F2cfe613 Fjbfe613

TIER 4i C SERIES
Industrial application
F2CFE613 - F3BFE613
Technical and Repair manual

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

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

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

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

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

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

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

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

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

illustrations included.
Publication edited by
FIAT Powertrain Technologies
Mkt. Advertising & Promotion
Viale dellIndustria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P2D32C009 E - 1a Ed. 11.2011
TIER 4i C SERIES 1
TIER 4i C SERIES
F2CFE613 Part 1
F3BFE613 Part 2
MALFUNCTION DIAGNOSIS Part 3
DENOX SYSTEM Part 4
Print P2D32C009 E Base - 11/2011

2 TIER 4i C SERIES
Base - 11/2011 Print P2D32C009 E

TIER 4i C SERIES 1
Introduction
Page
PREFACE TO USERS GUIDELINE MANUAL . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
CONVERSIONS BETWEEN THE MAIN UNITS

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

AND FOOTNOTES . . . . . . . . . . . . . . . . . . . 10

2 TIER 4i C SERIES

TIER 4i C SERIES 3
PREFACE TO USERS GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assemblys
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating
specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating
specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct
instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such
operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings
Danger for persons

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

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

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

4 TIER 4i C SERIES
Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer

TIER 4i C SERIES 5
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

6 TIER 4i C SERIES
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

TIER 4i C SERIES 7
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.

8 TIER 4i C SERIES
Bonding and screening

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

d. DISTANCE ! 0

TIER 4i C SERIES 9
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

10 TIER 4i C SERIES
KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

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

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

F2CFE613 1
Part 1
F2CFE613
Section
General specifications 1
Main engines diagrams 2
Electrical equipments 3
Maintenance planning 4
Removal and installation of main engine components 5
Engine overhaul 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix

2 F2CFE613

F2CFE613 3
MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING
Technical Code Commercial Code

F2CFE613G*A030
F2CFE613D*A030 C87 ENT
F2CFE613B*A030

4 F2CFE613
UPDATING
Section Description Page Date of revision

F2CFE613 SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
VIEWS OF THE ENGINE . . . . . . . . . . . . . . . . . . 3

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 6

2 SECTION 1 - GENERAL SPECIFICATIONS F2CFE613

VIEWS OF THE ENGINE

Figure 1
166167
LEFT-HAND SIDE VIEW
Figure 2
166721
RIGHT-HAND SIDE VIEW

Figure 3
166168
FRONT HAND SIDE VIEW

Figure 4
166169
REAR HAND SIDE VIEW

Figure 5
166170
TOP VIEW

CLEARANCE DATA
F2CFE613
Type
G*A030 D*A030 B*A030
Cycle 4-stroke Diesel engine

Fuel feed Turbocharged
Injection Direct
No. of cylinders 6 in line

Bore mm 117
Stroke mm 135
+ + + Total displacement cm3 8700
Compression ratio 16 : 1
Maximum kW 245 269 295

power (CV) 334 366 402
rpm 2150 2150 2150
Max. torque Nm 1430 1540 1640

(kgm) 146 157 168
rpm 1100 1600 1100 1600 1300 1600
Loadless
engine
idling rpm 810
Loadless engine
peak rpm 2200
Intercooler
SUPERCHARGING
Waste Gate
Turbocharger type HX52W

LUBRICATION
Oil pressure Forced by gear pump, relief valve single action

bar (warm engine) oil filter
- idling rpm bar 4
- peak rpm rpm bar 5
COOLING Liquid
Water pump control Through belt
Thermostat
- start of opening C 85 1,5
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

F2CFE613
Type
G*A030 D*A030 B*A030
Cooling circuit (1)

Total capacity -
Lubrication circuit (2)

Total capacity (3) 28 (25)
Periodical replacement:
Oil sump at minimum level 15 (13.5)
Oil sump at maximum level 22 (20)
Fuel tank (4) -
(1) The amounts indicated relate to the standard configuration of the engine only.
Use a water and PARAFLU 11 mixture at 50% also during summer. As an alternative to PARAFLU 11, use a product complying
with SAE J 1034 international standards.
(2) Use lubricants complying with the following international specifications: 15W-40 ACEA E7 / API CI-4, 10W-30 ACEA E7 /
API CI-4 for ambient temperature < -15 C; 10W-40 ACEA E9/API CJ-4 alternatively.
The grade of viscosity to be used in relation to environment temperature can be found in the table in the appendix.
The oil consumption is considered as acceptable up to a quantity equal to 0.5% of fuel consumption.
(3) The quantities shown refer to the first refilling and concern the refilling of engine, oil sump and filter.
(4) Use STANDARD fuel compliant to the EN 590.
Worning Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the
! injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
! by FPT.


F2CFE613 SECTION 2 - MAIN ENGINE DIAGRAMS 1
SECTION 2
Main engine diagrams
Page
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . . . 4
MECHANICAL SUPPLY PUMP . . . . . . . . . . . . . 5
- Normal operating conditions . . . . . . . . . . . . . . 5
- Overpressure condition at outlet . . . . . . . . . . . 5
- Drain conditions . . . . . . . . . . . . . . . . . . . . . . . 5
CP3 HIGH-PRESSURE PUMP . . . . . . . . . . . . . . . 6
HIGH-PRESSURE PUMP - INSIDE STRUCTURE 7
- Operating principle . . . . . . . . . . . . . . . . . . . . . 8
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RAIL (PRESSURE ACCUMULATOR) . . . . . . . . . 10
- Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . 11
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 12
- Oil pressure control valve . . . . . . . . . . . . . . . . 13
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . 14
- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Lock torques . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Installation rule . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . 14
- Replacing oil filter cartridge . . . . . . . . . . . . . . . 15

2 SECTION 2 - MAIN ENGINE DIAGRAMS F2CFE613
Page
- Oil fume recycle (Blow-by) . . . . . . . . . . . . . . . 16

COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 20
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SUPPLY
The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
Figure 1
Return
circuit
Supply
circuit
144843

FUEL SUPPLY DIAGRAM

Figure 2
High pressure
Low pressure
144820
1. High-pressure pump - 2. Fuel filter - 3.Tank - 4. Fuel pre-filter - 5.ECU - 6. Electric injectors - 7.Common Rail -
8. Pressure sensor
After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level.
!
(IT MUST NOT INCREASE).

MECHANICAL SUPPLY PUMP Drain conditions

Gear pump, fitted on the rear side of the high pressure pump
and used to supply it. Figure 5
It is controlled by high pressure pump shaft.
Normal operating conditions

Figure 3
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
72592
situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves through B.
in close position
NOTE The mechanical supply pump cannot be replaced

individually, therefore it cannot be removed from
the high pressure pump.
Overpressure condition at outlet
Figure 4
72593
The by-pass valve (1) cuts in when overpressure is generated

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

CP3 HIGH-PRESSURE PUMP

Pump with 3 radial pistons controlled by the timing gear,
without needing any setting. On the rear side of the high
pressure pump is fitted the mechanical supply pump
controlled by the high pressure pump shaft.
The following work must be carried out on the feed pump / high-pressure pump assembly:
- replacing the drive gear;
- replacing the pressure regulator.
Figure 6
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter -
6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from supply
pump to filter - 9. Mechanical supply pump

HIGH-PRESSURE PUMP - INSIDE STRUCTURE

Figure 7
sec. B-B
sec. C-C
70498
1. Cylinder 2. Three-lobe element 3. Cap intake valve 4. Ball delivery valve 5. Piston 6. Pump shaft
7. Low-pressure fuel inlet 8. Pumping elements supplying fuel ducts
Every pumping unit is composed of: - cap intake valve (3);

- a piston (5) actuated by a three-lobe element (2) floating - ball delivery valve (4).
on the pump shaft (6). The element (2), being floating on
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;

Operating principle
Figure 8
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct -
6. Pressure regulator supply duct - 7. Pressure regulator
Pumping element (3) is oriented to pump shaft (4) cam. the PWM signal received from ECU. During pumping
During intake, the pumping element is supplied through element compression stage, fuel reaches the pressure
supply duct (5). The fuel amount to be sent to the pumping required to open the delivery valve to common rail (2) and
element is set by the pressure regulator (7). The pressure to feed it through outlet (1).
regulator meters fuel flow to pumping element according to

Figure 9 Figure 10
72598 72601
Sec. C C Sec. A A
1. Pumping element inlet - 2. Pump lubrication ducts - 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
3. Pumping element inlet - 4. Main pumping element from pump with high pressure pipe fitting for common rail
supply duct - 5. Pressure regulator - 6. Pumping element
inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief
valve - 9. Fuel drain from regulator inlet
Figure 9 shows low pressure fuel paths inside the path and Figure 10 shows high pressure fuel flow through pumping
highlights: main pumping element supply duct (4), pumping element outlet ducts.
element supply ducts (1 3 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
Pressure regulator (5) establishes the fuel amount to send to
pumping elements; excess fuel is drained out through duct
(9).
5 bar pressure relief valve acts as fuel exhaust manifold and
keeps 5 bar constant pressure at regulator inlet.

Operation RAIL (PRESSURE ACCUMULATOR)

The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 11
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail. 114254
The thereby-generated pressure makes the exhaust valve

open and the compressed fuel reaches the high-pressure 1. Rail - 2. Fuel return - 3.Pipelines to injectors - 4. Fuel
circuit. supply to high pressure pump - 5. Pressure sensor -
6. Overpressure valve
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure The rail volume is of reduced sizes to allow a quick
decreases till the exhaust valve is closed. pressurisation at startup, at idle and in case of high flow-rates.
The pumping element piston goes back towards the bottom It anyway has enough volume as to minimise use of plenum
dead center and the remaining fuel is decompressed. chambers caused by injectors openings and closings and by
the high-pressure pump operation. This function is further
When the pumping element chamber pressure becomes less enabled by a calibrated hole being set downstream of the
than the supply pressure, the intake valve is again opened and high-pressure pump.
the cycle is repeated.
A fuel pressure sensor (5) is screwed to the rail. The signal
The delivery valves must always be free in their movements, sent by this sensor to the electronic control unit is a
free from impurities and oxidation. feed-back information, depending on which the rail pressure
The rail delivery pressure is modulated by the electronic value is checked and, if necessary, corrected.
control unit, through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional Electroinjector
injection pumps, because it does not require setting.
Figure 12
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
114255
1. Fuel return hole - 2. Fuel supply

LUBRICATION DIAGRAM
Figure 13
Dropping oil
Pressure oil
166171

Oil pump Overpressure valve

Figure 14 Figure 16
190 6N
324 9N
43.65
33.5
22.95
22.95
114245 117716
The oil pump (1) cannot be overhauled. On finding any MAIN DATA TO CHECK THE OVERPRESSURE
damage, replace the oil pump assembly. VALVE SPRING
See under the relevant heading for replacing the gear (2) of
the crankshaft.
Figure 15
112327
OIL PUMP CROSS-SECTION

1. Overpressure valve Start of opening pressure 10.1 0.7 bars.
Oil pressure control valve Figure 18

Figure 17
168 9
308 15
63
51
36.4
73542 88819
The oil pressure control valve is located on the left-hand side MAIN DATA TO CHECK THE OIL PRESSURE
of the crankcase. CONTROL VALVE SPRING
Start of opening pressure 5 bars.
Heat exchanger
Figure 19
114246
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4.Oil filter - 5. Oil filter seal

ENGINE OIL FILTER

Figure 20
114247
1. Closure cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tank O-ring - 6. Washer - 7. Washer - 8. Support -
9. Plug M14x1.5 - 10. Plug M38x1.5 - 11. By-pass valve 3.4 bars.
Characteristics Filter by-pass valve

1. Max working pressure: 13 bars Figure 21
2. Working temperature: - 30 C + 120 C
3. By-pass valve opening value: 3,4 0,3 bar
Lock torques
Cap (part 1): 60 5 Nm
Plug (part 9): 30 5 Nm
Plug (part 10): 90 5 Nm
Installation rule
Use threadlock for plug (part 10).
73545
Valve opens quickly at 3,4 0,3 bar pressure.

Replacing oil filter cartridge Figure 24

Dismantling
Figure 22
115878
Move the upper part of the casing thread close to the first
lower thread of the support (the cartridge cover element
should be in contact with the oil outlet duct on the support.
115876 Proceed with tightening the cartridge-casing assembly (1) on
the support (4).
Remove the plug (2).
During this stage both the seal (3) for the oil outlet
Undo the filter casing (1) by a couple of turns and wait for
duct-cartridge element and the casing-support seal (2) will
a few minutes.
gradually be involved.
In this way the remaining oil in the casing starts firstly to drip
Tighten the filter casing to a torque of 65 Nm.
and then to flow smoothly out.
Completely undo the casing and then replace the cartridge.
Figure 25
Refitting
Figure 23
115877
Insert the cartridge in the casing aligning the centering tabs

(2) on the upper plate (1) with the seats.
The cartridge should be pushed into the container until the
action of the attachment system at the bottom of the casing
is overcome. 115879
At the same time, the tabs on the upper plate should slide Tighten the protective cap (1) on the filter casing.
into the housings.

Oil fume recycle (Blow-by)

Part of gas produced by combustion during engine operation leaks through piston elastic ring openings into sump, mixing with
oil fumes in sump.
This mixture, conveyed upward, is partially separated from oil by a device located in timing cover upper part and introduced in
air intake circuit.
The device mainly consists of a rotary filter secured on propeller shaft and by a front cover housing normally closed valves
controlling mixture flow.
Figure 26
Gas with oil contents greater than 10 g/h

Gas with oil contents approx. 0,2 g/h
Condensed oil returning to oil sump
166174

COOLING
Description
The engine cooling system is of the closed-circuit, forced circulation type.
It consists mainly of the following components:
- expansion tank, not supplied (by FPT);
- a heat exchanger to cool down lubrication oil;
- a water pump with centrifugal system incorporated in the cylinder block;
- fan, not supplied;
- a 2-way thermostat controlling the coolant circulation.
Operation
The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the
cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the
thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan.
The pressure inside the system, due to temperature change, is adequately controlled through the expansion vessel.

Figure 27
166172
Water flowing out of the thermostat
Water circulating in the engine
Water flowing into the pump

Water pump Figure 30

Figure 28
TO THE HEATER
TO RADIATOR
TO EXPANSION TANK
FROM THE HEAD
45358
Water leaving the thermostat
144832 Check the thermostat works properly; replace it if in doubt.
CROSS-SECTION OF THE WATER PUMP Temperature of start of travel 85C 1.5C.

Minimum travel 9.5 mm at 95C 2C.
The water pump consists of: rotor, shaft with bearing,
T-gasket and drive pulley with dust shield.
NOTE Check that the pump body has no cracks or water

leakage; if it does, replace the entire water pump.
Thermostat
View of thermostat operation
Figure 29
TO THE HEATER
TO BY-PASS FROM THE HEAD
45357

TURBOCHARGING
The turbocharging system consists of:
- air filter;
- Wastegate turbocharger.
Figure 31
Exhaust gas
Compressed air (hot) 166173
Inlet air
Intake compressed air

F2CFE613 SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
COMPONENTS ON THE ENGINE F2C . . . . . . 3
ENGINE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 4
EDC 7 UC31 CONTROL UNIT PIN OUT . . . . 5
EDC 7 UC31 ELECTRONIC CONTROL UNIT 6
EDC CONTROL UNIT PIN-OUT . . . . . . . . . . . 7
- Sensor connector C . . . . . . . . . . . . . . . . . . . 8
- Electroinjectors . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine coolant temperature sensor . . . . . . . . 10
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 11
- High pressure pump (pressure regulator) . . . . 12
- Flywheel pulse transmitter . . . . . . . . . . . . . . . . 13
- Distribution pulse transmitter . . . . . . . . . . . . . 14
- Oil temperature/pressure sensor . . . . . . . . . . 15
- Air pressure/temperature sensor . . . . . . . . . . 16
- Fuel pressure sensor on rail . . . . . . . . . . . . . . . 17
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Starting motor . . . . . . . . . . . . . . . . . . . . . . . . . 19
EDC SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . 20

2 SECTION 3 - ELECTRICAL EQUIPMENT F2CFE613

COMPONENTS ON THE ENGINE F2C
Figure 1
166175
A. Fuel temperature sensor - B. Engine rpm sensor on camshaft - C. Starter motor - D. EDC 7 control unit - E. Conditioner
compressor - F. Pressure/temperature transmitter - G. Temperature/air pressure sensor - H. Alternator - I. Resistance for
engine warming - L. Connector on engine block for connection with electro injectors - M. Water temperature sensor -
N. Engine speed on flywheel sensor - O. Fuel adjustment valve on high pressure pump

ENGINE CABLE
Figure 2
171599
Sensor code FUNCTION

78247 Fuel injector
85157 Fuel pressure sensor on rail
85153 Engine coolant temperature sensor
85156 Air pressure and temperature sensor
42030 Engine oil pressure sensor
47032 Engine oil temperature sensor
47042 Fuel temperature sensor
48035 Driving shaft sensor
48042 Camshaft sensor
ST Cable routing inside head

EDC 7 UC31 CONTROL UNIT PIN-OUT

Figure 3
119977

EDC 7 UC31 ELECTRONIC CONTROL UNIT
Figure 4
C A
102373
A. Electro-injector connector - B. Chassis connector - C. Sensor connector

EDC CONTROL UNIT PIN-OUT

Electric injector connector A
Figure 5
12 16
6 11
1 5 102374
Colour legend
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
E grey
K pink
Pin Function
1 Solenoid valve for electronic cylinder 5 injection
7 -
8 -
9 -
10 -

Sensor connector C
Figure 6
6 8 16 9 15 22
4
Colour legend 5
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange 1 3 23 30 36 29 102375
E grey
K pink
Pin Function
18 -
9 Engine speed sensor (timing)
10 Engine speed sensor (timing)
11 -
12 Pressure sensor on rail
15 Coolant temperature sensor
16 -
17 -
19 Engine speed sensor (flywheel)
20 -
21 -
22 -
23 Engine speed sensor (flywheel)
24 Engine oil pressure/temperature sensor
25 Air pressure/temperature sensor supply
26 Coolant temperature sensor
27 Engine oil temperature/pressure sensor
29 -
30 -
31 -
33 Air pressure signal from air pressure/temperature sensor
34 Air temperature signal from air pressure/temperature sensor
36 Air temperature signal from air pressure/temperature sensor

Electroinjectors
Figure 7
114255
It is a N.O. solenoid valve.

They are connected to the EDC ECU on connector A.
The resistance of each injector coil is 0.56 - 0.57 Ohm.
The electroinjector can be considered as consisting of 2 parts:
- actuator - atomizer including pressure rod, needle and nozzle;
- control solenoid valve including coil and pilot valve.
The solenoid valve controls atomizer needle lift.
INJECTION START
When coil is energized, lock pin moves upward.
The control volume fuel flows to return duct causing control volume pressure drop.
At the same time, fuel pressure in pressure chamber causes needle uplift and therefore fuel injection in cylinder.
END OF INJECTION
When coil is de-energized, lock pin returns to lock position to look for a force balance such to return to needle close position and
stop injection.

Engine coolant temperature sensor

This N.T.C. type sensor located on the water outlet sump on the engine head left measures coolant temperature for the various
operating logics with a hot or cold engine and identifies injection enrichment requirements for a cold engine or fuel reduction
requirements for a hot engine.
It is connected to electronic center pins 15/26.
Figure 8
104266
Description Cable colour

To EDC center pin 15 (Sensor connector C) K
To EDC center pin 26 (Sensor connector C) Y

Fuel temperature sensor

Specifications
Supplier BOSCH
Max. tightening torque 35 Nm
Figure 9
104267

To pin 18 of EDC control unit (Sensor connector C) O/B
To pin 35 of EDC control unit (Sensor connector C) W/R

High pressure pump (pressure regulator) Figure 10

Pump with 3 radial pistons commanded by timing gear,
requiring no tuning, with rotor supply pump applied on rear
end.
A. Fuel drain outlet fitting to filter support
B. Fuel inlet fitting from ECU heat exchanger
C. Fuel inlet fitting from fuel filter
D. Fuel outlet fitting from supply pump to filter
E. Fuel outlet fitting to rail x
1. High-pressure pump
2. Supply pump
3. Pressure regulator (NO solenoid valve modulated by
ECU with PWM signal).
Pressure regulator
Located at high-pressure pump inlet, on low pressure system,
it modulates the amount of fuel for high-pressure pump supply
based on commands received from ECU.
It mainly consists of parts below:
- trapezoidal-section lock pin;
- valve control pin;
- pre-load valve;
- coils.
A
When no control signal is present, the pressure regulator is
normally open, therefore the high pressure pump is in max 1
delivery condition. B
C
The ECU modulates a PWM control signal to extend or
3
reduce section of fuel supply line to high-pressure pump.
The component cannot be replaced as an individual part, 2
therefore it cannot be removed. D
The quantity of high-pressure supply fuel is metered by a

proportional valve positioned on low-pressure system and it E
is managed by the ECDC 7 ECU.
The delivery pressure to rail is modulated between 250 and
1400 bars by ECU operating on pressure regulator solenoid
valve. 000912t
It is a NO solenoid valve.
Its resistance is 3,2 .
It is connected to ECU pins C5 - C7.

Flywheel pulse transmitter

Specifications
Supplier BOSCH
Max. tightening torque 8 2 Nm
Figure 11
104269

To EDC center pin 19 (Sensor connector C) B
To EDC center pin 23 (Sensor connector C) W

Distribution pulse transmitter

Features
Vendor BOSCH
Torque 8 2 Nm
Resistance 880 920
This induction type sensor located on the camshaft generates signals obtained from the magnetic flow lines that close through
the 6 plus 1 phase teeth of a sound wheel mounted on the shaft.
The electronic center uses the signal generated by this sensor as an injection step signal.
This sensors air gap is NOT ADJUSTABLE.
Figure 12
104269

To EDC center pin 9 (Sensor connector C) W
To EDC center pin 10 (Sensor connector C) R

Oil temperature/pressure sensor Figure 13

This component is identical to the air pressure/temperature
sensor.
It is fitted onto the engine oil filter, in a horizontal position.
It measures the engine oil temperature and pressure.
The measured signal is sent to the EDC control unit which
controls, in turn, the indicator instrument on the dashboard
(low pressure warning lights / gauge).
Pin (EDC) 24/C - 32/C Power supply
Pin (EDC) 27/C Pressure
Pin (EDC) 28/C Temperature
The engine oil temperature is used only by the EDC control
unit.
50324
Sensor external view
Ref. Description Control unit pin Figure 14
1 Ground 24C
2 Temp. Sign. 28C
3 +5 32C
4 Press. Sign. 27C
50323
Linking connector
Figure 15
50344
Wiring diagram

Air pressure/temperature sensor

Ref. Description Control unit pin
This component incorporates a temperature sensor and a
pressure sensor. 1 Ground 25C
It is fitted onto the intake manifold and measures the
maximum supplied air flow rate used to accurately calculate 2 Temp. Sign. 36C
the amount of fuel to be injected at every cycle.
3 +5 33C
The sensor is powered with 5 V.
The output voltage is proportional to the pressure or 4 Press. Sign. 34C
temperature measured by the sensor.
Figure 16
114273
Linking connector
Figure 17
50344
Wiring diagram

Fuel pressure sensor on rail

Installed on one rail end, it measures actual fuel pressure in order to determine injection pressure.
The injection pressure value is used for pressure check and to determine the injection electric command duration.
It is supplied with 5 volts.
It is connected to ECU on pins 12C - 13C - 14C.
Figure 18
114620
Pin
Ref. Description
ecu
1 ECU pin 12C
2 Ground 13C
3 Supply Pressure 14C

Alternator
Supplier MITSUBISHI
Technical features 24V - 90A
Figure 19 Figure 21
144837 116715
Figure 20
Figure 22
144836 116716
Pin Description
S + 30
L Battery recharge light
B- Negative
B+ Positive
IG + 15

Starting motor
Specifications
Supplier DENSO
Type 2280005641
Electrical system 24 Volt
Nominal output 4.5 Kw
Figure 23
114283

EDC SYSTEM FUNCTIONS

The EDC 7 UC31 electronic center manages the following main functions:
Fuel injection
Accessory functions such as cruise control, speed limiter, PTO and the like
Self-diagnosis
Recovery
It also enables:
Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating
Pressure can be adjusted in case of:

- engine brake actuation
- external device actuation (e.g. speed reducer, cruise control)
- serious defects involving load reduction or engine stop.
After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding
mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.
Delivery correction based on water temperature
When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays
are not optimized yet.
Fuel injected also tends to condense on cold metal surfaces.
Fuel dosing with a cold engine is therefore greater than when hot.
Delivery correction to prevent noise, fumes or overloads
Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center
to prevent them.
De-rating
In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

Injection lead electronic control

Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder
to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.
Lead is corrected as required:
- during acceleration
- according to water temperature
and to obtain:
- reduced emissions, noise abatement and no overload
- better vehicle acceleration
High injection lead is set at start, based on water temperature.
Delivery start feedback is given by injection electro valve impedance variation.
Engine start
Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator
pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables
the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn
by the starter motor.
Run Up
When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),
and diagnoses the system.
After Run
At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the
microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom)
memory to make tem available for the next start (Cf. Run Up).
These data essentially consists of:
- miscellaneous settings, such as engine idling and the like
- settings of some components
- breakdown memory
The process lasts for some seconds, typically from 2 to 7 according to the amount of data to be stored, after which the ECU sends
a command to the main relay and makes it disconnect from the battery.
This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before
10 seconds at least after engine cutout.
In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown
memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Repeated procedure interruptions could in fact lead to center damage.
Cut-off
It refers to the supply cut-off function during deceleration.
Cylinder Balancing
Individual cylinder balancing contributes to increasing comfort and operability.
This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each
cylinder, to compensate for injector hydraulic tolerances.
The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information
is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.
NOTE Not present on agricultural versions.
Synchronization search
The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.
If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the
sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection
occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence
and start the engine.


F2CFE613 SECTION 4 - MAINTENANCE PLANNING 1
SECTION 4
Maintenance planning
Page
MAINTENANCE PLANNING . . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Planning of controls and periodical intervention 3
OFF-PLANE OPERATIONS . . . . . . . . . . . . . . . . 5
MAINTENANCE PROCEDURES . . . . . . . . . . . . 6
- Checks and controls . . . . . . . . . . . . . . . . . . . . 6

2 SECTION 4 - MAINTENANCE PLANNING F2CFE613

MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by
common sense and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention
Control (when in use) Frequency
Visual check of engine Daily
Inspection presence of water in fuel filter or pre-filter Daily
Planned maintenance Frequency
Replacement of fuel filter 300 hours (1)
Replacement of fuel pre-filter (where applicable) 300 hours (1)
Replacement of engines oil and filter 600 hours (2) (3) (4)
Replacement of blow-by filter 600 hours
Replacement of belt 1500 hours
Special maintenance Frequency
Inspection and setting of tappet clearance 1500 hours
1) Refers to engines with traditional and automatic tensioning devices

2) Must be performed annually, even if the required number of working hours are not reached
3) Replace lubricants according to the frequency indicated in the REFUELLING table.
4) Only use filters with the following characteristics:
- filtration level < 12 m
- filtering efficiency s > 200.
NOTE The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided
by FTP.

