feeler gauge (1) as shown in the figure.
Use a micrometer (1) to check split ring (2) thickness.
Gudgeon pins
Figure 81 Figure 84
18857 32620
To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd
(2). and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Figure 85 Connecting rods

Figure 87
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
196435
between ring and slot: found value shall be the specified one.
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
* Value for inside diameter to be obtained after driving in

Figure 86 connecting rod small end and grinding.
NOTE The surface of connecting rod and rod cap are

knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).

Figure 88 Fitting connecting rod-piston assembly

Connecting rod-piston assembling
Figure 89
CONNECTING
ROD BODY CAP FLYWHEEL SIDE
CONN. WEIGHT CONN.
ROD Nr. ROD Nr.
FAN SIDE
162243
CONNECTING ROD CAP The piston crown is marked as follows:

F 1. Part number and design modification number;
YEAR DAY
F = 2003
2. Arrow showing piston assembling direction into cylinder
G = 2004 barrel, this arrow shall face the front key of the engine
H = 2005
I = 2006
block (fan side);
70196 3. Marking showing 1st slot insert testing;
4. Manufacturing date;
5. Product traceability
NOTE Every connecting rod is marked as follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the new connecting rod with the same Figure 90
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1560 to 1600 g (yellow marking);
S W, 1601 to 1640 g (green marking);
S X, 1641 to 1680 g (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
162244
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the cylin-
der barrel and the numbers (5) marked on the connecting
Bushes rod (5) are read as shown in the figure.
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.

Figure 91 BENCH ENGINE BLOCK ASSEMBLY

Replacing oil pump control gear
Figure 93
126312
Position the piston on the connecting rod according to the

diagram shown in the figure, fit the pin and stop it by the split
rings (2). 70184
Fitting split rings Check that gear toothing (1) is not damaged or worn, other-
wise remove it using the proper puller (3).
Figure 92 On mounting the new gear, the gear has to be heated for 10
at 180 C temperature and keyed on engine shaft by putting
the key in between.
Fitting main bearings

Figure 94
126311
Use pliers 99360183 (1) to fit the split rings on the piston (2).
Split rings shall be fitted with the marking TOP facing up-
wards and their openings shall be displaced with each other
70185
by 120.
NOTE Refit the main bearings that have not been re-
placed, in the same position found at removal.
NOTE Split rings are supplied spare with the following

sizes:
- standard; Main bearings (1) are supplied spare with 0.250 0.500 mm
- 0.4 mm oversize; undersize on the internal diameter.
- 0.8 mm oversize.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubri-
cating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.

Crankshaft installation Figure 97
Figure 95
70187
Tighten the pre-lubricated screws (1) in the following two

successive stages:
74774 - 1st stage, with torque wrench to 80 6 Nm.
Refit the output shaft (2).

Figure 98
Figure 96
70188
- 2nd stage, with tool 99395216 (1) set as shown in the fig-
ure, tighten the screws (2) with 90 2 angle.
Checking crankshaft end float

128169
Figure 99
- Clean accurately the parts and remove any trace of oil;
- fit caps (1), including the half bearings (2) on the relevant
supports.
NOTE Before reusing the fastening screws (1), perform

two diameter measurements as shown in figure,
registering diameters D1 and D2:
if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
70190
This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft journals and main half bearings.
75703

Fitting connecting rod half bearings Figure 102
Figure 100
162245
70200 DIAGRAM FOR INSTALLING CONNECTING ROD

PISTON ASSEMBLY INTO CYLINDER
(viewed from front)
Fit half bearings (1) on connecting rod and cap.
- split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
NOTE Refit the main bearings that have not been re- weight;
placed, in the same position found at removal. - the arrow marked on the piston crown shall be facing the
Do not try to adapt the half bearings. front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle posi-
tion.
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 103
Figure 101
70201
128170
Lubricate accurately the pistons, including the split rings and - Clean the parts accurately and remove any trace of oil;
the cylinder barrel inside. - install the big end caps (1) with the relative half-bearings
Use band 99360605 (2) to fit the connecting rod-piston as- (2).
sembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.

Figure 104 Checking piston protrusion

Figure 107
70204
166655
- lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench Once connecting rod-piston assemblies refitting is over, use
(2). dial gauge 99395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block, carrying out the following operations:
Figure 105
- measure the protrusions S1 and S2 of piston no. 1 from

the top surface of the engine block at a distance of 45
mm from the centre of the piston and then calculate the
average protrusion:
S cil1 = S1 + S2
2
- repeat the operation to calculate the average protrusion

of pistons 2, 3, 4, 5 and 6, then calculate the average value
70205 of the protrusions:
- apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60 2.
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6

S=
Figure 106 6
70207
Check manually that the connecting rods (1) are sliding

axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 0.33 mm.

CYLINDER HEAD DISMANTLING Figure 110

Removing the valves
Figure 108
70322
Remove the sealing rings (1 and 2) from the relevant valve

70319 guides.
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head distin- NOTE Sealing rings (1) for intake valves are yellow.
guishes it from the intake valve. Sealing rings (2) for exhaust valves are green.
NOTE Should valves be not replaced, number them

before removing in order to refit them in the same
position. Checking cylinder head wet seal
A = intake side S = exhaust side
Figure 111
Figure 109
70323
This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90 C and
2 to 3 bar pressure.
70321 Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4).
Repeat this operation for all the valves. NOTE Before refitting, smear the plug surfaces with water--
Overturn the cylinder head and withdraw the valves (5). repellent sealant.
Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface VALVES
Distortion found along the whole cylinder head shall not ex- Figure 113
ceed 0.20 mm.
If higher values are found grind the cylinder head according EXHAUST INTAKE
to values and indications shown in the following figure. VALVE VALVE
Figure 112
162247
INTAKE AND EXHAUST VALVE MAIN DATA
70325
The rated thickness A for the cylinder head is 105 0.25 mm, Removing carbon deposits, checking and grin-
max. metal removal shall not exceed thickness B by 0.13 mm. ding valves
Figure 114
NOTE After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.
18625
Remove carbon deposits from valves using the proper metal

brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, removing as less material
as possible.

Figure 115 VALVE GUIDES

Figure 117
18882
Check the valve stem (1) using a micrometer (2), it shall be

6.990 7.010 mm.
Checking clearance between valve stem and EXHAUST INTAKE

valve guide and valve centering 79457
Figure 116
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
VALVE SEATS
Regrinding replacing the valve seats
Figure 118
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.032 0.072 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
70330
Check the valve seats (2). If slight scoring or burnout is found,

regrind seats using tool (1) according to the angle values
shown in Figure 119.

