9-88960 - en F4be0484e SM

REPAIR MANUAL FOR ENGINES
F4BE0484E
F4BE0684D
F4BE0684B
F4BE0484E
F4BE0684D -- F4BE0684B
Every information, illustration and specification contained in the present manual is based on the most recent informa-
tion available at the time of printing.
CNH France S.A. reserves the right, to modify the text at any time without prior communication.
Edition – June 2003

2 WE
MOTORI
2
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician
and contains all the technical information needed
to repair this vehicle.
- Read this manual carefully for the information
concerning repairing operations.
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example:: T 1 -- 2 -- 3
Progressive page number for each group
Group number (if any)
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
This symbol regards safety.

! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min --1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
Section 1 -- Diagnostics EW--1--1
Section 2 -- Engine F4BE0484E overhaul EW--2--1
Section 3 -- Overhaul of F4BE0684B -- F4BE0684D engines EW--3--1
Section 4 -- Recharging and start--up EW--4--1

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

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

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

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

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

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

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

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

NO
YES
Thermostat in working order Replace.

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

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

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

NO
YES
Fan in working order Replace.

NO
3 ENGINE LACKS POWER AND WORKS

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

NO
YES
Fuel pump in working order Replace.

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

NO
YES

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

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

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

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

DARK GREY
Air filter in working order Replace.

NO
YES
Thermal starter in working order Replace.

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

NO
YES

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

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

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

ING ON WHITE)
The thermostat comes into operation correctly Replace.

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

NO 1094.
YES

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

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

NO
YES
Fuel filters in working order Replace.

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

NO
YES
Regular idle speed Adjust.

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

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

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

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

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

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

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

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

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

NO
YES
Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16
DIAGNOSTICS
NOTES
SECTION 2 ENGINE F4BE0484E
ENGINE F4BE0484E OVERHAUL
INDEX
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--3 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--50
Coding of source engines . . . . . . . . . . EW--2--4 Replacing the bushings . . . . . . . . . . . . . . EW--2--51
Main engine features . . . . . . . . . . . . . . EW--2--5 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--51
General engine features . . . . . . . . . . . EW--2--6 Mounting the tappets – Distributing shaft EW--2--51
Assembling play -- specifications . . EW--2--8 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--2--52
Tightening torque . . . . . . . . . . . . . . . . . EW--2--14
Measuring the journals and crankpins . EW--2--52
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15
Replacing the oil pump drive gears . . . . EW--2--55
Graphic indications and symbols . . . EW--2--16
Mounting the main bearings . . . . . . . . . . EW--2--55
General remarks . . . . . . . . . . . . . . . . . . EW--2--17
Description of main mechanic Measuring the journal assembling play EW--2--55
engine components . . . . . . . . . . . . . . . EW--2--18 Checking the drive shaft shoulder play . EW--2--56
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--18 Connecting rod--piston assembly . . . EW--2--57
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--58
Drive shaft seal rings . . . . . . . . . . . . . . . EW--2--19 Measuring the piston diameter . . . . . . . EW--2--58
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--20 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Conditions for correct pin/piston
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--22 matching. . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--2--23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--24 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--60
Valves and valve seats . . . . . . . . . . . . . . EW--2--25 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--2--26
Checking the connecting rods . . . . . . . . EW--2--61
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--27
Checking the torsion . . . . . . . . . . . . . . . . EW--2--61
Auxiliary component drive . . . . . . . . . . . EW--2--28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Checking the flexion . . . . . . . . . . . . . . . . EW--2--61
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--2--30 Mounting the connecting rod--piston
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--31
Connecting rod--piston match . . . . . . . . EW--2--62
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32
Oil vapour recirculation . . . . . . . . . . . . . . EW--2--33 Mounting the piston rings . . . . . . . . . . . . EW--2--62
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Mounting the connecting rod/piston
assemblies in the cylinder liners . . . . . . EW--2--63
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--2--35
Measuring the crankpin assembling play EW--2--63
Mechanic injection feeding system . EW--2--36
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--2--36 Checking piston protrusion . . . . . . . . . . . EW--2--64
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--36 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--64
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--2--37 Distribution gearbox case . . . . . . . . . . . . EW--2--64
Injection assembly . . . . . . . . . . . . . . . . EW--2--38 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--65
Engine bench--overhaul . . . . . . . . . . . . EW--2--39 Injection pump – 1st phase . . . . . . . . . . EW--2--66
Disassembling the engine . . . . . . . . . . . EW--2--39 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--66
Replacing the seal ring . . . . . . . . . . . . . . EW--2--41 Flywheel cover case . . . . . . . . . . . . . . . . EW--2--66
Removing the injection pump . . . . . . . . . EW--2--42 Engine flywheel . . . . . . . . . . . . . . . . . . . EW--2--67
Removing the rocker arm assembly . . . EW--2--44 Replacing the engine flywheel ring gear EW--2--67
Repair work on cylinder cluster . . . . . EW--2--47
Injection pump – 2nd phase . . . . . . . . . . EW--2--68
Checks and measurements . . . . . . . . . . EW--2--47
Mounting the injection pump –
Checking the surface supporting 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--68
the head on the cylinder cluster . . . . . . . EW--2--48
Mounting the oil and water pumps . . . . EW--2--68
Valve gear
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--49 Mounting the water / oil heat exchanger EW--2--71
Checking the eccentric lift and the Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--71
pin alignment . . . . . . . . . . . . . . . . . . . . . . EW--2--49 Removing the valves . . . . . . . . . . . . . . . . EW--2--71
INDEX
Checking the cylinder head supporting Rocker arm assembly . . . . . . . . . . . . . . . EW--2--77

surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--72
Mounting the injectors . . . . . . . . . . . . . . . EW--2--78
Checking the cylinder head water seal . EW--2--73
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--73 Replacing the injectors . . . . . . . . . . . . EW--2--81
Valve descaling, check and grinding . . . EW--2--73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Checking the play between the valve
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--81
stem, valve guide and valve centring . . EW--2--74
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--2--74 Adjusting the tappets . . . . . . . . . . . . . . EW--2--82
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--2--74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--82
Valve seat reconditioning -- replacement EW--2--74
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--82
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--2--76
Mounting the cylinder head . . . . . . . . EW--2--76 Rocher arm removal/refitting . . . . . . . EW--2--82
Reattaching the cylinder head . . . . . . . . EW--2--77 Valve timing . . . . . . . . . . . . . . . . . . . . . . EW--2--83
EW--2--3
ENGINE F4BE0484E
Figure 1
86451
EW--2--4
CODING OF SOURCE ENGINES
F 4 B E 0 4 8 4 E * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern:
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 4 = 4--cylinder
Group
Engines
8 = Direct injection turbo

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

Y = Engine model
EW--2--5
MAIN ENGINE FEATURES
A WX 150
B F4BE0484E
C *D604
E 3922 cm3
87 kW
F 2,000 rpm
G Direct injection
H Rotary injection pump
T.A.A.
I (Boosted by intercooler)
A Wheeled excavator code

B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6
GENERAL ENGINE FEATURES

F4BE0484
Type
*D601 *D607
Cycle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct
Number of cylinders In--line, 4--cylinder
Bore mm 102
Stroke mm 120
Total displacement cm3 3922
Compression ratio 17.5 : 1
Max. rating kW 87
min --1 2000
Max. torque Nm (kgm) 450 (46)

min --1 1400
No--load idle rpm min --1 800
No--load peak rpm min --1 --
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX25W
Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--2--7
F4BE0484E
Type
*D604
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
REFUELLING
Full filling capacity 1° litres --
Ambra Super Gold
15W40 kg
10W30 -- engine sump litres --
kg
-- engine sump + filter litres
kg
FEEDING
VE4 / 12 F 1000 L
Bosch--type injection
Pump setting 0° ± 0.5°
Start of delivery mm 1
Type of nozzle DSLA 145 P603
Injection sequence 1 -- 3 -- 4 -- 2
Injection pressure (bar) 245 bar

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

F4BE0484E
Tipo
*D604
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners ∅1 102.01 to 102.03
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 101.777 to 101.795
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253
Piston diameter ∅1 0.5
Position of pistons from crankcase X 0.28 to 0.52
Gudgeon pin ∅3 39.9968 to 40.0032
Gudgeon pin -- Pin seat 0.0028 to 0.0152
Type of piston X1* 2.70

Piston ring slots X2 2.74
X3 4.04 to 4.06
* measured on ∅ of 99 mm
S1* 2.567 to 2.618
Piston rings S2 2.560 to 2.605
S3 3.975 to 4.000
1 0.082 to 0.133
Piston rings – Slots 2 0.135 to 0.180
3 0.040 to 0.085
Piston rings 0.5

EW--2--9
F4BE0484E
Type
*D604
Piston ring end opening in cylinder
liner:
X1 0.40 to 0.70
X2 0.25 to 0.55
X3 0.25 to 0.55
Connecting rod small--end

bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 73.013
Connecting rod small--end bushing

diameter
Outer ∅4 43.279 to 43.553
Inner ∅3 40.019 to 40.033
Connecting rod small--end bushing –

0.266 to 0.566
seat
Gudgeon pin – Bushing 0.0158 to 0.0362
Measurement dimension X --
Max. error on connecting rod axis

parallelism = --
Journals ∅1 82.99 to 83.01

Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares
Bed supports no.:

n. 1--5 ∅3 87.982 to 88.008
n. 2--3--4 87.977 to 88.013
EW--2--10
F4BE0484E
Type
*D604
Half bearings -- journals:
n. 1--5 0.041 to 0.119
n. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.068 to 0.410

EW--2--11
F4BE0484E
Type
*D604
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
Valve stem and respective guide 0.052 to 0.092
Seat on head for valve seat:

∅1 46.987 to 47.013
∅1 43.637 to 43.663
Valve seat outer diameter;

inclination of valve seats on cylinder
head:
∅2 47.063 to 47.089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 0.356 to 1.102
X 0.104 to 0.840
Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102
Valve seats --
EW--2--12
F4BE0484E
Type
*D604
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for distributing shaft bushings

no. 1--5 --
Distributing shaft seats no. 2--3--4 --
Distributing shaft support pins:

1⇒5 ∅ 53.995 to 54.045
Bushing outer diameter for

distributing shaft: ∅ --
Bushing inner diameter ∅ 54.083 to 54.147
Bushings and seats in crankcase --
Bushings and support pins 0.038 to 0.162

Eccentric working lift:
6.045
7.239
EW--2--13
F4BE0484E
Type
*D604
∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030
∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Between the tappets and the seats 0.020 to 0.065
Tappets --
∅1
Rocker arm shaft ∅1 18.963 to 18.975
Rocker arms ∅2 19.000 to 19.026

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

EW--2--15
TOOLS
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Adapter for compressor check in cylinders (380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001002 All--purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Device for checking diesel engine cylinder compression
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380001005)
EW--2--16
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