NOTE The engine lubrication intervals apply with the use of Diesel fuel with sulphur content of less than 0.5%.
If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.
Use engine oil: 15W-40 ACEA E7 / API CI-4

10W-30 ACEA E7 / API CI-4 (for ambient temperature < -15 C).
10W-40 ACEA E9/API CJ-4 (alternatively).
NOTE Diesel fuel for low temperatures. Standard EN590 defines different classes of Diesel fuels, identifying the characteristics
of those most suitable for use in low ambient temperatures.
Compliance with the regulations regarding the distribution of fuels suitable for the climatic and geographic conditions
of the various countries is entirely up to the oil companies.
- The engine oil and filters must be changed every 12 months in case of very low annual use or less than 600 hours.
- Premature clogging of the air cleaner is generally due to the operating conditions. The filter should therefore be
renewed whenever clogging is signalled by the sensor regardless of the prescribed time interval, which should in
any case be respected in the absence of any specific indications.
The time intervals given in this plan are merely approximate as they refer to using the engines in an industrial
environment with average use in relation to displacement.

OFF-PLANE OPERATIONS
Every year Before winter

and possibly when a maintenance operation is carried out
Check the antifreeze percentage in the engine cooling water
Every two year

and possibly when a maintenance operation is carried out
Change engine coolant
NOTE Early air filter clogging is usually due to environmental conditions. For this reason, the filter should be changed if clogging
is signalled by the related sensor, regardless of the prescriptions that shall be observed if no specific indications have
been provided.

MAINTENANCE PROCEDURES Top up via the tappet cover cap (2). When filling, remove the
Checks and controls dipstick (1) to facilitate the flow of oil.
Engine oil level check
The check must be executed when the engine is
disconnected and possibly cool.
The engine oil is highly polluting and harmful.
The check can be made using the specially provided flexible
rod (1). In case of contact with the skin, rinse well with water
and detergent.
Figure 1 (Demonstration)
Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
Lubricating system check

The check must be executed both when the engine
disconnected and when it is running.
Verify the presence of any oil leakage or blow-by from the

head, from the engine pan of from the heat exchanger.
145841
The engine oil is highly polluting and harmful.

Draw off the rod from its slot and check that the level is In case of contact with the skin, rinse well with water
within the etched tags of minimum and maximum level. and detergent.
Whether it should be difficult to make the evaluation, Adequately protect the skin and the eyes, operate
proceed cleaning the rod using a clean cloth with no rag in full compliance with safety regulations.
grinding and put it back in its slot. Draw it off again and check
the level. Disposal must be carried out properly, and in full
In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engines
components.
145842

Engine oil change - Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
Figure 3 sick.
Engine oil filter change

Figure 4
119975
We recommend to carry out the oil drainage when the

motor is hot.
Warning: We recommend to wear proper protec-

119976
tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves. Drain the oil as described in the section Changing the engine
oil.
- Place a proper container for the oil collecting under the
pan connected with the drain plug (3).
- Unscrew the plug (3) and then take out the control dip- NOTE Warning: the oil filter contains inside a quantity of
sick (1) and the inserting plug (2) to ease the downflow oil of about 1 kg.
of the lubrication oil. Place properly a container for the liquid.
Warning: avoid the contact of skin with the motor
oil: in case of contact wash the skin with running
water.
The oil motor is very pollutant and harmful.
The motor oil is very pollutant: it must be disposed
In case of contact with the skin, wash with much of according to the rules.
water and detergent.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
NOTE Before refitting the new cartridge, wet seal using
engine oil.
- After draining completely, screw on the plug (3) under Screw the oil filter (1) by hand until it touches the support,
the sump and tighten it to the prescribed torque. then tighten of a turn to the required torque.
- Add the specified quantity of recommended engine oil Refit the plug under the sump, tightening it to the required
through the filler (2) of the tappets cover. torque.
Add the required amount of recommended engine oil
through the filler.
Complete the operation as described in the section
NOTE Use only the recommended oil or oil having the re- Changing the engine oil.
quested features for the corrrect motor function-
ing.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service
warranty is no more valid.

Changing the Blow-by filter Fuel filter change
Figure 5 Figure 7
145886
114018
Unlock screws (2) and remove cover (1). Remove the

centrifugal filter (3) underneath and replace it. During this operation dont smoke and dont use free
flames.
Avoid to breathe the vapors coming from filter.
Figure 6
After filters replacement the supply equipment
! deaeration must be carried out.
Unscrew the fuel filter cartridge (2).

Before fitting the new cartridge, wet seal with fuel oil or
engine oil.
Lock the new one by hand and carefully check that rubber
seal and contact surface are clean and in perfect conditions.
Lock cartridge by hand till contact with support and then lock
it for of a rev. at prescribed tightening torque.
When replacing the filter cartridge (2) do NOT fill

! it.
This operation is banned to avoid impurities
entering into the circuit, which would damage the
injector/pump system components.
Bleed air from the fuel as described below.
Fuel bleeding
Loosen the bleed screw (1) connecting the drainage by a
117692
transparent flexible hose to a suitable container.
Clean the surface of the parts to be joined removing

impurities and oil residuals.
Apply silicon LOCTITE 406 within the check valve (2)
housing (1) and on the Blow-by (3) as shown in the picture.

Figure 8 Use appropriate equipment (5) on the belt tensioner (6)

in the direction shown by the arrow and extract the belt
(4) from the pulleys of the alternator (1), of the coolant
pump (2) and from the idler pulleys (3).
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Further adjustments are not required.
145887 Replacing coolant

Only proceed with the engine stopped and at a low
With the hand pump (2) of the fuel pre-filter (1) pump until
temperature, so as to avoid the risk of burning.
fuel completely free of air bubbles flows from the bleed
screw. - Provide suitable containers to ensure that no coolant is
dispersed into the environment.
After the operation, tighten the bleed screw.
- Loosen the seal elements, remove the sleeves
Start the engine and allow it to run at minimum for a few
connecting the engine circuit to the heat exchanger and
minutes to expel any remaining air.
wait until it has emptied completely. When empty, repair
the circuit making sure that the sleeves are perfectly
Valve lash check a adjustment sealed.
For correct operation, follow instructions contained in
related chapter. - Fill up the circuit.
- Refill the engine and the heat exchanger until complete
top up.
Check of water pump/alternator control belt condition
- With the filler cap open, start the engine and keep it
Figure 9 idling for nearly one minute. This phase facilitates the
cooling liquid air bleed.
- Stop the engine and top up again.
171162
Visually check that belt (4) is not worn out or broken; change
it as described below, if required.
NOTE To be able to work on the engine belt you first

need to remove the protective casing (if applicable)
by unscrewing the screws.


F2CFE613 SECTION 5 - REMOVAL AND INSTALLATION OF MAIN ENGINE COMPONENTS 1
SECTION 5
Removal and installation of
main engine components
Page
DRIVE BELT DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR DISASSEMBLY/ASSEMBLY
PROCEDURE
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WATER PUMP DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THERMOSTAT UNIT
DISASSEMBLY/ASSEMBLY PROCEDURE . . . 6
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE CENTRAL UNIT

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL PUMP DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SECTION 5 - REMOVAL AND INSTALLATION OF MAIN ENGINE COMPONENTS F2CFE613
Page Page
COMMON RAIL DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8 OIL COOLER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ROCKER ARM SHAFT DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10 OIL SUMP DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Intake and exhaust rocker arm
clearance adjustment . . . . . . . . . . . . . . . . . . . 11 BLOW-BY DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 20
INJECTOR DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STARTER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TURBOCHARGER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EXHAUST MANIFOLD DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OIL FILTER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DRIVE BELT Figure 3

DISASSEMBLY/ASSEMBLY PROCEDURE
Disassembly
Figure 1
169281
166178
ASSEMBLY DIAGRAM OF FAN - WATER PUMP -

Use specific tool (1) and operate in the arrow direction to ALTERNATOR DRIVE BELT
remove water pump and alternator control belt (2). 1. Alternator - 2. Electromagnetic coupling -
3. Water pump - 4. Crankshaft
Fit the belt, as shown in Figure.
Assembly
Figure 2
NOTE Belt tensioner is of automatic type; therefore,

further adjusting is not provided after mounting.
169280
Using an appropriate tool (1) on automatic belt tensioner

(3), turn it in the direction shown by the arrow and install the
auxiliary member drive belt (2).
Turn the crankshaft anticlockwise () until the belt is
completely fitted onto the pulley.

ALTERNATOR Figure 6
Disassembly
Figure 4
169280

166178
Figure 7
Use specific tool (1) and operate in the arrow direction to
remove water pump and alternator control belt (2).
Figure 5
169281
169282
Unscrew n 1 M10 (1) and n 1 M8 (3) screws and remove ASSEMBLY DIAGRAM OF FAN - WATER PUMP -
alternator (2). ALTERNATOR DRIVE BELT
Unscrew N 2 M8 screws and remove alternator support (4).
1. Alternator - 2. Electromagnetic coupling -
Assembly
Fit the alternator support, screwing n 2 M8 screws.
Install alternator on support and screw n 1 M10 and n 1 M8
screws. NOTE Belt tensioner is of automatic type; therefore,

WATER PUMP
DISASSEMBLY/ASSEMBLY PROCEDURE NOTE Belt tensioner is of automatic type; therefore,
Disassembly
Drain off the coolant..
Figure 8 Figure 11
169280

166178
Use specific tool (1) and operate in the arrow direction to Turn the crankshaft anticlockwise () until the belt is
remove water pump and alternator control belt (2). completely fitted onto the pulley.
Figure 10
Figure 9
169283
Remove the n 4 M8 screws (1) and take off the water pump
(2). 169281

ALTERNATOR DRIVE BELT
Assembly 3. Water pump - 4. Crankshaft
Install water pump and screw n 4 M8 bolts.
Torque the bolts to 20 - 24 Nm.


THERMOSTAT UNIT ENGINE CENTRAL UNIT

DISASSEMBLY/ASSEMBLY PROCEDURE DISASSEMBLY/ASSEMBLY PROCEDURE
Disassembly Disassembly
Figure 12 Figure 14
114013
Disconnect connections of the engine cable from engine

169284 central unit (2).
Disconnect the fuel pipe (1) between engine central unit and
fuel filter.
To dismount the thermostat (1), proceed as follows:
Figure 15
Figure 13
169285
Unscrew n 5 M8 screws (2) and remove the thermostat

body (1) and its gasket (3);
167115
Unscrew n 8 M6 screws (1) and remove engine central unit

(4).
Assembly Unscrew n 3 M8 screws (2) and remove heat exchanger (3).
Install the complete thermostat body, with new gasket, on Assembly
the head and screw in 5 M8 screws to the specified torque. Install heat exchanger screwing n 3 M8 screws.
Install engine central unit screwing n 8 M6 screws.
Connect fuel pipe between engine central unit and fuel filter.
End the assembly procedure by connecting engine cable on
engine central unit.

FUEL FILTER FUEL PUMP

Figure 16
Figure 18
169286
During this operation dont smoke and dont use

free flames.
Avoid to breathe the vapours coming from filter.
169830
Disconnect sensor connection (1).

Disconnect fuel pipes (2).
Figure 17 Using the appropriate tool unscrew fuel filter.
Figure 19
169287
Using the appropriate tool unscrew fuel filter (1).

Unscrew n 2 M8 screws (2) and remove fuel filter support
(3).
When replacing the filter cartridge do NOT fill it.

! This operation is banned to avoid impurities
entering into the circuit, which would damage the
injector/pump system components.
Assembly
Fit fuel filter support and screw n 2 M8 screws. 169831
Before refitting the new cartridge, moisten the seal with

diesel or engine oil. Screw the new one on by hand, taking Unlock n 3 M8 retaining screws (1) and remove high
care to check that the rubber seal and the mating surface are pressure pump (2).
clean and in a perfect state of repair.
Screw the cartridge on by hand until it is in contact with the Assembly
mounting and then tighten by 3/4 of a turn to the required
Install high pressure pump screwing n 3 M8.
tightening torque. Bleed the air from the supply system as
Screw the cartridge on fuel filter support by hand until it is in
described in the Fuel bleeding paragraph.
contact with the mounting and then tighten by 3/4 of a turn
Connect the electrical connection to the fuel filter
to the required tightening torque.
temperature sensor.
End assembly procedure by connecting fuel pipes.
End the assembly procedure by connecting fuel pipes.

COMMON RAIL Assembly

Disassembly Figure 22
Remove cylinder head cover and gasket.

Remove cable on head.
Figure 20
169832
Install rail (2) and spacers (3) on cylinder head.

Lock n 3 M8 retaining screws (1) by hand.
The previously removed pipes ca no longer be refit

and must be replaced.
169816
Disconnect n 6 fuel pipelines (1) from injector rail, fuel

supply line (2) of high pressure pump to rail and return line NOTE Be very careful when fitting high pressure fuel pipes.
(3).
Figure 23
Figure 21
169816
Install new pipes on rail and lock fittings by hand.

- supply line (2) of high pressure pump to rail;
169832 - return line (3);
- n 6 fuel pipelines (1) between injectors and rail.
Unscrew n 3 M8 screws (1); remove common rail (2) and
spacers (3). Lock rail to cylinder head retaining screws at required torque.

Figure 24
169833
Lock fittings on rail (A, C) at required torque. NOTE After the assembly procedure, the fuel lines must
Lock fittings on injectors and head (B, C) at required torque. definitely not touch each other so as not to get
damaged because of the high stress due to engine
vibration.
The MINIMUM distance between the individual
TYPE DESCRIPTION LOCK pipes must NOT be LESS than 2 mm.
TORQUE
A M18 x 1.5 40 2 Nm
B M14 x 1.5 35 2 Nm
C M16 x 1.5 40 2 Nm
End assembly procedure by connecting engine cable on head
to injectors and rail sensor.
Fit the valve cover with the related gasket.
After fitting the high-pressure pipelines, during the
! following 20 hours of work, frequently check
engine oil level (IT MUST NOT INCREASE).

ROCKER ARM SHAFT Assembly

Disassembly NOTE Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws have been
Remove cylinder head cover and its gasket. fully unscrewed.
Mount the shaft on the cylinder head using appropriate tool.

Figure 25
Figure 27
169829 70567A
Unlock rocker arm shaft retaining screws (1). Lock screws following the tightening order shown in the
figure.
Figure 26 Figure 28
114025
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and remove Install crosspieces (3) on valve rod.
shaft, remove crosspieces (3) from cylinder head. Apply tool 99360558 (1) to rocker arm shaft (2) and install
shaft on cylinder head.
Remove tool 99360558 (1).

Intake and exhaust rocker arm clearance Figure 30

adjustment
Figure 29
114287
115880
Adjustment of clearance between rocker arms and Fit the head internal electric wire (injectors + pressure
intake/exhaust valve control crosspieces must be performed sensor) and securing it using bands as illustrated in the
with utmost care. Bring to blast phase cylinder to be adjusted; diagram ().
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced.
Symmetric cylinders are 1-6; 2-5 and 3-4.
In order to perform these operations correctly, refer to Figure 31
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
IGNITION ORDER 1-4-2-6-3-5
START AND BALANCE ADJUST

ROTATION VALVES OF CLEARANCE
CLOCKWISE CYLINDER No. OF VALVES 166177
CYLINDER No.
1 and 6 at TDC 6 1 Install cylinder head cover (1) and lock screws (2) at required
120 3 4 torque.
120 5 2
120 1 6 Figure 32
120 4 3
120 2 3
NOTE In order to correctly carry out adjustments above,

it is mandatory to perform the sequence indicated
in the table, checking exact positioning at each
phase by means of pin 99360612.
45363
Torque the lock nut to 34 - 44 Nm Lock screws following the tightening order shown in the
figure.

INJECTOR Figure 36
Disassembly
Remove cylinder head cover and its gasket.
Figure 33
169826
114024
Position the dedicated tool (1) and hook on the injector (2).
Disconnect fuel pipelines (1) from injector rail, fuel supply Figure 37
line (2) of high pressure pump to rail and return line (3).
Unlock rocker arm shaft retaining screws (4).
Figure 34
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and remove
shaft, remove crosspieces (3) from cylinder head.
Figure 35
169828
Drive out the injector (1) complete with bracket and seal (2).
Assembly
Lubricate the injector fastening O-Rings using the

following lubricants: PDE SILIKONFETT 22, NLG
12, PDE LUBRICOMET GR 220 NLG12.
Install the injector comprehensive of bracket and seal in the

seat on the cylinder head.
Tighten screws on injector fixing brackets to 26 Nm.

169827 and must be replaced.
Remove screws (1) from brackets (2) fixing injectors.

Install new pipes on rail and lock fittings by hand.

NOTE Be very careful when fitting high pressure fuel pipes. - supply line (2) of high pressure pump to rail;
- return line (3);
Figure 38
- n 6 fuel pipelines (1) between injectors and rail.
169816
Figure 39
169833

Intake and exhaust rocker arm clearance

Check that the injectors (2) are equidistant from adjustment
! the springs (1). Distance X which separates
them should always be the same.
Figure 41
Lock fittings on rail (A, C) at required torque.

Lock fittings on injectors and head (B, C) at required torque.
TYPE DESCRIPTION LOCK

TORQUE
A M18 x 1.5 40 2 Nm
B M14 x 1.5 35 2 Nm
C M16 x 1.5 40 2 Nm
After fitting the high-pressure pipelines, during the

! following 20 hours of work, frequently check 114287
engine oil level (IT MUST NOT INCREASE).
Adjustment of clearance between rocker arms and
intake/exhaust valve control crosspieces must be performed
NOTE After the assembly procedure, the fuel lines must with utmost care. Bring to blast phase cylinder to be adjusted;
definitely not touch each other so as not to get the valves of this cylinder are closed while the symmetric
damaged because of the high stress due to engine cylinder valves are balanced.
vibration. Symmetric cylinders are 1-6; 2-5 and 3-4.
The MINIMUM distance between the individual In order to perform these operations correctly, refer to
pipes must NOT be LESS than 2 mm. procedure and table below.
NOTE Before refitting the rocker-arm shaft assembly, clearance shown in Characteristic and data tables.
make sure that all the adjustment screws have been - Use special spanner to lock/unlock adjustment screw.
fully unscrewed. - Check that filler gage (3) slides with a low friction.
Figure 40 START AND BALANCE ADJUST

ROTATION VALVES OF CLEARANCE OF
CLOCKWISE CYLINDER No. VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
114025
NOTE In order to correctly carry out adjustments above,
it is mandatory to perform the sequence indicated
Install crosspieces (3) on valve rod. in the table, checking exact positioning at each
Apply tool 99360558 (1) to rocker arm shaft (2) and install phase by means of pin 99360612.
Remove tool 99360558 (1).
Torque the lock nut to 34 - 44 Nm

Figure 42 INTAKE MANIFOLD

Disassembly
Figure 45
115880
Fit the head internal electric wire (injectors + pressure

sensor) and securing it using bands as illustrated in the
diagram ().
169817
Figure 43 Remove engine cable connection from air temperature

sensor (1).
Figure 46
166177
Install cylinder head cover (1) and lock screws (2) at required
torque.
167122
Figure 44
Unscrew n 6 M10 bolts (2).
Remove following components:
- Intake manifold (1);
- Gasket (4);
- Spacer (3);
- Gasket (4).
Assembly
45363 Mount new gaskets, spacer and fit intake manifold.
Screw n 6 M10 screws to 45 - 55 Nm.
End the assembly procedure by connecting engine cable to
Lock screws following the tightening order shown in the air temperature sensor.
figure.

STARTER TURBOCHARGER
Figure 47 Figure 48
169819
Disconnect oil return pipe (1) and oil delivery pipe (2).
169818
Figure 49
Take off n 3 screws (2) and remove the starter (1).
Assembly
Install the starter screwing n 3 screws.
169820
Unscrew n 4 nuts (1).

Remove turbocharger (3) and gasket (2).
Assembly
Mount a new gasket on exhaust manifold; fit the
turbocharger and screw n 4 nuts.
End the assembly procedure by connecting oil pipes.

EXHAUST MANIFOLD OIL FILTER

Figure 50
WARNING: the oil filter contains inside a
quantity of oil of about 1 kg.
Place properly a container for the liquid.
Avoid the contact of skin with the motor
oil: in case of contact wash the skin with
running water.
The motor oil is very pollutant: it must be
disposed of according to the rules.
Figure 53
169821
To dismount the exhaust manifold (1), proceed as follows.

Proceed with the disassembly of the turbocharger:
- disconnect oil return pipe;
- disconnect oil delivery pipe;
- unscrew n 4 nuts;
- remove turbocharger and gasket.
Figure 51
119976
Use tool 99360252 to slacken the oil filters (1).
Figure 54
169822
Unscrew n 24 M10 screws (2).

Remove exhaust manifold (3) and n 6 gasket (1).
Assembly
Mount 6 new gaskets and fit exhaust manifold.
Screw n 24 M10 screws.
pre-tightening: 35 - 45 Nm tightening: 65 - 75 Nm.
End the assembly procedure by fitting new gasket and
turbocharger.
Screw n 4 nuts; connect oil pipes.
Figure 52
169823
Remove bracket fixing oil delivery pipe to turbocharger

unscrewing n 3 M8 screws.
60581 Unscrew n 2 M8 screws (1); remove oil filter body (2) and
Lock screws following the tightening order shown in the gasket (3).
figure.

Assembly OIL COOLER

Fit oil body filter with new gasket; screw n 2 M8 screws to
a torque of 65 Nm. Install bracket fixing oil delivery pipe. Disassembly
NOTE Before refitting the new cartridge, wet seal using NOTE Under oil cooler place a container for engine
engine oil. coolant drain.
Screw the oil filter by hand until it touches the support, then Figure 55
tighten 3/4 of a turn to the required torque.
Add the required amount of recommended engine oil
through the filler.
169824

Remove oil cooler body (4) and its gasket (2).
Separate oil cooler (3) from oil body cooler.
Assembly
Assemble the oil cooler body with oil cooler, screwing in 2
M8 screws.
Mount the oil cooler complete with new gasket to the
crankcase housing.
Torque n 16 M8 bolts to 56- 70 Nm.

OIL SUMP Figure 58

Disassembly
Figure 56
114031b
Unscrew the screws and take out the suction strainer (1).
Assembly
Figure 59
119975
Place a proper container for the oil collecting under the sump
connected with the drain plug (3).
Unscrew the plug (3) and then take out the control dipstick
(1) and the inserting plug (2) to ease the down flow of the
lubrication oil.
The oil motor is very pollutant and harmful. In case

of contact with the skin, wash with much water and 170127
detergent.
Protect properly skin and eyes: operate according Before assembling the suction rose, it is necessary to seal the
to safety rules. Dispose of the residual properly contact area (1) between basement, flywheel casing and
following the rules. front cover with LOCTITE, following the herein instructions.
Clean the surfaces of the parts to be joined removing
Apply silicon LOCTITE 275 (1) as shown in the picture.
Figure 57 The diameter of the sealing string must be 1.5 0.5/0.2 mm.
Fit oil suction strainer.
Tighten n 4 M12 bolts to 22 - 27 Nm.
Figure 60
114029
114029
Unscrew the screws (1) and take out the engine oil sump (3) Fit seal on oil sump (3), fit spacer (2) and install sump on
together with the spacer (2) and gasket. engine block locking screws (1) at required torque.

Figure 61 BLOW-BY
Disassembly
Figure 62
167126 169825
Lock plug (1) under oil sump at predefined tightening torque. Remove n 3 M6 screws (1) and blow-by box (2).
Pour oil in prescribed quantity and quality in engine through
filler (2) of tappet cover. Figure 63
NOTE Use only the recommended oil or oil having the

requested features for the correct motor
functioning.
features.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
114286
Unscrew n 6 M8 screws (2) and remove timing cover (1).
Figure 64
114285
Unscrew n 3 M6 screws (2) and remove centrifugal filter (1).

Assembly
Install centrifugal filter on tune wheel and lock n 3 M6 screws
at required torque.
Install timing cover and lock n 6 M8 retaining screws at
required torque.
Figure 65
117692
Apply silicon LOCTITE 406 within the check valve (2)

housing (1) and on the Blow-by (3) as shown in the picture.
Figure 66
169825
Install blow-by body (2) with related seal and lock screws
n 3 M6 (1) at required torque.


F2CFE613 SECTION 6 - ENGINE OVERHAUL 1
SECTION 6
Engine overhaul
Page
ENGINE DISASSEMBLY ON BENCH . . . . . . . . 3
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 8
ENGINE REMOVAL AT THE BENCH . . . . . . . . 8
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 9
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 9
- Checks and measurements . . . . . . . . . . . . . . . 9
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 10
- Replacing cylinder liners . . . . . . . . . . . . . . . . . 12
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Measuring main journals and crank pins . . . . . 14
PRELIMINARY MEASUREMENT OF MAIN AND BIG

END BEARING SHELL SELECTION DATA . 15
- Selecting the main and big end bearing shells . 16
- Replacing the timing control gear and

the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Checking main journal installation clearance . . 22
- Checking crankshaft end float . . . . . . . . . . . . . 23
PISTON-CONNECTING ROD ASSEMBLY . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Conditions for correct gudgeon pin-piston

coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Mounting the connecting rod - piston assembly 27
- Mounting the piston rings . . . . . . . . . . . . . . . . 27
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . 29
- Fitting the connecting rod-piston assembly into the

piston liners . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Piston protrusion check . . . . . . . . . . . . . . . . . 30

2 SECTION 6 - ENGINE OVERHAUL F2CFE613
Page Page
- Checking assembly clearance of big end pins . 31 - Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 47

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 31 TIMING CAMSHAFT AND FLYWHEEL WITHOUT
TOOL 99395223 . . . . . . . . . . . . . . . . . . . . . . . 47
- Dismounting the valves . . . . . . . . . . . . . . . . . . 31
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 47
- Checking the planarity of the head on the cylinder
block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 50
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 - Intake and exhaust rocker arm
clearance adjustment . . . . . . . . . . . . . . . . . . . 51
- Removing deposits and checking the valves . . 32
ENGINE ASSEMBLY COMPLETION . . . . . . . . . . 53
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Replacing of valve guides . . . . . . . . . . . . . . . . 33
- Replacing - Reaming the valve seats . . . . . . . . 33
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . 34
- Intermediate gear pin . . . . . . . . . . . . . . . . . . . 34
- Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . 34
- Replacing the bushings . . . . . . . . . . . . . . . . . . 34
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Checking cam lift and pin alignment . . . . . . . . 35
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Use beater 99360505 to change bushings . . . 37
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Fitting the valves and oil seal ring . . . . . . . . . . 37
ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- High pressure pump installation . . . . . . . . . . . 43
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 43
- Engine flywheel installation . . . . . . . . . . . . . . . 43
- Camshaft installation . . . . . . . . . . . . . . . . . . . . 44
TIMING CAMSHAFT AND FLYWHEEL
USING TOOL 99395223 . . . . . . . . . . . . . . . . 45
- Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 45

ENGINE DISASSEMBLY ON BENCH Figure 3
Handle all parts with great care.