Figure 119
EXHAUST INTAKE
107281
MAIN DATA OF ENGINE VALVE SEATS
The valve seats are cast in the cylinder head and machined.
Figure 120
EXHAUST INTAKE
107282
If the valve seats cannot be restored by only regrinding, it is To mount the valve seats in the cylinder head it is necessary
possible to mount the inserts supplied as spares. to heat the cylinder head to 80 - 100 C and, using a suitable
In this case, it is necessary to make the seats on the cylinder drift, mount the new valve seats (2) in them after they have
head with the dimensions shown in the figure and to mount been cooled.
the valve seats. Then use the specific tool to grind the valve seats to the
values given in Figure 121.

Figure 121
EXHAUST INTAKE
162248
MAIN VALVE SEAT DATA
Figure 122 VALVE SPRINGS

Figure 123
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

70333 VALVE SPRINGS
Prior to assembly, check valve spring flexibility using a suitable
After regrinding, check with the base 99370415 (2) and the tool. Compare the elastic deformation and load data with
dial gauge 99395603 (1) that the valve recessing (3) is as pres- those for new springs given in the following table.
cribed.
Height Under a load of

mm N
H 35.33 Free
H1 35.33 P1 339.8 9
H2 25.2 P2 741 39

ASSEMBLING CYLINDER HEAD REFITTING MAIN COMPONENTS
Figure 124 Figure 126
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green. 212850
LOCTITE 5205 SEALANT APPLICATION AREAS

Clean accurately the timing gear case and the engine block.
Figure 125
NOTE Perfect seal is only obtained by cleaning accurately

the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
770321
Position on the cylinder head: the spring (4) and upper plate
(3): using tool 99360268 (1), compress the spring (4) and
fasten the plate (3) to the valve (5) with the cotters (2).

212848
Ensure that, during the assembly of the timing gear (3) on the
212849
camshaft (2), the reference pins (1 and 4) match.
DIAGRAM FOR TIGHTENING THE REAR TIMING
GEAR CASE FASTENING SCREWS
Refit the timing gear case (1) to the crankcase (3). Figure 130
Screw the fastening screws (2, 4, 5 and 6) to the same posi-
tion found at removal and tighten them to the prescribed tor-
que following the sequence shown in the figure.

(2) 4 M8x1.25 24 4 Nm
(4) 3 M10x1.5 47 5 Nm
(5) 1 M12x1.75 77 12 Nm
(6) 2 M10x1.5 47 5 Nm
NOTE Before any assembly operation always verify that

the hole and screw threads have no evidence of 114791
wear or dirt. Turn the engine shaft (3) and the distribution shaft (4) so that
by mounting the bevel gear on the latter (1) the stencilled
Figure 128 mark on the gear (1) coincides with the groove on the gear
tooth (2).
Figure 131
70211
With a felt-tip pen, highlight the conducting gear tooth (1)

mounted on the engine shaft (2) upon the side surface of
which a groove has been created for the ignition timing.
212847
Tighten the screws (1) fastening gear (2) to camshaft (3) to

NOTE Fasten screwing of the two pins to facilitate the the specified torque.
operation of engine driving shaft rotation.

70214 212846
LOCTITE 5205 SEALANT APPLICATION AREAS SEQUENCE FOR TIGHTENING THE FLYWHEEL
HOUSING FASTENING SCREWS
NOTE Perfect seal is only obtained by cleaning accurately Refit the flywheel housing to the engine block.
the surface to seal. Screw the fastening screws (1, 2, 3 and 4) to the same posi-
Smear the case with LOCTITE 5205 to obtain a tion found at removal and tighten them to the prescribed tor-
bead of few mm diameter. que following the sequence shown in the figure.
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Ref No. Description Tightening torques
Excessive sealant could come out from joint sides (1) 2 M12x1.75 85 10 Nm
and cause lubricant passage clogging. (2) 2 M10x1.5 49 5 Nm
After applying the sealant, the joint shall be as- (3) 10 M10x1.5 49 5 Nm
sembled immediately (10 20 minutes). (4) 6 M12x1.75 85 10 Nm

the hole and screw threads have no evidence of
wear or dirt.

0901t
Apply tool 99346253 part (6) to the rear output shaft tang 212845
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing Screw up two medium length screws in the ports (2) to sling
sealing ring (3) fitting into flywheel housing (7). the engine flywheel (3).
Screw up two guide pins (4) having suitable length into the
crankshaft holes (1) and assemble the engine flywheel (3) by
means of a hoist with tool 99360595.
212844
Apply tool 99360351 on the flywheel housing in order to

block the engine flywheel (3) rotation.
Remove the two withdrawal pins in the ports (see the pre-
vious picture).
200508 Tighten the screws (1 and 2) fixing the engine flywheel (3)
to the crankshaft (4) in two phases.
Check the supporting surface (1) of the clutch plate and if it
is scratched, it is necessary to carry out turning.
Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel using Ref No. Description Tightening torques
a suitable hammer and fit the new one, previously heated to 30 4 Nm
(1,2) 8 M12x1.25
150 C for 15 to 20 minutes. Chamfering on ring gear inside 60
diameter shall be facing the engine flywheel.
NOTE Tightening to angle is performed using tool

99395216.
Before any assembly operation always verify that
wear or dirt.

Figure 138 Ref No. Description Tightening torques

(1) 7 M8x1.25x30 24 4 Nm
(3) 6 M8x1.25 24 4 Nm
Figure 141
70220
Fit the oil pump (1).

Tighten the fastening screws (2) to the specified torque.
Ref No. Description Tightening torques 00902t

M8x1.25 1st phase 8 1 Nm
(2) 4 2nd phase 24 4 Nm Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Figure 139 Position part (2) on part (4), screw nut (3) until completing
sealing ring (7) fitting into front cover (1).
Figure 142
106549
Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with LOC-
TITE 5205.
Figure 140
212842
Turn the engine upside-down.