α
Replacement
Countersink
Genuine spares
Adjustment
Rotation
Setting
Warning Angle
! Note Angular value
Visual check
Preload
Mounting position check
Measurement
Dimension to be measured Revs number
Check
Equipment Temperature
Surface to be machined
Pressure
Machining finish bar
Increase
Interference
Greater than .....
Forced mounting
Maximum
Decrease
Thickness
Smaller than ....
Play
Minimum
Lubricate Selection
Moisten Classes
Grease Increases
Temperature < 0 °C
Sealant Cold
Winter
Temperature < 0 °C
Air bleed Hot
Summer
EW--2--17
GENERAL REMARKS
Figure 2
86453
1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump drive belt – 6. Automatic belt stretcher – 7. Pulley on crankshaft – 8. Fixed guide pulley – 9. Fan
pulley – 10. In--line injection pump – 11. Cold start air heater – 12. Blow--by
EW--2--18
DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.
Figure 3
86605
EW--2--19
Drive shaft
It is made of steel and rests on five induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
Inside the drive shaft are the lubricating oil ducts.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
The second main half bearing is equipped with a
flywheel and auxiliary component drive pulley.
shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 4
84207
1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear
Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.
EW--2--20
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 5
84038
EW--2--21
Pistons
Figure 6
84039
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1 and 2, trapezoidal in shape and with ce-
Three slots (piston ring seats) are provided: the first ramic chrome coating.
one and the second one are obtained from a cast-- Ring 3, with double scraper ring shoe with inner
iron insert with trapezoidal section. spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 7
84040
EW--2--22
Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.
Figure 8
70164
84238
EW--2--23
Valve control
Figure 9
84239
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--24
Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);
Figure 10
84240
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--25
Valves and valve seats
Figure 11
S 1
84241
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side.
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 12
84242
Figure 12 shows the oil seals mounted on valve

stems.
EW--2--26
Valve guides
Figure 13
INTAKE EXHAUST
84046
DETAIL OF VALVE GUIDES AND SEATS

EW--2--27
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 14
86454
EW--2--28
Auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft The belt is stretched by means of automatic belt
(5) to water pump (1), alternator (2) and fan (6). stretcher (3).
Figure 15
86455
1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft

EW--2--29
LUBRICATION
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the crank-
lowing components: case;
- rotor--equipped oil pump housed in the crank- - oil pressure regulating valve incorporated in the
case front part, controlled by the straight--tooth oil filter support;
gear force--fitted on the drive shaft shank; - bypass valve for bypassing the clogged oil filter,
in the oil filter support;
- cartridge--type oil filter.
Figure 16
86457
Oil return drop--type path Oil supply
Pressure oil path

EW--2--30
Heat exchanger
Figure 17
86458
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger --

4. Gasket between exchanger unit and engine block
EW--2--31
Oil pump
Figure 18
84052
Figure 19
70150
1. Drive shaft with oil pump drive gear

EW--2--32
Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2) (fitted onto the oil
case by means of an aluminium plate (3), Figure 20. sump leading profile) enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 20
84245
Figure 21
86459
The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--2--33
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
Figure 22
84056
EW--2--34
COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.
Figure 23
86461
Water flowing out of the thermostat Water flowing into the pump
Water recirculating in the engine

EW--2--35
Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 24
84058
Figure 25
84059
EW--2--36
MECHANIC INJECTION FEEDING SYSTEM

Fuel prefilter
The filter support (1) incorporates manual priming

pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 26
84060
Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.
Figure 27
84248
EW--2--37
Mechanic fuel pump

Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.
Figure 28
84249
1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank
Figure 29
84250
1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--38
INJECTION ASSEMBLY
Figure 30
84251
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KKSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--39
ENGINE BENCH--OVERHAUL Figure 33

Disassembling the engine
Figure 31
84252 84254
Drain the engine oil by taking the cap off the sump - disconnect the engine oil vapour recovery pipe
and the oil filling cap off the head cover. from blow--by (1);
Remove the fan unit from the fan pulley. - take off tappet covers (4);
In order to be able to fit bracket 380000995 (which - disconnect electric wiring (8);
fastens the engine to the overhaul stand) to the - take off fuel filter (9);
crankcase, it is necessary to:
- take off intake manifold (3);
- remove electric wiring (1).
- take off container (2);
from the engine left side. - take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
Figure 32
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 34;
- take off fuel filter support (6).
Figure 34
4
86463
To fit bracket 380000995 to the engine block on the
right--hand side, remove:
- the fastening bracket (2) and harness (1);
- the starter motor (3);
- the turbine lubrication delivery hose (5).
Fasten the engine to rotary stand 380000978.
- the heat exchanger assy with the oil filter car-
70126
tridge (4);
Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--40
Figure 35 - Remove the screws (3) and then remove the tur-
bine (1).
- Remove the exhaust manifold (2).
Figure 38
84255
- Remove injector (5) feed pipes (5) from injection

pump (6); remove the rackets fastening the pipe
unit (1), (2) and (3) on the cylinder head.
- Remove the priming pump (4).
Figure 36
86466
- Remove the belt tightener (4).

- Remove the auxiliary component belt (6).
- Remove the bracket (1), the alternator (2), the
water pump (5) and the guide pulleys (7).
- Remove the engine cooling system connection
(3) from the cylinder block.
86464
- Remove the feed pipe unit from injectors (1).

- Remove fuel drain pipe (2) from injectors by re- Figure 39
moving the screw (4) and the seal (3).
Figure 37
84068
Apply tool 380000990 (1) to the flywheel housing to

stop flywheel rotation.
86465
EW--2--41
Figure 40 Figure 42
84259 78257
Unscrew fastening screws (1) from pulley (2). Apply the proper tension rod (3) of tool 380000996 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
Replacing the seal ring

Figure 41 Figure 43
78256 84237
Apply tool 380000980 (4) on drive shaft front shank Remove gear oil pump (1).
(2).
Drill inner seal ring (1), through tool 380000980 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth IMPORTANT -- Oil pump (1) cannot be recondi-
of 5 mm. tioned.
Secure tool 380000980 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).
EW--2--42
Removing the injection pump Figure 46

Figure 44
84073
84071
Prior to removing the injection pump, take off the fly- - Remove cover (1) from gear covering case (2).
wheel locking tool described in Figure 39. - Lock the engine flywheel as described in
Rotate the drive shaft until it reaches the condition of Figure 39.
1° cylinder at top dead centre. - Loosen nut (3) securing the injection pump drive
Such condition is obtained when, by pushing pin (1) gear (4).
shown by the arrow, it is housed in its own seat ob-
tained on distributing shaft drive gear (2).
Figure 45 Figure 47
84260 84261
To correctly preset the injection pump prior to remov- Loosen the three nuts (2) (4) (5) securing the injection
ing it, loosen screw (2) and remove L--shaped spacer pump (1) to the flywheel covering case (3), then take
(1). the pump out of its housing by means of tool
380000979 through proper application to gear (4) in
Fasten again screw (2) to its abutting end.
Figure 46B.
IMPORTANT -- Carefully store the L--shaped

spacer with the pump body.
EW--2--43
Figure 48 Figure 50
84075 78258
Remove screws (3) securing engine flywheel (4) to the Apply tool 380000981 (3) on drive shaft rear shank
drive shaft. (5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by fastening the
6 screws (4) provided.
Figure 49 Figure 51
78257
84076
Screw two pins (2) of adequate length into drive shaft Apply the proper torsion bar (3) of tool 380000996 to
holes (3). outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever
Remove tool 380000990 (2).
(4).
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
EW--2--44
Figure 52 Figure 54
84077
Remove screws (2) and take off rear cover (1).

86470
Remove screws (1) and (4) and take off oil suction
strainer (5).
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. Remove screws (2) and take off stiffening plate (3).
Figure 55
70156
Remove screws (1) and take off gear (3) from distrib-
uting shaft (2).
Figure 53 Removing the rocker arm assembly
Figure 56
86469 84081
Turn the engine upside down, remove screws (2), For each cylinder, remove rocker arm assembly (1),
take off both plate (3) and oil sump (1). loosen adjusting nuts (3), unscrew registers (2) and
remove screws (4).
EW--2--45
Figure 57 Figure 60
84082 84085
Take out injectors (2) by means of tool (1) 380000982. Remove screws (2) and take off timing gear case (1).

of screws (2), due to the different size of the latter.
Figure 58
84265 Figure 61
Remove screws (1) securing the head to the crank-
case.
Figure 59
70158
Remove connecting rod cap (2) fastening screws (1),

then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part.
84266
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
EW--2--46
Figure 62 Figure 65
70159
Remove screws (1) and take off bed caps (2). 70162
Take off main half bearings (1).

Figure 63
Remove screws (2) and take off oil nozzles (3).
Figure 66
70160
The penultimate bed cap (1) and its respective sup-

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

IMPORTANT -- Take note of the mounting position retaining plate (2).
of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in IMPORTANT -- Take note of plate (2) mounting
the same position they had prior to being taken off. position.
Figure 64
Figure 67
70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000992(1) and a hoist. crankcase.
EW--2--47
Figure 68 Figure 69
70165 70166
Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
NOTE – If no ring gauge is available, use a micro-

meter to perform reset.
REPAIR WORK ON CYLINDER CLUSTER Figure 70

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

der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
EW--2--48
Figure 71 Checking the surface supporting the head on

the cylinder cluster
Figure 72
70170
Verify that the head supporting plane on the cylinder

cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
70168 The flatness error must not be greater than 0.075 mm.
IMPORTANT -- In case of reconditioning, all the

liners must be machined to the same increase (0.5
mm).
NOTE -- Crankcase flattening may be carried out
Check the main bearing seats as follows: only after making sure, when the repair work has
- mount the bed caps on the supports without bear- been completed, that the protrusion of the piston
ings; from the cylinder liner is not greater than the speci-
fied value.
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com- Check the condition of cylinder cluster working caps
parator, that the seat diameter is the same as the (1); they must be replaced if they are rusty or their
specified value. sealing properties are in doubt.
If a greater value is found, replace the crankcase. After flattening, restore the cylinder liner countersink,
as shown in Figure 71.
EW--2--49
VALVE GEAR
Distributing shaft
Figure 73
70169
MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins
The shaft support pin and eccentric surfaces must be Figure 74

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm for ex-
haust eccentrics and 6.045 mm for intake eccentrics;
if different values are found, replace the shaft.
70171
Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--2--50
BUSHINGS Figure 75
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
70172
Figure 76
sec. A--A
70173
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
EW--2--51
Replacing the bushings Mounting the tappets – Distributing shaft

Figure 77 Figure 79
70174 70176
To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000991 (2) and handle 380000999 (3) to remove seats of the crankcase.
and reassemble the bushings.
IMPORTANT -- Bushings (1) must, upon mount-

ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.
Tappets
Figure 78 Figure 80
84053 70164
MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
EW--2--52
Figure 81 Figure 83
70238 70180
Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.
DRIVE SHAFT
Measuring the journals and crankpins
Figure 84
Figure 82
70182
If traces of excessive seizing, scoring or out--of--

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

values on a table.
See Figure 85.
70179
Check the distributing shaft end play (1).