Never put your hands or fingers between one part
and another.
Wear suitable personal protective equipment such
as a visor, gloves and safety shoes.
Cover all electrical components before washing with

high-pressure water jets.
Before securing the engine to the rotary stand 99322230,
remove: the electrical cable of the engine by unplugging it from
the control unit and from all sensors transmitters to which it
is connected.
Proceed to remove all those parts that can interfere with the
assembly of the brackets as shown hereunder.
Figure 1
166178
If air conditioner compressor is installed, cut belt as it must not

be reused.
Use specific tool (1) and operate in the arrow direction to
remove water pump and alternator control belt (2).
Figure 4
166176
Under heat exchanger (2) place a container for engine coolant

drain.
Unlock retaining screws and remove heat exchanger assembly
(2).
Remove oil outlet line (1).
Install engine on rotary stand 99322230.
Drain sump oil in specific container.
Figure 2
166179
Remove parts below:

- if present, air conditioner compressor;
- water pump (3);
- flanged pipe;
- fixed belt tensioner (4);
- thermostat assembly (2).
- complete damping flywheel with pulley (5);
166177
- alternator (1);
Unlock retaining screws (2) and remove head cover (1) to
reach injector and rail wiring. - automatic belt tensioner (6).

Figure 5 Figure 7
166340
Remove parts below:

166329
- fuel filter (3);
- oil level rod (2);
Apply extractor 99340051 (2) and remove seal (1). - intake manifold (1).
Unlock screws and remove front cover (3).
Figure 8
Figure 6
114013
Disconnect line (1) from high pressure pump support and

remove ECU (2) with support below.
Figure 9
166330
Remove parts below:

- oil filter (1);
- oil inlet line (2);
- turbocompressor (4) and exhaust manifold (3). 114015
On opposite engine side, remove start-up motor. Remove screws (1) and blow-by box (2).

Figure 10 Figure 12
114014
114018
Disconnect fuel lines (2), unlock retaining screws and remove
Unlock screws (2) and remove cover (1). Remove centrifugal high pressure pump (1). Remove fuel filter support (3)
filter (3) below. complete with pipeline.
Figure 13
Figure 11
114020
Unlock screws (1) and remove thrust plate (2).

Use specific spanner to unlock screws (4) and remove relay
gear (5).
Remove high pressure pump mount flange (3).
Figure 14
114019
Use specific spanner to unlock screws (2) and remove gear (3)
complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure
pump.
Remove rpm sensor (1).
NOTE In case removal of gear (5) is difficult, release high

pressure pump screws with light beater strokes on 114009
control shaft and remove gear (5).
Use specific tool lock engine flywheel (2) rotation, unlock
retaining screws (1) and remove engine flywheel.

Figure 15 Figure 18
45257 114022
Apply extractor 99340054 (2) and remove seal (1). Unlock screws (1) and remove flywheel box (2).
Figure 19
Figure 16
114023
114029 Remove screws (2) and double gear (3).

Remove retaining screw (5) and connecting rod (4).
Unlock screws (1) and remove engine oil sump (3) complete
with spacer (2) and seal. Remove oil pump (1).
Figure 17 Figure 20
114024
114031b - Unlock rocker arm shaft retaining screws (4).

Unlock screws and remove suction rose (1). - Disconnect fuel pipelines (1) from injector rail, fuel supply
line (2) of high pressure pump to rail and return line (3).

Figure 21 Figure 23
114025 45266
Apply tool 99360558 (1) to rocker arm shaft (2) and remove Remove camshaft and remove cylinder head retaining screws.
shaft, remove crosspieces (3) from cylinder head.
Use metallic ropes to lift cylinder head (1) and remove seal (2).
Figure 24
Figure 22
117690
Clean the surface of the parts to be joined removing impurities

and oil residuals. Apply silicon LOCTITE 5970 (1) to the cover
(2) as shown in the picture.
The diameter of the sealing string must be 1.5 0.5/0.2.
114027
Remove retaining brackets (3) and remove injectors (4). Fit the front cover within 10 minutes after applying
the sealer.
Remove retaining screws (1) and remove rail (2).

ENGINE OVERHAUL Figure 27

ENGINE REMOVAL AT THE BENCH
The following instructions are prescribed on the
understanding that the engine has previously been placed on
the rotating bench and that removal of all specific components
of the equipment have been already removed as well.
The section illustrates therefore all the most important engine
overhaul procedures.
Figure 25
114615
Use adequate hexagonal spanner, unlock screws (1 and 3) and

remove stiffening plate (2) as well as main journals (4).
NOTE Note down the assembly position of the top and
bottom main bearing shells since, if reusing them, they
will need to be fitted in the position found upon
removal.
Figure 28
115881
Rotate the block (1) to the vertical position.
114035
Figure 26 Using tool 99360500 (1), remove the crankshaft (2).

Figure 29
115882 47571
Remove the main bearing shells (1), unscrew the screws and
Untighten screws (2) fixing the connecting rod cap (3) and take out the oil nozzles (2).
remove it. Remove the connecting rod-piston (1) assembly Remove the cylinder liners as described under the relevant
from the upper side. subheading on Replacing cylinder liners paragraph.
Repeat these operations for the other pistons.
After disassembling the engine, thoroughly clean
disassembled parts and check their integrity.
Keep the big end bearing shells in their respective
housings and/or note down their assembly position Instructions for main checks and measures are given
since, if reusing them, they will need to be fitted in the in the following pages, in order to determine whether
position found upon removal. the parts can be re-used.

REPAIR OPERATIONS Figure 32

CYLINDER BLOCK
Checks and measurements
225036
34994
A = Selection class 117 117.012 mm
B = Selection class 117.010 117.022 mm
Internal diameter of the cylinder liners is checked for X = Selection class marking area
ovalization, taper and wear, using a bore dial (1) centesimal
In case of maximum wear >0.150 mm or maximum
gauge 99395687 (2) previously reset to ring gauge (3),
ovalization >0.100 mm compared to the values indicated in
diameter 117 mm.
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
NOTE If dia.117 mm ring gage is not available, use a NOTE Cylinder liners are equipped with spare parts with
micrometer. A selection class.
Figure 31 Figure 33
114035 114037
1 = 1st measuring A = 130.500 to 130.525 mm

2 = 2nd measuring B = 129.510 to 129.535 mm
3 = 3rd measuring C = 130.461 to 130.486
D = 129.475 to 129.500 mm
Carry out measurings on each cylinder liner at three different
The figure shows the outer diameters of the cylinder liners and
levels and on two (A-B) surfaces, to one another
the relative seat inner diameters.
perpendicular, as shown in Figure.
The cylinder liners can be extracted and installed several times
in different seats, if necessary.

CYLINDER LINERS
Figure 34
114038
CYLINDER BLOCK ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS
Figure 35
145836
CYLINDER LINERS MAIN DATA
Selection class A mm 117.000 to 117.012

B mm 117.010 to 117.022

Figure 36
DETAIL A
145837
Figure 37
DETAIL B
145838

Replacing cylinder liners Figure 40

Removal
Figure 38
77812
Check cylinder barrel protrusion with tool 99360334

(1-2-3-4) and tighten screw (1) to 170 Nm.
47577 With dial gauge 99395603 (5) placed on base 99370415 (6)
measure the cylinder barrel protrusion compared to the
Place details 99360706 (1 and 2) and plate 99360724 (4) as cylinder head supporting plane, it must be 0,035 to 0,065 mm
shown in the figure, by making sure that the plate (4) is (figure below); otherwise replace the adjusting ring
properly placed on the cylinder liners. (1, previous figure) fitted with spare parts having different
Tighten the screw nut (1) and remove the cylinder liner (3) thickness.
from the block.
Figure 41
Fitting and checking protrusion
Figure 39
114041
CYLINDER LINER PROTRUSION
16798
Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2); lubricate
lower part of liner and install it in the cylinder unit using the
proper tool.
NOTE The adjustment ring (1) is supplied as spare parts in

the following thicknesses: 0.08 mm - 0.10 mm - 0.12 35012
mm. When the installation is completed, block the cylinder liners

(1) to the block (2) with studs 99360703 (3).

CRANKSHAFT
Figure 43
Upper main journal half bearing
Lower main journal half bearings

144835
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
Figure 44 Figure 45
114043 114044
X. Detail of main journals connections Y. Detail of crank pins connections

Measuring main journals and crank pins Figure 47

Before grinding the crank pins using a micrometer (1),
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.
Figure 46
47536
MEASURING CRANK PINS

During grinding, pay attention to journal and crank pins values
47535
specified previous figures.
MEASURING THE MAIN JOURNALS
NOTE It is advisable to enter the values found in a table NOTE All journals and crank pins must also be ground to
(Figure below). the same undersizing class, in order to avoid any
alteration to shaft balance.
Figure 48
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
MIN.
MAX.
MIN.
MAX.
CRANK PINS 114045

PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:

- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure below at top).
- The first set of digits (four) is the coupling number of the crankcase with its base (Figure below at bottom).
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure below at bottom).
- Each of these digits may be 1, 2 or 3.
Figure 49
CLASS MAIN BEARING HOUSING

NOMINAL DIAMETER
99.000 to 89.009
99.010 to 99.019
99.020 to 99.030
114046

Selecting the main and big end bearing shells

NOTE To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described
hereunder.
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected in The following tables give the specifications of the main and big
classes of tolerance marked by a coloured sign (red-green end bearing shells available as spares in the standard sizes
red/black green/black). (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Figure 50
STD +0.127
red 1.994 to 2.002
red/black 2.057 to 2.065
green 2.002 to 2.010
green/black 2.065 to 2.073
yellow* 2.010 to 2.018
yellow/black* 2.073 to 2.081
STD +0.127
red 2.968 to 2.978
green 2.978 to 2.988
yellow* 2.988 to 2.998
yellow/black* 3.051 to 3061
* Fitted in production only and not supplied as spares

DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure below at top):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins they
refer to (Figure below at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the status
of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the main journals
they refer to (Figure below at bottom).
Figure 51
CRANKPIN
CLASS
NOMINAL DIAMETER
81.915 to 81.925
81.925 to 81.935
81.935 to 81.945
CLASS MAIN JOURNALS

NOMINAL DIAMETER
92.970 to 92.980
92.980 to 92.990
92.990 to 93.000

Selection of main half-bearings (nominal diameter pins)
After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in compliance
with the following table:
Figure 52
STD.
114048
1 2 3
green green yellow
1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green
114055

Selection of main half--bearings (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type required
for this undersizing.
Figure 53
red/black =
mm 3.031 to 3.041
green/black =
mm 3.041 to 3.051
-0.127
green/black =
mm 3.0513 to 3.061
1 2 3
92.843 green/black green/black yellow/black
1
92.853 green/black yellow/black yellow/black
92.853 red/black green/black green/black

2
92.863 red/black red/black green/black

3

SELECTING THE BIG END BEARING SHELLS Figure 54

(JOURNALS WITH NOMINAL DIAMETER)
There are 4 references on the connecting rod casing in the
positions illustrated:
1. Coloured mark for identifying the weight
2. Coloured mark for identifying the diameter grade
3. Positioning stud visible from the front of the engine
4. Progressive number for identifying the connecting rod
NOTE The identification colours of the marks are given in

the table on CONNECTING ROD paragraph..
The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure below).
47557
Figure 55
STD.
1 2 3
Class yellow blue
green
green green yellow

1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green

Selection of connecting rod half--bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings identified
according to the relative table.
Figure 56
red/black =
mm 2.057 to 2.065
green/black =
mm 2.065 to 2.073 -0.127
green/black =
mm 2.073 to 2.081
1 2 3
1
81.799 green/black yellow/black yellow/black

2

3

Replacing the timing control gear and the oil Figure 59

pump
Check that the teeth of the gears are not damaged or worn,
otherwise remove them using the appropriate extractor.
Figure 57
114034
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
144834
NOTE Before fitting the gear, spread Loctite type 603 on

approx. 5 mm wide band on crankshaft, at 30 mm
from contact surface.
After fitting the gear (1) on the crankshaft (2), heat it for ~15
minutes in an oven at temperature not higher than 180C.
Let them cool down after the installation.
Checking main journal installation clearance

Figure 58 Figure 60
114049 114050
Fit the oil jets (2) aligning the dowel with the opening (3) in Place bearing halves (1) on main journals (2).
the crankcase.
Check the installation clearance between the main journals
Position the half-bearings (1) and the thrust washers on the and the relative bearings as follows.
main journal supports as illustrated on CRANKSHAFT
paragraph.

Figure 61 Figure 62
145839 114615
- Clean accurately the parts and remove any trace of oil; - Position the main journal caps (4) and fit the strengthening
plate (2) following the procedure described:
- Fit caps (1), including the half bearings (2) on the relevant
supports. - Tighten the inner bolts and then the outer bolts by hand
starting from main journal 7 and continuing until main
journal 1.
- Tightening the bolts using torque wrench always starting
from main journal 7 and continuing until main journal
1:
1st stage: 140 Nm
2nd stage 60+60
Checking crankshaft end float
Figure 63
47588
End float is checked by placing a magnetic dial gauge (1) on the

crankshaft (2), as shown in the figure.
If the value obtained is higher than specified, replace the rear
thrust half-bearings and repeat this check.

PISTON-CONNECTING ROD ASSEMBLY

Figure 64
47580
PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring with
spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
Figure 65 Figure 66
126311 126312
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).

Figure 67 Conditions for correct gudgeon pin-piston

coupling
Figure 69
49026
Remove the piston pin (1).

If removal is difficult use the appropriate beater.
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.
Figure 68
32618
Measuring the gudgeon pin diameter (1) with a micrometer

(2).

Figure 70
114053
MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0,6 0,15
The dimension is measured on a of 113 mm
Piston rings
Figure 72
Figure 71
16552
16552
Check the thickness of the piston ring (2) using a micrometer Check the clearance between the sealing rings (2) and the
(1). relative piston housings (1) using a thikness gauge (3).

Figure 73 Mounting the connecting rod - piston assembly

Carry out the steps for removal described on
PISTON-CONNECTING ROD ASSEMBLY/Removal
paragraph in reverse order.
Figure 75
3513
The sealing ring (2) of the 1 cavity is trapezoidal. Clearance 117694

X between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3),
so that the sealing ring is half-projected out of the cylinder
NOTE The connecting rod screws can be reused as long
barrel.
as the diameter of the thread is not less than 11.4
mm.
Figure 74
Mounting the piston rings
Figure 76
36134
49029
Check the opening between the ends of the sealing rings (1), To fit the piston rings (1) on the piston (2) use the pliers
using a thickness gauge (2), entered in the cylinder barrel (3). 99360184 (3).
The rings need to be mounted with the word TOP (4)
If the distance between ends is lower or higher than the value
facing upwards. Direct the ring openings so they are
required, replace split rings.
staggered 120 apart.

Figure 77
115884
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from
the front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
Yellow 3308 g - 3338 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
Green 3339 g - 3368 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
Blue 3369 g - 3398 g 85.997-86.005 Green
86.006-86.013 Blue

CONNECTING ROD
When fitting the connecting rods, check that all of them are of same weight class and from the same supplier. The
connecting rod/cap is of torn type; before assembly verify that the connecting rod is not damaged. Each connecting
rod can assembled with the relative cap only. If the cap is assembled on the reverse side, the connecting rod must be
rejected.
Figure 78
114054
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Values to be obtained after installing the bush
1 Between the connecting rod bush and the connecting rod profile there must be a distance > 0.4 mm.
2 On the external breaking line, gap area allowed must be < 5 mm2.
3 No cracks are allowed in the threaded area.

Fitting the connecting rod-piston assembly Figure 80

into the piston liners
Figure 79
47593
115885
Fit the half-bearings (1), selected as described on pages 19 - all pistons belong to the same class, A or B;
to 24, both on the connecting rod and on the stand.
- ideogram stamped on the piston crown is placed toward
the engine flywheel, or the cavity, on the piston cover,
If the cap (1) is fitted upsidedown, the connecting corresponds to the position of the oil spray nozzles.
rod should be discarded.
Piston protrusion check

NOTE As spares, class A pistons are provided and can be Once assembly is complete, check piston protrusion from
fitted also to cylinder barrels belonging to class B. cylinder barrels: it must be 0.873 to 1.177 mm.
Fit the connecting rod-piston assemblies (1) into the piston

liners (2) using band 99360605 (1, following Figure). Check
the following:
- the openings of the split rings are offset by 120;
Figure 81
1 Connecting rod-piston assembly
2 Marking area on the piston crown of ideogram

specifying the assembly position and the
selection class
3 Connecting rod marking area.
61831

Checking assembly clearance of big end pins Figure 83
To check the clearance proceed as follows:

connect the connecting rods to the relative main journals,
place a length of calibrated wire on the latter.
Figure 82
47583
Install and fix tool 99360264 (2) with bracket (4); tighten by
lever (1) until cotters are removed (3); remove the tool (2)
and the upper plate (5), the spring (6) and the lower plate (7).
Repeat the operation on all the valves.
Turn the cylinder head upside down and remove the valves
115886 (8).
Install the connecting rod caps (1) with half-bearings; tighten

the connecting rod cap fixing screws (2) to 50 Nm (5 kgm)
torque. By tool 99395216 (3), tighten the screws further at
90 angle.
Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire.
Checking the planarity of the head on the
cylinder block
CYLINDER HEAD Figure 84 (Demonstration)
Before dismounting cylinder head, check cylinder head for
hydraulic seal by proper tooling; in case of leaks not caused
by cup plugs or threaded plugs, replace cylinder head.
NOTE In case of plugs dismounting/replacement, on

mounting, apply sealant Loctite 270 on plugs.
36159
Dismounting the valves The planarity (1) is checked using a ruler (2) and a thikness
gauge (3). If deformations exist, surface the head using proper
NOTE Before dismounting cylinder head valves, number surface grinder; the maximum amount of material to be
them in view of their remounting in the position removed is 0.2 mm.
observed on dismounting should they not have to
be overhauled or replaced.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre. NOTE After leveling, make sure that valve sinking and
injector protrusion are as described in the relative
paragraph.

VALVE Figure 86
Removing deposits and checking the valves
Figure 85
92841
MAIN DATA - VALVES AND VALVE GUIDES

48625
* Values to be obtained after installing the valve guides
Remove carbon deposits using the metal brush supplied.
Check that the valves show no signs of seizure or cracking. Check, by means of a micrometer, that valve stem diameters
Check the diameter of the valve stem using a micrometer are as specified; if necessary, grind the valves seat with a
(see following Figure) and replace if necessary. grinder, removing the minimum quantity of material.
VALVE GUIDES
Figure 87
47509
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves

Replacing of valve guides Checking protrusion of injectors

Remove valve guides by means of tool 99360288.
Figure 89
Install by means of tool 99360288 equipped with part
99360294, which determines the exact installation position
of valve guides into the cylinder heads; if they are not
available, install the valve guides in the cylinder head so that
they project out by mm 16.3 to 16.7 (Previous Figure).
After installing the valve guides, smooth their holes with
sleeker 99390310.
Replacing - Reaming the valve seats

To replace the valve seats, remove them using the
appropriate tool.
47585
Figure 88
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.2 to 1.5 mm.
41032
Ream the valve seats (2) on cylinder head using tool (1).
NOTE Valve seats must be reamed whenever valves or

valve guides are replaced or ground.
After reaming the valve seats, use tool 99370415, to make

sure that the valve position, with respect to the cylinder head
surface, is the following:
- -0.5 to -0.8 mm (recessing) of exhaust valves;
- -1.6 to 1.9 mm (recessing) of discharge valves.

TIMING GEAR Idler gear

Camshaft drive
Figure 90 Figure 92
114210 114211
TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear
- 8. Drive shaft driving gear.
Intermediate gear pin Twin idler gear
Figure 91 Figure 93
86926 114212
Rated assembling play between idler gear bushings and pins: Replacing the bushings
0.040 0.080 mm.
Bushings (1) can be replaced when they are worn. Put up the
bushing, then grind it so as to bring it to a dimension of
65.010 0.10 mm.
NOTE Bushing fitting in gears (2, previous Figures) must be

performed in arrow direction, placing them as
shown in figures.

Camshaft
Checking cam lift and pin alignment
Figure 94
47506
Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2).
Figure 95
47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not
exceed 0.035 mm.
If misalignment exceeds this value, replace the shaft.
Figure 96
1
47505
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.

Figure 97
114213
MAIN DATA - CAMSHAFT AND TOLERANCES

The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the
shaft and the relative bushes.
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Bushes
Figure 98
114214
MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS
* Bush inner diameter after installation
The bush surfaces must not show any sign of seizing or Measure the bush inner diameters with a baremeter and replace
scoring; if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360487.
Use beater 99360505 to change bushings Fitting the valves and oil seal ring
Removal
Figure 101
Figure 99
114280
Use tool 99360505 (3) fitted as shown in fig. to remove

bushings (2).
Accurately position beater during removal phase.
Fitting
For fitting, reverse operations performed for
removal, with care to make lube hole (1), drilled on
bushing, coincide with corresponding hole in housing.
87051
Lubricate the valve stem and insert the valves in the
respective valve guides; fit the lower caps (1). Use tool
VALVE SPRINGS 99360292 to fit the oil seal (2) on the valve guides (3) of the
exhaust valves; then, to fit the valves, proceed as follows.
Figure 100
Valve closed
NOTE Should valves not have been overhauled or
replaced, remount them according to numbering
performed on dismounting.
that they have a notch placed at valve head centre.
Valve open
Figure 102
114215
MAIN DATA TO CONTROL EXHAUST AND

DISCHARGE VALVE SPRING
86290
- fit springs (6) and the upper plate (5);

- apply tool 99360264 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3),
remove tool (2).

ROCKER SHAFT
Figure 103
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker
a rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
Shaft
Figure 104
114217
MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
Rocker
Figure 105
114219
DISCHARGE VALVE ROCKER

Figure 106
114218
EXHAUST VALVES ROCKER

The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.

ASSEMBLY Figure 109
Figure 107
42566
166331
Install front cover (1) and lock retaining screw at required Check that pistons 1-6 are exactly at T.D.C.
torque. Place seal (2) on cylinder block.
Install cylinder head (1) and lock screws as shown in figures
below.
Removed screws must not be used again. Employ

new screws only.
Figure 108
166332
Secure seal (1), install special tool 99346260 (2), lock nut (3)
to secure seal (1).

Figure 110 Figure 112
114259
Cylinder head retaining screw locking sequence diagram.
45268
- Angle locking by means of tool 99395216 (1):

3rd phase: 90 angle
4th phase: 75 angle.
Figure 111
Figure 113
45267
- Pre-lock by torque wrench (1):

1st phase: 50 Nm (5 kgm);
2nd phase: 100 Nm (10 kgm).
145833
Install oil pump (1), double gear (3) complete with

connecting rod (4) and lock screws (2) in two phases:
pre-lock 30 Nm
90 angle lock

Figure 114
114260
5. Fit pipes on injectors and head locking fittings by hand.

and must be replaced. 6. Lock fittings on rail (A, C) at required torque .
7. Lock fittings on injectors and head (B, C) at required
torque.
Lubricate the injector fastening O-Rings using the
following lubricants: PDE SILIKONFETT 22, NLG
12, PDE LUBRICOMET GR 220 NLG12. TYPE DESCRIPTION LOCK TORQUE
A M18 x 1.5 40 2 Nm
1. Install rail on cylinder head and lock retaining screws by B M14 x 1.5 35 2 Nm
hand.
C M16 x 1.5 40 2 Nm
2. Install injectors in correct position and lock to required
torque.
Check that the injectors (2) are equidistant from the

! springs (1). Distance X which separates them
should always be the same. After fitting the high-pressure pipelines, during the
! following 20 hours of work, frequently check engine
3. Install pipes on rail and lock fittings by hand. oil level (IT MUST NOT INCREASE).
4. Lock rail to cylinder head retaining screws at required
torque.

114261
Clean surfaces to be coupled to remove dirt and oil residuals.

Apply LOCTITE 5970 (2) silicone on gear casing (1) as 114263
shown in the figure.
The sealant seam diameter must be 1.5 0.5/0.2 mm. Clean surfaces to be coupled to remove dirt and oil residuals.
Apply LOCTITE 5970 silicone on gear casing (1) as shown
in the figure.
Install gear casing within 10 min. from sealant The sealant seam diameter must be 1.5 0.5/0.2 mm.
! application.
Install gear casing within 10 min. from sealant

Figure 116 ! application.
Figure 118
114264
114262
Apply gage 99395221 (1) to check and adjust position of
high-pressure pump connection flange (2).
Use torque wrench to lock screws (1) at required torque.
Fix flange screws (2) at required torque.

High pressure pump installation Figure 120

Figure 119
45258
114272
Secure seal (1), install special tool 99346260 (2), lock nut (3)
Install high-pressure pump (1) on flange (2). to secure seal.
Engine flywheel installation

ENGINE FLYWHEEL
NOTE If toothing on engine flywheel for engine start-up NOTE Crankshaft has a reference pin that must match
is very damaged, change crown wheel. with related housing on engine flywheel.
Refit crown wheel after heating up at approx.
200C.
Figure 121
114265
DETAIL OF PISTON POSITION STAMPING ON ENGINE FLYWHEEL

A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to
piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2
notches, position corresponding to 54.

Figure 122 This condition is obtained when:

1. the opening with one reference (5) for the engine
flywheel (4) is visible from the inspection window;
2. tool 99360612 (1), through housing (2) of engine rpm
sensor, inserts in hole (3) drilled on engine flywheel (4).
Otherwise, adjust engine flywheel orientation (4).
Remove too 99360612 (1).
145832
Position flywheel (1) on crankshaft, lubricate screws (2)

threading with engine oil and lock them.
Stop rotation using specific tool. Figure 125
Lock screws (2) in three phases.
1st phase: pre-lock with torque wrench (3) at 100 Nm torque
(10 kgm).
Figure 123
49036
2nd phase: 60 angle locking using tool 99395216 (1).
Camshaft installation 114267

Figure 124
Install camshaft (3) and orient it with references ()
positioned as in the figure.
Clean the matching surfaces of the plate (1) to remove
impurities and oil residues.
Apply silicon LOCTITE 5970 (6) on the plate (1) as shown
in the picture.
NOTE Take care NOT to get sealant on the inner groove

(5).
The diameter of the sealant bead should be 1.5 - 0.5/0.2 mm.

Fit the plate (1) within 10 mins of applying the sealant with
72436
the gasket (2) and tighten the bolts (4) to 16 - 22 Nm.
Position crankshaft with pistons 1 and 6 at TDC.

Figure 126 TIMING CAMSHAFT AND FLYWHEEL

USING TOOL 99395223
Timing camshaft
Figure 128
114269
Apply gage 99395222 (1), check and adjust position of

connecting rod (3) for relay gear, lock screw (2) at required
torque.
115064
Rotate the crankshaft with the tool 99360341 so that the

opening marked with two references (5) is visible from the
lower inspection window in the flywheel cover casing.
In this condition, insert the tool 99360612 (1) via the housing
(2) for the engine rpm sensor in the opening (3) in the engine
flywheel (4).
114270 116052
Refit relay gear (2) and lock screws (1) using six-splined Fit the tool 99395223 (1) at the front of the camshaft.
spanner at required torque.
NOTE The relay gear (2) bushing can be replaced when

worn out. After securing bushing, grind it to reach
dia. 58.010 0.10 mm.