Fit the oil suction strainer pipe (5) on the crankcase (7) after
having interposed a new gasket and tighten the fastening
screws (3) to the specified torque.
Fit the stiffening plate (4) and the oil suction strainer pipe
brackets (1) on the crankcase (7) and tighten the fastening
screws (2, 6 and 8) to the specified torque.
212843 Ref No. Description Tightening torques

Fit the front cover (2) together with the crankshaft rpm incre- (2) 1 M10x1.5x20 45 Nm
ment speed sensor to the engine block. (3) 2 M8x20 25 Nm
Screw the fastening screws (1 and 3) to the same position (6) 3 M10x1.5x25 43 5 Nm
found at removal and tighten them to the prescribed torque. (8) 1 M10x1.5x25 43 5 Nm

74770
Set the gasket (1) on the oil sump (2).

212840
Assemble the oil filter / heat exchanger together with oil

NOTE If it does not show any signs of damage the gasket pressure and temperature sensor (5) to the block, including
can be reused. the following elements: oil filter support (6), heat exchanger
plate (3) and relative gaskets (1 and 2).
Tighten the fastening screws (4) to the prescribed torque.
Figure 144

(4) 15 M8x1.25x35 26 4 Nm

212841
Fit the oil sump (2) in position on the crankcase (5) and apply
the relevant plate (4) to it.
Tighten the fastening screws (1 and 3) to the prescribed tor-
que.

(1) 14 M8x1.25x40 25 Nm
(3) 4 M8x1.25x45 25 Nm

of dirt before fitting

212838
After having correctly positioned the gasket on the crank-

case, assemble the cylinder head (2) and tighten the fastening
screws (1 and 3) in three phases, following order and mode
212839
shown in the figure below.
Use suitable lifting hooks (1 and 2) in order to lift and fit the Ref No. Description Tightening torques
cylinder head (5) on the engine block (4) after having interpo-
sed a new gasket (3) by using a hoist with tool 99360595. (1) 12 M12x1.75x130
1st phase 35 5 Nm
2nd phase 90
3rd phase 90
NOTE Check cleanness of cylinder head (5) and engine (3) 14 M12x1.75x150
block (4) coupling surface. 1st phase 55 5 Nm
There are two types of head gasket: 2nd phase 90
3rd phase 90
- Type A - 1.25 mm thick
- Type B - 1.15 mm thick
NOTE The screws (1 and 3) must be lubricated before
Check the average protrusion S of the pistons. being mounted on the cylinder head (2).
If S > 0.40 mm use gasket type A.
If S 0.40 mm use gasket type B.
Do not get the cylinder head gasket dirty.
Place the gasket (3) in position with the marking NOTE The screws (1 and 3) must be tightened following
TOP facing the head. a spiral pattern starting in the middle and going
The arrow shows the point where the gasket thick- outwards.
ness is given.
NOTE The angle tightening is carried out through tool

99395216.
If the valves have been removed from the head, it is necessary NOTE Before any assembly operation always verify that
to assemble them before assembling the head itself on the the hole and screw threads have no evidence of
engine block. wear or dirt.
NOTE Before reusing the fastening screws (1), perform Figure 148
two diameter measurements as shown in figure,
registering diameters D1 and D2:
if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
D2 D1
A 70476
Tightening order layout for cylinder head fastening screws:

75703 A = Front side

Figure 149
NOTE The flywheel blocking device can aid the installa-
tion of the damper pulley (8) fitted onto the crank-
shaft pulley (9).
Figure 151
70221
Apply a new sealing ring (2) to the water pump (1).
Figure 150
212836
Assemble the engine coolant inlet (1), after having interpo-

sed a new gasket (2), so that the two reference hollow pins
are set against the crankcase.
Tighten the fastening screws (3 and 4) to the prescribed tor-
que.

(3) 2 M10x1.5x130 43 6 Nm
(4) 1 M10x1.5x70 43 6 Nm

212837
wear or dirt.
Install the water pump (11) and tighten the fastening screws
(10) to the prescribed torque.
Install the crankshaft pulley (9) together with the damper pul-
ley (8) on the crankshaft and tighten the fastening screws (7)
to the prescribed torque.
Install the idler guide pulley (5) and tighten the fastening Figure 152
screw (6) to the prescribed torque.
Install the automatic belt tensioner mounting (12) and
tighten the fastening screws (13) to the prescribed torque.
Install the fan pulley mounting (2) and tighten the fastening
screws (1) to the prescribed torque.
Install the fan control pulley (3) and tighten the fastening
screws (4).

(1) 4 M8x1.25x45 24 4 Nm
(4) 4 M10x25 68 7 Nm
(6) 1 M10x1.5 43 6 Nm
M12x1.25
(7) 6 1st phase 50 5 Nm 70338
2nd phase 90 Fit a new sealing ring (2) lubricated with petroleum jelly and
(10) 2 M8x1.25x35 24 4 Nm a new sealing washer (3) on injector (1).
(13) 2 M8x1.25x30 24 4 Nm

Figure 153 NOTE Disassembled fuel manifolds (2) must not be used
again. Replace with new items.
The fuel manifolds (2) for engines have 2 position-
ing spheres.
Figure 156
203451
Fit injectors (1) on the cylinder head seats, directed so that

the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

Figure 154
212835
Screw the fastening nuts (2) without locking them;

Tighten gradually and alternately the electro-injector (4)
fastening screws (1) to the prescribed torque in four stages;
Tighten the fuel manifold (3) fastening nuts (2) to the prescri-
bed torque.

(1) 12 M6x1x35
181861 1st phase 3.5 0.35 Nm
Use tool 99342101 (1) to fit the injector (2) into its seat. 2nd phase 25
3rd phase 25
Screw injector fastening screws without tightening them. 4th phase 25
(2) 6 M22x1.5x9.5 55 5 Nm
Figure 155
NOTE During this operation, the injector (4) shall be
moved so that the manifold (3) is properly inserted
into the fuel inlet hole.
NOTE Tightening to angle is performed using tool

99395216.
91572
Fit a new sealing ring (3) lubricated with petroleum jelly on

the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) is coinciding with the relevant
housing (4).