EW--2--53
Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crank-
pins must be marked with a special stamping
made on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
Figure 85
70181
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--54
Figure 86
70183
MAIN TOLERANCES OF DRIVE SHAFT

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

CRITICAL 
IMPORTANT
SECONDARY
Figure 87
BEARINGS ON TIMING INTERMEDIATE FIRST

SIDE BEARINGS BEARING ON
UPPER SIDE
84275
EW--2--55
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 88 Figure 90
70184 70161
Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
Mounting the main bearings
Figure 89 Figure 91
70185 70186
Check the play between the drive shaft journals and

IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
EW--2--56
Figure 92 Figure 94
70187 70189
Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
Checking the drive shaft shoulder play

Figure 93 Figure 95
70188 70190
- 3rd phase with tool 380001001 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60° ± 5°. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--57
CONNECTING ROD--PISTON ASSEMBLY
Figure 96
70191
PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing
NOTE -- Pistons are supplied as spares increased by 0.5 mm.
Figure 97 Figure 98
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--2--58
Figure 99
84095
MAIN DATA OF PISTON
Pistons
Measuring the piston diameter
Figure 100 Figure 101
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 61 mm far

from the piston skirt base.
EW--2--59
Gudgeon pins Figure 105

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

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

TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
EW--2--60
70194
Measuring the play between the ends of piston rings CONNECTING ROD BODY
(2) inserted into cylinder liner (3), by means of a thick-

ness gauge (1).
CONNECT-- WEIGHT
ING ROD
NO.
Connecting rods
Figure 108
CONNECTING ROD CAP
CONNECTING ROD YEAR DAY

NO.
70196
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
86472 ment, it is therefore necessary to number the
MAIN DATA OF CONNECTING ROD, GUDGEON new connecting rod with the same number as
PIN BUSHING AND HALF BEARINGS the replaced one.
* Dimension of inner diameter to be obtained after - By a letter (on the connecting rod body) which
driving into the connecting rod small--end and refacing indicates the weight class of the factory--as-
by means of a reamer. sembled connecting rod:
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure
better match. Material removal is not permitted.
Therefore, it is recommended not to remove
knurls.
EW--2--61
Bushings Checking the torsion

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

Figure 112
61696
Check the parallelism of connecting rod axes (1) by
means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--62
Mounting the connecting rod--piston assembly Mounting the piston rings

Connecting rod--piston match Figure 116
Figure 113
84103 84093
The following reference data are engraved on the pis- Use pliers 380000986 (3) to fit piston rings (1) on pis-
ton crown: ton (2).
1. Spare part number and design modification The rings must be mounted with the writing “TOP”
number; facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
2. Date of manufacture;
by 120°.
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin- IMPORTANT -- Spare piston rings are supplied in
der liner. the following dimensions:
Figure 114 -- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;
Figure 117
84104
Connect piston (2) to connecting rod (4) by means of
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5)
stamped on connecting rod (4) can be seen as shown
in the figure.
Figure 115
70200
Mount half bearings (1) both on the connecting rod
and the cap.
IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
EW--2--63
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 120
Figure 118
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 121
Figure 119
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 122
84040
SCHEME FOR MOUNTING THE CONNECTING

ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the writing stamped on the piston crown faces the 70205
crankcase front side, or the notch obtained on the - Apply tool 380001001 (1) on the compass
piston skirt corresponds to the position of oil nozz- wrench, then tighten screws (2) further in a criss--
les. cross sequence.
EW--2--64
Figure 123 Checking piston protrusion

Figure 125
70206 70208
- Take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
70207
If the measured play is different from the specified 84105

one, replace half bearings and repeat the check.
SCHEME FOR SEALANT LOCTITE 5999
Once the specified play has been obtained, lubricate APPLICATION AREA
the connecting rod half bearings and mount them defi- Clean thoroughly distribution gearbox case (1) and
nitely by tightening the connecting rod cap fastening the engine crankcase.
screws as described. Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case so as to
IMPORTANT -- Prior to mounting the connecting make a bead with a diameter of a few millimetres.
rod cap fastening screws definitely, verify that the The bead must be smooth (no lumps) and free from
diameter of the same (as measured at the middle air bubbles, thin areas or gaps.
of the thread length) is not smaller than 0.1 mm of Any defect must be corrected as soon as practicable.
the diameter measured at about 10 mm from the Avoid using excess material to seal the joint.
screw end. An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
Check manually that connecting rods (1) run axially After completing sealant application, the joints must
on the drive shaft pins, and that the end play of the be mounted immediately (within 10 -- 20 minutes).
same (as measured by means of a thickness gauge
(2) is 0.10 to 0.33 mm.
EW--2--65
84106 84107
SCHEME FOR REAR GEARBOX CASE FASTEN- Turn drive shaft (4) and distributing shaft (2) in such
ING SCREW TIGHTENING SEQUENCE a direction that when mounting driven gear (1) on the
Reassemble case to the crankcase. distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.
Valve timing
70211 70213
Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--66
Injection pump – 1st phase Figure 133

Timing
Figure 131
84108
Force--fit gear (1) transmitting the motion to the pump,
then fasten nut (2) by hand.
84071
Flywheel cover case
Bring cylinder 1 to the top dead centre. This condition
occurs when pin (1) (shown by an arrow) is housed in Figure 134
the seat available on the distributing shaft drive gear
(2).
86473
SCHEME FOR SEALANT LOCTITE 5999 AP-

PLICATION AREA
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox.
Figure 132
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case (1) so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
84273
Mount the injection pump body (1) in the gearbox seat
(2), then secure it by means of screws (3).
EW--2--67
Figure 135 ENGINE FLYWHEEL

Figure 137
86474
84111
SCHEME FOR FLYWHEEL COVER CASE Check the clutch disc supporting surface and turn it if
FASTENING SCREW TIGHTENING SEQUENCE scoring is detected.
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
taken off, then fasten them to the specified torque. NOTE -- The rated thickness of the engine flywheel
is 70.5 mm.
Screws:
- M12 x 1.75 x 100 80 ± 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 ± 20 Nm Check the condition of ring gear (2) teeth. If breaks or
- M16 x 1.50 x 100 200 ± 20 Nm excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 137) by using a
- M12 x 1.75 x 78 80 ± 10 Nm normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.
70216 84076
Apply part (5) of tool 380000983 on drive shaft rear Screw down two pins (2) of adequate length into the
shank (6), secure it by means of screws (4) and force-- shaft holes (3), then remove the engine flywheel (1)
fit the new seal ring (3) on the same. by means of suitable harnesses and a hoist.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--68
Figure 139 Injection pump – 2nd phase

Mounting the injection pump – 2nd phase
Figure 141
84075 84115
Apply tool 380000990 (2) to the flywheel cover case Torque--tighten nut (1) by means of torque wrench (2).
(1) to stop engine flywheel (4) rotation.
Tighten screws (3) fastening engine flywheel (4) to the
Figure 142
drive shaft.
Figure 140
α 84116
Apply sealant (1) as shown in the figure, then put on

small cover (2).
Figure 143
84114
Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: tighten to an angle of 60° ± 5°. 84260
Remove plug (1) from the distribution gear seat

Figure 44.
IMPORTANT -- Angle tightening is carried out by
means of tool 380001001. Remove presetting screw (2) and insert L--shaped
spacer (1). Fasten again the screw to its abutting end.
EW--2--69
Mounting the oil and water pumps Figure 147
Figure 144
70223
Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5999 onto the same.
70220
Figure 148
Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 145
70224
Clean thoroughly the surface of front cover (2) attach-

ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
70221 Figure 149
Apply a new seal ring (2) onto water pump (1).
Figure 146
70225
Apply part (5) of tool 380000983 on drive shaft front
shank (6), secure it by means of screws (4) and force--
70222 fit the new seal ring (3) on the same.
Mount water pump (1). Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in front cover (7).
torque.
EW--2--70
86469
Mount oil sump (1) and apply plate (3) on the same.
torque.
86470 Screws:
Mount plate (3) and strainer (5), then screw down - M10 x 1.50 x 70 70 ± 5 Nm
fastening screws (2, 4 and 1) and tighten them to the - M10 x 1.50 x 45 50 ± 5 Nm
specified torque.
- M10 x 1.50 x 100 70 ± 5 Nm
- M10 x 1.50 x 90 70 ± 5 Nm
Figure 153
Figure 151
70227 86476
Place gasket (1) on oil sump (2). Force--fit pulley (1) complete with spacer (2) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Fasten the guide pulley (4) using the screws (3), tight-
ening to the required torque.
EW--2--71
Mounting the water / oil heat exchanger Figure 156

Figure 154
86477
84175
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support (3).
gasket (1), heat exchanger (2), a new gasket (3), and
Fasten screws (2) without torque--tightening them.
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Fit the new oil filter cartridge.
Cylinder head
Removing the valves
Figure 157
Figure 155
84179
Valves can be removed by means of tool 380000987

(1) by pressing slightly on collar (3) so that lock cones
84177
(2) can be removed by compressing springs (4). Then
Position alternator support (1) in such a way that pins
remove collar (3) and springs (4).
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified Repeat the procedure on all valves.
torque.
EW--2--72
84282 84283
Take off oil seals (1) fitted to the valve stems. Remove the thermostat unit (2) and brackets (1) and
(3).
To remove the valves, properly turn the head upside
down.
IMPORTANT -- Mark the exhaust and intake

valves prior to removing them.
Checking the cylinder head supporting surface
INTAKE EXHAUST
84181 84183
In addition to the head dimensions, the exhaust The plane of the supporting surface of head (1) to cyl-
valves differ from intake valves in that they are inder cluster is checked by means of a ruler (2) and
equipped with a supplementary notch (1) obtained on a thickness gauge (3).
the stem for intake valves. The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
EW--2--73
Checking the cylinder head water seal VALVES

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

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

must be replaced. 84185
MAIN DATA OF INTAKE AND EXHAUST VALVES
Valve descaling, check and grinding

Figure 162
Figure 164
84284
Nominal thickness A of the cylinder head is 95 ± 0.25

84186
mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm. Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
IMPORTANT -- After regrinding, check valve sink- crimping or burns.
ing and regrind valve seats if required, to obtain
the required value. Reface, if necessary, the valve seats by means of a
grinder 380000975, by removing as less material as
possible.
EW--2--74
Figure 165 VALVE GUIDE

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

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

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

valve guide and valve centring
Valve seat reconditioning -- replacement
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). If slight burns or scoring are
parator (1) placed as shown. Assembling play must found, proceed with reconditioning by means of tool
be equal to 0.039 to 0.079 mm. 380000975 (1) according to the inclination values
shown in Figure 169.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
EW--2--75
Figure 169
INTAKE EXHAUST
84190
VALVE SEAT DIMENSIONS
Figure 170
EXHAUST INTAKE
86591
VALVE SEAT HOUSING DIMENSIONS
If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 168) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 169.
EW--2--76
Figure 171 MOUNTING THE CYLINDER HEAD

Figure 173
84192 84282
After the reconditioning operations, verify, by means Lubricate the valve stem and insert into the respective
of base 380001000 (2) and comparator 380001004 valve guide according to the position marked upon
(1), that valve hollow (3) corresponds to the specified disassembling.
value.
Mount seal rings (1) onto the valve guide.
VALVE SPRINGS
Figure 172
Figure 174
84193
MAIN DATA FOR INTAKE AND EXHAUST VALVE

SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of tool 380000976. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.
Height Under a load of

mm N 84179
H(Free) 63.50 No load Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000987 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).
EW--2--77
Reattaching the cylinder head Figure 177

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

ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
84265 84196
Mount the cylinder head on the crankcase by fastening MAIN DATA OF ARBOUR--ROCKER ARM
screws (1) without torque--tightening them. Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--78
84197
Verify that the tappet adjusters are unscrewed to pre- 84200

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

Figure 184
84198
Fasten the head screws according to the instructions

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

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; Mount a new seal ring (2) lubricated with petrolatum
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; and a new seal washer (3) on injector (1).
- 2nd phase: angle tightening: 90° Mount the injectors on their seats on the cylinder
- 3rd phase: angle tightening only for screws 140 head, then tighten them by means of a torque wrench.
and 180 mm long: 90°.
EW--2--79
Figure 185
Figure 188
86464
Mount the injector feeding pipe assembly (1). Mount

84286
the pipes for fuel discharge (2) from injectors, by using
gaskets (3) and by tightening screws (4). The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
Figure 186 cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5999 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
Figure 189
84257
- Mount exhaust manifold (3).
- Mount turbine (1) by means of screws (2).
Figure 187
84254
- Mount tappet covers (4).
- Mount container (2).
- Mount intake manifold elbow (3).
- Mount container control unit (5).
- Mount fuel filter support (6).
- Mount fuel filter (9).
- Attach quick coupling pipes (7), (10), (11) and (12)
84255
by following the indications given in Figure 192.
Mount the injection pump (6) injector feeding pipes - Mount electric wiring (8).
(5), then secure brackets (1), (2) and (3) fastening the - Mount L.D.A. system piping (13).
pipe assembly onto the cylinder head.
- Connect the engine oil vapour recovery pipe to
Mount priming pump (4). blow--by (1).
EW--2--80
86479
70126
Press clip (1) in the direction of the arrow (detail B), - Mount thermostat unit (1) to cylinder head (3) by
then connect the piping. Bring the clip back to the in- torque--tightening screws (2).
itial locking position (detail A). - Fit the water temperature sensor (4) tightening
this with the torque wrench.
Figure 191
84252
- Mount electric wiring (1). Figure 194

Figure 192
86480
86478
Fit the Poli--V belt (5) on the pulley (6) of the crank-
- Mount the starter motor (1). shaft, on the guide pulley (7), on the water pump (4)
and on the alternator (2); stretch the belt using the au-
- Fit the fastening bracket (2) and harness (1). tomatic take--up unit (3).
EW--2--81
REPLACING THE INJECTORS Reassembling

Removal Figure 197
Figure 195
84289
Place the vehicle in safe conditions.

Lift the engine compartment cover, disconnect the 84201
battery cables and proceed as follows:
- disconnect engine oil vapour recovery pipe (2) Mount a new seal ring (2) lubricated with petrolatum
from blow--by; and a new seal washer (3) on injector (1).
- take off tappet cover (1);
Mount the injectors on their seats on the cylinder
- disconnect the fuel manifold pipes from injectors head, then tighten them by means of a torque wrench.
(3).
Figure 198
Figure 196
84290
Mount new seal rings (1) on fuel manifolds (2).

Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
84082
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
Remove injectors (2) by means of tool 380000982 (1) blow--by.
and take them off the cylinder head.
EW--2--82
ROCKER ARM REMOVAL/REASSEMBLING ADJUSTING THE TAPPETS

Removal Figure 200
Figure 199
84200
84081 Ad just the play between the rocker arms and the
Loosen tappet adjuster fastening nuts (3), then un- valves by means of an Allen wrench (2), box wrench
screw adjusters (2). (3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem- The operation play is:
bly (1) made up of the rocker arm support and ar-
-- ± 0.05 mm
bours, then take off valves.
– intake valves: 0.25 ± 0.05 mm
Reassembling
-- exhaust valves: 0.50 ± 0.05 mm.
Verify that the tappet adjusters are unscrewed to pre-
vent the latter from crawling on the rods when the Take the cylinder where clearance must be adjusted
rocker arm assembly is mounted. to the bursting phase; its valves are closed while bal-
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl- Symmetric cylinders are 1--4 and 3--2.
inder head by tightening the fastening screws to a
torque of 36 Nm.
FIRING ORDER 1--3--4--2
Ad just the tappets as described above.
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
EW--3--83
OVERHAUL OF F4BE0684B -- F4BE0684D ENGINES
ADJUSTING THE TAPPETS ROCKER ARM REMOVAL/REASSEMBLING

Figure 192 Removal
Figure 193
84200
84081
Ad just the play between the rocker arms and the Loosen tappet adjuster fastening nuts (3), then un-
valves by means of an Allen wrench (2), box wrench screw adjusters (2).
(3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem-
The operation play is: bly (1) made up of the rocker arm support and ar-
-- ± 0,05 mm bours, then take off valves.
– intake valves: 0,25 ± 0,05 mm Reassembling
-- exhaust valves: 0,50 ± 0,05 mm. Verify that the tappet adjusters are unscrewed to pre-
Take the cylinder where clearance must be adjusted vent the latter from crawling on the rods when the
to the bursting phase; its valves are closed while bal- rocker arm assembly is mounted.
ancing the symmetric cylinder valves. Mount the rocker arm assemblies made up of rocker
Symmetric cylinders are 1--6, 2--5 and 3--4. arm support and arbours, then secure them to the cyl-
FIRING ORDER 1--5--3--6--2--4 torque of 36 Nm.
Adjuting cylinder Ad just the tappets as described above.
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
VALVE TIMING
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 194
84210
EW--3--84

S
SECTION 3 F4BE0684B -- F4BE0684D
OVERHAUL OF
F4BE0684B -- F4BE0684D ENGINES
INDEX
Engine F4BE0684B . . . . . . . . . . . . . . . . EW--3--3 Replacing the seal ring . . . . . . . . . . . . . . EW--3--42
Engine coding . . . . . . . . . . . . . . . . . . . . EW--3--4 Removing the injection pump . . . . . . . . . EW--3--42
Main engine features . . . . . . . . . . . . . . EW--3--5 Removing the rocker arm assembly . . . EW--3--45
Main engine features . . . . . . . . . . . . . . EW--3--6 Repair work on cylinder cluster . . . . . EW--3--47
Assembling play -- specifications . . . EW--3--8 Checks and measurements . . . . . . . . . . EW--3--47
Tightening torque . . . . . . . . . . . . . . . . . EW--3--14 Checking the surface supporting
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--15 the head on the cylinder cluster . . . . . . . EW--3--48
Graphic indications and symbols . . . EW--3--16 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--3--49
General remarks . . . . . . . . . . . . . . . . . . EW--3--17 Distributing shaft . . . . . . . . . . . . . . . . . . . EW--3--49
Description of main mechanic Checking the eccentric lift and the
engine components . . . . . . . . . . . . . . . EW--3--18 pin alignment . . . . . . . . . . . . . . . . . . . . . . EW--3--49
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--18 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--19 Replacing the bushings . . . . . . . . . . . . . . EW--3--51
Drive shaft seal rings . . . . . . . . . . . . . . . EW--3--19 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--51
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--20 Mounting the tappets – Distributing shaft EW--3--51
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--21 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--3--52
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--3--22 Measuring the journals and crankpins . EW--3--52
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--3--23 Replacing the oil pump drive gears . . . . EW--3--55
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--3--24 Mounting the main bearings . . . . . . . . . . EW--3--55
Valves and valve seats . . . . . . . . . . . . . . EW--3--25 Measuring the journal assembling play EW--3--55
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--3--26 Checking the drive shaft shoulder play . EW--3--56
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--3--27 Connecting rod--piston assembly . . . EW--3--57
Auxiliary component drive . . . . . . . . . . . EW--3--28 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--58
Lubrification . . . . . . . . . . . . . . . . . . . . . . EW--3--29 Measuring the piston diameter . . . . . . . EW--3--58
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--3--30
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--3--59
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--31
Conditions for correct pin/piston
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--32 matching . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--59
Oil vapour recirculation . . . . . . . . . . . . . . EW--3--33 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--3--59
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--34 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--60
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--3--35 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--61
Mechanic injection feeding system . EW--3--36 Checking the connecting rods . . . . . . . . EW--3--61
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--3--36 Checking the torsion . . . . . . . . . . . . . . . . EW--3--61
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--36 Checking the flexion . . . . . . . . . . . . . . . . EW--3--61
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--3--37 Mounting the connecting rod--piston
Injection assembly . . . . . . . . . . . . . . . . EW--3--38 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--62
Engine bench--overhaul . . . . . . . . . . . . EW--3--39 Connecting rod--piston match . . . . . . . . EW--3--62
Disassembling the engine . . . . . . . . . . . EW--3--39 Mounting the piston rings . . . . . . . . . . . . EW--3--62
INDEX
Mounting the connecting rod/piston Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--73

assemblies in the cylinder liners . . . . . . EW--3--63 Valve descaling, check and grinding . . . . EW--3--74
Measuring the crankpin assembling play EW--3--63 Checking the play between the
Checking piston protrusion . . . . . . . . . . . EW--3--64 valve stem, valve guide and valve
centring . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--74
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--65
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--3--74
Distribution gearbox case . . . . . . . . . . . . EW--3--65
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--3--74
Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--3--65
Valve seat reconditioning -- replacement EW--3--74
Injection pump – 1st phase . . . . . . . . . . EW--3--66
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--3--76
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--66
Flywheel cover case . . . . . . . . . . . . . . . . . EW--3--67 Mounting the cylinder head . . . . . . . . EW--3--76
Engine flywheel . . . . . . . . . . . . . . . . . . . EW--3--68 Reattaching the cylinder head . . . . . . . . . EW--3--76
Replacing the engine flywheel ring gear . EW--3--68 Rocker arm assembly . . . . . . . . . . . . . . . . EW--3--77
Injection pump – 2nd phase . . . . . . . . . . . EW--3--69 Mounting the injectors . . . . . . . . . . . . . . . . EW--3--78
Mounting the injection pump – 2nd phase EW--3--69 Replacing the injectors . . . . . . . . . . . . EW--3--81
Mounting the oil and water pumps . . . . . EW--3--69 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--81
Mounting the oil sump . . . . . . . . . . . . . . . . EW--3--70 Reassembling . . . . . . . . . . . . . . . . . . . . . . . EW--3--81
Mounting the water/oil heat exchanger . . EW--3--71 Adjusting the tappets . . . . . . . . . . . . . . EW--3--83
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--3--72 Rocker arm removal/reassembling . . EW--3--83
Removing the valves . . . . . . . . . . . . . . . . . EW--3--72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--83
Checking the cylinder head supporting
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--73 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--3--83
Checking the cylinder head water seal . . EW--3--73 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--3--83
EW--3--3
ENGINE F4BE0684B -- F4BE0684D
Figure 1
86450
EW--3--4
ENGINE CODING
F 4 B E 0 6 8 4 B * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non--structural 6 = 6--cylinder
Engine
group
8 = Direct injection turbo

diesel with intercooler
4 = Earthmovers
X Y Y Y Y Y Y Y Y
X = 4 in--line, 2--valve injection pump Manufacturing sequence number