116053 116055
Rotate the tool (1) 99395223 in order to insert the pin (3) Install crosspieces (1) on valve rod.
in the opening (2, previous Figure) in the head. Fasten the
tool (1) 99395223 using two M8x1.25 bolts (2).
NOTE Before refitting rocker arm shaft assembly, check
that all adjustment screws have been fully
unlocked.
114025
117691
Apply tool 99360558 (1) to rocker arm shaft (2) and install
Fit the camshaft drive gear (1) so that the fastening openings shaft on cylinder head.
in the shaft are aligned with the slots (2) in the drive gear. Lock retaining screws at required torque.
Position the gear (1) taking care to position the spokes (4)
as illustrated. This operation is necessary in order to be able
to fit the flywheel correctly which can only be fitted in one
position in relation to the gear.
Tighten the fixing bolts (3).

Timing flywheel TIMING CAMSHAFT AND FLYWHEEL

WITHOUT TOOL 99395223
Figure 134
Timing camshaft
Figure 135
145834
Fit the high pressure pump gear (5) tightening the nut (4) to
torque.
Use the flat washer (PN 17095914) in conjunction with the
nut (4) replacing the one supplied with the Bosch CP3 pump.
Fit the flywheel (6) so that the toothe marked with the arrow
() is in line with the sensor housing (2).
To check that the position is correct, insert tool (1)
99360613 in the timing sensor (2) housing.
Proceed with tightening the bolts (3).
114279
Remove the tools 99395223, 99360612 and 99360613.
Secure special tool 99360341 (3) to gear casing.
NOTE The arrow indicated engine rotation direction.

Use tool above to rotate engine flywheel (1) in
engine rotation direction to bring cylinder 1 piston
approx. to TDC in blast phase.
This condition is reached when hole with notch (4),
following hole with two notches (5) drilled on
engine flywheel (1), is visible through manhole (2).
Figure 136
71774
The exact position of piston no.1 at TDC is obtained when,

in conditions described above, tool 99360612 (1), through
engine rpm sensor housing (2), inserts in hole (3) drilled on
engine flywheel (4).
Otherwise, rotate engine flywheel (4) to adjust its
orientation.
114276
Install crosspieces (1) on valve rod.
NOTE Before refitting rocker arm shaft assembly, check

that all adjustment screws have been fully
unlocked.
Figure 140
115063
Rotate the camshaft so that the openings at the rear of the

engine are arranged in the configuration illustrated in the
diagram.
Figure 138
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and install
Lock retaining screws at required torque.
Remove tool 99360612.
Figure 141
117691
Install gear (1) controlling camshaft so that fastening holes on

shaft coincide with slots (2) on control gear.
NOTE Position the gear (1) taking care to position the

spokes (4) as illustrated.
This operation is necessary in order to be able to
fit the flywheel correctly which can only be fitted
in one position in relation to the gear.
117693

impurities and oil residuals. Apply silicon LOCTITE 5970 (1)
Lock retaining screws (3). on the front cover (2) as shown in the picture. The diameter
of the sealing string must be 1.5 0.5/0.2 mm.

115064
Rotate crankshaft to check conditions below: 115064
1) hole identified with two notches (5) is visible through Camshaft is timed if conditions below are found at cam lift
manhole; values 4.70 0.05:
2) fixture 99360612 (1) through housing (2) of engine rpm 1) hole identified with two notches (5) is visible through
sensor inserts in hole (3) on engine flywheel (4). manhole;
2) fixture 99360612 (1) through housing (2) of engine rpm
NOTE To recover the clearances, rotate the crankshaft in sensor inserts in hole (3) on engine flywheel (4).
a clockwise direction until the opening with the
two references is passed and then rotate in the
opposite direction to produce the conditions
described above.
106535
Position the dial gauge with a magnetic base (1) with the 114281
(flat-based) rod positioned on the roller (2) for the rocker
arms which controls the exhaust valve for cylinder no. 3 and
apply a pre-loading of 6 mm. In case conditions shown in previous Figure and shown at
paras 1 and 2 are not found, operate as follows:
NOTE During the measurement the rod for the dial gauge
should always be perpendicular to the engine axis 1) release screws (2) securing gear (1) of camshaft to as to
and NOT to the surface of the head. make control gear and camshaft independent;
2) conveniently operate on engine flywheel so as to obtain
Using tool 99360341, rotate crankshaft clockwise till dial gage conditions indicated at paras 1 and 2, previous Figure,
arrow reaches minimum value (max cam lift), after which it considering that cam lift value must remain unchanged;
no longer varies. 3) lock screws (2) and repeat control as already described;
Zero set dial gage. 4) lock screws (2) at required torque.
Rotate engine flywheel anticlockwise till dial gage reads
camshaft cam lift value = 4.70 0.05 mm.

Timing flywheel Figure 147

Figure 146
114275
NOTE Pipes previously removed ca no longer be refit.

Change them.
Install fuel supply pipeline (1) from high pressure pump to rail.
Lock nuts at 35 Nm torque.
After high-pressure pipe installation, during the

! following 20 hours of work, frequently check engine
oil level (IT MUST NOT INCREASE).
Figure 148
145835
Install gear (5) of high pressure pump and lock nut (4) at
required torque.
NOTE When refitting, use the flat washer (PN 17095914)

in conjunction with the nut (4) replacing the one
supplied with BOSCH pump CP3.
Rotate crankshaft and bring cylinder n.1 piston to

compression phase at TDC: Rotate flywheel opposite to 114285
regular rotation direction by 1/4 of rev. Install centrifugal filter (1) on tune wheel and lock screws (2)
Rotate flywheel again in regular rotation direction till hole at required torque.
identified by double notch (3, second box) shows through
inspection hole under flywheel cover box. Figure 149
Insert tool 99360612 (1, second box) in flywheel sensor
housing (2, second box).
Fit the flywheel (6) so that the tooth marked with the arrow
() is in line with the sensor housing (2, first box).
Insert tool 99360613 (1, first box) through phase sensor
housing (2, first box) on tooth machined on tune wheel.
In case tool (1, first box) is difficult to insert, unlock screws
(3, first box) and orient tune wheel (6) to properly match the
tooth (1, first box).
Lock screws (3, first box).
114286
Install timing cover (1) and lock retaining screws (2) at

required torque.

Intake and exhaust rocker arm clearance Figure 151

adjustment
Figure 150
114287 114288
Install blow-by body (1) with related seal and lock screws (2)
Adjustment of clearance between rocker arms and at required torque.
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted; Install cover (3) and lock screws (4) at required torque.
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4.
In order to perform these operations correctly, refer to Figure 152
procedure and table below.
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
Torque the lock nut to 34 - 44 Nm

START AND BALANCE ADJUST
ROTATION VALVES OF CLEARANCE
CLOCKWISE CYLINDER No. OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
117692
NOTE In order to correctly carry out adjustments above, Clean the surface of the parts to be joined removing
it is mandatory to perform the sequence indicated impurities and oil residuals. Apply silicon LOCTITE 406
in the table, checking exact positioning at each within the check valve (2) housing (1) and on the Blow-by
phase by means of pin 99360612. (3) as shown in the picture.

166177
Install cylinder head cover (1) and lock screws (2) at required
115880 torque following order shown in Figure below diagram.
Fit the head internal electric wire (injectors+pressure sensor) Figure 155
passing it through the opening and securing it using bands as
illustrated in the diagram ().
45363
Figure 156
117695
Rotate the engine

Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel casing and front cover
with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing impurities and oil residuals.
Apply silicon LOCTITE 5970 (1) as shown in the picture. The diameter of the sealing string must be 1.5 0.5/0.2 mm.

Figure 157 ENGINE ASSEMBLY COMPLETION

Complete engine assembly fitting or connecting parts below:
- complete fuel filter support and pipelines;
- EDC ecu;
- intake manifold with pre-heating resistor;
- heat exchanger;
- exhaust manifold;
- turbocharger and related oil pipes;
- thermostat assy;
- oil level rod;
- start-up motor;
- oil filter;
- electric connections and sensors.
114031b
Install suction rose (1).

Torque the n 4 M12 retaining screws to 22 - 27 Nm
Figure 158 NOTE Fittings of pipelines, cooling water and

turbocharger lube oil must be locked at:
- 55 5Nm, oil pipeline female fitting;
- 20-25 Nm, oil pipeline make fitting.
Figure 159
114029
Fit seal on oil sump (3), fit spacer (2) and install sump on
engine block locking screws (1) at required torque.
169279
Fit alternator (1) with support, water pump (2); pulleys (3);
automatic belt tensioner (6) and damper flywheel assembly
(7).
Using an appropriate tool (4) on automatic belt tensioner (6),
turn it in the direction shown by the arrow and install the

Figure 160
169281

NOTE Belt tensioner is automatic, therefore no further

adjustments are required after installation.

F2CFE613 SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3
ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 5
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 11

2 SECTION 7 - TECHNICAL SPECIFICATIONS F2CFE613

GENERAL CHARACTERISTICS
F2CFE613
Type
G*A030 D*A030 B*A030

Injection Direct

Bore mm 117
Stroke mm 135
+ + +.. = Total displacement cm3 8710

Type F2CFE613
G*A030 D*A030 B*A030

A
VALVE TIMING
opens before T.D.C. A 17
closes after B.D.C. B 31

B
opens before B.D.C. D 48
closes after T.D.C. C 9

D
For timing check
mm -
X
X mm -
Running
mm 0.35 to 0.45
X
mm 0.55 to 0.65
Bosch Common Rail with CRIN2 injectors and high pressure

FEED pump CP3.3 NH
Nozzle type DLLA 145
Injection order 1-4-2-6-3-5
bar
Injection pressure bar
1800
Injector calibration bar

ASSEMBLY CLEARANCE DATA

F2CFE613
Type
G*A030 D*A030 B*A030
CYLINDER BLOCK AND mm
CRANKMECHANISM COMPONENTS
1
Bores for cylinder liners:
upper 130.500 to 130.525
1
lower 129.510 to 129.535
Cylinder liners:
external diameter:
L upper 130.461 to 130.486
2
lower 129.475 to 129.500
2 length L 226.15
Cylinder liners -
crankcase bores
upper 0.014 to 0.064
lower 0.010 to 0.060
External diameter 2 -
Cylinder sleeve
3
inside diameter 3A* 117.000 to 117.012
X
inside diameter 3B* 117.010 to 117.022
Protrusion X 0.035 to 0.065

* Selection class
Pistons: Federal Mogul Mahle
1 measuring dimension X 15 18
X external diameter 1A 116.894 to 116.906 116.871 to 116.883
external diameter 1B 116.904 to 116.916 116.881 to 116.893
2
pin bore 2 52.016 to 52.022 52.010 to 52.018
Piston - cylinder sleeve Federal Mogul Mahle
A* 0.094 to 0.118 0.117 to 0.141
B* 0.094 to 0.118 0.117 to 0.141
* Selection class
Piston diameter 1 -
X
Pistons protrusion X 0.873 to 1.117
3 Gudgeon pin 3 51.994 to 52.000
Federal Mogul Mahle

Gudgeon pin - pin housing
0.016 to 0.028 0.010 to 0.024

Type F2CFE613
G*A030 D*A030 B*A030

mm
X1
X1 3.120 to 3.140
X2
X3 Piston ring grooves X2 2.550 to 2.570
X3 4.020 to 4.040
Piston rings:
trapezoidal seal S1 3.000
S1 lune seal S2 2.470 to 2.500
S2
S3 milled scraper ring
with slits and internal
spring S3 3.970 to 3.990
1 -
Piston rings - grooves 2 0.050 to 0.100
3 0.030 to 0.070
Piston rings -
X1 Piston ring end gap
in cylinder liners
X2
X1 0.3 to 0.4
X3
X2 0.60 to 0.75
X3 0.35 to 0.65
Small end bush housing

1 1 55.700 to 55.730
Big end bearing

housing 2
2 85.987 to 85.996
1
Selection classes { 2
3
85.997 to 86.005
86.006 to 86.013
4 Small end bush diameter
outside 4 55.780 to 55.820
3
inside 3 52.015 to 52.030
Big end bearing shell S
S Red 1.994 to 2.002
Green 2.002 to 2.010
Yellow D 2.010 to 2.018
Small end bush - housing 0.05 to 0.08
Piston pin - bush 0.015 to 0.036
Big end bearing 0.127 - 0.254 - 0.508

Connecting rod weight
A g
A 3308 to 3338
Class B 3339 to 3368
C 3369 to 3398
D Fitted in production only and not supplied as spares

Type F2CFE613
G*A030 D*A030 B*A030
mm
X
Measuring dimension X 125
Max. connecting rod

axis misalignment
0.08
tolerance
Main journals 1
- nominal 92.970 to 93.000
- class 1 92.970 to 92.980
- class 2 92.980 to 92.990
1 2 - class 3 92.990 to 93.000
Crankpins 2
- nominal 81.915 to 81.945
- class 1 81.915 to 81.925
- class 2 81.925 to 81.935
- class 3 81.935 to 81.945
S1 S 2 Main bearing shells S1
Red 2.968 to 2.978
Green 2.978 to 2.988
Yellow* 2.988 to 2.998
Big end bearing shells S2
Red 1.994 to 2.002
Green 2.002 to 2.010
Yellow* 2.010 to 2.018
Main bearing housings 3
- nominal 99.000 to 99.030
3 - class 1 99.000 to 99.009
- class 2 99.010 to 99.019
- class 3 99.020 to 99.030
Bearing shells -
main journals 0.050 to 0.090
Bearing shells -
big ends 0.040 to 0.080
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508
Main journal,
thrust bearing X1 39.96 to 40.04
X1
Main bearing housing,

thrust bearing X2 38.94 to 38.99
X2
X3 Thrust washer
halves X3 3.38 to 3.43
Crankshaft end float 0.10 to 0.30
1 2 Alignment 1-2 -
Ovalization 1-2 0.04
Taper 1-2 -
* Fitted in production only and not supplied as spares

Type F2CFE613
G*A030 D*A030 B*A030
CYLINDER HEAD - VALVE TRAIN mm

1
Valve guide housings

in cylinder head
1 12.9800 to 12.997
Valve guide 2 8.023 to 8.038

3 13.012 to 13.025
3
Valve guides - housings

in the cylinder heads 0.015 to 0.045
Valve guide 0.2 - 0.4

4 Valves:
4 7.970 to 7.985
60 30 7 30
4 7.970 to 7.985
+15
+15
45 -0
-0
Valve stem and its guide 0.040 to 0.070

Valve seat in
head
1 41.985 to 42.020
1 1 40.985 to 41.020
Outside diameter of valve
2 seat; angle of valve seat
in cylinder head:
0
-0,5
2 42.060 to 42.075
60 - 30
0
-0,5
2 41.060 to 41.075
45 - 30
X 0.5 to 0.8
Recessing of valve
X X 1.6 to 1.9
Between valve
seat and head 0.040 to 0.090

Table 1
Type F2CFE613
G*A030 D*A030 B*A030
mm
Valve spring height:
A B
free height H 70.77 71.34
under a load of:
H H1 N 460 23 H1A {
H 2 N 460 22 H1B 51
N 740 33 H2A {
N 731,4 42 H2B 39
Injector protrusion X 1.2 to 1.5

X
Camshaft bushing housing

in the cylinder head:
17 69.000 to 69.030

2
Camshaft bearing
journals:
17 64.924 to 64.940
1 3
Outer diameter of
camshaft bushings:
69.090 to 69.130
Inner diameter of
camshaft bushings: 65.080 to 65.116
Bushings and housings

in the cylinder head 0.060 to 0.130
Bushings and bearing
journals 0.100 to 0.192
Cam lift:
H 7.4034
8.2108
1
Rocker shaft 1 31.964 to 31.980

Type F2CFE613
G*A030 D*A030 B*A030
mm
Bushing housing in
rocker arms
32.025 to 32.041
32.025 to 32.041
Between bushings and

housings
0.045 to 0.077
0.045 to 0.077
TURBOCHARGER
Type HX52W
End float 0.025 to 0.127
Radial play 0.406 to 0.610

TIGHTENING TORQUES
PART TORQUE
Nm kgm
Pipe union for piston cooling nozzle M12x1.5 50 5 5.0 0.5
Heat exchanger retaining screws 63 7 6.3 0.7
Plug 125 15 12.5 1.5
Spacer and oil sump fastening screws
M10x1.5x45 41.5 3.5 4.1 0.3
Gearcase fastening screws to cylinder block:
M10x1.25 41.5 3.5 4.1 0.3
M12x1.75 63 7 6.3 0.7
M8x1.25 23.5 1.5 2.3 1.5
Cylinder head fastening screw
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90
Fourth stage angle closing 75
Rocker arm shaft fastening screw M12x1.75x130 104.5 10.5 10.4 1
Locknut for rocker arm adjusting screw 39 5 3.9 5
Electroinjector retaining bracket screws
M10x1.5x40 39 43 3.9 4.3
Shoulder plate fastening screws to head 20 2 2.0 0.2
Engine support bracket fastening screws to cylinder head 74 8 7.4 0.8
Gear fastening screws to camshaft
First stage pre-tightening 25 2.5
Second stage pre-tightening 45
Phonic wheel fastening screws to distribution gear 8.5 1.5 0.8 0.1
Exhaust pipe fastening screws
pre-tightening 32.5 7.5 3.2 0.7
tightening 47.5 2.5 4.7 0.2
Connecting rod cap fastening screws: M12x1.25x69
Engine flywheel fastening screws M18x1.5x72
Flywheel pulley fastening screws to crankshaft
Main journal retaining screws M16x2x168
Second stage pre-tightening 60 + 60
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly

PART TORQUE
Nm kgm
Damper flywheel fastening screws 115 15 11.5 1.5
Idler gear pin fastening screws
Second stage angle closing 90
Idle gear link rod fastening screw 24.5 2.5 2.4 0.2
Oil pump fastening screw 24.5 2.5 2.4 0.2
Oil pump suction rose fastening screw 24.5 2.5 2.4 0.2
Front cover fastening screw to cylinder block 19 3 1.9 0.3
Control unit fastening screw to cylinder block 19 3 1.9 0.3
Fuel filter support fastening screw to cylinder head 24.5 2.5 2.4 0.2
Screw securing the engine support to the wheelcase
Second stage angle closing 60
Turbo-compressor fastening screws and nuts
pre-tightening 35 5 3.5 0.5
tightening 46 2 4.6 0.2
Water pump fastening screw to cylinder block 22 2 2.2 0.2
Pulley fastening screw to hub 55 5 5.5 0.5
Rocker arm cover fastening screws 8.5 1.5 0.8 0.1
Thermostat box fastening screws to cylinder head 24.5 2.5 2.4 0.2
Automatic tightener fastening screws to cylinder block 45 5 4.5 0.5
Fixed tightener fastening screws to cylinder block 105 5 10.5 0.5
Fan support fastening screws to cylinder block 24.5 2.5 2.4 0.2
Starter fastening screws 44 4 4 0.4
Air heater on cylinder head 50 5 5 0.5
Hydraulic power steering pump gear fastening nut 105 5 10.5 0.5
Air conditioner compressor fastening screw to support 24.5 2.5 2.4 2.5
Alternator support superior fastening screw 71.5 4.5 7.1 0.4
Alternator bracket fastening screw to cylinder block 24.5 2.5 2.4 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5 2.5 3.2 0.2
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly

PART TORQUE
Nm kgm
Flywheel rev sensor fastening screw 82 0.8 0.2
Camshaft rev sensor fastening screw 82 0.8 0.4
Overboost pressure sensor fastening screw 82 0.8 0.2
Absolute pressure sensor fastening screw 22.5 2.5 2.2 0.2
P.W.M. control valve fastening screw/nut 82 0.8 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5 2.5 2.3 0.2
Filter clogging sensor 10 1
Oil temperature switch 25 1 2.5 0.1
Oil pressure sensor 25 1 2.5 0.1
Electric wire fastening screw 82 0.8 0.2
Engine support fastening screws to gearcase M14x2x50
First stage pre-tightening 40 4.0
Engine support fastening screws to gearcase M14x2x50
150 184 15 18.4
Oil filter body fastening screw 24.5 2.5 2.5 0.2
M8 x 60
M8 x 90 24.5 2.5 2.5 0.2
Ladder frame fastening screws to crankcase M10 x 1.25 x 20
46.5 52 4.65 5.2
Strainer / ladder frame fastening screws to crankcase
46.5 52 4.65 5.2
Alternator positive retaining nut M8x1.25 12.5 2.5 1.3 0.3
Starter terminal nut 30 M10x1.5 21 3.4 2.1 0.3
Starter terminal nut 50 M5x0.8 3.6 1 0.4 0.1
Exhaust manifold
pre-tightening 40 5 (4 0.5)
tightening 70 5 (7 0.5)
Screw securing thermometric switch/transmitter 25 2.5
Screw securing air temperature sensor 35 3.5
Screw securing timing sensor 82 0.8 0.2
Screw securing injector connections 1.64 0.28 0.164 0.028

Figure 1
171163
DIAGRAM OF TIGHTENING SEQUENCE OF CYLINDER HEAD FIXING SCREWS
Figure 2
171164
DIAGRAM OF TIGHTENING SEQUENCE OF CYLINDER HEAD COVER FIXING SCREWS
Figure 3
70567A
DIAGRAM OF TIGHTENING SEQUENCE OF ROCKER ARMS SHAFT FIXING SCREWS

Figure 4
60581
DIAGRAM OF TIGHTENING SEQUENCE OF EXHAUST MANIFOLD FIXING SCREWS
Figure 5
60582
DIAGRAM OF TIGHTENING SEQUENCE OF TURBOCHARGER ON EXHAUST MANIFOLD FIXING SCREWS


F2CFE613 SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT MODIFIED FOR ADAPTATION TO

CURSOR 9 ENGINE . . . . . . . . . . . . . . . . . . . 10

2 SECTION 8 - TOOLS F2CFE613

TOOLS
TOOL NO. DESCRIPTION
99322230 Rotary telescopic stand
99340051 Extractor for crankshaft front gasket
99340054 Extractor for crankshaft rear gasket
99342157 Tool to extract injectors
99346245 Tool to install the crankshaft front gasket
99346260 Tool to install the crankshaft back gasket

TOOLS
Pliers for assembling and disassembling piston split rings

99360184 (105-160 mm)
99360264 Tool for assembly and disassembly engine valves
99360288 Box wrench for block junction bolts to the underblock
99360294 Tool to fit back valve guide

(to be used with 99360288)

TOOLS
Compression tool for checking the protrusion of cylinder liners

99360334 (to be used with 99370415-99395603 and special plates)
Cylinder liner compression plate

99360335 (to be used with 99360334)
Tool for rotating flywheel

99360341
99360500 Tool to lift crankshaft
99360505 Beater for tree removal and replacement bushings distribution

TOOLS
99360558 Tool for lifting and carrying shaft rockers
99360585 Swing hoist for engine disassembly assembly
99360603 Belt to insert piston in cylinder liner (90 - 175 mm)
Belt to insert piston in cylinder liner (60 - 125 mm)

99360605
99360612 Tool for positioning engine P.M.S.

TOOLS
99360613 Tool for timing of phonic wheel on timing gear
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners
99360724 Ring (115 mm) (to be used with 99360706)
Rotary engine stand mounting bracket 99322230

99361042

TOOLS
Series 8 keys to insert 14x18 (13-17-18-19-21-22-24-27-30 mm)

99368542
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99389833 14x18 plug wrench (20-120 Nm)
Torque screwdriver for calibrating the injector solenoid valve

99389834 connector check nut
99390310 Valve guide sleeker

TOOLS
Measuring pair for angular tightening with 1/2

99395216 and 3/4 square couplings
Gauge for determining distance between tree distribution and high

99395221 pressure pump
Gauge for determining distance between camshaft and gear for

99395222 reference
99395223 Gauge for camshaft phasing
99395603 Dial gauge (0 - 5 mm)

EQUIPMENT MODIFIED FOR ADAPTATION TO CURSOR 9 ENGINE



F2CFE613 APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F2CFE613

F2CFE613 APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX F2CFE613
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

F3BFE613 1
Part 2
F3BFE613
Page
General specifications 1
Main engines diagrams 2
Electrical equipments 3
Maintenance planning 4
Removal and installation of main engine components 5
Engine overhaul 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix

2 F3BFE613

F3BFE613 3
MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING
Technical Code Commercial Code

F3BFE613C*A010
F3BFE613B*A010 C13 ENT
F3BFE613A*A010

4 F3BFE613
UPDATING
Section Description Page Date of revision

F3BFE613 SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
VIEWS OF ENGINE . . . . . . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 6

2 SECTION 1 - GENERAL SPECIFICATIONS F3BFE613

VIEWS OF ENGINE
Figure 1
166350
LEFT-HAND SIDE VIEW
Figure 2
166351
RIGHT-HAND SIDE VIEW

Figure 3
166352
FRONT VIEW
Figure 4
166353
REAR VIEW

Figure 5
166354
TOP VIEW

CLEARANCE DATA
F3BFE613
Type
C*A010 B*A010 B*A010

Injection Direct

Bore mm 135
Stroke mm 150
+ + + Total displacement cm3 12880
Compression ratio 16.5: 1
Maximum kW 332 369 407

power (HP) (452) (502) (554)
rpm 2100 2100 2100
Max. torque Nm 1924 2161 2400

(kgm) (197) (221) (245)
rpm 1400 1400 1400
Loadless
engine
idling rpm 850
Loadless engine
peak rpm 2280
Intercooler
SUPERCHARGING
Waste Gate
Turbocharger type CTT HE551 WG

LUBRICATION
Oil pressure Forced by gear pump, relief valve single action

bar (warm engine) oil filter
- idling bar 3
- peak rpm bar 4,5
COOLING Liquid
Water pump control Through belt
Thermostat
- start of opening C 842
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.

F3BFE613
Type
C*A010 B*A010 A*A010
REFUELLING Cooling circuit (1)

Total capacity -
Lubrication circuit (2)

Total capacity (3) 35 (31.5)
Periodical replacement:
Oil sump at minimum level 20 (18)
Oil sump at maximum level 28 (25.2)
Fuel tank (4)
(1) The amounts indicated relate to the standard configuration of the engine only.
Use a water and PARAFLU 11 mixture at 50% also during summer. As an alternative to PARAFLU 11, use a product complying
with SAE J 1034 international standards.
(2) Use lubricants complying with the following international specifications:
15W-40 ACEA E7 / API CI-4, 10W-30 ACEA E7 / API CI-4 for ambient temperature < -15 C;
10W-40 ACEA E9/API CJ-4 alternatively.
The grade of viscosity to be used in relation to environment temperature can be found in the table in the appendix.
The oil consumption is considered as acceptable up to a quantity equal to 0.5% of fuel consumption.
(3) The quantities shown refer to the first refilling and concern the refilling of engine, oil sump and filter.
(4) Use STANDARD fuel compliant to the EN 590.
Worning Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the
! injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
! by FPT.