70343
70345
ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers. Fit the rods (2).
Position jumpers (1) on valves with marks () facing the ex-
haust manifold.
Figure 158
Figure 161
SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
Figure 159
212834
Check that tappet adjusters screws and retaining nuts (3) are
loose to prevent their balking on the rods when refitting the
rocker assembly.
Install the rocker unit consisting of bracket (2), rockers (1),
shafts (5) and secure them to the cylinder head by tightening
122587 the fastening screws (4) to the prescribed torque.
Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets (ar-
rows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and Ref No. Description Tightening torques
are therefore interchangeable. (4) 12 M8x1.25 36 5 Nm

70352
Check the condition of the electrical cables (5), if they are

182221 damaged replace them by cutting the straps (2) securing
The adjustment of the clearance between the rocker arms them to the bracket and removing the screws (4) securing
and the intake and exhaust valves must be strictly carried out the connectors to this (3).
using an Allen wrench (1), box-end wrench (3) and a feeler Fit a new gasket (1) on the bracket (2).
gauge (2).
Clearance shall be as follows:
- exhaust valves 0.50 0.05 mm. Figure 164
NOTE In order to perform the rocker arm - valve

clearance adjustment more quickly, proceed as
follows:

the asterisk as shown in the tables below:
intake - - * - * *
exhaust - * - * - *

cylinder no. 6 and adjust the valves marked by 212833
the asterisk as shown in the tables below: Fit the electro-injector wiring support (3) complete with a
new gasket (4) and tighten the screws (1, 7 and 8) to the pre-
scribed torque.
cylinder no. 1 2 3 4 5 6 Connect the electrical cables (6) to the electro-injectors (5)
intake * * - * - - and use the torque wrench 99389834 to tighten the faste-
ning nuts (2) to the prescribed torque.
exhaust * - * - * -

(1,7) 2 M8x1.25 24 4 Nm
(2) 12 M4 1.5 0.25 Nm
(8) 5 M8x1.25 24 4 Nm

wear or dirt.

70355
214769
Fit a new gasket (2) on the tappet cover (1). Fit the exhaust manifold (3) in position with new gaskets (2)
to the cylinder head (1) and tighten the fastening screws (5)
after having interposed spacers (4) to the prescribed torque
following order and mode shown in the figure below.
Figure 166 Ref No. Description Tightening torques

(5) 12 M10x1.5x65 55 3 Nm
NOTE Always replace the gaskets (2) using new ones.

Check the threads of the fixing screws: there shall
be no evidence of wear or dirt deposit.
Figure 168
212832
Screw the threaded double-shank shoulder screws (4 and 6)

in the wiring support (5).
Install the tappet cover (1) on the wiring support (5) after
having interposed a new gasket (3).
Tighten the fastening nuts (2 and 7) to the prescribed torque. 209215
Tightening order layout for exhaust manifold fastening

screws
A = Front side
(2,7) 6 M8x1.25 24 4 Nm

209211
Carefully clean the contact surfaces and apply a continuous
sealant bead of LOCTITE 5970 to the surface of the cylinder
head as shown in the figure below.
212830
Install the common rail and high pressure fuel delivery pipes
NOTE Perfect seal is only obtained by cleaning accurately by proceeding as follows:
the surface to seal. Smear with LOCTITE 5970 to - fit the common rail (6) on the intake manifold (5) and
obtain a bead of few mm diameter. manually tighten the threaded double-shank shoulder
screws (4);
thin areas or discontinuities. - tighten two central screws (4) to a torque of 0.1 Nm;
Any imperfection shall be corrected as soon as - fit the high pressure fuel delivery pipes (2 and 10) and
possible. manually tighten the hose couplings (1, 3, 8 and 9) fist of
Avoid to use excess material to seal the joint. all from common rail side and then from cylinder head
Excessive sealant could come out from joint side- side;
sand cause lubricant passage clogging. - tighten the hose couplings (1, 3, 8 and 9) to a torque of
After applying the sealant, the joint shall be assem- 5 Nm, fist of all from cylinder head side and then from
bled immediately (10 - 20 minutes). common rail side;
- tighten the threaded double-shank shoulder screws (4)
fixing the common rail (6) on the intake manifold (5) to
the prescribed torque;
- tighten the hose couplings (1, 3, 8 and 9) to the prescri-
Figure 170 bed torque, fist of all from common rail side and then
from cylinder head side.

(1,8) 6 M14x1.5
1st phase 10 Nm
2nd phase 55
(3,9) 6 M14x1.5
1st phase 10 Nm
212831 2nd phase 55
Install the intake manifold (3) together with the boost pres- (4) 4 M8x1.25x125 36 5 Nm
sure and air temperature sensor (2) on the cylinder head and
tighten the fastening screws (1 and 5) to the prescribed tor-
que.
NOTE The high pressure fuel delivery pipes must be repla-
ced every time they are removed. The hose cou-
plings must be tightened to torque using spanner
99317915 and torque wrench 99389829.
(1) 7 M8x1.25x25 24 4 Nm
(5) 3 M8x1.25x70 24 4 Nm

4
212829
Ensure that the the fuel high pressure pump (4) is suitably
supported.
Screw the studs (5). Fit the fuel high pressure pump (4) com-
plete with the mechanical pump, the flange and the gear and
tighten the fastening nuts (5) to the prescribed torque.
Install the stud, the support with a new sealing ring and the
camshaft timing segment speed sensor (6). Tighten the fixing
nut (7) to the prescribed torque.
212828
If present, install the power take-off (PTO) equipped with the
flange and the gear. Fit the blow-by filter (8) in position on the on the flywheel
Fit the cover (2), after having interposed a new gasket and housing and tighten the fastening screws (7) to the prescri-
tighten the fastening screws (1 and 3) to the prescribed tor- bed torque.
que. Install the oil return pipe (5) with new copper washers and
tighten the hose connectors (2 and 6) to the prescribed tor-
que.
Fit the blow-by breather pipe (3) into the coupling located
on the timing gear case and secure it with the retaining
clamps (4). Tighten the screw (1) fastening to the tappet
cover to the prescribed torque.
(5) 3 M8x1.25x50 11 3 Nm (1) 1 M6x1 10 2 Nm
(5) 3 M8-8 24 4 Nm (2,6) 2 M12x1.5 20 4 Nm
(1,3) 2 M12x1.75x25 80 5 Nm (7) 3 M6x1 10 2 Nm
(7) 1 M6x1x5 12 Nm


214768 215022
Proceed assembling the turbocharger (3):

- screw the studs (5) on the exhaust manifold (6);
- hold the turbocharger (3) together with the waste-gate
valve (2) and place it on the exhaust manifold (6) after
having interposed a new gasket (4);

(1) 4 M10 43 6 Nm
(5) 4 M10x1.5x42 25 5 Nm

215027 215025
Proceed assembling the turbocharger (5): Install the motorized throttle valve (1) onto the turbocharger
- screw the studs (3) on the exhaust manifold (2); (2).
Screw the screw (3) and tighten the V-clamping collar (4) to
- hold the turbocharger (5) and place it on the exhaust
the prescribed torque.
manifold (2) after having interposed a new gasket (4);
(1) 4 M10 43 6 Nm (3) 1 M6x1x50 10 2 Nm
(3) 4 M10x1.5x42 25 5 Nm