Y = Engine model
EW--3--5
A WX 170 WX 200
B F4BE0684D F4BE0684B
C *D402 *D403
E 5883 cm3
105 kW 118 kW
F 2000 rpm 2150 rpm.
G Direct injection
H In--line injection pump
T.A.A.
I (Boosted by intercooler)
A Wheeled excavator code

B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--3--6

F4BE6484D F4BE6484B
Type
*D402 *D403
Cycle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct
Number of cylinders In--line, 6--cylinder
Bore mm 102
Stroke mm 120
Total displacement cm3 5883
Compression ratio 17.5 : 1
Max. rating kW 105 118

min --1 2000 2150
Max. torque Nm (kgm) 550 (56) 625 (64)

min --1 1400 1400
No--load idle rpm min --1 700
No--load peak rpm min --1 --
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX35W
Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--3--7
F4BE0684D F4BE0684B
Type
*D402 *D403
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
start of opening: °C 81 ± 2
REFUELLING
Full filling capacity 1° litres --
Ambra Super Gold
15W40 kg
10W30 -- engine sump litres --
kg
-- engine sump + filter litres 7.6
kg
FEEDING
PES 6A
Bosch--type injection
Pump setting 0° ± 0°.5
Start of delivery mm 3.1
Type of nozzle DSLA 145 P1174 DSLA 145 P603
Injection sequence 1 -- 5 -- 3 --6 --2 -- 4
Injection pressure bar 245 bar

EW--3--8
ASSEMBLING PLAY -- SPECIFICATIONS

F4BE0684D F4BE0684B
Type
*D402 *D403
Cylinder liners ∅1 102.01 to 102.03
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 101.777 to 101.795
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253
Piston diameter ∅1 0.5
Position of pistons
from crankcase X --
Gudgeon pin ∅3 39.9938 to 40.0002
Gudgeon pin--Pin seat 0.0058 to 0.0182
Type of piston X1* 2.69 2.70

Piston ring slots X2 2.425 ÷ 2.445 2.74
X3 4.04 ÷ 4.06 4.04 ÷ 4.06
S1* 2.31 ÷ 2.34 2.567 ÷ 2.618
Piston rings S2 2.560 ÷ 2.605

S3 3.975 ÷ 4.000
1 0.34 ÷ 0.38 0.082 ÷ 0.133
Piston rings -- Slots 2 0.115 ÷ 0.18 0.135 ÷ 0.180
3 0.040 ÷ 0.085
Piston rings 0.5

EW--3--9
F4BE0684D F4BE0684B
Type
*D402 *D403
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Connecting rod small--end

bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 ÷ 73.013
Connecting rod small--end bushing

diameter
Outer ∅4 43.279 to 43.553
Inner ∅3 40.019 to 40.033
Connecting rod small--end bushing –

0.266 to 0.566
seat
Gudgeon pin – Bushing 0.0158 to 0.0362
Measurement dimension X --
Max. error on connecting rod axis

parallelism = --
Journals ∅1 82.99 to 83.01

Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares
Bed supports no.:

n. 1--5 ∅3 87.982 to 88.008
n. 2--3--4 87.977 to 88.013
EW--3--10
F4BE0684D F4BE0684B
Type
*D402 *D403
Half bearings -- journals:
n. 1--7 0.041 to 0.119
n. 2--3--4--5--6 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 3738
Drive shaft shoulder 0.068 to 0.410

EW--3--11
F4BE0684D F4BE0684B
Type
*D402 *D403
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°
Valve stem and respective guide 0.052 to 0.092
Seat on head for valve seat:

∅1 46.987 to 47.013
∅1 43.637 to 43.663
Valve seat outer diameter; inclination

of valve seats on cylinder head:
∅2 47.063 to 47.089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 0.356 to 1.102
X 0.104 to 0.840
Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102
Valve seats --
EW--3--12
F4BE0684D F4BE0684B
Type
*D402 *D403
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for distributing shaft bushings

no. n. 1--7
--
Distributing shaft seats no.
--
2--3--4--5--6
Distributing shaft support pins:
1⇒7 ∅ 53.995 to 54.045
Bushing inner diameter ∅ 54.083 to 54.147
Bushings and seats in crankcase --
Bushings and support pins 0.038 to 0.162

Eccentric working lift:
6.045
7.239
EW--3--13
F4BE0684D F4BE0684B
Type
*D402 *D403
∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030
∅2
Outer diameter of
tappet collar:
∅3
∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980
Between the tappets and the seats 0.020 to 0.065
Tappets --
∅1
Rocker arm shaft ∅1 18.963 to 18.975
Rocker arms ∅2 19.000 to 19.026

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

EW--3--15
TOOLS
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check.
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Adapter for compressor check in cylinders (380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000997 Comparator holder tool for rotary injection pump timing (to be used with 380001005)
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001002 All--purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Device for checking diesel engine cylinder compression
EW--3--16
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

α
Replacement
Countersink
Genuine spares
Adjustment
Rotation
Setting
Warning Angle
! Note Angular value
Visual check
Preload
Mounting position check
Measurement
Dimension to be measured Revs number
Check
Equipment Temperature
Surface to be machined
Pressure
Machining finish bar
Increase
Interference
Greater than .....
Forced mounting
Maximum
Decrease
Thickness
Smaller than .....
Play
Minimum
Lubricate Selection
Moisten Classes
Grease Increases
Temperature < 0 °C
Sealant Cold
Winter
Temperature > 0 °C
Air bleed Hot
Summer
EW--3--17
GENERAL REMARKS
Figure 2
86452
1. Turbocompressor – 2. Fixed guide pulley – 2. Alternator – 4. 4. Poly--V water pump and alternator drive
belt – 5. Automatic belt stretcher – 6. Fixed guide pulley – 7. Damping unit flywheel pulley – 8. Diesel oil
filters – 9. Oil sump -- 10. In--line injection pump – 11. Blow--by -- 12. Cold start air heater
EW--3--18
DESCRIPTION OF MAIN MECHANIC EN-

GINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the follow- It also incorporates the coolant circulation chambers
ing items are realized: cylinder liners (1); bed sup- and the engine member lubricating circuit ducts.
ports (5) and seats for: distributing shaft bushings
(3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.
Figure 3
86605
EW--3--19
Drive shaft
It is made of steel and rests on seven induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
Inside the drive shaft are the lubricating oil ducts. wheel mounting hub.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley. The penultimate main half bearings are equipped
with a shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.
Figure 4
1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear -- 84037
4. Flywheel attachment hub
Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983and 380000984.
EW--3--20
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 5
84038
EW--3--21
Pistons
Figure 6
84039
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1° and 2°, trapezoidal in shape and with
Three slots (piston ring seats) are provided: the first ceramic chrome coating.
one and the second one are obtained from a cast-- Piston ring 3°, with double scraper ring shoe with
iron insert with trapezoidal section. inner spring.
The identification number and manufacturing data
(1) are shown on the piston crown.
Figure 7
84040
EW--3--22
Distributing shaft
The distributing shaft rests on seven supports in the trics are provided for each cylinder.
crankcase. A. Intake valve control
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and The distributing shaft is controlled directly by the
coated with anti--friction material; two control eccen- drive shaft by means of straight--tooth gears.
Figure 8
70164
84041
EW--3--23
Valve control
Figure 9
84042
1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--3--24
Cylinder head
The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injectors (6); - intake manifold (2) with seat for cold start air
- thermostat (5); heater (3).
Figure 10
84043
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--3--25
Valves and valve seats

Figure 11
84044
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).
Figure 12
84045
Figure 12, shows the oil seals mounted on valve

stems.
EW--3--26
Valve guides
Figure 13
INTAKE EXHAUST
84046
DETAIL OF VALVE GUIDES AND SEATS

EW--3--27
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 14
86454
EW--3--28
Auxiliary component drive

The Poly -- V belt (4) transmits the movement of the The belt is stretched by means of automatic belt
crankshaft (5) to the water pump (1) and alternator stretcher (3).
(2).
Figure 15
86455
1. Water pump -- 2. Alternator -- 3. Automatic belt stretcher -- 4. Poly--V belt -- 5. Drive shaft
EW--3--29
LUBRICATION
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the engine
lowing components: crankcase, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure regulating valve incorporated in the
case front part, controlled by the straight--tooth oil filter support;
gear force--fitted on the drive shaft shank; - bypass valve for bypassing the clogged oil filter,
in the oil filter support;
- cartridge--type oil filter.
Figure 16
86456
Oil return drop--type path
Pressure oil path

EW--3--30
Heat exchanger
Figure 17
86458
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block
EW--3--31
Oil pump
Figure 18
84052
Figure 19
70150
1. Drive shaft with oil pump drive gear

EW--3--32
Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2), fitted onto the oil
case by means of an aluminium plate (3), Figure 21. sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 20
84054
Figure 21
84055
EW--3--33
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
Figure 22
86460
EW--3--34
COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components:
- heat exchanger, used to cool the lubricating oil; - thermostat, used to regulate coolant flow.
Figure 23
86462
Water flowing out Water flowing in
Water recirculating
EW--3--35
Water pump
The water pump is housed in a seat obtained from the The engine temperature is controlled by a thermo-
crankcase and is controlled by means of a poly--V stat.
belt. The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 24
84058
Figure 25
84059
EW--3--36
MECHANIC INJECTION FEEDING SYSTEM

Fuel prefilter
The filter support (1) incorporates: manual priming

pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 26
84060
Fuel filters
The support (2) incorporates: fuel temperature sen- Maximum working pressure: 5 bar.
sor (1), heater resistors (4), air bleeding screws (3) Working temperature: --25 °C to + 90 °C.
and filter (5).
Degree of filtration of cartridge: 10 micron.
Figure 27
84061
EW--3--37
MECHANIC FUEL PUMP