F3BFE613 SECTION 2 - MAIN ENGINE DIAGRAMS 1
SECTION 2
Main engine diagrams
Page
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Injector-pump . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Pressure damper . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Oil pressure control valve . . . . . . . . . . . . . . . . 7
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 7
- By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE OIL FILTERS . . . . . . . . . . . . . . . . . . . . . 8
- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 8
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 11
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TURBOCHARGER HOLSET CTT HE 551 WG . 12

2 SECTION 2 - MAIN ENGINE DIAGRAMS F3BFE613

SUPPLY
Fuel is supplied via a fuel pump, filter and pre-filter, 6
pump-injectors governed by the camshaft via rocker arms
and by the electronic control unit.
Figure 1
Return circuit
Supply circuit
166365
ENGINE FEED SCHEME

1. Fuel filter - 2. Valve for fuel recirculation from injectors integrated in the fuel pump (start opening 3,5 bar) -
3. Fuel pump - 4. Overpressure valve for fuel return to the tank (start opening 0,2 bar) - 5. Pressure control valve (start
opening 5 bar) - 6. Prefilter with priming pump - 7. ECU - 8. Heat exchanger - 9. Pump injectors.
.
A. Fuel arriving at injectors - B. Fuel returning to tank

Overpressure valve Injector-pump

Figure 2 Figure 4
92829
An overpressure valve is a single-acting valve, calibrated to 0.2

0.3 bar, placed on the piping that returns fuel to tank. The
overpressure valve prevents fuel duct in cylinder head from
emptying with engine stopped.
Feed pump
Figure 3
102405
INJECTOR SECTION
The new pump injectors are capable, thanks to the higher
injection pressure, of atomizing the fuel in the combustion
chamber to a greater extent, thus improving combustion and
therefore reducing the polluting exhaust emissions.
131088
Pressure damper
Engine feed pump Figure 5
1 Delivery. - 2 By pass nut - 3. Return from injector -
4. Delivery pressure limiting valve - 5. Feed.
Pump performances
Pump rotation speed (rpm) 4100 900 250 140
Minimum flow rate (l/h) 310 45 12 6

Negative pressure
on aspiration (bar) 0.5 0.3 0.3 0.3
Pressure on delivery
Test (bar) 5 3 0,3 0.3
conditions
Test liquid
temperature (C) 50 50 50 20 102606
Test liquid ISO 4113

FUEL PRESSURE DAMPER
Field of use
Pump rotation speed (rpm) 4100
The function of the fuel pressure damper located on the
Overrunning rotation speed (max 5 min) (rpm) 5800 max delivery pipe between the fuel filter and the cylinder head is
Diesel oil temperature (C) -25/+80 to attenuate the supply return back pressure due to the
Filtering rate on aspiration increase of the injection pressure.
(micron) 30
Negative pressure on aspiration (bar) 0.5 max
Pressure control valve

Valve calibration 5 5.8
Injectors return valve

Valve calibration 3.4 3.8

LUBRICATION
Engine lubrication is obtained with a gear pump driven by the
crankshaft via gears.
A heat exchanger governs the temperature of the lubricating
oil.
Figure 6
Lubrication circuit
Dropping oil
Pressure oil
166355

Oil pump Overpressure valve

Figure 7 Figure 8
73540
60560
MAIN DATA TO CHECK THE OVERPRESSURE
The oil pump (1) cannot be overhauled. On finding any
VALVE SPRING
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.
Figure 9
108846
OIL PUMP CROSS-SECTION

Overpressure valve Start of opening pressure 10 1 bars.

Oil pressure control valve Figure 11

Figure 10
73543
73542
MAIN DATA TO CHECK THE OIL PRESSURE
The oil pressure control valve is located on the left-hand side
CONTROL VALVE SPRING
of the crankcase.
Start of opening pressure 5 bars. Heat exchanger
Figure 12
124517
HEAT EXCHANGER
1. Position of engine oil pressure/temperature sensor - 2. Turbocharger oil supply line fitting - 3. Heat exchanger retaining
screws - 4. Heat exchanger elements (qty. 11) - 5. Oil inlet - 6. Oil outlet - 7. By-pass valve (3.5 bar)

By-pass valve ENGINE OIL FILTERS
Figure 13 Figure 14
73545
The valve quickly opens at a pressure of: 3.5 bars.
124518
1. Cartridge O-ring - 2. Cap O-ring - 3. Cartridge -

4. Cover cap - 5. Direction of oil flow
Characteristics
1. Maximum operating pressure : 20 bar
2. Operating temperature: -30C +120C
3. Bypass valve opening pressure: 3.4 0.3 bar
4. Tightening torque: 45 55 Nm

COOLING
Figure 15

Water entering the pump
166356
COOLING CIRCUIT VERSION
Description Operation
The engine cooling system works with forced circulation The water pump is actuated by the crankshaft through a
inside closed circuit and can be connected to an additional poli-V belt and sends coolant to the cylinder block, especially
heater (if any) and to the intarder intercooler. to the cylinder head (bigger quantity). When the coolant
It consists mainly of the following components: temperature reaches and overcomes the operating
temperature, the thermostat is opened and from here the
- an expansion reservoir whose plug incorporates two
coolant flows into the radiator and is cooled down by the fan.
valves discharge and charge controlling the system
The pressure inside the system depending on the
pressure;
temperature variation is controlled by the discharge and
- a coolant level sensor; charge valves incorporated in the expansion reservoir filling
plug.
- an engine cooling unit to dissipate the heat taken by the
The discharge valve has a double function:
coolant from the engine through the intercooler;
- keep the system under light pressure in order to raise the
- a heat exchanger to cool down lubrication oil; coolant boiling point;
- a water pump with centrifugal system incorporated in - discharge the pressure surplus in the atmosphere as a re-
the cylinder block; sult of the coolant high temperature.
- an electric fan; The charge valve makes it possible to transfer the coolant
- a thermostat controlling the coolant circulation. from the expansion reservoir to the radiator when a
depression is generated inside the system as a result of the
coolant volume reduction depending on the fall in the
coolant temperature.

Water pump Figure 18

Figure 16
TO THE
RADIATOR
TO THE
EXPANSION
TUB
TO THE
FROM BY PASS
THE ENGINE 60748
60631 Check the thermostat works properly; replace it if in doubt.

CROSS-SECTION OF THE WATER PUMP
Temperature of start of travel 84C 2C.
Minimum travel 15 mm at 94C 2C.
The water pump is composed of: impeller, bearing, seal and
driving pulley.
Check that the pump body has no cracks or water

! leakage; if it does, replace the entire water pump.
Thermostat
View of thermostat operation
Figure 17
TO THE
RADIATOR
TO THE
EXPANSION
TUB
FROM TO THE
THE ENGINE BY PASS
60747

TURBOCHARGING
The turbocharging system is composed of:
- an air filter;
- a turbocharger;
- an intercooler radiator.
Figure 19
Engine exhaust gas

Intake air
Compressed air (hot)
Compressed air (cooled) 166357
TURBOCHARGING DIAGRAM
Description Figure 20
The turbocharging system is composed of: air cleaner,

turbocharger and intercooler.
The air cleaner is a dry type composed of a filtering cartridge

that is periodically replaceable.
The turbocharger has got the function of using the energy of

engine exhaust gas in order to send pressure air to the
cylinders.
The intercooler is composed of a radiator applied on the

engine coolant radiator, and it is used for lowering the
temperature of the air coming out from the turbocharger to
send it to the cylinders. 166358

TURBOCHARGER HOLSET CTT HE 551 WG
Figure 21
75532
A. THROTTLE VALVE SHUT B. THROTTLE VALVE OPEN
Figure 22
75533
It is basically composed of: - an overpressure relief valve fitted on the turbine casing.
- a central casing housing a shaft supported by bushings at Its function is to choke the exhaust gas outlet (detail B),
whose opposite ends are fitted the turbine wheel and the sending a portion of the exhaust gas straight into the
compressor rotor; exhaust pipe when the turbocharging pressure
downstream from the turbocharger reaches the setting.
- a turbine casing and a compressor casing mounted on the
end of the central body;

F3BFE613 SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
- Components on the engine . . . . . . . . . . . . . . 3
BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 4
EDC SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . 5
- EDC 7 UC31 electronic control unit . . . . . . . 8
- Electric injector connector A . . . . . . . . . . . . 9
- Sensor connector C . . . . . . . . . . . . . . . . . . . 10
- Chassis connector B . . . . . . . . . . . . . . . . . . . 11
- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Cable on head . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Pump injector . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Flywheel sensor . . . . . . . . . . . . . . . . . . . . . . . . 17
- Engine coolant temperature sensor . . . . . . . . 18
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 19
- Air pressure/temperature sensor . . . . . . . . . . 20
- Oil temperature/pressure sensor . . . . . . . . . . 20
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Alternator 90 A . . . . . . . . . . . . . . . . . . . . . . . . 22

2 SECTION 3 - ELECTRICAL EQUIPMENT F3BFE613

Components on the engine

Figure 1
166367
RIGHT SIDE VIEW OF ENGINE
1. Sensor for engine revs on distribution shaft - 2. Fuel temperature sensor - 3. Boost pressure sensor - 4. Alternator -
5. EDC7 UC31 Control unit - 6. Starter - 7. Engine feed pump.
Figure 2
166366
LEFT SIDE VIEW OF ENGINE
1. Water temperature - 2. Sensor for engine revs on flywheel - 3. Engine oil temperature/pressure sensor.

BLOCK DIAGRAM
Figure 3
CONNECTION
OF FRAME SIDE
171600
KEYS
1. Engine oil pressure/temperature sensor -
2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Distribution sensor -
5. Flywheel sensor - 6. Pump injectors.

EDC SYSTEM FUNCTIONS

The EDC7 UC31 electronic center manages the following main functions:
Fuel injection
Accessory functions such as cruise control, speed limiter, PTO and the like
Self-diagnosis
Recovery
It also enables:
Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator pedal position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating
Pressure can be adjusted in case of:

- external device actuation (e.g. speed reducer, cruise control)
- serious defects involving load reduction or engine stop.
After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding
mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.
Delivery correction based on water temperature
When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays
are not optimized yet.
Fuel injected also tends to condense on cold metal surfaces.
Fuel dosing with a cold engine is therefore greater than when hot.
Delivery correction to prevent noise, fumes or overloads
Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center
to prevent them.
De-rating
In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

Injection lead electronic control

Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder
to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.
Lead is corrected as required:
- during acceleration
- according to water temperature
and to obtain:
- reduced emissions, noise abatement and no overload
- better vehicle acceleration
High injection lead is set at start, based on water temperature.
Delivery start feedback is given by injection electro valve impedance variation.
Engine start
Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator
pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables
the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn
by the starter motor.
Cold start
Pre-post reheating is activated when even only one of the three water, air or gas oil temperature sensors records a temperature
of below 10 _C. The pre-heat warning light goes on when the ignition key is inserted and stays on for a variable period of time
according to temperature, while the intake duct input resistor heats the air, then starts blinking, at which point the engine can be
started.
The warning light switches off with the engine revving, while the resistor continues being fed for a variable period of time to
complete post-heating. The operation is cancelled to avoid uselessly discharging the batteries if the engine is not started within 20
25 seconds with the warning light blinking. The pre-heat curve is also variable based on battery voltage.
Hot start
On inserting the ignition key the warning light goes on for some 2 seconds for a short test and then switches off when all reference
temperatures are above 10 _C. The engine can be started at this point.
Run Up
When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),
and diagnoses the system.
After Run
At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the
microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom)
memory to make tem available for the next start (Cf. Run Up).
These data essentially consists of:
- miscellaneous settings, such as engine idling and the like
- settings of some components
- breakdown memory
The process lasts for some seconds, typically from 2 to 7 according to the amount of data to be stored, after which the ECU sends
a command to the main relay and makes it disconnect from the battery.

This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before
10 seconds at least after engine cutout.
In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown
memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Repeated procedure interruptions could in fact lead to center damage.
Cut-off
It refers to the supply cut-off function during deceleration.
Cylinder Balancing
Individual cylinder balancing contributes to increasing comfort and operability.
This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each
cylinder, to compensate for injector hydraulic tolerances.
The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information
is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.
Synchronization search
The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.
If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the
sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection
occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence
and start the engine.
In order to reduce the number of connections, and of the cables connecting the injectors, and to consequently reduce the nose
on transmitted signal, the central unit is directly mounted on the engine by a heat exchanger enabling its cooling, using spring blocks
which reduce vibrations transmitted from engine.
It is connected to vehicle wiring harness by two 35-pole connectors:
connector A for components present on the engine
connector B for components present on the cab
Internally, there is a pressure ambient sensor use to further improve injection system management.
The central unit is equipped with a much advanced self-diagnosis system and, depending on environmental conditions, is capable
to identify and store any faults, even of intermittent type, occurred to the system during vehicle running, ensuring a more correct
and reliable repair intervention.

EDC 7 UC31 electronic control unit

Figure 4
C A
102373
A. Injector connector - B. Chassis connector - C. Sensor connector.

Electric injector connector A

Figure 5
12 16
6 11
Colour legend
B black
1 5 102374
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
E grey
K pink
ECU
Colour legend Function
Pin
1 - Free
2 - Free
3 B Solenoid valve for electronic cylinder (4-5-6) injection
4 - Free
5 - Free
6 W Solenoid valve for electronic cylinder 2 injection
7 - Free
8 - Free
9 - Free
10 - Free
11 R Solenoid valve for electronic cylinder (1-2-3) injection
12 G Solenoid valve for electronic cylinder 3 injection
13 W Solenoid valve for electronic cylinder 1 injection
14 U Solenoid valve for electronic cylinder 4 injection
15 E Solenoid valve for electronic cylinder 6 injection
16 P Solenoid valve for electronic cylinder 5 injection

Sensor connector C
Figure 6
6 8 16 9 15 22
4
Colour legend
5
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
E grey 1 3 23 30 36 29
K pink 102375
ECU
Cable colour Function
Pin
1 - Free
2 - Free
3 - Free
48 - Free
9 W Distribution sensor
10 R Distribution sensor
1114 - Free
15 K Coolant temperature sensor
16 - Free
17 - Fuel temperature sensor mass
18 O/B Fuel temperature sensor
19 B Flywheel sensor
20 N Booster speed sensor
2122 - Free
23 W Flywheel sensor
24 N Engine oil temperature/pressure sensor ground
25 W Mass for air pressure / temperature sensor
26 Y Coolant temperature sensor
27 O/B Oil pressure signal from engine oil pressure / temperature sensor
28 U Oil temperature signal from engine oil pressure / temperature sensor
29 - Free
30 W Booster speed sensor
31 - Free
32 O Engine oil temperature/pressure sensor power supply
33 R Air temperature/pressure sensor power supply
34 G Air pressure signal from the air temperature/ pressure sensor
35 W/R Fuel temperature sensor
36 O Air temperature signal from the air temperature / pressure sensor

Chassis connector B
Figure 7 71 89 72 54 6 11
1
7
12
53 35 18 36 17 102376
ECU pin FUNCTION

1 Lambda sensor heater signal (*)
2 Positive voltage direct from battery
4 Lambda sensor heater supply (*)
5 Battery negative
6 Battery negative
7 Negative voltage for control relay of heater grid control 2 (*)
10 Battery negative voltage
11 Battery negative voltage
12 Signal from grid on heater 1 (*)
13 Positive voltage +15
14 Positive voltage for air conditioning compressor (*)
15 Signal from air conditioning compressor (*)
16 Negative voltage speed 1 fan
17 Starting relay negative voltage
18 Turbine sensor signal (*)
19 Turbine sensor earth (*)
20 Negative voltage intercooler by-pass valve (*)
21 Supply voltage for switches
22 To diagnostic warning light
23 Additional solenoid valve signal
24 Earth for particle filter temperature sensor (*)
25 Signal for particle filter temperature sensor (*)
26 Intake air humidity and temperature sensor signal
27 Intake air humidity and temperature sensor signal
28 Intake air humidity and temperature sensor earth
30 To diagnostic warning light
31 Cruise control positive signal (*)
32 Negative voltage from engine start switch from engine compartment
33 Tachometer output signal (*)
34 (Low) signal CAN 2 line interface input
35 (High) signal CAN 2 line interface

ECU pin FUNCTION

36 Negative voltage for fuel filter heater switch (*)
37 Starting relay positive voltage
38 OBD lamp negative voltage (*)
39 Speed limiter lamp negative voltage (*)
40 Positive voltage +15 under lock
41 Positive voltage from main brake switch
42 Negative voltage from sensor detecting water in the pre-filter
43 Signal 1 from Lambda probe (*)
47 Negative voltage from engine stop switch from engine compartment
48 Negative voltage from accelerator pedal idling switch
49 Positive voltage from brake switch (redundant signal)
50 Positive voltage +12
52 (Low) signal CAN 1 line interface input
53 (High) signal CAN 1 line interface
54 Negative voltage for fan second speed control switch (*)
55 Positive voltage for engine brake exhaust gas solenoid valve (*)
56 Negative voltage for pre-heating lamp (*)
57 Positive voltage speed 1 fan (*)
58 Earth for engine brake exhaust gas solenoid valve (*)
59 Earth for blow-by pressure difference sensor (*)
61 Positive voltage for blow-by pressure difference sensor (*)
62 Passive analogue signal from torque limiter multiple resistor (*)
65 Earth from multiple resistor torque limiter (*)
66 Positive voltage from clutch switch (torque converter) (*)
67 Earth for cooling fan speed sensor (*)
69 Signal from cooling fan speed sensor (*)
70 Vehicle speed sensor earth (*)
71 Vehicle speed sensor signal (*)
72 Synchronising bit on serial interface input signal
73 Local area network interconnection input signal
75 Supply voltage for grid on heater 1 (*)
76 Earth for exhaust gas temperature sensor (*)
77 Supply voltage for accelerator potentiometer
78 Earth for accelerator potentiometer
79 Signal from accelerator potentiometer
80 Signal from exhaust gas temperature sensor (*)
81 Signal from particle trap differential pressure sensor (*)
82 Positive voltage from particle trap differential pressure sensor (*)
83 Earth from particle trap differential pressure sensor (*)
85 Negative voltage from diagnostic request switch
87 Crankshaft rotation output signal
88 Camshaft rotation output signal
89 ISO-K interface input signal
* If present

Engine cable
Figure 8
166369
CONNECTOR A. Electric injector connector - CONNECTOR C. Sensor connector - A. Fuel temperature sensor -
B. Engine speed sensor (flywheel) - C. Engine speed sensor (camshaft) - E. Connector for unit injectors - F. Coolant
temperature sensor - HP. Boost pressure air temperature sensor - VS. Oil pressure/temperature sensor.

Cable on head
Figure 9
166718
1. Connectors to injectors - 2. Wire passage.

Pump injector
It consists mainly of:
A) Solenoid valve
B) Pumping element
C) Nozzle
These three parts CANNOT be replaced individually and CANNOT be overhauled.
The pumping element, mechanically actuated at every rocker arm cycle, compresses the fuel container in the delivery chamber.
The nozzle, whose composition and operation are similar to those of traditional injectors, is opened by the fuel under pressure
and sprays it into the combustion chamber.
A solenoid valve, directly controlled by the electronic control unit, determines delivery according to the control signal.
A casing houses the lower part of the pump injector in the cylinder head.
Figure 10
115791

The electro valve is of the N.A. type.

Coil resistance is ~ 0.56 0.57 Ohm.
Maximum operating voltage is ~ 12 15 Amp.
Based on voltage absorbed by the electro valve, the electronic center can identify whether injection was correct or mechanical
problems exist. It can also detect injector errors ONLY with the engine running or during starts.
They are connected to the electronic center with a positive common to groups of three injectors:
Cylinder 1 - 2 3 injector to pin A 11
Cylinder 4 - 5 - 6 injector to pin A 3.
Injectors are individually connected to the center between pins:
A11 / A13 cylinder 1 injector
Injectors are connected to the center with connector ST - E mounted on the engine front with a twisted cable, to avoid possible
electromagnetic interference problems, so junctions or repairs on it must NOT be performed.
Figure 11
166720
Colour legend
B white
R red
G yellow
V green
N black
L blue
Z purple
H grey

Timing sensor Flywheel sensor

This inductive sensor is located on the camshaft. Number of Inductive sensor located on the flywheel. The flywheel has 60
teeth 6 plus 1. sections, on 54 of which there is a hole. The sensor reads the
The signal generated by the sensor is used bythe ECU: signal generated by the holes. The ECU uses this signal to:
- on starting to facilitate phase recognition; - recognise the position of the pistons during normal oper-
ation;
- during normal operation as a redundant piston position
signal. - determine the engine speed.
Impulse wheel
Flywheel
Figure 12
Figure 15
6+1
116183
Figure 13
115825
Figure 16
115826
The sensor resistance is 880 920 Ohm.

The two sensors are equal and can be interchanged.
Figure 14
116184
ENGINE - LH SIDE VIEW

1. Flywheel sensor
ENGINE - RH SIDE VIEW
1. Camshaft timing sensor

Engine coolant temperature sensor

This N.T.C. type sensor located on the water outlet sump on the engine head left measures coolant temperature for the various
operating logics with a hot or cold engine and identifies injection enrichment requirements for a cold engine or fuel reduction
requirements for a hot engine.
The coolant temperature signal is used for display on the Cluster and to control the fan.
It is connected to electronic center pins C15/C26.
Sensor behavior as a function of temperature:
- 10 C 8,10 10,77 kOhm
+ 20 C 2,28 2,72 kOhm
+ 80 C 0,29 0,364 kOhm
At 60 to 90 _C, voltage at A5 and A22 ranges from 0.6 to 2.4V.
Figure 17
104266
Connector Function Cable colour

2 To EDC center pin C 15

Fuel temperature sensor

Features
Vendor BOSCH
Maximum torque 35 Nm
This N.T.C. type sensor located on the fuel filter on the engine left side detects fuel temperature and enables the electronic center
to measure fuel density and volume for delivery correction.
Figure 18
104267
Connector Function Cable colour


Figure 19 Air pressure/temperature sensor

This component incorporates a temperature sensor and a
pressure sensor.
IIt replaces the temperature sensors and pressure sensors
available in the preceding systems.
It is fitted onto the intake manifold and measures the
maximum supplied air flow rate used to accurately calculate
the amount of fuel to be injected at every cycle.
The sensor is powered with 5 V.
The output voltage is proportional to the pressure or
temperature measured by the sensor.
114273
Sensor external view
Figure 20 Oil temperature/pressure sensor

This component is identical to the air pressure/temperature
sensor and replaced single sensors.
It is fitted onto the engine oil filter, in a horizontal position.
It measures the engine oil temperature and pressure.
The measured signal is sent to the EDC control unit which
controls, in turn, the indicator instrument on the dashboard
(low pressure warning lights / gauge).
The engine oil temperature is used only by the EDC control
unit.
50323
Linking connector
Figure 21
Control unit pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 Temp. Sign. 28C 36C
3 +5 32C 33C
4 Press. Sign. 27C 34C
50344
Wiring diagram

Starter motor
Figure 22
166722
TECHNICAL VIEW
Figure 23 Figure 24
149567
A WIRING DIAGRAM
149566
1. Control dynamo - 2. Electric motor -
CHARACTERISTIC CURVES 3. Batteries
Test
Main characteristics Electric parameters Performances
conditions
Nominal output 5.5 kW No load 23 V 120 A MAX (3800 rpm MIN.)
power
Load 16 V and 49.0 Nm 690 A MAX
Nominal output 24 V
voltage 900 rpm MIN.
stall 6V 1260 A MAX
Engaging system Auxiliary rotation system 73.5 Nm MIN.
Rated time 30 s
Direction of rotation clockwise (view from the
Weight drive end)
about 10.5 kg

Figure 25 Alternator 90 A
Main characteristics
Supplier MITSUBISHI 28 V 90A
Voltage rating 28.3 0.5 V (20C)
Nominal power output 90 A
Normal operating speed 5,000 r.p.m.
Belt tension 730 N
Direction of rotation clockwise, from pulley side
Weight 6.9 kg
Tightening torque on terminal B:+ 12.5 2 Nm
106281
ALTERNATOR WIRING DIAGRAM

L: to recharging indicatorI
G: alternator ignition
S: battery voltage sensor
Figure 26 Figure 28
106282
106300
ALTERNATOR CURRENT DELIVERY CURVE
OVERALL VIEW
Figure 27
106283
TECHNICAL VIEW

F3BFE613 SECTION 4 - MAINTENANCE PLANNING 1
SECTION 4
Maintenance planning
Page
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE PROCEDURES . . . . . . . . . . . . 4
- Checks and controls . . . . . . . . . . . . . . . . . . . . 4
- Check/Replace miscellaneous drive belts . . . . 7
- Bleeding air from the fuel circuit . . . . . . . . . . . 7
- Replace fuel filter . . . . . . . . . . . . . . . . . . . . . . . 7
- Bleeding air from the fuel circuit . . . . . . . . . . . 7
- Replacing engine Blow-by filter . . . . . . . . . . . . 8
- Check valve clearance and adjust if necessary . 8

2 SECTION 4 - MAINTENANCE PLANNING F3BFE613

MAINTENANCE
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the maintenance interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by
common sense and by the specific conditions in which the engine is run.
Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
Maintenance interventions
Checks Frequency
Check oil level in engine Every trip
Check coolant level Every trip
Draining water from the fuel pre-filter Weekly
Check/top up electrolyte level in batteries and clean terminals Weekly
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
NOTE The engine lubrication intervals apply with the use of Diesel fuel with sulphur content of less than 0.5%.
If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.
Use engine oil: 15W-40 ACEA E7 / API CI-4

10W-30 ACEA E7 / API CI-4 (for ambient temperature < -15 C).
10W-40 ACEA E9/API CJ-4 (alternatively).
NOTE Diesel fuel for low temperatures. Standard EN590 defines different classes of Diesel fuels, identifying the characteristics
of those most suitable for use in low ambient temperatures.
Compliance with the regulations regarding the distribution of fuels suitable for the climatic and geographic conditions
of the various countries is entirely up to the oil companies.

MAINTENANCE PROCEDURES
Due to the high temperatures achieved by the
Checks and controls system, do not operate immediately after the
engines disconnection, but wait for the time
Engine oil level check. deemed necessary for the cooling.
The check must be executed when the engine is Protect the eyes and the skin from any eventual high
disconnected and possibly cool. pressure jet of cooling liquid.
The check can be made using the specially provided flexible
rod.
Draw off the rod from its slot and check that the level is
within the etched tags of minimum and maximum level. The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
Whether it should be difficult to make the evaluation, every two year.
proceed cleaning the rod using a clean cloth with no rag
grinding and put it back in its slot. Draw it off again and check NOTE In case of new filling, proceed bleeding system,
the level. through the bleeds on the engine.
In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engines If bleeding of the system is not carried out, serious
components. inconvenience might be caused to the engine due
to the presence of air pockets in the engines head.
To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier.
Refill through upper tappet cover plug. During refill, remove
dipstick for easier oil drain.
Lubricating system check
The engine oil is highly polluting and harmful. disconnected and when it is running.
In case of contact with the skin, rinse well with Verify the presence of any oil leakage or blow-by from the
water and detergent. head, from the engine pan of from the heat exchanger.
Adequately protect the skin and the eyes, operate

in full compliance with safety regulations. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
Disposal must be carried out properly, and in full and detergent.
compliance with the law and regulations in force. Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
Check of fuel system

disconnected and when it is running.
The check is made by observing the fuel pipes from the tank
to the fuel pump and to the injectors. Check for any water in the fuel filter
The components of the system can be damaged

very quickly in presence of water or impurity
within the fuel.
Take prompt action on the filter to drain off the

Cooling system check water in the fuel circuit.
disconnected and when it is running. Fuel filter is equipped with pump screw-valve to drain the
Check the pipes from the engine to the radiator and vice water eventually mixed with fuel.
versa; note any seepage and the state of the pipes especially
near the coupling clamps. Place a container underneath the filter and slightly loosen the
Verify that the radiator is clean, the correct working of the screw. Drain the water eventually contained in the filters
fan flywheels, the presence of any leakage from the bottom.
connectors, from the manifold and from the radiating unit.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.