214772 215033
215026 215035
Assemble the bracket (2) fixing the motorized throttle valve Install the motorized throttle valve water inlet and outlet
(4) to the exhaust manifold (1) and tighten the fastening pipes by proceeding as follows:
screws (3) to the prescribed torque. - fit the water delivery pipe (11) and tighten the fastening
nut (10) and connector (12) to the prescribed torque;
- fit the water return pipe union (8) and tighten the faste-
ning screws (3) to the prescribed torque;
- fit the lower-part water return pipe (7) and tighten the
fastening nut (4), connector (5) and screw (6) to the pre-
scribed torque;
- fit the upper-part water return pipe (9) and tighten the
fastening nut (2) and connector (1) to the prescribed
torque.
(3) 4 M8x1.25x25 25 Nm (1,12) 2 M10x1 20 Nm
(2,4,10) 3 M12x1.5 45 Nm
(3) 2 M8x20 23 2.3 Nm
(5) 1 M10x1 25 Nm
(6) 1 M8x16 23 2.3 Nm

(F4HFE6131*B003 - F4HFE6131*B005 - Figure 184

F4HFE613K*B004 - F4HFE613K*B005)
Figure 182
209220
Moisten the sealing gasket (2) of the oil filter (3) with a thin
layer of oil.
Manually tighten the oil filter (3) on the support (1) until it
Additionally tighten the oil filter (3) to the prescribed torque
215032 using a specific tool.
Operate the engine for a few minutes and then check the
(F4HFE613N*B002 - F4HFE613N*B003) level using the dipstick. If necessary, top up to compensate
for the quantity of oil used to fill up the filtering cartridge.
Figure 183

(3) 1 M27x2 18 2 Nm
Figure 185
215034
Install the lubrication oil discharge pipe (4) onto the turbo-
charger by proceeding as follows:
- screw the coupling (7) on the crankcase;
- screw the fastening screws (3) in the lower part of the
turbocharger, after fitting a new gasket; 215031
- screw the screw (6) that retain the piping (4) to the block Install the bracket (7) fixing the alternator (5) and tighten the
by means of the fastening collar. fastening screws (3, 4 and 6) to the prescribed torque.
Fit the lubrication oil delivery pipe (2) from the upper part of Fit the automatic belt tensioner (1) and tighten the fastening
the heat exchanger to the turbocharger and tighten the hose screw (2) to the prescribed torque.
couplings (1 and 5) to the prescribed torque.
(1,5) 2 11/16-16 (M16) 36 5 Nm (2) 1 M10x1.5x70 43 6 Nm
(3) 2 M8x1.25x25 23 2 Nm (3) 1 M10x1.5x110 43 6 Nm
(6) 1 M8x1.25x16 23 2 Nm (4) 1 M10x1.5x20 43 6 Nm
(6) 1 M10x1.5x30 43 6 Nm

215030 215029
Fit the Poly V belt (2) on the pulleys and guide roller. Fit the ECU (1), including the heat exchanger and tighten the
Use the appropriate tool (6) on the automatic belt tensioner supporting screws (2) to the prescribed torque.
(8) in order to fit the new belt (2) in the operating position. In case the rubber buffers are cracked or excessively defor-
Additional adjustments are not required. The belt (2) tension med, provide replacing them.
is adjusted automatically by the calibrated spring in the auto- Install the low pressure fuel pipe from fuel pre-filter to the
matic belt tensioner (8). engine control unit heat exchanger and connect the retainer.

(2) 3 M8x1.25x45 14 Nm

Figure 188
215028
Fit the high pressure fuel pipe (19) to the engine block and Fit backflow fuel pipes (3, 5 and 8) from common rail and elec-
tighten the fastening screws (6 and 7) to the prescribed tor- tro-injectors to the fuel filter support and connect the retai-
que. ners (2 and 4).
Connect the pipe (19) both to the high pressure pump and Fit backflow fuel pipe (9) from high pressure pump to fuel filter
to the common rail and tighten the hose couplings (1) to the support and connect the retainer (10).
prescribed torque. Fit low pressure fuel pipe (14) from mechanical pump to fuel
filter and connect the retainer (12).
Fit low pressure fuel pipe (16) from engine control unit heat
exchanger to mechanical pump, tighten the fastening screw
(15) to the prescribed torque and connect the retainers (13
Ref No. Description Tightening torques and 17).
(1) 2 M14x1.5 24 4 Nm Fit low pressure fuel pipe (18) from fuel filter to high pressure
(6) 1 M8x1.25x20 25 Nm pump and connect the retainer (11).
(7) 1 M8x1.25x16 25 Nm
NOTE The high pressure fuel hose must always be repla-

ced with a new one whenever it is removed. The
hose couplings must be tightened to torque using
spanner 99317915 and torque wrench 99389829.

Figure 189 COMPLETING ENGINE ASSEMBLY

Figure 190
116237
To connect the low pressure fuel hose to the connection fit-

ting, insert the quick-fit coupling (2) in the connection fitting
and push it in until the catch (3) engages.
215015
NOTE Check proper fuel hose connection. Screw the studs (4) and fit the electric starter motor (2) into
the internal part of the flywheel housing (1). Tighten the
fastening nuts (3) to the prescribed torque.
Place the engine cable in position and close the straps retain-
ing the engine cable to the engine block. Connect the engine Ref No. Description Tightening torques
cable to the ECU (8), to the motorized throttle valve actu-
(3) 3 M10x1.5 43 6 Nm
ator connector (2) and to all the sensors and transmitters
indicated in the electrical equipment section. (4) 3 M10x1.5x50 -
Figure 191
REMOVING THE ENGINE FROM THE
ROTATING STAND
To complete engine assembly it is necessary to remove it
from the turning stand 99322205.
- Using a hoist with tool 99360595 hold the engine and
loosen the screws fixing the brackets 99361037 to the
turning stand 99322205.
- Disassemble the brackets 99361037 from the engine
after having properly put it on a suitable support.
166072
- Place the fuel filter support (4) in position together with

the bracket, if present, and tighten the retaining screws
to the specified torque.
- Connect the low-pressure fuel hoses (3) to the filter sup-
port.
- Connect the fuel temperature sensor and camshaft tim-
ing sensor electrical connections (2).
- Fully screw the fuel filter (1) onto the connection on its
support by hand, then further tighten to a torque of
20 2 Nm.

CHECKS AND INSPECTIONS
NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle.
Preventively check that the liquid levels have been
correctly restored.
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the tem-
perature necessary to open the thermostat and then
check:
- that there are no water leaks from the connecting

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low pres-
sure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the cyl-
inder head, between oil sump and engine block, between
heat exchanger oil filter and the relevant housings and
between the different pipes in the lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment discon-
nected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.