Displacement pump mounted on the injection pump
left side; it is used to feed the injection pump.
Figure 28
84062
1. Injection pump -- 2. Fuel outflow to the filter -- 3. Fuel pump -- 4. Fuel inflow from the tank -- 5. Manual
control lever
EW--3--38
INJECTION ASSEMBLY
Figure 29
84063
1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Injector 5
fuel pipe -- 6. Injector 6 fuel pipe -- 7. Pipe for fuel discharge from injectors -- 8. Connector for pipe
measuring the pressure inside the L.D.A. intake manifold -- 9. Injection pump -- 10. Injector
EW--3--39
ENGINE BENCH--OVERHAUL
Disassembling the engine
- Disconnect electric wiring; - disconnect quick--coupling pipes (8) and (14) by
- drain the engine oil by taking the cap off the sump following the indications given in Figure 32;
and the oil filling cap off the head cover; - take off fuel filters (12);
- fit bracket 380000995 (which fastens the engine
to the overhaul stand) to the crankcase; - take off fuel filter support (13).
- disconnect the engine oil vapour recovery pipe - disconnect injector feed pipes (7) from injection
from blow--by (4); pump (9); remove the brackets fastening pipe (2),
(5) and (15) unit on the cylinder head;
- take off tappet covers (6);
- take off intake manifold unit (1); - take off injection pump (10) lubrication pipes;
- disconnect the piping from L.D.A. system (3); - take off oil level check piping (11).
Figure 30
84064
EW--3--40
Figure 31 Figure 33
70126
84464
Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid deformations, bring
fork (1) back to the locking position (detail B) after the - Take off the feed pipe assembly from injectors (1).
adapter has been removed. - Take off the pipe (2) for discharging fuel from the
injectors by removing screw (4) and gasket (3).
Figure 34
Figure 32
5 84465
- Remove screws (2) and take off turbine (1).
- Remove the exhaust manifold (3).
4 Figure 35
86463
To fit bracket 75301886 to the engine block on the

right--hand side, remove:
- the fastening bracket (2) of the harness (1);
- the harness (1);
- the starter motor (3);
- the turbine lubrication delivery hose (5).
Fasten the engine to the rotary stand 380000978.
- Detach the heat exchanger assy with the oil filter 84068
cartridge (4). Apply tool 380000990 (1) to the flywheel cover case
to stop flywheel rotation.
EW--3--41
- Remove automatic belt stretcher (5). - Remove engine cooling system adapter from the
crankcase.
- Remove Poly--V belt (7).
- Remove damper flywheel (8) with underlying
- Remove alternator fastening bracket (1). pulley (9).
- Remove the alternator (2), the water pump (4),

the guide pulleys (3) and (6).
Figure 36
86467
EW--3--42
Replacing the seal ring Figure 39

Figure 37
84237
Remove screws (1) and take off gear oil pump.
78256
Apply tool 380000980 (4) on drive shaft front shank

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

Figure 40
Figure 38
84071
Prior to removing the injection pump, take off the fly-

wheel locking tool described in Figure 35.
Rotate the drive shaft until it reaches the condition of
78257
1° cylinder at top dead centre.
Apply the proper tension rod (3) of tool 380000996 to Such condition is obtained when, by pushing pin (1)
outer seal ring (2) as shown in the figure, then take the shown by the arrow, it is housed in its own seat ob-
same off front cover (1) by means of lever (4). tained on distributing shaft drive gear (2).
Remove the front cover.
EW--3--43
Figure 41 Figure 43
84074
Loosen the four symmetrically arranged nuts (two of

84072 which – (2) and (4) – within sight) which secure injec-
To correctly preset the injection pump prior to remov- tion pump (1) to flywheel cover case (3), then take the
ing it, loosen screw (2), take out the timing pin, turn pump out of its housing by means of tool 380000979
it upside down and insert it again until the pump shaft through proper application to gear (4) in Figure 42B.
is locked.
Fasten again screw (2). Figure 44
84075
Apply tool 380000990 (2) to unlock screws (3).

Figure 42 Remove tool 380000990 (2).
Remove screws (3) fastening engine flywheel (4) to
the drive shaft.
Figure 45
84073
- Remove cover (1) from gear covering case (2). 84076

- Lock the engine flywheel as described in Screw two pins (2) of adequate length into drive shaft
Figure 35. holes (3).
- Loosen nut (3) securing the injection pump drive Take out engine flywheel (1) so that it can be har-
gear (4). nessed by means of a hoist and placed into its own
container.
EW--3--44
Figure 46 Figure 48
84077
Remove screws (2) and take off rear cover (1).
78258
Apply tool 380000981 (3) on drive shaft rear shank of screws (2), due to the different size of the latter.
(5).
Drill inner seal ring (1), through tool 380000981 (3) Figure 49
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by screwing the
six screws (4) provided.
86468
Turn the engine upside down, remove screws (2),
take off both plate (3) and oil sump (1).
Figure 50
Figure 47
86517
78257
Apply the proper tension rod (3) of tool 380000996 to Remove screws (1) and (4) and dismantle oil suction
outer seal ring (2) as shown in the figure, then take the strainer (5).
same off flywheel cover case (1) by means of lever
(4). Remove screws (2) and dismantle stiffening plate (3).
EW--3--45
Figure 51 Figure 53
70156
Remove screws (1) and take gear (3) off distributing 84082
shaft (2). Take out injectors (2) by means of tool (1) 380000982.
Figure 54
84083
Remove screws (1) securing the head to the crank-

case.
Removing the rocker arm assembly
Figure 52 Figure 55
84081 84084
For each cylinder, remove rocker arm assembly (1), Hook the wire ropes to brackets (1) and (2), then sep-
loosen adjusting nuts (3), unscrew registers (2) and arate the cylinder head from the crankcase by means
remove screws (4). of a hoist.
EW--3--46
Figure 56 Figure 59
84085 70160
Remove screws (2) and take off timing gear case (1). The penultimate bed cap (1) and its respective sup-
port have half bearing (2) provided with shoulder.
IMPORTANT -- Take note of the mounting position IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in the
Figure 57 same position they had prior to being taken off.
Figure 60
70158
Remove connecting rod cap (2) fastening screws
(1), then take off the caps.
Remove the pistons (complete with connecting 84086
rods) from the crankcase upper part.
Remove drive shaft (2) from crankcase by means of
tool 380000992 (1) and a hoist.
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be
used again, they must be mounted in the same
position they had prior to being taken off. Figure 61
Figure 58
70162
70159
Remove screws (1) and take off bed caps (2). Take off main half bearings (1).
Remove screws (2) and take off oil nozzles (3).
EW--3--47
Figure 62 REPAIR WORK ON CYLINDER CLUSTER

Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
70163
Remove screws (1) and take off distributing shaft (3)

retaining plate (2). Figure 65
IMPORTANT -- Take note of plate (2) mounting

position.
Figure 63
84087
The check of cylinder liner inner diameter (in order to

measure the amount of out--of--roundness, taper and
70164 wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
Carefully remove distributing shaft (1) from the engine ring gauge (2) of the cylinder liner diameter.
crankcase.
Figure 64 NOTE -- If no ring gauge is available, use a micro-
meter to perform reset.
70165
Remove tappets (1) from the engine crankcase.

EW--3--48
Figure 66 Checking the surface supporting the head on

the cylinder cluster
Figure 68
70167
Measurements must be taken for each single cylinder,

at three different heights of the liner and on two planes
perpendicular to each other: one parallel to the engine
longitudinal axis (A), the other perpendicular (B); the
greatest amount of wear is usually found on the latter
plane and during the first measurement. When detect- 84088
ing out--of--roundness, taper or wear, the cylinder
liners must be bored and refaced. Cylinder liner re- Verify that the head supporting plane on the cylinder
conditioning must be performed with regard to the cluster does not show deformations.
spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play. This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
Figure 67 After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.
NOTE -- Crankcase flattening may be carried out

only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
After flattening, restore the cylinder liner countersink,
as shown in Figure 67.
70168
IMPORTANT -- In case of reconditioning, all the

liners must be machined to the same increase (0.5
mm).
Check the main bearing seats as follows:
- mount the bed caps on the supports without bear-
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.
EW--3--49
VALVE GEAR
Distributing shaft
Figure 69
84089
MAIN FEATURES OF DISTRIBUTING SHAFT

The features described given below refer to the normal diameter of pins.
The shaft support pin and eccentric surfaces must be Figure 70

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm (for ex-
haust eccentrics) and 6.045 mm (for intake eccen-
trics). If different values are found, replace the shaft.
70171
Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
EW--3--50
BUSHINGS Figure 71
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
70172
Figure 72
sec. A-A
70173
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
EW--3--51
Replacing the bushings Figure 76

Figure 73
70174 70164
To replace front and rear bushings (1), use beater Lubricate the distributing shaft support bushings and
380000991 (2) and handle 380000999 (3) to remove mount distributing shaft (1) taking care not to damage
and reassemble the bushings. the bushings or supporting seats.
IMPORTANT -- Bushings (1) must, upon mount-

ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.
Tappets
Figure 74
84053
MAIN FEATURES OF TAPPETS AND THEIR RE-
SPECTIVE SEATS ON THE CRANKCASE Figure 77
Mounting the tappets – Distributing shaft
Figure 75
70238
Place distributing shaft (3) retaining plate (1) with

70176 the slotted hole facing the crankcase upper side and
Lubricate tappets (1) and fit them to their respective the stamping facing the operator, then fasten
seats of the crankcase. screws (2) to the specified torque.
EW--3--52
Figure 78 DRIVE SHAFT

Measuring the journals and crankpins
Figure 80
70179
Check the distributing shaft end play (1).
70182
Figure 79 If traces of excessive seizing, scoring or out--of--

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

values on a table.
See Figure 81.
Reduction classes are 0.250 and 0.500 mm.
70180
IMPORTANT -- Journals and crankpins must al-
Mount nozzles (2) and tighten fastening screws (1) to ways be ground to the same reduction class.
the specified torque. The reduction carried out on journals and crank-
pins must be marked with a special stamping made
on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
EW--3--53
Figure 81
84090
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--3--54
Figure 82
84091
MAIN TOLERANCES OF DRIVE SHAFT

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

CRITICAL 
IMPORTANT
SECONDARY
Figure 83
BEARINGS ON TIMING INTERMEDI- FIRST

SIDE ATE BEARINGS BEARING ON
UPPER SIDE
84275
EW--3--55
Replacing the oil pump drive gears Measuring the journal assembling play
Figure 84 Figure 86
70184 84092
Verify that the teeth of gear (1) are not damaged or Mount drive shaft (1).
worn; otherwise, proceed with removal by means of Check the play between the drive shaft journals and
a suitable extractor (3) foce--fitted on drive shaft (2). their respective bearings by following the procedure
When fitting the new gear, the latter must be heated below:
for 10 minutes in a small furnace at a temperature of
180 °C and force--fitted onto the drive shaft by putting
the key in between.
Mounting the main bearings

Figure 85
Figure 87
70185
IMPORTANT -- If main bearings do not need re-

placing, they must be fitted in the same order and
positions they had prior to being taken off.
Main bearings (1) are supplied as spares reduced on

their inner diameter by 0.250 – 0.500 mm. 70186
Check the play between the drive shaft journals and

their respective bearings by following the procedure
IMPORTANT -- No matching operation must be
below:
carried out on bearings.
- clean thoroughly the parts and eliminate traces (if
Clean thoroughly the main half bearings (1) provided any) of oil;
with lubrication holes, then fit them to their seats. - place a piece of gauged wire (3) (parallel to the
The penultimate main half bearing (1) is provided with longitudinal axis) on drive shaft pins (4);
shoulder half rings. - mount caps (1), complete with half bearings (2),
on their respective supports.
EW--3--56
Figure 88 Figure 90
70187 70189
Fasten pre--lubricated screws (1) by tightening them - take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.
Checking the drive shaft shoulder play