Engine oil change - Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
Figure 1 sick.
Engine oil filter change

Figure 2
85493
We recommend to carry out the oil drainage when the

motor is hot.
Warning: We recommend to wear proper protec- 125518

tions because of high motor service temperature.
Drain oil as described in Engine oil change chapter.
The motor oil reaches very high temperature: you To disassemble oil filter (1), using tool 99360252..
must always wear protection gloves.
- Place a proper container for the oil collecting under the

pan connected with the drain plug (3).
Warning: the oil filter contains inside a quantity of
- Unscrew the plug (3) and then take out the control dip- NOTE oil of about 1 kg.
sick (1) and the inserting plug (2) to ease the downflow
of the lubrication oil.
Warning: avoid the contact of skin with the motor
oil: in case of contact wash the skin with running
water.
The motor oil is very pollutant: it must be disposed
In case of contact with the skin, wash with much of according to the rules.
safety rules.
NOTE Before refitting the new cartridge, wet seal using
engine oil.
Lock plus (3) under oil sump at predefined tightening torque. Lock oil filter (1) by hand till contact to support and then lock
Pour oil in prescribed quantity and quality in engine through by of a rev. at prescribed tightening torque; pour oil in
filler (2) of tappet cover. engine ad described in Engine oil change chapter.
- After the complete drainage, screw the plug and carry
out the clean oil filling.
NOTE Use only the recommended oil or oil having the re-
quested features for the corrrect motor function-
ing.
features.

Control (when in use) Frequency

Check oil level in engine Daily
Check coolant level Daily
Check that the heat exchangers are clean Daily
Check that the air filter is clean Daily
Drain water from the fuel pre-filter 150 hours (1)
Check/top up electrolyte level in batteries and clean terminals Half-yearly
Planned maintenance Frequency
Check state and tension of belt 300 hours (2)
Check state of oil vapour filter (indicator may be present) 300 hours (3)
Change oil 600 hours (3) (4)
Change oil filter/s 600 hours (3) (4) (5)
Change fuel filter/s 600 hours (3) (1) (5)
Change fuel pre-filter 600 hours (3) (1)
Check exhaust pipe/s for damage Half-yearly
Impurity drainage/suction from the fuel tank Half-yearly (1)
Change auxiliary member belt 1200 hours
Change air filter 1200 hours (6)
Change coolant 1200 hours or 2 years
Change oil vapour filter 2 years (4)
Special maintenance Frequency
Clean the turbocharger 1200 hours (7)
Check the efficiency of the pre-post heating system (if there is one) 1200 hours
Adjusting play in valves-rocker arms and pumps-rocker arms 1200 hours
(1) Maximum period when using good quality fuel, (EN 590 standard); this is reduced if the fuel is contaminated and alarms are
triggered due to blockage of the filters and presence of water in the pre-filter. When blockage of the filter is indicated, it must
be replaced. If the water in pre-filter indicator does not go out after drainage, the prefilter must be replaced.
(2) Refers to engines with traditional and automatic tensioning devices
(3) Must be performed annually, even if the required number of working hours are not reached
(4) Replace lubricants according to the frequency indicated in the REFUELLING table.
(5) Only use filters with the following characteristics:
- filtration level < 12 m
- filtering efficiency > 200.
(6) The frequency with which operations are carried out will depend on the working conditions and efficiency/wear of the
product.
(7) Required by oil vapour recirculation.

Check/Replace miscellaneous drive belts Replace fuel filter
Figure 3 Figure 5
1 2 3 4 5
6
171166
150676
ASSEMBLY DIAGRAM OF BELTS FOR FAN WATER Remove the fuel filter (1) with tool 99360252.
PUMP ALTERNATOR Before refitting the new cartridge, moisten the seal with
diesel or engine oil.
1. Alternator - 2. Water/alternator pump drivebelt - Screw the new one on by hand, taking care to check that the
3. Automatic belt tensioner - 4. Fan - 5. Water pump - rubber seal and the mating surface are clean and in a perfect
6. Crankshaft state of repair. Screw the cartridge on by hand until it is in
contact with the mounting and then tighten by 3/4 of a turn
to the required tightening torque.
Check by sight that belts (2) are not worn or deteriorated. Bleed the air from the supply system as described in the
following paragraph.
Replace AdBlue filter and prefilter Bleeding air from the fuel circuit
Figure 4
- Open the bleed screws, connecting them with tubes to
run off the bled fluid into suitable containers to prevent
dirtiness:
1 = located on the pre-filter mount;
2 = located on the filter mount;
3 = located on the front of the cylinder head.
- Work the hand pump on the pre-filter till you see fuel
with no air in it coming out of the bleed screw (1)
(retighten the screw when the operation is over).
Keep on pumping until you see fuel with no air in it come
out of the bleed screw (2) on the filter as well (then
retighten the screw) and from the screw (3) on the front
of the cylinder head (retighten the screw when the
operation is over) and tighten them to the required
torque.
The circuit has now been bled. Start up the engine and run
it for a few minutes at idling speed to get rid of all remaining
108617
air.
Undo the hex of the cover (1) and remove it from the pump
module together with the filter. Disconnect fitting (2) and NOTE Never let the fuel soil the drive belt: alternator,
remove the prefilter embedded inside. Remove the filter and pump, water, etc.
prefilter, reversing the disassembly operations.

Replacing engine Blow-by filter

Figure 6
72563
To replace the Blow-by filter, work through the internal hatch

and remove bolts (2), remove cover one and remove filter
(3) with its gasket.
Clean the filter and cover housing.
Fit a new filter with new gaskets, the cover and tighten bolts
(2) to the specified torque.
Filter (3) works in one direction and must therefore

! be fitted with the two reinforcement bars visible, as
Check valve clearance and adjust if necessary
Figure 7
105183
It is very important to adjust a clearance between the intake

and exhaust valve rockers and beams and to adjust the pump
injector drive rocker preload very carefully.
To carry out these operations correctly, proceed as de-
scribed in the relevant chapter.

F3BFE613 SECTION 5 - REMOVAL AND INSTALLATION OF MAIN ENGINE COMPONENTS 1
SECTION 5
Removal and installation
of main engine components
Page
DRIVE BELT DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WATER PUMP DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THERMOSTAT UNIT DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE CENTRAL UNIT DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THERMOSTAT UNIT
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP DISASSEMBLY/ASSEMBLY

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 SECTION 5 - REMOVAL AND INSTALLATION OF MAIN ENGINE COMPONENTS F3BFE613
Page Page
INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Intake and exhaust rocker play
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 adjustment and pre-loading of
rockers controlling pump injectors . . . . . . . . . 18
STARTER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10 INJECTORS DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TURBOCHARGER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Intake and exhaust rocker play
adjustment and pre-loading of
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10 rockers controlling pump injectors . . . . . . . . . 21
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXHAUST MANIFOLD DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OIL FILTER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OIL COOLER DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OIL PAN DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BLOW-BY DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ROCKER ARM SHAFT DISASSEMBLY/ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 17

DRIVE BELT Figure 3

Disassembly
Figure 1
167110
Using an appropriate tool (3) on automatic belt tensioner (2), 150675
turn it in the direction shown by the arrow and remove the


Assembly 1. Alternator - 2. Electromagnetic coupling -
Figure 2

167110
Using an appropriate tool (3) on automatic belt tensioner (2),

turn it in the direction shown by the arrow and install the

ALTERNATOR Figure 6
Disassembly
Figure 4
167110
To mount belt (1), belt tensioner (2) has to be operated by

167110
proper tooling (3) according to the direction indicated by the
arrow in Figure.
Using an appropriate tool (3) on automatic belt tensioner (2), Turn the crankshaft anticlockwise () until the belt is
turn it in the direction shown by the arrow and remove the completely fitted onto the pulley.
Figure 7
Figure 5
171598
150675
Unscrew n 1 M10 (1) and n 1 M8 (3) screws and remove ASSEMBLY DIAGRAM OF FAN - WATER PUMP -
alternator (2). ALTERNATOR DRIVE BELT
Unscrew N 2 M8 screws and remove alternator support (4). 1. Alternator - 2. Electromagnetic coupling -
Assembly Fit the belt, as shown in Figure.
Fit the alternator support, screwing n 2 M8 screws.
Install alternator on support and screw n 1 M10 and n 1 M8
screws. NOTE Belt tensioner is of automatic type; therefore,

WATER PUMP
DISASSEMBLY/ASSEMBLY PROCEDURE NOTE Once installed, fill the engine coolant circuit.
Disassembly Start the engine and check for coolant leaks.
Drain off the coolant.
Figure 10
Figure 8
167110 167110
Using an appropriate tool (3) on automatic belt tensioner (2), Using an appropriate tool (3) on automatic belt tensioner (2),
turn it in the direction shown by the arrow and remove the turn it in the direction shown by the arrow and install the
auxiliary member drive belt (1). auxiliary member drive belt (1).
Figure 9 Figure 11
167112
150675
Remove the n 4 M8 screws (1) and take off the water pump ASSEMBLY DIAGRAM OF FAN - WATER PUMP -
(2). ALTERNATOR DRIVE BELT
Assembly
Install warter pump and screw n 4 M8 bolts. Fit the belt, as shown in Figure.

Start the engine and check for coolant leaks.

THERMOSTAT UNIT Assembly

Install the complete thermostat body, with new gasket, on the
Disassembly head and screw in 7 M8 screws to the specified torque.
Follow the tightening order shown in the figure below.
Figure 12
Figure 14
166730
To dismount the thermostat (1), proceed as follows:
Figure 13
170520
167113
Unscrew n 7 M8 screws (2) and remove the thermostat body

(1) and its gasket (3);

ENGINE CENTRAL UNIT Figure 16

Disassembly
Figure 15
167114
Disconnect connections of the engine cable from engine 167115
central unit (2).

Disconnect the fuel pipe (1) between engine central unit and Unscrew n 8 M6 screws (1) and remove engine central unit
fuel filter. (4).
Unscrew n 3 M8 screws (2) and remove heat exchanger (3).
Assembly
Install heat exchanger screwing n 3 M8 screws.
Install engine central unit screwing n 8 M6 screws.
Connect fuel pipe between engine central unit and fuel filter.
End the assembly procedure by connecting engine cable on
engine central unit.

THERMOSTAT UNIT Figure 18

Disassembly
Figure 17
169815
167116
During this operation dont smoke and dont use free Using the appropriate tool unscrew fuel filter (1).
flames. Avoid to breathe the vapors coming from Unscrew n 2 M 10 screws (2) and remove fuel filter support
filter. (3).
Disconnect sensor connection (1).

When replacing the filter cartridge do NOT fill it. This
operation is banned to avoid impurities entering into
the circuit, which would damage the injector/pump
system components.
Assembly
Fit fuel filter support and screw n 2 M10 screws.
Before refitting the new cartridge, moisten the seal with diesel
or engine oil. Screw the new one on by hand, taking care to
check that the rubber seal and the mating surface are clean
and in a perfect state of repair.
Screw the cartridge on by hand until it is in contact with the
mounting and then tighten by 3/4 of a turn to the required
tightening torque.
Bleed the air from the supply system as described in the
Bleeding air from the fuel circuit paragraph.
Connect the electrical connection to the fuel filter
temperature sensor.
End the assembly procedure by connecting fuel pipes.

FUEL PUMP INTAKE MANIFOLD

Figure 19 Figure 21
167127
167121

Remove engine cable connection from air temperature sensor
(1).
Figure 22
Figure 20
167122
Unscrew n 6 M10 bolts (2).

Remove following components:
167128
- Intake manifold (1);
- Gasket (4);
- Spacer (3);
Unscrew n 3 M8 screws (1). - Gasket (4).
Remove fuel pump (3) and the gasket (2).
Assembly
Assembly Mount new gaskets, spacer and fit intake manifold.
Install fuel pump with new gasket screwing n 3 M8 screws. Screw n 6 M10 screws.
End the assembly procedure by connecting fuel pipes. End the assembly procedure by connecting engine cable to
air temperature sensor.

STARTER TURBOCHARGER
Figure 23 Figure 24
167117
Disconnect oil return pipe (1) and oil delivery pipe (2).
169277
Figure 25
Take off n 3 screws (2) and remove the starter (1).
Assembly
Install the starter screwing n 3 screws.
167118
Unscrew n 2 nuts (1) and n 2 M10 screws (2).

Remove turbocharger (3) and gasket (4).
Assembly
Mount a new gasket on exhaust manifold; fit the turbocharger
and screw n 2 nuts and n 2 M10 screws.
Figure 26
161279
End the assembly procedure by connecting oil pipes.

EXHAUST MANIFOLD Assembly

Disassembly Mount 6 new gaskets and fit exhaust manifold.
Screw n 24 M10 screws.
Figure 27 End the assembly procedure by fitting new gasket and
turbocharger.
Screw n 2 nuts; screw n 2 M10 screws and connect oil pipes.
Figure 29
167119
To dismount the exhaust manifold (1), proceed as follows. 171577

Proceed with the disassembly of the turbocharger:
- disconnect oil return pipe;
- disconnect oil delivery pipe;
- unscrew n 2 nuts and n 2 M10 screws;
- remove turbocharger and gasket.
Figure 28
167120

Remove exhaust manifold (3) and n 6 gasket (1).

OIL FILTER OIL COOLER

NOTE Warning: the oil filter contains inside a NOTE Under oil cooler place a container for engine
quantity of oil of about 1 kg. coolant drain.
Avoid the contact of skin with the motor oil: in case
of contact wash the skin with running water.
The motor oil is very pollutant: it must
be disposed of according to the rules.
Figure 31
Figure 30
125518
167123
Use tool 99360252 (2) to slacken the oil filters (1). Remove oil pipes (1).
Unscrew and remove oil filter (2).
NOTE Before refitting the new cartridge, wet

seal using engine oil.
Assembly
Screw the oil filter by hand until it touches the support, then
tighten of a turn to the required torque.
Refit the plug under the sump, tightening it to the required
torque.
Add the required amount of recommended engine oil through
the filler.

Figure 32 Assembly
Assemble the oil cooler body and oil cooler, screwing in 4 M8
screws.
Mount the oil cooler complete with gasket to the crankcase
housing and tighten 18 M8 screws to the specified torque.
Figure 34
167124

Remove oil cooler body (3) and the gasket (2). 171573
Figure 33 End the assembly procedure by connecting oil pipes and oil
filter
167125
Remove oil cooler (1).

OIL PAN Figure 36

Disassembly
Figure 35
60516
Unscrew the screws (2) and take out the engine oil sump (1)
119975 together with the spacer (3) and gasket.
Place a proper container for the oil collecting under the pan
connected with the drain plug (3).
Unscrew the plug (3) and then take out the control dipstick
(1) and the inserting plug (2) to ease the down flow of the
Figure 37
lubrication oil.

In case of contact with the skin, wash with much
safety rules.
60517

Assembly Figure 40
Fit oil suction strainer.
Figure 38
167126
60665
Lock plus (1) under oil sump at predefined tightening torque.

Pour oil in prescribed quantity and quality in engine through
Arrange gasket (4) on oil sump (1), position spacer (3) and filler (2) of tappet cover.
mount the sump on engine block screwing up screws (2) at
prescribed torque.
NOTE Use only the recommended oil or oil having the

requested features for the correct motor
functioning.
features.
Figure 39
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
17578

BLOW-BY Figure 43
Disassembly
Figure 41
167129
Fit the blow-by case (6) and new gasket and then tighten the
screws (7) to the prescribed torque.
167129
Take off the screws (1) and extract the cover (2), the filter (4) NOTE The filter (4) operation is unidirectional, therefore it
and the gaskets (3 and 5).
must be assembled with the two sight supports as
Remove the screws (7) and the blow-by case (6) with its
illustrated in the figure.
gasket.
Assembly
Clean the filter seat and cover housing.
Install the filter (4) and new gaskets (3 and 5).
Figure 42 Fit the cover (2) and tighten the fastening screws (1) to the
prescribed torque.
Figure 44
167130
Apply silicone LOCTITE 5970 on the blow-by case and form

a string (2) of width 1,3 to 2 mm, as shown in the figure.
NOTE Fit the blow-by case (1) within 10 from sealer

application.
171575

ROCKER ARM SHAFT Figure 47

Disassembly
Figure 45
70567A
Screw screws (1 - 2 - 3) until rocker arms are brought to

contact relating seats on cylinder head, tighten the screws
according to sequence indicated in figure operating in two
steps as indicated in successive figure.
169278
Unscrew screws (1) fixing the rocker arm shaft.

Figure 48
Figure 46
116722
116190
Apply tool 99360553 (1) to the rocker holder shaft (2) and Lock the screws (2) fixing the rocker-arm shaft as follows:
remove the shaft (2) from the cylinder head. - 1st phase: tightening to a torque of 80 Nm (8 kgm) with
Assembly the torque wrench (1).
- 2nd phase: closing with an angle of 60 using the tool
99395216 (3).
NOTE Before refitting the rocker-arm shaft assembly, make
sure that all the adjustment screws have been fully
unscrewed.

Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
Figure 49
167109
Adjustment of clearances between rockers and valve studs FIRING ORDER 1-4-2-6-3-5
and preloading of pump injector rockers should be carried out
with extreme care.
Bring the cylinder under examination to the firing stage, the CLOCKWISE ADJUSTING ADJUSTING ADJUSTING
START-UP CYLINDER CLEARANCE PRE-
valves of this cylinder remain closed while the valves of the AND VALVE NO. OF LOADING
other cylinder in the pair can be adjusted. ROTATION CYLINDER OF
The cylinder pairs are 1-6,2-5,3-4. VALVE NO. CYLINDER
Strictly adhere to directions and data given on the table INJECTOR
below. NO.
Adjusting clearances between rockers and 1 and 6 at 6 1 5
intake/exhaust/valve studs: TDC
- Use a box wrench to loosen the adjusting screw locking 120 3 4 1
nut (1).
120 5 2 4
- Insert the feeler gauge blade (3).
120 1 6 2
- By using proper wrench, screw or unscrew rocker arm 120 4 3 6
adjusting screw (2);
120 2 5 3
- Ensure the feeler gauge blade (3) can slide between the
parts concerned with a slight friction.
- Hold the screw still while tightening the nut (1).
Setting pump-injector rocker preloading:
- Use a box wrench to loosen the nut fastening the NOTE In order to properly carry out the above-mentioned
adjusting screw for rocker arm (5) controlling adjustments, follow the sequence specified in the
pump-injector (6). table, checking the exact position in each rotation
- With a suitable wrench (4) tighten the adjusting screw phase by means of pin 99360612, to be inserted in
until the pumping element reaches its-end-of-stroke the 11th hole in each of the three sectors with 18
point. holes each.
- Lock the adjusting screw to a torque of 5 Nm (0.5 kgm)
by means of a torque wrench.
End the assembly procedure by mounting cylinder head cover
- Back off the adjusting screw 1/2 to 3/4 turn. and its gasket.
- Tighten the lock nut.

INJECTORS Figure 52
Disassembly
Figure 50
166734
Remove the electric connections (1).

Unscrew screws (2) fixing the rocker arm shaft.
Remove the head injection wiring.
The wiring has to be extracted from the front.
166735
Figure 51
Unscrew the screws (2) fixing the brackets (3).

Hook tool 99342155 part (6) to pump injector (1).
Mount part (5) on part (6) resting part on cylinder head.
Screw nut (4) and extract pump injector (1) from cylinder
head.
116190
Apply tool 99360553 (1) to the rocker holder shaft (2) and
remove the shaft (2) from the cylinder head.
Remove crosspieces from valves.

Assembly Figure 55
Figure 53
70567A
Screw screws until rocker arms are brought to contact relating

seats on cylinder head, tighten the screws according to
tightening sequence.
108843
Fit the seals (1) (2) (3) on the injectors. Figure 56
Figure 54
167108
166726
Mount The injectors (1) and, using a torque wrench, lock the Mount the electric wiring (1).
bracket fixing screws to a torque of 30 35 Nm. Connect cable on head.
The crosspieces (2) on the valve stem, all with the largest hole
on the same side.

unscrewed.

Figure 57
167109
ADJUSTING INTAKE/EXHAUST ROCKERS AND INJECTION

Adjustment of clearances between rockers and valve studs

and preloading of pump injector rockers should be carried out NOTE In order to properly carry out the above-mentioned
with extreme care. adjustments, follow the sequence specified in the
Bring the cylinder under examination to the firing stage, the table, checking the exact position in each rotation
valves of this cylinder remain closed while the valves of the phase by means of pin 99360612, to be inserted in
other cylinder in the pair can be adjusted. the 11th hole in each of the three sectors with 18
holes each.
The cylinder pairs are 1-6,2-5,3-4.
Strictly adhere to directions and data given on the table below.
Adjusting clearances between rockers and intake/exhaust/valve End the assembly procedure by mounting cylinder head cover
studs: and its gasket.
- Use a box wrench to loosen the adjusting screw locking
nut (1).
- Insert the feeler gauge blade (3).
- By using proper wrench, screw or unscrew rocker arm
- Ensure the feeler gauge blade (3) can slide between the
parts concerned with a slight friction.
- Hold the screw still while tightening the nut (1).
Setting pump-injector rocker preloading:
- Use a box wrench to loosen the nut fastening the
adjusting screw for rocker arm (5) controlling
pump-injector (6).
- With a suitable wrench (4) tighten the adjusting screw
until the pumping element reaches its-end-of-stroke
point.
- Lock the adjusting screw to a torque of 5 Nm (0.5 kgm)
by means of a torque wrench.
- Back off the adjusting screw 1/2 to 3/4 turn.
- Tighten the lock nut.
FIRING ORDER 1-4-2-6-3-5
CLOCKWISE ADJUSTING ADJUSTING ADJUSTING

START-UP CYLINDER CLEARANCE PRE-
AND VALVE NO. OF LOADING
ROTATION CYLINDER OF
VALVE NO. CYLINDER
INJECTOR
NO.
1 and 6 at 6 1 5
TDC
120 3 4 1
120 5 2 4
120 1 6 2
120 4 3 6
120 2 5 3

F3BFE613 SECTION 6 - ENGINE OVERHAUL 1
SECTION 6
Engine overhaul
Page
DISASSEMBLY THE ENGINE ON THE BENCH 3
ENGINE OVERHAUL ENGINE REMOVAL

AT THE BENCH . . . . . . . . . . . . . . . . . . . . . . 9
REPAIRS CYLINDER BLOCK . . . . . . . . . . . . . . . 11
- Checks and measurements . . . . . . . . . . . . . . . 11
- Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Removing cylinder liners . . . . . . . . . . . . . . . . . 13
- Assembly and checking protrusion . . . . . . . . . 13
- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Measuring the main journals and crankpins . . . 15
- Preliminary measurement of main

and big end bearing shell selection data . . . . . 16
- Selecting the main bearing and

big end bearing shells . . . . . . . . . . . . . . . . . . . 17
- Defining the class of diameter of the main journals

and crankpins (Journals with nominal diameter) 18
- Selecting the main bearing shells (Journals with

nominal diameter) . . . . . . . . . . . . . . . . . . . . . . 19
- Selecting the main bearing shells

(ground journals) . . . . . . . . . . . . . . . . . . . . . . . 20
- Selecting the big end bearing shells

(journals with nominal diameter) . . . . . . . . . . 21
- Replacing the timing gear and oil pump . . . . . 23
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 23
- Checking crankshaft end float . . . . . . . . . . . . . 24
PISTON CONNECTING ROD ASSEMBLY . . . . 25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Conditions for correct gudgeon

pin-piston coupling . . . . . . . . . . . . . . . . . . . . . 26
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2 SECTION 6 - ENGINE OVERHAUL F3BFE613
Page Page
- Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . 28 ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 41

- Mounting the connecting rod - Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
piston assembly . . . . . . . . . . . . . . . . . . . . . . . . 29
- Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Mounting the piston rings . . . . . . . . . . . . . . . . 29
ASSEMBLING THE ENGINE ON THE BENCH . 43
- Fitting the big end bearing shells . . . . . . . . . . . 29
- Diagram of tightening sequence of crankcase
- Fitting connecting rod - piston assemblies base fixing screws . . . . . . . . . . . . . . . . . . . . . . 45
in the cylinder liners . . . . . . . . . . . . . . . . . . . . 30
- Fitting connecting rod - piston assemblies
- Checking piston protrusion . . . . . . . . . . . . . . . 30 in cylinder liners . . . . . . . . . . . . . . . . . . . . . . . 46
- Checking crankpin assembly clearance . . . . . . 31 - Mounting cylinder head . . . . . . . . . . . . . . . . . 47
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 31 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 49
- Dismounting the valves . . . . . . . . . . . . . . . . . . 31 - Fitting flywheel box . . . . . . . . . . . . . . . . . . . . . 48
- Checking head bearing surface - Fitting engine flywheel . . . . . . . . . . . . . . . . . . . 49
on cylinder block . . . . . . . . . . . . . . . . . . . . . . 31
- Fitting camshaft . . . . . . . . . . . . . . . . . . . . . . . . 50
- Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Fitting pump-injectors . . . . . . . . . . . . . . . . . . . 51
- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Fitting rocker-arm shaft assembly . . . . . . . . . . 51
- Checking clearance between valve-stem and
associated valve guide . . . . . . . . . . . . . . . . . . . 33 - Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . 52
- Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - Phonic wheel timing . . . . . . . . . . . . . . . . . . . . 54
- Replacing injector cases . . . . . . . . . . . . . . . . . 33 - Intake and exhaust rocker play adjustment and
pre-loading of rockers controlling
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 pump injectors . . . . . . . . . . . . . . . . . . . . . . . . 55
- Checking injector protrusion . . . . . . . . . . . . . 35 - Completing Engine Assembly . . . . . . . . . . . . . 56
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . 36
- Idler gear pin . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Twin intermediate gear pin . . . . . . . . . . . . . . . 36
- Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . 36
- Replacing the bushings . . . . . . . . . . . . . . . . . . 36
- Timing system . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Checking cam lift and pin alignment . . . . . . . . 37
- Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . 40

DISASSEMBLY THE ENGINE ON THE On the left-hand side of the engine

BENCH Figure 3
Handle all parts with great care.

Never put your hands or fingers between one part
and another.
Wear suitable personal protective equipment such
as a visor, gloves and safety shoes.
Cover all electrical components before washing with

high-pressure water jets. Before securing the engine to the
rotary stand 99322230, remove: the electrical cable of the
engine by unplugging it from the control unit and from all
sensors transmitters to which it is connected. Proceed to
remove all those parts that can interfere with the assembly of
the brackets as shown hereunder.
Figure 1
166725
- the engine mounting (1).
Figure 4
166723
On the right-hand side of the engine

- Using appropriate tool, remove the fuel cartridge filter
(1), fuel pipes (3) and body fuel filter (2).
Figure 2
104246/A
166724
- Remove the feed pump (1). - the oil pressure adjustment valve (1).
- Remove flange (2).

166336
Secure the engine to the rotary stand 99322230 with the brackets 99361036 (1).

Figure 6 Figure 8
166728
71702 Using an appropriate tool (1), turn it in the direction shown

by the arrow and remove the auxiliary member drive belt (2).
Use tool (1) 99360351 to lock the engine flywheel.
If present, dismount compressor for climate control system
and relating driving spring belt.
Figure 7 NOTE Spring belt must be replaced by a new one after

every dismounting operation.
Figure 9
166727
Operate the 6 Allen screws (1) to remove the damper

flywheel (2).
166729
Remove the alternator (1), pulley (2), automatic tensioners (3

and 5), pulley (4), water pump (6) and pulley (7).