F4HFE613 ENGINE SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 10

2 SECTION 7 - TECHNICAL SPECIFICATIONS F4HFE613 ENGINE

GENERAL SPECIFICATIONS
F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
Cycle Four-stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 6

Bore mm 104
Stroke mm 132
+ + + .. = Total displacement cm3 6728
TIMING
start before T.D.C.. A 18.5

end after B.D.C. B 29.5
start before B.D.C. D 67

end after T.D.C. C 35
Checking operation
mm 0,20 0,30
X X
mm 0,45 0,55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC17CV41 ECU
Injector CRIN2
DLLA137 PV3 198
Nozzle type DLLA 137 PV3 208 244
878
Injection sequence 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA
F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm
1
Cylinder barrels 1 104.000 104.024
X
1 0.4 - 0.8
Pistons type:
1 49.5
Size X
X 103.739 103.757
Outside diameter 1
Pin housing 2 40.010 40.016
2
Piston diameter 1 0.4 - 0.8
Piston - cylinder liners 0.243 0.285
X
Piston protrusion X 0.28 0.52
3 Piston pin 3 39.994 40.000
Piston pin pin housing 0.010 0.022

F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
X1 X1* 2.705 2.735

X2 Piston ring slots: X2 2.420 2.440
X3 4.030 4.050
X3
* measured on 101 mm
S 1 S 1* 2.563 2.597
S 2 2.350 2.380
Piston rings: S2
S 3 3.970 3.990
S3
0.108 0.172
Piston rings - slots 0.040 0.090
0.040 0.080
Piston rings 0.4 - 0.8
X1
Piston ring end opening
X2 X1 0.30 0.40
X3 X2 0.60 0.80
X3 0.30 0.55
1 Small end bush

housing 1 42.987 43.013
Big end bearing
housing 2 73.987 74.013
2
3 Small end bush diameter
S Inside 3 40.019 40.033

Big end half
bearings S 1.958 1.968
Piston pin bush 0.019 0.039
Big end half bearings 0.250 - 0.500

F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
1 2
Journals 1 82.990 83.010
Crankpins 2 69.987 70.013
Main half bearings S1 2.464 2.472

S 1 S 2 Big end half bearings S2 1.958 1.968
Main bearings
3 No. 1 - 7 3 87.982 88.008
No. 2 - 3 - 4 - 5 - 6 3 87.977 88.013
Half bearings Journals

No. 1 - 7 0.028 0.090
No. 2 - 3 - 4 - 5 - 6 0.023 0.095
Half bearings - Crankpins 0.038 0.110
Main half bearings

0.250 - 0.500
Big end half bearings
Shoulder journal
37.475 37.545
X1
X 1
Shoulder main bearing

32.180 32.280
X2
X 2
X 3 Shoulder half-rings
37.28 37.38
X3
Output shaft shoulder 0.095 0.265

F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
CYLINDER HEAD TIMING SYSTEM mm
1
Valve guide seats on

cylinder head 1 7.042 7.062
4 Valves:
4 6.990 7.010
60 0.25
4 6.990 7.010
a 45 0.25
Valve stem and guide 0.032 0.072

Housing on head for
valve seat:
1 34.837 34.863
1 1 34.837 34.863
Valve seat outside diameter;

valve seat angle on cylinder
2 head:
2 34.917 34.931
60
2 34.917 34.931
a 45
X 0.59 1.11
hollowing
X X 0.96 1.48
0.054 0.094
Between valve seat
and head
0.054 0.094
Valve seats -

F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
Valve spring height:
free spring H 47.75

H H1
H 2 under a load equal to:
339.8 19 N H1 35.33
741 39 N H2 25.2
Injector protrusion X not adjustable

X
Camshaft bush housings

No. 1 (flywheel side) 59.222 59.248
Camshaft pin seats
No. 2-3-4-5-6-7 54.089 54.139
Camshaft journals:
17 53.995 54.045
1 3
Bush inside
diameter 54.083 54.147
Bushes and journals 0.038 0.152

Cam lift:
H H 6.045
H 7.582

F4HFE613
Type 1*B003 K*B004 N*B002
1*B005 K*B005 N*B003
1
Tappet cap housing
on block 1 16.000 16.030
2
3 Tappet cap outside
diameter: 2 15.924 15.954
3 15.960 15.975
2
Between tappets and housings 0.025 0.070
Tappets -
1
Rocker shaft 1 21.965 21.977
Rockers 2 22.001 22.027
2
Between rockers and shaft 0.024 0.062

TIGHTENING TORQUE
DESCRIPTION TORQUE
Nm Kgm
Piston cooling nozzles (6 unions M8x1.25x20) 15 3 1.5 0.3
Crankshaft caps (14 screws M12x1.5) 1st phase 80 6 8.0 0.6
2nd phase 90
Crankshaft caps (14 screws M12x1.5) 1st phase 50 5 5.0 0.5
2nd phase 60
Camshaft longitudinal retaining plate (2 screws M8x1.25) 24 4 2.4 0.4
Rear gear case
(1 screw M12x1.75) 77 12 7.7 1.2
(4 screws M8x1.25) 24 4 2.4 0.4
(5 screws M10x1.5) 47 5 4.7 0.5
Timing gear (6 screws M8x1.25) 36 2 3.6 0.2
Flywheel housing
(8 screws M12x1.75) 85 10 8.5 1.0
(12 screws M10x1.5) 49 5 4.9 0.5
Engine flywheel (8 screws M12x1.25) 1st phase 30 4 3.0 0.4
2nd phase 60
Oil pump (4 screws M8x1.25) 1st phase 81 0.8 0.1
2nd phase 24 4 2.4 0.4
Front cover
(7 screws M8x1.25x30) 24 4 2.4 0.4
(6 screws M8x1.25) 24 4 2.4 0.4
Crankcase stiffening plate (4 screws M10x1.5x25) 43 5 4.3 0.5
Oil suction strainer pipe (2 screws M8x20) 25 2.5
Oil suction strainer pipe bracket (1 screw M10x1.5x20) 45 4.5
Oil sump
(14 screws M8x1.25x40) 25 2.5
(4 screws M8x1.25x45) 25 2.5
Oil sump plug (M22x1.5) 50 5 5.0 0.5
Heat exchanger and oil filter support (15 screws M8x1.25x35) 26 4 2.6 0.4
Oil pressure relief valve on oil filter support (1 plug M22x1.5) 80 8 8.0 0.8
Oil filter (1 adapter M27x2) 18 2 1.8 0.2
Oil filler pipe (2 screws M12x1.75x25) 80 4 8.0 0.4
Brackets for lifting engine
(4 screws M8x1.25x25) 36 5 3.6 0.5
(2 screws M12x1.75x25) 77 12 7.7 1.2
Cylinder head
(12 screws M12x1.75x130) 1st phase 35 5 3.5 0.5
2nd phase 90
3rd phase 90
(14 screws M12x1.75x150) 1st phase 55 5 5.5 0.5
2nd phase 90
3rd phase 90
Electro-injectors 1st phase 3.5 0.35 0.35 0.04
(12 screws M6x1x35) 2nd phase 25
3rd phase 25
4th phase 25
Fuel manifolds on cylinder head (6 nuts M22x1.5x9.5) 55 5 5.5 0.5