Figure 91
Figure 89
70190
The shoulder play is checked by placing a magnetic

comparator (2) on drive shaft (3) as shown in the fig-
ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
70188 again the play between the drive shaft pins and the
- 3rd phase with tool 380001001 (1) placed as main half bearings.
shown in the figure: tighten screws (2) further to
an angle of 60° ± 5°.
EW--3--57
CONNECTING ROD--PISTON ASSEMBLY
Figure 92
70191
PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing
NOTE -- Pistons are supplied as spares increased

by 0.5 mm.
Figure 93 Figure 94
84093 84094
Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--3--58
Figure 95
84095
MAIN DATA OF PISTON WX 200
86471
MAIN DATA OF PISTON WX 170
Pistons
Measuring the piston diameter
Figure 96 Figure 97
84096 70192
Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 61 mm far

from the piston skirt base.
EW--3--59
Gudgeon pins Figure 101

Figure 98
84097 84100
Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 99
Figure 102
84098
Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 100
84101
SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the two trapezoidal
cross--sectioned seal ring, the play between the slot
and the ring itself must be measured as follows; allow
piston (1) to protrude from the crankcase so that ring
(2) at issue comes out of about half from cylinder liner
(3).
84099 In this position, check, by means of a thickness
Check the thickness of seal rings (2) by means of a gauge, the play (X) between the ring and the slot: it
micrometer (1). must correspond to the specified value.
EW--3--60
CONNECTING ROD BODY
70194
Measuring the play between the ends of piston rings

CONNECT-- WEIGHT
ING ROD
NO.
(2) inserted into cylinder liner (3), by means of a thick-

ness gauge (1).
Connecting rods
Figure 104
CONNECTING ROD CAP
CONNECTING ROD YEAR DAY

NO.
70196
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted.
86472 In case of replacement, it is therefore necess-
ary to number the new connecting rod with the
MAIN DATA OF CONNECTING ROD, GUDGEON
same number as the replaced one.
PIN BUSHING AND HALF BEARINGS
- By a letter (on the connecting rod body) which
* Dimension of inner diameter to be obtained after
indicates the weight class of the factory--as-
driving into the connecting rod small--end and refacing
sembled connecting rod:
by means of a reamer.
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure Material removal is not permitted.
better match.
Therefore, it is recommended not to remove
knurls.
EW--3--61
Bushings Checking the torsion

Verify that the bushing in the connecting rod small-- Figure 107
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 106
61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ~ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.
Checking the flexion

Figure 108
61696
Check the parallelism of connecting rod axes (1) by

means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).
61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--3--62
Mounting the connecting rod--piston assembly Figure 111

Connecting rod--piston match
Figure 109
72705
Insert pin (1) fastening piston rings (2).

84103
The following reference data are engraved on the pis-

ton crown:
1. Spare part number and design modification
number;
2. Date of manufacture;
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin-
der liner.
Mounting the piston rings
Figure 112
Figure 110
84093
Use pliers 380000986 (3) to fit piston rings (1) on pis-

ton (2).
The rings must be mounted with the writing “TOP”
facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
by 120°.
IMPORTANT -- Spare piston rings are supplied in

84104 the following dimensions:
Connect piston (2) to connecting rod (4) by means of
-- standard, marked with yellow paint;
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5) -- increased by 0.5 mm, marked with yellow/green
stamped on connecting rod (4) can be seen as shown paint;
in the figure.
EW--3--63
70200 84040
Mount half bearings (1) both on the connecting rod SCHEME FOR MOUNTING THE CONNECTING
and the cap. ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
IMPORTANT -- If connecting rod bearings do not by 120°;
need replacing, they must be fitted in the same - all the connecting rod/piston assemblies weigh
order and positions they had prior to being taken the same;
off. - the writing stamped on the piston crown faces the
No matching operation must be carried out on half crankcase front side, or the notch obtained on the
bearings. piston skirt corresponds to the position of oil nozz-
les.
Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 116
Figure 114
70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4).
EW--3--64
70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a 70207
torque wrench (2); If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
Figure 118 screws as described.
IMPORTANT -- Prior to mounting the connecting
α rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.
Check manually that connecting rods (1) run axially

on the drive shaft pins, and that the end play of the
same (as measured by means of a thickness gauge
(2)) is 0.10 to 0.33 mm.
70205
- Apply tool 380001001 (1) on the compass

wrench, then tighten screws (2) further in a criss--
cross sequence.
Checking piston protrusion
70206 70208
- take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane. Said protrusion
must be 0.28 to 0.52 mm.
EW--3--65
Valve gear Figure 123

Distribution gearbox case
Figure 122
84105 84106
SCHEME FOR SEALANT LOCTITE 5999 AP- SCHEME FOR REAR GEARBOX CASE FASTEN-
PLICATION AREA ING SCREW TIGHTENING SEQUENCE
Clean thoroughly distribution gearbox case (1) and Reassemble case to the crankcase.
the engine crankcase. Tighten the fastening screws in the same positions
Cleaning the surface to be sealed is necessary and they had prior to being taken off, then fasten the
unavoidable in order to ensure optimum seal. screws to the specified torque.
Apply sealant LOCTITE 5999 on the case so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
An excessive amount of sealant tends to come out on
passages.
be mounted immediately (within 10 -- 20 minutes). Valve timing
Figure 124
70211
Mark, with a felt--tip pen, the tooth of drive gear (1)

mounted on drive shaft (2), the side surface of which
bears a stamped notch (→) for timing.
EW--3--66
84107 84112
Turn drive shaft (4) and distributing shaft (2) in such Mount the injection pump body (1) in the gearbox case
a direction that when mounting driven gear (1) on the seat (4), then secure it by means of the four symmetri-
distributing shaft, the stamped marks on gears (1 and cally arranged screws (two of which – (2) and (3) –
3) correspond to each other. within sight).
Figure 126
70213
Tighten gear (2) fastening screws (1) to distributing
shaft (3), then fasten them to the specified torque.
Injection pump – 1st phase
Timing
84071 84108
Bring cylinder 1 to the top dead centre. This condition Force--fit gear (1) transmitting the motion to the
occurs when pin (1) (shown by an arrow) is housed pump, then fasten nut (2) by hand.
in the seat available on distributing shaft drive gear
(2).
EW--3--67
Flywheel cover case Figure 131

Figure 130
86474
86473
SCHEME FOR SEALANT LOCTITE 5999 AP- SCHEME FOR FLYWHEEL COVER CASE
PLICATION AREA FASTENING SCREW TIGHTENING SEQUENCE
Clean thoroughly the attaching surfaces of flywheel Fit case (1) back to the crankcase, tighten the fasten-
case (1) and distribution gearbox case. ing screws in the positions they had prior to being
Cleaning the surface to be sealed is necessary and taken off, then fasten them to the specified torque.
unavoidable in order to ensure optimum seal. Screws:
Apply sealant LOCTITE 5999 on the case (1) so as to - M12 x 1.75 x 100 80 ± 10 Nm
make a bead with a diameter of a few millimetres. - M16 x 1.50 x 80 200 ± 20 Nm
The bead must be smooth (no lumps) and free from - M12 x 1.75 x 78 80 ± 10 Nm
An excessive amount of sealant tends to come out on Figure 132
passages.
be mounted immediately (within 10 -- 20 minutes).
70216
Apply part (5) of tool 380000983 on drive shaft rear
shank (6), secure it by means of screws (4) and
force--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--3--68
ENGINE FLYWHEEL Figure 135

Figure 133
84111 84075
Check the clutch disc supporting surface and turn it if Apply tool 380000990 (2) to the flywheel cover case
scoring is detected. (1) to stop engine flywheel (3) rotation.
Tighten screws (4) fastening engine flywheel (3) to
the drive shaft.
NOTE -- The rated thickness of the engine flywheel
is 70,5 mm.
Replacing the engine flywheel ring gear

Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 133) by using a
normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter Figure 136
must face the engine flywheel.
Figure 134
84114
Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: angle--tighten to 60° ± 5°.
84076
Screw down two pins (2) of adequate length into the

IMPORTANT -- Angle tightening is carried out by
shaft holes (3), then remove the engine flywheel (1)
means of tool 380001001.
by means of suitable harnesses and a hoist.
EW--3--69
Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 140
Figure 137
84115 70220
Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 138
Figure 141
84116
Apply sealant (1) as shown in the figure, then put on
small cover (2), then tighten screws to the specified 70221
torque.
Apply a new seal ring (2) onto water pump (1).
Figure 139
Figure 142
84072
Unscrew cover (2), take out timing pin (1), turn it up-
side down, insert it again in such a way that the pump
shaft is not locked, then screw cover (2) again.
70222
IMPORTANT -- Always check the direction of in- Mount water pump (1). Fasten screws (2) and tighten
sertion of the timing pin. them to the specified torque.
EW--3--70
70223 70225
Take seal ring (2) off front cover (1), clean thoroughly Apply part (5) of tool 380000983 on drive shaft front
the attaching surface and apply sealant LOCTITE shank (6), secure it by means of screws (4) and force--
5999 onto the same. fit the new seal ring (3) onto the same. Position part
(1) on part (5), then screw nut (2) to fully mount seal
ring (3) in front cover (7).
Mounting the oil sump
Figure 146
Figure 144
70224 86517
Clean thoroughly the surface of front cover (2) attach- Fit the plate (3), the suction rose (5).
ing base, then mount front cover. Draw up the lock screws (1), (2) and (4) and tighten
Fasten screws (1) and tighten them to the specified to the prescribed torque.
torque.
EW--3--71
86475
84117
Place gasket (1) on oil sump (2). Force--fit pulley (3) with damper flywheel (4) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (1) and (5) to the front cover by
means of screws (2) and (6) and tighten them to the
specified torque.
Figure 148
Mounting the water / oil heat exchanger

Figure 150
86468
70224
Mount oil sump (1) and apply plate (3) on the same.
torque.
Screws:
- M10 x 1.50 x 90 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 190 70 ± 5 Nm
- M10 x 1.50 x 125 70 ± 5 Nm
84175
Mount the following items on the crankcase: a new

gasket (1), heat exchanger (2), a new gasket (3), and
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Fit the new oil filter cartridge.
EW--3--72
Figure 151 Cylinder head

Removing the valves
Figure 153
84177
84179
Position alternator support (1) in such a way that pins
(3 and 4) are placed against the engine crankcase. Valves can be removed by means of tool 380000987
Fasten screws (2) and tighten them to the specified (1) by pressing slightly on collar (3) so that lock cones
torque. (2) can be removed by compressing springs (4). Then
remove collar (3) and springs (4).
Repeat the operation on all valves.
84180
Take off oil seals (1) fitted to the valve stems.