Figure 10 Figure 13
125518
Use tool 99360252 to slacken the oil filters (1).
166730 NOTE Under heat exchanger place a container for engine

coolant drain.
Remove the thermostat assembly (1).
Figure 14
Figure 11
60490 166732
Apply extractor 99340053 (2) and take out the crankshaft seal - Slacken the screws (1) and remove the intercooler (4);
(1); now remove the flange (3). - Slacken the screws (2) and remove the water pipe (3).
Figure 12 Figure 15
166731
166733
Remove the following components: oil returns pipes (1); oil Dismount following parts: starter (1); intake manifold (2)
delivery pipes (2); turbocompressor unit (3); exhaust manifold complete with resistance for engine preheating; engine central
(4). unit (3); relating pipes.

Figure 16 Figure 18
85480 60497
Remove the rocker arm cover (1), take off the screws (2) and - Slacken the screws (1); drive one of them in a torque hole
extract the cover (3), the filter (5) and the gaskets (4 and 6). in order to remove the shoulder plate (2) and extract the
Remove the screws (8) and the blow-by case (7). metal sheet gasket.
Figure 17 Figure 19
60575 60498
- Slacken the screws (2) and remove the gear (1) together Unscrew the screws (2) and remove the idle gear (1).
with the phonic wheel.

Figure 20 Figure 23
60499
106219
With the engine flywheel locking tool 99360351 (1) fitted,
unscrew the fixing screws (2). Take off the tool (1) and extract If present, dismount P.T.O. driving gear (1).
the flywheel (3). Remove screws (3) and dismount double gear (2).
Remove securing screw and dismount articulated rod (5).
Figure 21 Dismount oil pump (4).
Figure 24
60500
166734
Fit on the extractor 99340054 (2) and extract the gasket (1). - Remove the electric connections (1).
- Unscrew the screws (2) fixing the rocker arm shaft.
Figure 22
- Remove the head injection wiring. The wiring has to be
extracted from the front.
Figure 25
116190
60501
Apply tool 99360553 (1) to the rocker holder shaft (2) and
Unscrew the screws (1) and remove the gearbox (2). remove the shaft (2) from the cylinder head.

Figure 26 Figure 29
60516
Unscrew the screws (2) and take out the engine oil sump (1)
166735
together with the spacer (3) and gasket.
- Unscrew the screws (2) fixing the brackets (3); Figure 30

- hook tool 99342155 part (6) to pump injector (1);
- mount part (5) on part (6) resting part on cylinder head;
- screw nut (4) and extract pump injector (1) from cylinder
head.
Figure 27
60517
ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH
The following instructions are prescribed on the
60514
understanding that the engine has previously been placed on
the rotating bench and that removal of all specific components
- Insert the plugs 99360180 (1) in place of the injectors. of the equipment have been already removed as well. (See
- Extract the camshaft (2). Section 3 of the manual herein). The section illustrates
- Unscrew the screws fixing the cylinder head (3). therefore all the most important engine overhaul procedures.
Figure 31
Figure 28
60515
- Using metal ropes, lift the cylinder head (1). 47574

- Take off the gasket (2).
Turn the crankcase (1) upright.

Figure 32
NOTE Note down the assembly position of the top and
bottom main bearing shells since, if reusing them,
they will need to be fitted in the position found
upon removal.
Figure 34
60518
Untighten screws (2) fixing the connecting rod cap (3) and
remove it. Remove the connecting rod-piston (1) assembly
from the upper side. Repeat these operations for the other
pistons.
47570
NOTE Keep the big end bearing shells in their respective Using tool 99360500 (1), remove the crankshaft (2).
housings and/or note down their assembly position
since, if reusing them, they will need to be fitted in
the position found upon removal.
Figure 35
Figure 33
47571
Extract the main bearing shells (1), unscrew the screws and
take out the oil nozzles (2).
Dismount cylinder liners as described in Section 4.
60519
NOTE After removing the engine, you need to clean the

Using an appropriate wrench and the hex wrench unscrew the removed parts thoroughly and check their integrity.
screws (1) and (2) and take off the crankcase base. The following pages give the instructions for making
the checks and the main measurements to make to
determine whether the parts can be reused.

REPAIRS Figure 38
CYLINDER BLOCK X
Checks and measurements
60595
A = Selection class 135.000 to 135.013 mm

34994 B = Selection class 135.011 to 135.024 mm
The inside diameter of the cylinder liners is checked to X = Selection class marking area
ascertain the extent of ovalization, taper and wear using the On finding maximum wear greater than 0.150 mm or
gauge (2) fitted with the dial gauge (1), zeroed beforehand on maximum ovalization of 0.100 mm compared to the values
the ring gauge (3) of diameter 135 mm. shown in the figure, you need to replace the cylinder liner as
no grinding, facing or reconditioning is permitted.
NOTE If you do not have a ring gauge of diameter 135 mm,

use a micrometer for this purpose. NOTE The cylinder liners are supplied as spare parts with
selection class A.
Figure 37
Figure 39
60596 60597
A = 153.500 to 153.525 mm
B = 152.000 to 152.025 mm
1 = 1st measurement C = 153.461 to 153.486 mm
2 = 2nd measurement D = 151.890 to 151.915 mm
3 = 3rd measurement The diagram shown in the figure gives the outside diameter of
the cylinder liner and inside diameter of its seat.
The measurements have to be made on each single cylinder
liner at three different heights and on two levels (A-B) at right The cylinder liners can, if necessary, be extracted and fitted
angles to each other as shown in figure. several times in different seats.

Cylinder liners
Figure 40
60598
CRANKCASE ASSEMBLY WITH CYLINDER LINERS
Figure 41
108832
* Selection class A mm 135.000 to 135.013
B mm 135.011 to 135.024
MAIN CYLINDER LINER DATA
Figure 42
108833
DETAIL X
Y - Selection class marking area
Removing cylinder liners Figure 45 (Demonstration)

Figure 43
47577 60520
Position the parts 99360706 (2) and the plate 99360728 (4) Check the protrusion of the cylinder liners with tool 99360334
as shown in the figure, checking that the plate (4) rests on the (2) and tightening the screw (1) to a torque of 225 Nm.
cylinder liner correctly. Using the dial gauge 99395603 supplied as standard with the
Screw down the nut of screw (1) and extract the cylinder liner dial gauge base 99370415 (3), check that the protrusion of the
(3) from the crankcase. cylinder liner over the supporting face of the cylinder head is
0.045 - 0.075 mm; if this is not so, replace the adjustment ring,
supplied as a spare part with several thicknesses.
Assembly and checking protrusion
Figure 44
Figure 46 0.045 to 0.075
49017
CYLINDER LINER PROTRUSION
Figure 47
16798
Always replace the water seals (3, 4 and 5).

Fit the adjustment ring (1) on the cylinder liner (2). Lubricate
the bottom of it and mount it in the cylinder assembly using
the appropriate tool.
! The adjustment ring (1) is supplied as a spare part

with the following thicknesses: 0.08 mm - 0.10 mm -
0.12 mm - 0.14 mm.
60521
On completing assembly, lock the cylinder liners (1) to the

crankcase (2) with the pins 99360703 (3).

Crankshaft
Figure 48
Top main bearing shells
169834
Bottom main bearing shells

MAIN DATA OF CRANKSHAFT AND MAIN BEARING SHELLS
Check the state of the main journals and crankpins of the crankshaft. They must not be scored or be too ovalized or worn.
The data given refer to the normal diameter of the journals.
Figure 49 Figure 50
POLISHED POLISHED
GROUND
GROUND
GROUND
108834 108835
X. Detail of the main journal unions Y. Detail of the crankpin unions

Measuring the main journals and crankpins Figure 53

Before grinding the journals, use a micrometric gauge (1) to
measure the journals of the shaft (2) and establish, on the basis
of the undersizing of the spare bearing shells, to what diameter
it is necessary to reduce the journals.
Figure 51
47536
MEASURING CRANKPINS
When grinding, pay the utmost attention to the values of the
47535
unions of the main journals and of the crankpins given in
previous figure.
MEASURING THE MAIN JOURNALS
NOTE It is advisable to note the measurements in a table NOTE All the main journals and crankpins should always be
(Figure below). ground to the same undersizing class so as not to
alter the balance of the shaft.
Figure 52
Table for noting down the measurements of the main journals and crankpins of the crankshaft.
MAIN JOURNALS
MIN.
MAX.
MIN.
MAX.
CRANKPINS 36061

Preliminary measurement of main and big end bearing shell selection data
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:
- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure below at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure below at bottom).
- Each of these digits may be 1, 2 or 3.
CLASS MAIN BEARING HOUSING

Figure 54 NOMINAL DIAMETER
106.300 to 106.309
106.310 to 106.319
106.320 to 106.330
47535

Selecting the main bearing and big end bearing shells
NOTE To obtain the required assembly clearances, the main bearing and big end bearing shells have to be selected as described
hereunder.
This operation makes it possible to identify the most suited bearing shells for each of the journals of the shaft (the bearing shells
may even have different classes for different pins).
Depending on the thickness, the bearing shells are selected in Figure below gives the specifications of the main bearing and
classes of tolerance marked by a colour (red-green - red/black big end bearing shells available as spare parts in the standard
- green/black). sizes (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Figure 55
Big end bearing shells STD +0.127 +0.254 +0.508
red 1.965 to 1.975 2.092 to 2.102 2.219 to 2.229
green 1.976 to 1.985 2.103 to 2.112 2.230 to 2.239
Main bearing shells STD +0.127 +0.254 +0.508
red 3.110 to 3.120 3.237 to 3.247 3.364 to 3.374
green 3.121 to 3.130

Defining the class of diameter of the main journals and crankpins (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure below):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins they
refer to (Figure below at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the status
of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the main journals
they refer to (Figure below at bottom).
Figure 56
CRANKPIN
CLASS
NOMINAL DIAMETER
89.970 to 89.979
89.980 to 89.989
89.990 to 90.000
CLASS MAIN JOURNALS

NOMINAL DIAMETER
99.970 to 99.979
99.980 to 99.989
99.990 to 100.000

Selecting the main bearing shells (Journals with nominal diameter)

After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells
to use according to the following table:
Figure 57
STD.
1 2 3
green green green
1
green green green
red green green
2
red green green
red red green
3
red red green

Selecting the main bearing shells (ground journals)

If the journals have been ground, the procedure described so far cannot be applied.
In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only type of
bearing shell envisaged for the relevant undersizing.
Figure 58
red/black = -0.127
3.173 to 3183 mm
green/black =
3.184 to 3.193 mm
1 2 3
99.843 green/black green/black green/black
1

2

3
-0.254
red =
3.237 to 3.247 mm
1 2 3
red red red

99.726
99.746 red red red
-0.508
red =
3.364 to 3.374 mm
1 2 3
red red red

99.472
99.492 red red red

Selecting the big end bearing shells Figure 59

(journals with nominal diameter)
There are three markings on the body of the connecting rod
in the position indicated as A:
1 Letter indicating the class of weight:

VIEW FROM A
A = 4741 to 4780 g.
B = 4781 to 4820 g.
C = 4821 to 4860 g.
2 Number indicating the selection of the diameter of the big
end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Numbers identifying the cap-connecting rod coupling.
The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table below. 47557
Figure 60
STD.
CLASS 1 2 3
green green green

1
green green green
red green green
2
red green green
red red green
3
red red green

SELECTING BIG END BEARING SHELLS (GROUND JOURNALS)

If the journals have been ground, the procedure described so far cannot be applied.
In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crankpins
and to mount the bearing shells identified with the relevant table.
Figure 61
red/black =
mm 2.028 to 2.038 -0.127
green/black =
mm 2.039 to 2.048
CLASS 1 2 3
1

2

3
-0.254
red =
mm 2.092 to 2.102
green =
1 2 3
mm 2.103 to 2.112
89.726 red green green
89.736 red red green
-0.508
red =
mm 2.219 to 2.229
green =
1 2 3
mm 2.230 to 2.239
red green green

89.472

Replacing the timing gear and oil pump Figure 64

Check that the toothing of the gear is neither damaged nor
worn; if it is, take it out with an appropriate extractor and
replace it.
Figure 62
47578
Using the tackle and hook 99360500 (1), mount the

crankshaft (2).
108836
Figure 65
When fitting the gear (1) on the crankshaft (2), heat it for no
longer than 2 hours in an oven at a temperature of 180C.
After driving it in, leave it to cool.
If changing the pin (3), after fitting it on, check it protrudes from
the crankshaft as shown in the figure.
Fitting main bearings

Figure 63 49021
Arrange the bearing shells (1) on the main bearing housings

in the crankcase base (2).
47579
Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
Arrange the bearing shells (1) on the main bearing housings.

Figure 66 Figure 67
60559 47578
Using appropriate hooks and tackle, mount the crankcase base - Lubricate the internal screws (1) with UTDM oil and
(1). tighten them with a torque wrench (3) to a torque of
120 Nm, using tool 99395216 (4), to an angle of 60,
following the diagram below.
Figure 68
FRONT SIDE
60593
DIAGRAM OF SEQUENCE FOR TIGHTENING THE SCREWS FIXING

THE BOTTOM CRANKCASE BASE TO THE CRANKCASE
Checking crankshaft end float
Figure 69
47588
The end float is checked by setting a dial gauge (1) 99395603

with a magnetic base on the crankshaft (2) as shown in the
figure. If you find the clearance to be greater than as required,
replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check.


Figure 70
60607

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring -
6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
Figure 72
Figure 71
126311 126312
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).

Figure 73
49026
Remove the piston pin (1).

If removal is difficult use the appropriate beater.
Figure 74
32618
Measuring the gudgeon pin diameter (1) with a micrometer (2).
Conditions for correct gudgeon pin-piston

coupling
Figure 75
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.

Figure 76
108837
MAIN DATA OF THE PISTON, PISTON RINGS AND PIN

X = 0,80,1
Figure 79
Piston rings
Figure 77
3513
The seal (2) of the 1st slot has a V shape. The clearance X
between the seal and its seat is measured by setting the
piston (1) with the ring in the cylinder liner (3) so that the
16552
seal comes half out of the cylinder liner.
Check the thickness of the piston ring (2) with a micrometer
(1).
Figure 80
Figure 78
36134
Using a feeler gauge (2), check the opening between the ends
of the seals (1) inserted in the cylinder liner (3).
60610
If you find the distance between the ends is less than or
Check the clearance between the seals (2) and their seats on greater than as required, replace the piston rings.
the piston (1) with a feeler gauge (3).

Connecting rod
Figure 81
Punched on the big end of the connecting rod are the data
relating to the section in classes relating to the connecting
rod seats and the weights.
NOTE On assembling the connecting rods, check VIEW FROM A

they are all of the same class of weight.
Connecting rod punch markings
1 Letter indicating the class of weight:

A = 4741 to 4780 g.
B = 4781 to 4820 g.
C = 4821 to 4860 g.
2 Number indicating the selection of the diameter
of the big end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Number indicating the selection of diameter
for the big end bearing housing:
47957
Figure 82
71716
MAIN DATA OF THE BUSHING, CONNECTING ROD, PIN AND BEARING SHELLS
* Measurement to be made after driving in the bushing.

Mounting the connecting rod piston assembly Mounting the piston rings
Figure 83 Figure 85
126313
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
The rings need to be mounted with the word TOP (4)
73536
facing upwards. Direct the ring openings so they are
staggered 120 apart.
The piston (1) has to be fitted on the connecting rod (2) so
that the graphic symbol (4), showing the assembly position
in the cylinder liner, and the punch marks (3) on the
connecting rod are observed as shown in the figure.
Fitting the big end bearing shells
Figure 86
Figure 84
1
2
49030
74052
Fit the bearing shells (1), selected as described under the
Fit the pin (2) and fasten it on the piston (1) with the split rings heading Selecting the main and big end bearing shells, on
(3). both the connecting rod and the cap.
If reusing bearing shells that have been removed, fit them
back into their respective seats in the positions marked
during removal.

Fitting connecting rod - piston assemblies in Figure 87

the cylinder liners
With the aid of the clamp 99360603 (1), fit the connecting
rod piston assembly (2) in the cylinder liners, according to
the diagram of Figure below, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.
60616
Checking piston protrusion

NOTE The pistons are supplied as spares in class A and can On completing assembly, check the protrusion of the pistons
be fitted in class B cylinder liners. from the cylinder liners; it must be 0.12 0.42 mm.
Figure 88
60615
ASSEMBLY DIAGRAM OF CONNECTING ROD PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod piston assembly 2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class 3. Connecting rod punch mark area

Checking crankpin assembly clearance Figure 90

To measure the clearance, carry out the following
operations.
Connect the connecting rods to the relevant journals of the
crankshaft, placing a length of calibrated wire on the journals.
Figure 89
47583
Mount and secure the tool 99360263 (2) with the bracket
(4). Screw down with the device 99360259 (1) to be able to
remove the cotters (3). Take out the tool (2) and extract the
top plate (5), spring (6) and bottom plate (7).
47594
Repeat this process on all the valves.
Mount the connecting rod caps (1) together with the bearing Turn over the cylinder head and take out the valves (8).
shells. Tighten the screws (2) fixing the connecting rod caps
to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),
further tighten the screws with an angle of 60.
NOTE The thread of the screws (2), before assembly, has

to be lubricated with engine oil.
Remove the caps and determine the clearance by comparing

the width of the calibrated wire with the graduated scale on Checking head bearing surface on cylinder
the case containing the calibrated wire. block
Upon final assembly: check the diameter of the thread of the
screws (2), it must be no less than 13.4 mm; if it is, change the Figure 91 (Demonstration)
screw. Lubricate the crankpins and connecting rod bearings.
Tighten the screws (2) as described above.
CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal by proper tooling; in case of leaks not caused
by cup plugs or threaded plugs, replace cylinder head.
NOTE In case of plugs dismounting/replacement, on

mounting, apply sealant Loctite 270 on plugs.
36159
Check the supporting surface (1) of the head on the cylinder

Dismounting the valves block with a rule (2) and a feeler gauge (3). If you find any
deformation, level the head on a surface grinder; maximum
amount of material that can be removed 0.2 mm.
NOTE Before dismounting cylinder head valves, number
them in view of their remounting in the position
observed on dismounting should they not have to
be overhauled or replaced.
Intake valves are different form exhaust valves in NOTE After this process, you need to check the valve
that they have a notch placed at valve head centre. recessing and injector protrusion.

Valves Figure 93
Decarbonizing and checking valves
Figure 92
71718
48625 MAIN DATA OF VALVES AND VALVE GUIDES

Remove the carbon deposits on the valves with a wire brush. * Measurement to be made after driving in the valve guides
Check that the valves show no signs of seizure or cracking
and check with a micrometer that the valve stem diameter
comes within the required values; replace the valves if it does Check with a micrometer that the diameter of the valve
not. stems is as indicated. If necessary, grind the valve seats with
a grinding machine, removing as little material as possible.
Valve seats
Regrinding replacing valve seats
NOTE The valve seats are reground whenever the valves

or valve guides are ground and replaced.
Figure 94
1 2
73555
MAIN DATA OF VALVE SEATS

1. Intake valve seat 2. Exhaust valve seat

Figure 95 Part 99360296 determines the exact position of assembly of

the valve guides in the cylinder head. If they are not available,
you need to drive the valve guides into the cylinder head so
they protrude by 30.831.2 mm.
After driving in the valve guides, rebore their holes with the
smoother 99390330.
Replacing injector cases

Removal
Figure 97
41032
Ream the valve seats (2) on cylinder head using tool (1).
NOTE Valve seats must be reamed whenever valves or

valve guides are replaced or ground.
After regrinding the valve seats, using tool 99370415 and dial
gauge 99395603, check that the position of the valves in
relation to the plane of the cylinder head is:
- -0.45 -0.75 mm (recessing) intake valves
- -1.65 -1.95 mm (recessing) exhaust valves.
Checking clearance between valve-stem and

associated valve guide
Using a dial gauge with a magnetic base, check the clearance
between the valve stem and the associated guide. If the
clearance is too great, change the valve and, if necessary, the
valve guide.
Valve guides
Replacing valve guides
Figure 96
60619
To replace the injector case (2), proceed as follows:

- Thread the case (2) with tool 99390804 (1).
The steps described in the following figures need to be
carried out by fixing the tools, with the bracket A, to the
cylinder head.
108838
The valve guides are removed with the drift 99360143.

They are fitted with the drift 99360143 equipped with part
99360296.

Figure 98 Assembly
Figure 100
60622
- Lubricate the seals (3) and fit them on the case (4). Using
tool 99365056 (2) secured to the cylinder head with
bracket A, drive in the new case, screwing down the
60620
screw (1) upsetting the bottom portion of the case.
- Screw the extractor 99342149 (2) into the case (3).
Screw down the nut (1) and take the case out of the Figure 101
cylinder head.
Figure 99
60621
- Using the tool 99390772 (2) remove any residues (1) left
60623
in the groove of the cylinder head.
- Using the reamer 99394041 (1-2), rebore the hole in the
case (3).
to
108839
INJECTOR CASE ASSEMBLY DIAGRAM
60624
- Using the milling cutter 99394043 (1-2), regrind the

injector seat in the case (3).
Checking injector protrusion
Figure 103
47585
Check injector protrusion (2) with the dial gauge (1).

The protrusion must be 0.53 - 1.34 mm.

TIMING GEAR Twin intermediate gear pin

Camshaft drive Twin idler gear
86925
TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod - 86934
5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear -
8. Drive shaft driving gear. Rated assembling play between gear bushings and pins:
0.045 0.085 mm.
Idler gear pin Replacing the bushings

Idler gear
Bushings can be replaced when they are worn. Put up the
bushing, then bore it to obtain the diameter shown on
Figure 106
previous figures.
NOTE The bushing must be driven into the gear by following

the direction of the arrow and setting the latter to the
dimension shown on previous figures.
108840
Rated assembling play between gear bushings and pins:

0.045 0.075 mm.

Timing system
Checking cam lift and pin alignment
Figure 108
47506
Set the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) with the dial gauge (2).
Figure 109
47507
Still with the camshaft (4) set on the tailstocks (1), check the alignment of the supporting pins (3) with the dial gauge (2); it must
be no greater than 0.030 mm. If you find a greater misalignment, replace the shaft.
Figure 110
47505
To check the assembly clearance, measure the inside diameter of the bushings and the diameter of the pins (1) of the camshaft:
the difference will give the actual clearance.
If you find any clearances over 0.135 mm, replace the bushings and, if necessary, the camshaft as well.
Figure 111
108841
MAIN DATA OF THE CAMSHAFT AND TOLERANCES

The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth.
Whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings.
TOLERANCES FEATURE SUBJECT OF TOLERANCE SYMBOL

DIRECTION Perpendicularity
POSITION Concentricity or coaxiality
SWING Circular oscillation
CLASS OF IMPORTANT ASCRIBED TO PRODUCT CHARACTERISTICS SYMBOL
CRUCIAL
IMPORTANT
SECONDARY
Bushings
Figure 112
60627
MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD
* Bushing inside diameter after driving in
The surface of the bushings must show no sign of seizing or If you find a higher value than the tolerance, replace them.
scoring; replace them if they do. To remove and fit the bushings, use the appropriate drift
Measure the inside diameter of the bushings with a bore 99360499.
gauge.
Replacing camshaft bushings with drift 99360499

Drift
Figure 113
107217
A = Drift with seat for bushings to insert/extract.

B = Grub screw for positioning bushings.
C = Reference mark to insert seventh bushing correctly.
D = Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (yellow marks).
E = Guide bushing.
F = Guide line.
G = Guide bushing to secure to the seventh bushing mount.
H = Plate fixing bushing G to cylinder head.
I = Grip.
L = Extension coupling.
Removal Assembly
Front
77795
Assemble the drift together with the extension.

Rear To insert bushings 1, 2, 3, 4 and 5, proceed as follows:
1 position the bushing to insert on the drift (A) making the
71725
grub screw on it coincide with the seat (B) on the
bushing;
The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, 1. 2 position the guide bushing (E) and secure the guide
The bushings are extracted from the front of the single seats. bushing (G) on the seat of the 7th bushing with the plate
Removal does not require the drift extension for bushings 5, (H);
6 and 7 and it is not necessary to use the guide bushing.
3 while driving in the bushing, make the reference mark (F)
For bushings 1, 2, 3 and 4 it is necessary to use the extension
match the mark (M). In this way, when it is driven home,
and the guide bushings.
the lubrication hole on the bushing will coincide with the
Position the drift accurately during the phase of removal.
oil pipe in its seat.
The bushing is driven home when the 1st yellow
reference mark (D) is flush with the guide bushing (G).

Figure 116 Valve springs

Front Figure 118
Free spring
Valve closed
73,40 mm
547 to 603 N
1041 to 1149 N
59 mm
Valve open
46 mm
Rear
108842
71723
MAIN DATA TO CHECK THE SPRING FOR INTAKE

To insert the bushing (6), proceed as follows: AND EXHAUST VALVES
- Unscrew the grip (I) and the extension (N).
- Position the extension (N) and the guide bushing E as
- Repeat steps 1, 2, 3.
Figure 117
Front
Rear
71724
To insert bushing (7), proceed as follows:

- Unscrew the grip (I) and the extension (N).
- Refit the guide (G) from the inside as shown in the figure.
- Position the bushing on the drift (A) and bring it close
up to the seat, making the bushing hole match the
lubrication hole in the head. Drive it home.
The 7th bushing is driven in when the reference mark (C)
is flush with the bushing seat.

Fitting valves and oil seal Figure 120

Figure 119
86290
- Mount the springs (6) and the top plate (5).

- Fit the tool 99360263 (2) and secure it with the bracket
(4). Screw down the lever (1) to be able to fit on the
cotters (3). Take off the tool (2).
87051
Lubricate the valve stem and insert the valves in the

respective valve guides; fit the lower caps (1). Use tool
99360329 to fit the oil seal (2) on the valve guides (3) of the
exhaust valves; then, to fit the valves, proceed as follows.
NOTE Should valves not have been overhauled or

replaced, remount them according to numbering
performed on dismounting.
that they have a notch placed at valve head centre.
ROCKER SHAFT
Figure 121
99281
The cams of the camshaft control the rocker arms directly: 6 for the injectors and 12 for the valves.
Injectors and intake valves control rocker arms are keyed on rocker arms shaft directly.
The rocker arms run directly on the profiles of the cams by means of rollers.
The other end acts on a crosspiece that rests on the stem of the two valves.
There is a pad between the rocker arm adjustment screw and the crosspiece.
There are two lubrication ducts inside the rocker arms.
The length of the rocker arm shaft is basically the same as that of the cylinder head. It has to be detached to be able to reach
all the parts beneath.

Shaft
Figure 122
73557
MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
Rocker arms
SECTION
SECTION A-A
SECTION
A-A SECTIO B-B
N
B-B
71728 71730
PUMP INJECTOR ROCKER ARMS EXHAUST VALVE ROCKER ARMS
Figure 124
SECTION
A-A SECTION
B-B
71729
INTAKE VALVE ROCKER ARMS
Check the surfaces of the bushings, which must show no signs of scoring or excessive wear; if they do, replace the rocker arm
assembly.