DESCRIPTION TORQUE
Nm Kgm
Rocker assembly bracket (12 screws M8x1.25) 36 5 3.6 0.5
Valve clearance adjustment (12 nuts M8x1.25) 24 4 2.4 0.4
Electro-injector wiring support (7 screws M8x1.25) 24 4 2.4 0.4
Wiring on each electro-injector (12 nuts M4) 1.5 0.25 0.15 0.025
Tappet cover (6 nuts M8x1.25) 2424 4 4 2.4 0.4
Intake manifold
(7 screws M8x1.25x25) 24 4 2.4 0.4
(3 screws M8x1.25x70) 24 4 2.4 0.4
Pre-heating grid-heater resistor (6 screws M6x1x16) 10 2 1.0 0.2
Common Rail (4 screws M8x1.25x125) 36 5 3.6 0.5
Overpressure valve DBV4 (M20x1.5) 100 5 10.0 0.5
High pressure fuel delivery pipes 1st phase 10 1.0
(12 hose couplings M14x1.5) 2nd phase 55
Power take-off cover (2 screws M12x1.75x25) 80 5 8.0 0.5
High pressure pump gear (1 nut M18x1.5) 105 5 10.5 0.5
High pressure pump
(3 nuts M8-8) 24 4 2.4 0.4
(3 studs M8x1.25x50) 11 3 1.1 0.3
Fuel supply pipe from high-pressure pump to common rail
10 1.0
(2 hose couplings M14x1.5) 1st phase
2nd phase 55
(1 screw M8x1.25x20) 25 2.5
(1 screw M8x1.25x16) 25 2.5
Fuel suction pump crankcase cover (2 screws M8x1.25x20) 24 4 2.4 0.4
Blow-by breather plate to tappet cover (1 screw M6x1) 10 2 1.0 0.2
Blow-by breather pipe (2 hose connectors M12x1.5) 20 4 2.0 0.4
Blow-by filter (3 screws M6x1) 10 2 1.0 0.2
Exhaust manifold (12 screws M10x1.5x65) 55 3 5.5 0.3
Turbocharger
(4 nuts M10x1.5) 45 2 4.5 0.2
(4 studs M10x1.5x42) 25 5 2.5 0.5
Turbocharger air outlet to intercooler (1 screw M6x1x55) 10 2 1.0 0.2
Turbocharger exhaust outlet to throttle valve (1 screw M6x1x50) 61 0.6 0.1
Motorized throttle valve water pipes
(2 connectors M10x1) 20 2.0
(3 nuts M12x1.5) 45 4.5
(2 screws M8x20) 23 2.3 2.3 0.23
(1 connector M10x1) 25 2.5
(1 screw M8x16) 23 2.3 2.3 0.23
Bracket fixing motorized throttle valve to exhaust manifold
(4 screws M8x1.25x25) 25 2.5
Turbocharger lubrication oil pipes
(2 nuts M16 11/16-16) 36 5 3.6 0.5
(2 screws M8x1.25x25) 23 2 2.3 0.2
(2 screws M8x1.25x16) 23 2 2.3 0.2
Engine coolant inlet
(2 screws M10x1.5x130) 43 6 4.3 0.6
(1 screw M10x1.5x70) 43 6 4.3 0.6
Engine coolant outlet / thermostat cover (3 screws M6x1x12) 13.5 1.5 1.35 0.15

DESCRIPTION TORQUE
Nm Kgm
Water pump (2 screws M8x1.25x35) 24 4 2.4 0.4
Crankshaft pulley with damper pulley 1st phase 50 5 5.0 0.5
(6 screws M12x1.25) 2nd phase 90
Fan pulley mounting (4 screws M8x1.25x45) 24 4 2.4 0.4
Fan control pulley (4 screws M10x25) 68 7 6.8 0.7
Idler guide pulley (1 screw M10x1.5) 43 6 4.3 0.6
Automatic belt tensioner mounting (2 screws M8x1.25x30) 24 4 2.4 0.4
Automatic belt tensioner (1 screw M10x1.5x70) 43 6 4.3 0.6
Fuel filter mounting (2 screws M12x1.75x30) 80 8 8.0 0.8
Fuel filter (1 adapter M20x1.5) 20 2 2.0 0.2
Engine control unit (3 screws M8x1.25x45) 14 1.4
Camshaft timing sensor (1 nut with stud M6x1x5) 12 1.2
Crankshaft rpm sensor (1 screw M6x1x20) 10 2 1.0 0.2
Coolant temperature sensor (M14x1.5x12) 24 4 2.4 0.4
Engine oil pressure and temperature sensor (2 screws M6x1x20) 10 2 1.0 0.2
Rail pressure sensor (M18x1.5) 70 5 7.0 0.5
Fuel temperature sensor (M14x1.5) 24 4 2.4 0.4
Boost pressure and air temperature sensor (1 screw M6x1x20) 10 2 1.0 0.2
Alternator
(1 screw M10x1.5x110) 43 6 4.3 0.6
(1 screw M10x1.5x20) 43 6 4.3 0.6
(1 screw M10x1.5x30) 43 6 4.3 0.6
Electric starter motor (3 nuts M10x1.5) 43 6 4.3 0.6
1/2 inch plug on the cylinder head 24 4 2.4 0.4
M18x1.5 plug on engine block 24 4 2.4 0.4
M22x1.5 plug on cylinder head 80 5 8.0 0.5
M6x1.5 plug on engine block 10 2 1.0 0.2
M18x1.5x14.5 plug on engine block 24 4 2.4 0.4
M10x1x9.5 plug on engine block 24 4 2.4 0.4
M14x1.5x11 plug on engine block 24 4 2.4 0.4
M16x1.5 couplings 24 4 2.4 0.4
3/4 coupling 36 4 3.6 0.4
M12x1.5 coupling on cylinder head 22 2 2.2 0.2
M10x1 cap 24 4 2.4 0.4