84178 To remove the valves, properly turn the head upside
Fit alternator (1) back to alternator support (3). down.
Fasten screws (2) without torque--tightening them.
Fit automatic belt stretcher (4) back to alternator sup-
IMPORTANT -- Mark the exhaust and intake
port (3).
valves prior to removing them.
EW--3--73
Figure 155 Checking the cylinder head water seal

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

water--repellent sealant on the sealing surface of
the same.
INTAKE EXHAUST If leaks are detected from the cylinder head, the latter
84181
must be replaced.
In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are Figure 158
equipped with a supplementary notch (1) obtained on
the stem for intake valves.
Figure 156
84184
The rated thickness A of the cylinder head is 95 ± 0,25

mm; maximum allowed metal removal must not ex-
ceed thickness B by 0.13 mm.
84182
Remove the thermostat unit (2) and brackets (1) and IMPORTANT -- After reconditioning, check valve
(3). hollow and recondition, if necessary, the valve
Checking the cylinder head supporting surface seats to obtain the prescribed hollow.
Figure 157
VALVES
Figure 159
EXHAUST INTAKE
VALVE VALVE
84183
The plane of the supporting surface of head (1) to cyl-

inder cluster is checked by means of a ruler (2) and
a thickness gauge (3).
The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
84185
If greater values are found, reface the cylinder head
according to the values and instructions given in the MAIN DATA OF INTAKE AND EXHAUST VALVES
next figure.
EW--3--74
Valve descaling, check and grinding VALVE GUIDE

84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns. INTAKE EXHAUST
Reface, if necessary, the valve seats by means of
grinder 380000975, by removing as less material as 84046
possible. Use a bore gauge to measure the valve guide inner

Figure 161 diameter, which must be equal to the value shown in
the figure.
84187
Use a micrometer (2) to measure valve stem (1), VALVE SEATS

which must be equal to 7.96 to 7.98.
Valve seat reconditioning -- replacement
Checking the play between the valve stem,
Figure 164
valve guide and valve centring
Figure 162
84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). If slight burns or scoring are
parator (1) placed as shown. Assembling play must found, proceed with reconditioning by means of tool
be equal to 0.039 to 0.079 mm. 380000975 (1) according to the inclination values
Check, by making valve (2) rotate, that the centring shown in Figure 165.
error is not greater than 0.03 mm.
EW--3--75
Figure 165
INTAKE EXHAUST
84190
VALVE SEAT DIMENSIONS
Figure 166
EXHAUST INTAKE
84191
VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 164) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 75301453, according to the values shown in Figure 165.
EW--3--76
Figure 167 MOUNTING THE CYLINDER HEAD

Figure 169
84180
Lubricate the valve stem and insert into the respective

valve guide according to the position marked upon
disassembling.
84192 Mount seal rings (1) onto the valve guide.
Figure 170
After the reconditioning operations, verify, by means
of base 380001000 (2) and comparator 380001004
(1), that valve hollow (3) corresponds to the specified
value.
VALVE SPRINGS
Figure 168
84179
Position spring (4) and upper collar (3) on the cylinder

head: use tool 380000987 (1) to compress spring (4)
and link the parts to the valve by means of lock cones
(2).
Reattaching the cylinder head
Figure 171
84193
MAIN DATA FOR INTAKE AND EXHAUST VALVE

SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of tool 380000976. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below. 84113
Verify that the cylinder head attaching plane and the

crankcase attaching plane are both clean.
Height Under a load of Do not spoil the cylinder head gasket.
mm N
H (free) 63.50 No load IMPORTANT -- Prior to reusing the cylinder head
H1 49.02 P1 329 fastening screws, verify that they do not show
H2 38.20 P2 641 traces of wear or deformations; otherwise, replace
them.
EW--3--77
84194
84196
Mount the cylinder head on the crankcase by fasten-
ing screws (1) without torque--tightening them. MAIN DATA OF ARBOUR--ROCKER ARM
Verify that the arbour/rocker arm matching surfaces
Figure 173
do not show excessive wear or damages.
Figure 176
84209
Prior to inserting the pushrods, verify their state of

preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must 84197
not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in- Verify that the tappet adjusters are unscrewed to pre-
take and exhaust valves are identical and, therefore, vent the latter from crawling on the rods when the
they are interchangeable. rocker arm assembly (1) is mounted. Mount the
rocker arm assembly made up of the arbours and
Rocker arm assembly rocker arm support, then secure them to the head
Figure 174 without torque--tightening screws (2).
Figure 177
84195
PARTS MAKING UP THE ROCKER ARM ASSEM- 84198

BLY: Fasten the head screws (1) according to the instruc-
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws tions given Figure 178.
EW--3--78
Figure 178 Mounting the injectors

Figure 180
84199
Scheme of cylinder head fastening screw tightening

sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201
screw M12 x 1.75 x 70 [ ] 50 Nm ± 5 Nm;

s
screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; Mount a new seal ring (2) lubricated with petrolatum
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; and a new seal washer (3) on injector (1).
- 2nd phase: angle tightening: 90° Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.
- 3rdphase: angle tightening only for screws 140
and 180 mm long: 90°.
84200
Ad just the play between the rocker arms and the
valves by means of an Allen wrench (2), box wrench 84202
(3) and thickness gauge (1). Mount the injector feeding pipe assembly (1).
The operation play is: Mount the pipes for fuel discharge (2) from injectors,
-- intake valves: 0,25 ± 0,05 mm by using gaskets (3) and by tightening screws (4).
-- exhaust valves: 0,50 ± 0,05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
Symmetric cylinders are 1--6, 2--5 and 3--4.
FIRING ORDER 1--5--3--6--2--4
Adjuting cylinder
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
EW--3--79
- Mount tappet covers (6); - mount the injector feed pipes to injection pump
(9), then secure brackets (2), (5) and (15) fasten-
- mount intake manifold unit (1);
ing the pipe assembly onto the cylinder head;
- connect the engine oil vapour recovery pipe to - mount injection pump lubricating pipes (10);
blow--by (4);
- mount oil level check pipe (11);
- mount injection pump (9);
- mount L.D.A. system piping (3);
- mount fuel filter support (13);
- mount quick coupling pipes (8) and (14) by follow-
- mount fuel filters (12); ing the indications given in Figure 183.
Figure 182
84064
EW--3--80
70126
Act on fork (1) as shown in the figure (detail A), then 86478
remove the adapter. To avoid deformations, bring fork
(1) back to the locking position (detail B) after the - Mount starter motor (3).
adapter has been removed.
Figure 184
Figure 186
86479
- Mount thermostat unit (1) to cylinder head (3) by

86465 torque--tightening screws (2).
- Mount exhaust manifold (3). - Fit the water temperature sensor (4) tightening
- Fit bracket (2) with harness (1). this with the torque wrench.
EW--3--81
84082
Remove injectors (2) by means of tool 380000982 (1)

and take them off the cylinder head.
86481
Mount Poli--V belt (1) on fan pulley, drive shaft pulley,

guide pulleys, water pump and on alternator; then,
stretch the belt by acting on automatic belt stretcher
(2).
Reassembling
Figure 190
REPLACING THE INJECTORS
Removal
Figure 188
84201
84206
Place the vehicle in safe conditions. Mount a new seal ring (2) lubricated with petrolatum
Lift the engine compartment cover, disconnect the and a new seal washer (3) on injector (1).
battery cables and proceed as follows: Mount the injectors on their seats on the cylinder
- disconnect engine oil vapour recovery pipe (2) head, then tighten them by means of a torque wrench.
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
EW--3--82
Mount new seal rings (1) on fuel manifolds (2). Reassemble the tappet cover.
Connect the manifolds to the injectors, by tightening Re--connect the engine oil vapour recovery pipe to the
the fastening nuts to a torque of 50 Nm. blow--by.
Figure 191
84208
EW--3--83
ADJUSTING THE TAPPETS ROCKER ARM REMOVAL/REASSEMBLING

Figure 192 Removal
Figure 193
84200
84081
Ad just the play between the rocker arms and the Loosen tappet adjuster fastening nuts (3), then un-
valves by means of an Allen wrench (2), box wrench screw adjusters (2).
(3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem-
The operation play is: bly (1) made up of the rocker arm support and ar-
-- ± 0,05 mm bours, then take off valves.
– intake valves: 0,25 ± 0,05 mm Reassembling
-- exhaust valves: 0,50 ± 0,05 mm. Verify that the tappet adjusters are unscrewed to pre-
Take the cylinder where clearance must be adjusted vent the latter from crawling on the rods when the
to the bursting phase; its valves are closed while bal- rocker arm assembly is mounted.
ancing the symmetric cylinder valves. Mount the rocker arm assemblies made up of rocker
Symmetric cylinders are 1--6, 2--5 and 3--4. arm support and arbours, then secure them to the cyl-
FIRING ORDER 1--5--3--6--2--4 torque of 36 Nm.
Adjuting cylinder Ad just the tappets as described above.
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
VALVE TIMING
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 194
84210
EW--3--84

S
SECTION 4
RECHARGE AND START--UP
INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . EW--4--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--4--5
Quick diagnosis . . . . . . . . . . . . . . . . . . . . EW--4--3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . EW--4--5
Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . EW--4--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--4--6

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

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

EW--4--5
ALTERNATOR
BOSCH NCBI 28 V 35--70 A
Quick diagnosis
Fault Possible causes Remedy
No recharge 1. Interruption of recharge circuit Check the recharge circuit con-

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

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

minals and cable terminals of
batteries, starter motor and al-
ternator
2. Voltage regulator not in wor- Replace the component
king order
3. Earth fault Check earth connections
EW--4--6
Bosch NCBI 28 V 35--70 A

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

DELIVERY REGULATOR

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REPAIR MANUAL FOR ENGINES

Edition – June 2003

Progressive page number for each group

Group number (if any)

This symbol regards safety.

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

Section 2 -- Engine F4BE0484E overhaul EW--2--1

Section 3 -- Overhaul of F4BE0684B -- F4BE0684D engines EW--3--1

Section 4 -- Recharging and start--up EW--4--1

Main engine operating anomalies:

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

1 ENGINE WON’T START

Thermal starter in working order Replace.

Injection pump timed Verify correct timing as described in the relevant

Injectors in working order Check operation and adjust.

Prescribed compression ratio Overhaul the engine or make repairs only on

Fuel filters in working order Replace.

Fuel tank supplied correctly Refuel.

Water pump in working order Overhaul or replace the unit.

Thermostat in working order Replace.

Valve timing correct Check and perform correct timing.

Injection pump timed Check correct timing as described in the relevant

Cylinder head gasket in working order Replace.

Fan in working order Replace.

3 ENGINE LACKS POWER AND WORKS

Thermostat in working order Replace.

Fuel pump in working order Replace.

Injectors in working order Check operation and adjust them.

Injection pump timed Check correct timing as described in the relevant

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

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

Turbocharger in working order Repair or replace the unit.

4 ENGINE EXHAUST SMOKE BLACK OR

Air filter in working order Replace.

Thermal starter in working order Replace.

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

Injection pump timed Check correct timing as described in the relevant

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

Prescribed compression ratio Check by means of a Motometer 75301430 tool

5 ENGINE EXHAUST SMOKE GREY (VERG-

The thermostat comes into operation correctly Replace.

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

Injection pump timed Check correct timing as described in the relevant

Coolant level correct Possible flow of coolant into the combustion

6 ENGINE EXHAUST SMOKE LIGHT BLUE

7 ENGINE KNOCKS IRREGULARLY

Fuel tank filled Refuel and drain (if necessary).

Fuel filters in working order Replace.

Feeling circuit in working order Check the circuit and drain.

Regular idle speed Adjust.

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

Intact valves Replace the valves.

9 ENGINE EXCEEDS MAX. REVS NUMBER

10 EXCESSIVE OR INSUFFICIENT OIL

11 EXCESSIVE FUEL CONSUMPTION

Air filter in working order Replace.

Correct injector adjustment Check operation and adjust them.

Correct injection pump adjustment Check and bench--adjust.

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