F4HFE613 ENGINE SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 8 - TOOLS F4HFE613 ENGINE

TOOLS
TOOL NO. DESCRIPTION
99305453 Tool used to check the low-/high-pressure system fuel supply circuit
99317915 Set of five ring spanners with insert 9x12 (14 - 15 - 17 - 18 - 19)
Revolving stand for overhauling units (1000 daN capacity, 120 daNm
99322205 torque)
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99341001 Double acting puller

TOOLS
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)

TOOLS
99360183 Pliers for removing/refitting piston rings (65 110 mm)
99360268 Tool for removing/refitting engine valves
99360330 Tool for rotating engine flywheel
99360351 Equipment for flywheel holding
Beater for removing/refitting camshaft bushes (to be used with

99360362 99370006)
99360500 Tool for lifting the output shaft

TOOLS
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121 Manual pump for measuring pressure and vacuum
99370006 Handgrip for interchangeable beaters

TOOLS
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)
Torque screwdriver (1-6 Nm) for injector solenoid valve connector

99389834 stop nut setting
99395216 Pair of gauges with and square head for angle tightening
99395603 Dial gauge (0 5 mm)


F4HFE613 ENGINE APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F4HFE613 ENGINE

F4HFE613 ENGINE APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones theyve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge - In case of test or calibration operations requiring engine
of maintenance. running, ensure that the area is sufficiently aerated or
- Be informed and inform personnel as well of the laws in utilize specific vacuum equipment to eliminate exhaust
force regulating safety, providing information gas. Danger: poisoning and death.
documentation available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Never open filler cap of cooling circuit when the engine
- Ensure that working areas are provided with emergency is hot. Operating pressure would provoke high
boxes, that must be clearly visible and always provided temperature with serious danger and risk of burn. Wait
with adequate sanitary equipment. unit the temperature decreases under 50 C.
- Provide for adequate fire extinguishing means, properly - Never top up an overheated engine with cooler and
indicated and always having free access. Their efficiency utilize only appropriate liquids.
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities. - Always operate when the engine is turned off: whether
particular circumstances require maintenance
- Organize and displace specific exit points to evacuate intervention on running engine, be aware of all risks
the areas in case of emergency, providing for adequate involved with such operation.
indications of the emergency exit lines.
- Be equipped with adequate and safe containers for
- Smoking in working areas subject to fire danger must be drainage operation of engine liquids and exhaust oil.
strictly prohibited.
- Keep the engine clean from oil tangles, diesel fuel and or
- Provide Warnings throughout adequate boards signaling chemical solvents.
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of - Use of solvents or detergents during maintenance may
emergency. originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
Prevention of injury
- Do not leave rags impregnated with flammable
- Do not wear unsuitable cloths for work, with fluttering substances close to the engine.
ends, nor jewels such as rings and chains when working - Upon engine start after maintenance, undertake proper
close to engines and equipment in motion. preventing actions to stop air suction in case of runaway
- Wear safety gloves and goggles when performing the speed rate.
following operations: - Do not utilize fast screw-tightening tools.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Never disconnect batteries when the engine is running.
- utilization of compressed air or liquids under pressure - Disconnect batteries before any intervention on the
(pressure allowed: 2 bar) electrical system.
- Wear safety helmet when working close to hanging - Disconnect batteries from system aboard to load them
loads or equipment working at head height level. with the battery loader.
- Always wear safety shoes when and cloths adhering to - After every intervention, verify that battery clamp
the body, better if provided with elastics at the ends. polarity is correct and that the clamps are tight and safe
- Use protection cream for hands. from accidental short circuit and oxidation.
- Change wet cloths as soon as possible - Do not disconnect and connect electrical connections
in presence of electrical feed.
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections. - Before proceeding with pipelines disassembly
Ensure that hands and feet are dry and execute working (pneumatic, hydraulic, fuel pipes) verify presence of liquid
operations utilizing isolating foot-boards. Do not carry or air under pressure. Take all necessary precautions
out working operations if not trained for. bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
- Do not smoke nor light up flames close to batteries and Non fulfillment of these prescriptions may cause serious
to any fuel material. injury and poisoning.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.

4 APPENDIX F4HFE613 ENGINE
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engines
components, affecting engines duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnels safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
specific approval has been released. Any unauthorized - Collect exhaust oils in adequate specially provided
modification will compromise warranty assistance and containers with hermetic sealing ensuring that storage is
furthermore may affect engine correct working and made in specific, properly identified areas that shall be
duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80 C temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

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What safety precautions should be followed when working on the engine?

What safety precautions should be followed when working on the engine?

What are some prohibited actions when working on the engine?

What are some prohibited actions when working on the engine?

NEF SERIES TIER

Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

Data included in this publication may not be up-to-date

If issues on this publication differ from what is actually noticed

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

Publication edited by:

- Bonding and screening . . . . . . . . . . . . . . . . . . . 8

OPTIONAL ELECTRICAL AND MECHANICAL

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32N028 E Base - May 2014

Base - May 2014 Print P2D32N028 E

Danger for persons

Danger of serious damage for the assembly

NOTE It indicates an additional explanation for a piece of information.

1 1 = Seat of small end bush

Print P2D32N028 E Base - May 2014

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Air bleeding Preload

Base - May 2014 Print P2D32N028 E

Print P2D32N028 E Base - May 2014

Base - May 2014 Print P2D32N028 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32N028 E Base - May 2014

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

Base - May 2014 Print P2D32N028 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32N028 E Base - May 2014

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Basic edition referred to When month - year update

Base - May 2014 Print P2D32N028 E

Removal - refitting of main components 5

General mechanical overhauling 6

Safety prescriptions Appendix

Print P2D32N028 E Base - May 2014

Base - May 2014 Print P2D32N028 E

Section Section name Description of change Page Date of revision

Print P2D32N028 E Base - May 2014

Base - May 2014 Print P2D32N028 E

CORRESPONDENCE BETWEEN TECHNICAL CODE

TORQUE AND POWER TYPICAL CURVES . . . 8

Print P2D32N028 E Base - May 2014

TIER 4B (F4HFE6131B003 - F4HFE613KB004 - F4HFE613N*B002)

STAGE IV (F4HFE6131B005 - F4HFE613KB005 - F4HFE613N*B003)