ASSEMBLING THE ENGINE ON THE Figure 128

BENCH
Using the brackets 99361036, secure the crankcase to the
stand 99322230.
Mount cylinder liners.
Figure 126
49021
Arrange the bearing shells (1) on the main bearing housings

in the crankcase base (2).
47586
Figure 129
Mount the oil nozzles (2), making the grub screw coincide
with the hole (3) in the crankcase.
Arrange the bearing shells (1) on the main bearing housings.
NOTE Not finding it necessary to replace the main

bearings, you need to fit them back in exactly the
same sequence and position as in removal.
If to be changed, choose the main bearings
according to the procedure in chapter Selection of
main bearings and connecting rod bearings.
Figure 127
47595
Apply LOCTITE 5970 silicone on the crankcase using the

appropriate tools (1) as shown in Figure below.
Figure 130
47570
60632
Lubricate the bearing shells then mount the crankshaft (2)
using the tackle and hook 99360500 (1). Sealant application diagram.
NOTE Mount the crankcase base within 10 min. of

applying the sealant.

Figure 131
60559
Mount the crankcase base (1) using appropriate tackle and

hooks.
Figure 132
47581
Using a torque wrench (2), tighten the outside hex grooved

screws (1) to a torque of 30 Nm, following the diagrams given
on the following page.
Figure 133
47579
Using a torque wrench (3), tighten the inside screws (1) to

a torque of 120 Nm. Then tighten them to an angle of 60
and 55 with tool 99395216 (4) with another two phases.
Regrind the outside screws (1, previous figure) with closure
to an angle of 60 using tool 99395216 (4).

Diagram of tightening sequence of crankcase base fixing screws

Figure 134
First phase:
FRONT SIDE
pre-tightening
outside screws
30 Nm
60592
Second phase:
FRONT SIDE
pre-tightening
inside screws
120 Nm
60593
Third phase:
FRONT SIDE
closing inside
screws to angle
60
60593
Fourth phase:
FRONT SIDE closing inside
screws to angle
55
60593
Fifth phase:
FRONT SIDE closing outside
screws to angle
60
60594

Fitting connecting rod - piston assemblies in Figure 137

cylinder liners
Figure 135
60616
Turn the cylinder block, setting it upright.

49030
Lubricate the pistons, piston rings and inside the cylinder
liners. With the aid of the clamp 99360603 (1) mount the
NOTE Not finding it necessary to replace the connecting connecting rod piston assemblies (2) in the cylinder liners
rod bearings, you need to fit them back in exactly according to Figure below. Check that:
the same sequence and position as in removal.
If to be changed, choose the main bearings - The number of each connecting rod corresponds to the
according to the procedure in chapter Selection of cap coupling number.
main bearings and connecting rod bearings. - The symbol (2, Figure below) punched on the top of the
pistons faces the engine flywheel or the recess in the
piston skirt tallies with the position of the oil nozzles.
Lubricate the bearing shells (1 and 3) and fit them on the
connecting rod (2) and on the cap (4).
NOTE The pistons are supplied as spares in class A and can
NOTE Do not make any adjustment on the bearing shells. also be fitted in class B cylinder liners.
Figure 136
1 Connecting rod piston assembly
2 Area of punch marking on the top of the

piston with the symbol for the mounting
position and selection class.
3 Area of connecting rod punch marking
60615

Montaje de la culata
Figure 138 Mounting cylinder head

Figure 141
60515
47594
Check that the pistons 1-6 are exactly at the T.D.C.
NOTE Before reusing the screws (2), measure the Put the gasket (2) on the crankcase.
diameter of the thread; it must be no less than 13.4 Mount the cylinder head (1) and tighten the screws as shown
mm; if it is, change the screw. in following figures.
Lubricate the thread of the screws with engine oil
before assembly. NOTE Lubricate the thread of the screws with engine oil
before assembly.
Connect the connecting rods to the relevant pins of the
crankshaft, mount the connecting rod caps (1) together with
the bearing shells. Tighten the screws (2) fixing the connecting Figure 142
rod caps to a torque of 60 Nm (6 kgm). Using tool 99395216
(3), tighten the screws further with an angle of 60.
Figure 139
61270
Diagram of the tightening sequence of the screws fixing the

cylinder head.
60563
Using the centring ring 99396035 (2), check the exact
position of the cover (1). If it is wrong, proceed accordingly Figure 143
and lock the screws (3).
Figure 140
60565
60564 - Pre-tightening with the torque wrench (1):

Key on the gasket (1), mount the key 99346250 (2) and, 1st phase: 60 Nm (6 kgm).
screwing down the nut (3), drive in the gasket (1). 2nd phase: 120 Nm (12 kgm).

Figure 144
NOTE Mount the gearbox within 10 min. of applying the
sealant.
Figure 147

60566
- Closing to angle with tool 99395216 (1):

3rd phase: angle of 90
4th phase: angle of 65.
Figure 145
60633
Using a torque wrench, tighten the highlighted screws with

the following sequence and torque:
10 screws M12 x 1.75 x 100 56 to 70 Nm

2 screws M12 x 1.75 x 70 56 to 70 Nm
71773
Mount the oil pump (5), the middle gears (2) together with 4 screws M12 x 1.75 x 35 56 to 70 Nm
the link rod (1) and the PTO driving gear (3).
1 screw M12 x 1.75 x 120 56 to 70 Nm
Tighten the screws (4) to the required torque.
Fitting flywheel box : 2 screws M12 x 1.75 x 193 56 to 70 Nm
47592 60568
Apply LOCTITE 5970 silicone on the gearbox using Key on the gasket (1), fit the key 99346260 (2) and, screwing
appropriate tools (1) as shown in the figure. down the nut (3), drive in the gasket.

ENGINE FLYWHEEL
Fitting engine flywheel
Figure 149
VIEW OF HOLES: VIEW OF HOLES:

A-B-C D
60668
DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A. Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4. - B. Hole on flywheel with one
reference mark, corresponding to the TDC of pistons 1-6. - C. Hole on flywheel with one reference mark, corresponding
to the TDC of pistons 2-5. - D. Hole on flywheel with two reference marks, position corresponding to 54.
Figure 151
NOTE If the teeth of the ring gear mounted on the engine
flywheel, for starting the engine, are very damaged,
replace the ring gear. It must be fitted after heating the
ring gear to a temperature of approx. 200C.

Figure 150

49036
Second phase: closing to angle of 90 with tool 99395216 (1).
49037
NOTE The crankshaft has a locating peg that has to couple

with the relevant seat on the engine flywheel.
Position the flywheel (1) on the crankshaft, lubricate the

thread of the screws (2) with engine oil and screw them down.
Lock rotation with tool 99360351 (3). Lock the screws (2) in
three phases.
First phase: pre-tightening with torque wrench (4) to a torque
of 120 Nm (12 kgm).

Fitting camshaft Figure 154
Figure 152
60570
- Apply the gauge 99395219 (1). Check and adjust the

position of the link rod (3) for the idle gear. Lock the screw
(2) to the required torque.
72436
Position the crankshaft with the pistons 1 and 6 at the top dead
centre (T.D.C.). Figure 155
This situation occurs when:
1. The hole with reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
2. The tool 99360612 (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the engine flywheel (4).
If this condition does not occur, turn the engine flywheel (4)
appropriately.
Remove the tool 99360612 (1).
Figure 153
60571
- Fit the idle gear (1) back on and lock the screws (2) to the
required torque.
73843
Fit the camshaft (4), positioning it observing the reference

marks () as shown in the figure.
Lubricate the seal (3) and fit it on the shoulder plate (2).
Mount the shoulder plate (2) with the sheet metal gasket (1)
and tighten the screws (5) to the required torque.

5
60572
166726
Position the gear (2) on the camshaft so that the 4 slots are Mount:
centred with the holes for fixing the camshaft, without fully
locking the screws (5). - The injectors (1) and, using a torque wrench, lock the
Using the dial gauge with a magnetic base (1), check that the bracket fixing screws to a torque of 30 35 Nm.
clearance between the gears (2 and 3) is 0.073 0.195 mm; - The crosspieces (2) on the valve stem, all with the largest
if this is not so, adjust the clearance as follows: hole on the same side.
- Loosen the screws (4) fixing the idle gear (3).
- Loosen the screw fixing the link rod. Shift the link rod to
obtain the required clearance (see previous figures).
- Lock the screw fixing the link rod and screws (previous
figure) fixing the idle gear to the required torque.
Fitting rocker-arm shaft assembly

Fitting pump-injectors unscrewed.
Figure 157
Figure 159
108843 116190
Apply the tool 99360553 (1) to the rocker arm shaft (2) and
mount the shaft on the cylinder head.
Fit the seals (1) (2) (3) on the injectors.

Figure 160 1
Camshaft timing
Figure 163
70567A
SCHEME OF SCREW TIGHTENING SEQUENCE

SECURING ROCKER ARMS
Screw screws (1 - 2 - 3) until rocker arms are brought to
contact relating seats on cylinder head, tighten the screws
according to sequence indicated in figure operating in two
steps as indicated in successive figure.
Figure 161
71776
Apply tool 99360321 (7) and spacer (6) to gears box (3).
NOTE The arrow shows the direction of rotation of the

engine when running.
Using the above-mentioned tool, turn the engine
flywheel (1) in the direction of rotation of the engine
so as to take the piston of cylinder no.1 to
approximately the T.D.C. in the phase of combustion.
This condition occurs when the hole with one
reference mark (4), after the hole with two
reference marks (5) on the engine flywheel (1), can
116722 be seen through the inspection window (2).
Lock the screws (2) fixing the rocker-arm shaft as follows:
- 1st phase: tightening to a torque of 80 Nm (8 kgm) with
the torque wrench (1). Figure 164
- 2nd phase: closing with an angle of 60 using the tool
99395216 (3).
Figure 162
71774
The exact position of piston no.1 at the T.D.C. is obtained

when in the above-described conditions the tool 99360612
(1) goes through the seat (2) of the engine speed sensor into
the hole (3) in the engine flywheel (4).
167108 If this is not the case, turn and adjust the engine flywheel (4)
appropriately.
Mount the electric wiring (1). Remove the tool 99360612 (1).

106535
60575
Set the dial gauge with the magnetic base (1) with the rod on If you do not obtain the conditions illustrated in the previous
the roller (2) of the rocker arm that governs the injector of figure and described in points 1 and 2, proceed as follows:
cylinder no.1 and pre-load it by 6 mm. 1) loosen the screws (2) securing the gear (1) to the camshaft
With tool 99360321, turn the crankshaft clockwise until the and utilize the slots on the gear (1, Figure below);
pointer of the dial gauge reaches the minimum value beyond 2) turn the engine flywheel appropriately so as to bring about
which it can no longer fall. the conditions described in points 1 and 2 previous figure,
Reset the dial gauge. it being understood that the cam lift must not change at
all;
Turn the engine flywheel anticlockwise until the dial gauge 3) lock the screws (2) and repeat the check as described
gives a reading for the lift of the cam of the camshaft of 5.26 above;
to 5.36 mm.
4) tighten the screws (2) to the required torque.
Figure 168
Figure 166
71778
When the adjustment with the slots (1) is not enough to make
up the phase difference and the camshaft turns because it
becomes integral with the gear (2); as a result, the reference
value of the cam lift varies, in this situation it is necessary to
proceed as follows:
77259
1) lock the screws (2, previous figure) and turn the engine
The camshaft is in step if at the cam lift values of 5.26 to flywheel clockwise by approx. 1/2 turn;
5.36 mm there are the following conditions:
2) turn the engine flywheel anticlockwise until the dial gauge
1) a notch (5) can be seen through the inspection window; gives a reading of the lift of the cam of the camshaft of
2) the tool 99360612 (1) through the seat (2) of the engine 5.26 to 5.36 mm;
speed sensor goes into the hole (3) in the engine flywheel 3) take out the screws (2, previous figure) and remove the
(4). gear (2) from the camshaft.

Figure 169 Phonic wheel timing

Figure 170
77259
Turn the flywheel (4) again to bring about the following

conditions:
- a notch (5) can be seen through the inspection window;
- the tool 99360612 (1) inserted in the hole (3) in the
engine flywheel (4) through the seat (2) of the engine
speed sensor.
Mount the gear (2, previous figure) with the 4 slots
(1, previous figure) centred with the fixing holes of the
camshaft, locking the relevant screws to the required
tightening torque.
Check the timing of the shaft by first turning the flywheel
clockwise to discharge the cam completely and then turn the
flywheel anticlockwise until the dial gauge gives a reading of
5.26 to 5.36 mm. 77260
Check the timing conditions described in previous figure.
Turn the crankshaft by taking the piston of cylinder no. 1 into

the compression phase at T.D.C.; turn the flywheel in the
opposite direction to the normal direction of rotation by
approximately 1/4 of a turn.
Again turn the flywheel in its normal direction of rotation until
you see the hole marked with the double notch (4) through
the inspection hole under the flywheel housing. Insert tool
99360612 (5) into the seat of the flywheel sensor (6).
Insert the tool 99360613 (2), via the seat of the phase sensor,
onto the tooth obtained on the phonic wheel.
Should inserting the tool (2) prove difficult, loosen the screws
(3) and adjust the phonic wheel (1) appropriately so that the
tool (2) gets positioned on the tooth correctly. Go ahead and
tighten the screws (3).

Figure 171
167109
ADJUSTING INTAKE/EXHAUST ROCKERS AND INJECTION

Adjustment of clearances between rockers and valve studs - Lock the adjusting screw to a torque of 5 Nm (0.5 kgm)
and preloading of pump injector rockers should be carried out by means of a torque wrench.
with extreme care. - Back off the adjusting screw 1/2 to 3/4 turn.
Bring the cylinder under examination to the firing stage, the - Tighten the lock nut.
valves of this cylinder remain closed while the valves of the
other cylinder in the pair can be adjusted. FIRING ORDER 1-4-2-6-3-5
The cylinder pairs are 1-6,2-5,3-4.
Strictly adhere to directions and data given on the table below.
Adjusting clearances between rockers and Clockwise Adjusting Adjusting Adjusting
intake/exhaust/valve studs: start-up cylinder clearance pre-loading
- Use a box wrench to loosen the adjusting screw locking and rotation valve no. of cylinder of cylinder
nut (1). valve no. injector no.
- Insert the feeler gauge blade (3). 1 and 6 at TDC 6 1 5
- By using proper wrench, screw or unscrew rocker arm 120 3 4 1
- Ensure the feeler gauge blade (3) can slide between the 120 5 2 4
parts concerned with a slight friction. 120 1 6 2
- Hold the screw still while tightening the nut (1). 120 4 3 6
Setting pump-injector rocker preloading: 120 2 5 3
- Use a box wrench to loosen the nut fastening the
adjusting screw for rocker arm (5) controlling NOTE In order to properly carry out the above-mentioned
pump-injector (6). adjustments, follow the sequence specified in the
- With a suitable wrench (4) tighten the adjusting screw table, checking the exact position in each rotation
until the pumping element reaches its-end-of-stroke phase by means of pin 99360612, to be inserted in
point. the 11th hole in each of the three sectors with 18
holes each.

60665
85480
Turn engine and mount oil rose pipe.
Arrange gasket (4) on oil sump (1), position spacer (3) and
Fit the distribution cover (1). mount the sump on engine block screwing up screws (2) at
Fit the blow-by case (7) and its gasket and then tighten the prescribed torque:
screws (8) to the prescribed torque.
Install the filter (5) and the gaskets (4 and 6).
NOTE The filter (5) operation is unidirectional, therefore it Completing Engine Assembly
must be assembled with the two sight supports as Complete the engine by fitting or hooking up the following
illustrated in the figure. parts:
- power take-off (P.T.O., if present) and relating pipes;
Fit the cover (3) and tighten the fastening screws (2) to the - fuel pump;
prescribed torque. - support complete with fuel filter and pipes;
- EDC central unit;
- intake manifold;
Figure 173 - preheating resistance;
- heat exchanger;
- oil filter, lubricating the gasket;
- exhaust manifold;
- turbocompressor and relating oil pipes;
- pulley and damping flywheel;
- thermostat assembly;
- belt tensioner, water pump, alternator;
- starter;
- oil level rod;
- electrical connections and sensors.
167130
Apply silicone LOCTITE 5970 on the blow-by case and form

a string (2) of 1,5 , 0.5
0.2 as shown in the figure. NOTE The fittings of the cooling water and lubricating oil
. pipes of the turbocharger have to be tightened to a
torque of:
NOTE Fit the blow-by case (1) within 10 from sealer - 55 5 Nm, oil pipe female fitting;
application. - 20-25 Nm, oil pipe male fitting.

Figure 175
167110
- driving belt.
To mount belt (1), belt tensioner (2) has to be operated by
proper tooling (3) according to the direction indicated by the
arrow in Figure.
Figure 176
150675
ASSEMBLY DIAGRAM OF FAN WATER PUMP

1. Alternator 2. Electromagnetic coupling
3. Water pump 4. Crankshaft
NOTE Belt tensioner is of automatic type; therefore, further

adjusting is not provided after mounting.
- refuel engine with provided oil quantity;

- dismount engine from rotary stand and take off brackets
(99361036) securing the engine.
Mount:
- oil pressure regulation valve;
- engine left support;
- pipes.


F3BFE613 SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3
ASSEMBLY DATA - CLEARANCE . . . . . . . . . . . 5
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 11
DIAGRAM OF TIGHTENING SEQUENCE

OF CRANKCASE BASE FIXING SCREWS . . 14

2 SECTION 7 - TECHNICAL SPECIFICATIONS F3BFE613

GENERAL CHARACTERISTICS
F3BFE613
Type
C*A010 B*A010 A*A010
Fuel feed Overfed with aftercooler
Injection Direct

Bore mm 135
Stroke mm 150
+ + +.. = Total displacement cm3 12880

F3BFE613
Type
C*A010 B*A010 A*A010
A
VALVE TIMING
opens before T.D.C. A

17
closes after B.D.C. B
B 30
C
opens before B.D.C. D

50
closes after T.D.C. C
9
D
For timing check
X mm 0.4
X
mm 0.6
FEED Through fuel pump - filters

Injection With electronically regulated injectors UIN 3.1
type: Bosch pump injectors controlled by overhead camshaft
Nozzle type DLLA 145 P1534
Injection order 1-4-2-6-3-5
bar
Injection pressure bar 2000

ASSEMBLY DATA - CLEARANCE
F3BFE613
Type
C*A010 B*A010 A*A010
CYLINDER ASSEMBLY AND CRANK MEMBERS mm
1
Cylinder liner seats
top 153.500 to 153.525
1
bottom 152.000 to 152.025
Cylinder liners:
outside diameter:
L top 153.461 to 153.486
2
bottom 151.890 to 151.915
2 length L _
Cylinder liners -
crankcase seats
top 0.014 to 0.039
bottom 0.085 to 0.135
Outside diameter 2 _
3 Cylinder liners:
X inside diameter 3A* 135.000 to 135.013

inside diameter 3B* 135.011 to 135.024
protrusion X** 0.045 to 0.075
* Selection class
** Under a load of 8000 kg
Pistons: FEDERAL MOGUL MAHLE
1 18
measurement X 22.25
X
outside diameter 1AD 134.861 to 134.873 134.861 to 134.873
2 outside diameter 1BDD 134.872 to 134.884 134.872 to 134.884
seat for pin 2 54.022 to 54.030 54.022 to 54.030
Piston - cylinder liners
A* 0.127 to 0.152
B* 0.127 to 0.152
* Selection class
Piston diameter 1 _
X
Piston protrusion X 0.12 to 0.42
3 Piston gudgeon pin 3 53.994 to 54.000
Piston gudgeon pin - pin seat 0.022 to 0.036
D Class A pistons supplied as spares.

DD Class B pistons are fitted in production only and are not supplied as spares.
F3BFE613
Type
C*A010 B*A010 A*A010
mm
FEDERAL MOGUL MAHLE

X1
X2 X1 3.10 to 3.12 3
X3 Piston ring slots X2 3.06 to 3.08 3.05 to 3.08
X3 5.02 to 5.04 5.02 to 5.04
Piston rings: FEDERAL MOGUL MAHLE

S1 - sealing trapezoidal S1 3 -
S2 - sealing bevelled S2 2.970 to 2.990 -
S3
- milled scraper ring with
slots and internal spring S3 4.970 to 4.990 -
FEDERAL MOGUL MAHLE

1 0.10 to 0.12 -
Piston rings - slots 2 0.07 to 0.1 -
3 0.03 to 0.07 -
Piston rings _
X1 Piston ring end opening in
cylinder liner FEDERAL MOGUL MAHLE
X2 -
X1 0.40 to 0.50
X3 -
X2 0.65 to 0.80
X3 0.40 to 0.75 -
Small end bushing seat

1 1 59.000 to 59.030
Connecting rod bearing seat
2
2 1 94.000 to 94.010
Selection class 2 2 94.011 to 94.020
3 94.021 to 94.030
4 Small end bushing diameter
outside 4 59.085 to 59.110
3 inside 3 54.019 to 54.035
Big end bearing shells S
S Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow* 1.986 to 1.995
Small end pushing - seat 0.055 to 0.110
Piston gudgeon pin - bushing 0.019 to 0.041
Big end bearing shells -
Weight of connecting rod

A 4741 to 4780 g.
Classes B 4781 to 4820 g.
C 4821 to 4860 g.
* Only mounted on production and not provided with spare.

F3BFE613
Type
C*A010 B*A010 A*A010
mm
Main journals 1
- nominal 99.970 to 100.000
- class 1 99.970 to 99.979
- class 2 99.980 to 99.989
1 2 - class 3 99.990 to 100.000
Crankpins 2
- nominal 89.970 to 90.000
- class 1 89.970 to 89.979
- class 2 89.980 to 89.989
- class 3 89.990 to 90.000
S1 S 2 Main bearing shells S1
Red 3.110 to 3.120
Green 3.121 to 3.130
Yellow* 3.131 to 3.140
Big end bearing shells S2
Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow* 1.986 to 1.995
3 Main bearing housings 3 106.300 to 106.330
Bearing shells - main journals f 0,060 to 0,108 * - 0,061 to 0,119 ** - 0,060 to 0,130 ***
Bearing shells - crankpins f 0,050 to 0,108 * - 0,051 to 0,109 ** - 0,050 to 0,098 ***
Main bearing shells 0.127 - 0.254 - 0.508
Big end bearing shells 0.127 - 0.254 - 0.508
Main journal for shoulder X1 47.95 to 48.00

X1
Main bearing housing

for shoulder X2 40.94 to 40.99
X2
X3
Half thrust washers X3 3.38 to 3.43
Crankshaft shoulder 0.10 to 0.30
* Fitted in production only and not supplied as spares.

f Supplied as spares: * standard; ** = 0.127; *** = 0.254 - 0.508.

F3BFE613
Type
C*A010 B*A010 A*A010
CYLINDER HEAD - TIMING SYSTEM mm
1
Guide valve seats

on cylinder head 1
15.980 to 15.997
2
2 10.015 to 10.030
Valve guides
3 16.012 to 16.025
3
Valve guides and seats on head 0.015 to 0.045
Valve guides _
4 Valves:
4 9.960 to 9.975
60 30 7 30
4 9.960 to 9.975
45 30 7 30
a
Valve stem and relevant guide 0.040 to 0.070
Seat on head for valve seat:
1 49.185 to 49.220
1 1 46.985 to 47.020
Outside diameter of valve

2 seats on cylinder head:
2
49.260 to 49.275 49.460 to 49.475*
2 47.060 to 47.075 47.260 to 47.275*

* provided with spare
Valve seats 0,2
X 0.45 to 0.75
Recessing
X X 1.65 to 1.95

F3BFE613
Type C*A010 B*A010 A*A010
mm
Between valve
seat and head 0.040 to 0.090
Valve spring height:

free spring H 73.40
H under a load of:
H1
H2 547 to 603 N H1 59
1041 to 1149 N H2 46
Injector protrusion X 0.53 to 1.34

X
Seats for camshaft bushings

in cylinder head:
17 88.020 to 88.050

2
Camshaft supporting pins:

17 82.950 to 82.968
1 3
Outside diameter of
bushings for camshaft: 88.153 to 88.183
Bushing inside diameter: 83.018 to 83.085
Bushings and seats in

cylinder head 0.103 to 0.163
Bushings and supporting pins 0.050 to 0.135

Useful cam height
9.3
H 9.3
11.216
1
Rocker arm shaft 1 41.984 to 42.000

F3BFE613
Type C*A010 B*A010 A*A010
mm
Seats for bushings in
rocker arms:
45.000 to 45.016
59.000 to 59.019

46.000 to 46.016
Outside diameter of
bushings for rocker arms:
45.090 to 45.130
59.100 to 59.140
46.066 to 46.091
Inside diameter of bushings

for rocker arms:
42.025 to 42.041
56.030 to 56.049
42.015 to 42.071
Bushings and seats:

0.074 to 0.130
0.081 to 0.140
0.050 to 0.091
Rocker arm bushings and shaft:

0.025 to 0.057
0.015 to 0.087
TURBOCHARGER Holset CTT Waste Gate

Type HE 551 WG
End play 0.051 0.127
Radial movement 0.483 0.711

TIGHTENING TORQUE
TORQUE
PART
Nm kgm
Screws fixing crankcase base to crankcase
Outside screws M12x1.75 First phase: pre-tightening 30 (3)
Inside screws M18x2 Second phase: pre-tightening 120 (12)
Inside screws Third phase: closing to angle 60
Inside screws Fourth phase: closing to angle 55
Outside screws Fifth phase: closing to angle 60
Piston cooling nozzle union 35 2 (3,5 0,2)
Screws fixing heat exchanger to crankcase
pre-tightening 11.5 3.5 (1.15 0.35)
tightening 19 3 (1.9 0.3)
Screws fixing suction strainer to crankcase base 24.5 2.5 (2.4 0.25)
Screws fixing oil sump spacer
pre-tightening 38 (3.8)
tightening 45 (4.5)
Screws fixing gearbox to crankcase M12x1.75 63 7 (6.3 0.7)
Screws fixing control unit to crankcase base 24 2.5 (2.4 0.25)
Screws fixing cylinder head
First phase pre-tightening 60 (6)
Second phase pre-tightening 120 (12)
Third phase closing to angle 90
Fourth phase closing to angle 65
Screws fixing rocker arm shaft
Second phase closing to angle 60
Lock nut for rocker arm adjustment screw 39 5 (3.9 0.5)
Screws for injector brackets 26 (2.6)
Screws fixing shoulder plate to head 19 3 (1.9 0.3)
Screws fixing engine mount bracket to cylinder head
Before assembly, lubricate with UTDM oil

Before assembly, lubricate with graphitized oil

TORQUE
PART
Nm kgm
Screws fixing engine mount bracket to flywheel casing
Screws fixing camshaft gear
First phase pre-tighteningirst 60 (6)
Screws fixing phonic wheel on camshaft gear 8.5 1.5 (0.85 0.15)
Screws fixing exhaust manifold
tightening 705 (3.2)
Screws fixing connecting rod cap
Screws fixing engine flywheel
Screws fixing damper flywheel
Screws fixing middle gear pins
Screws fixing oil pump 24.5 2.5 (2.45 0.25)
Screws fixing fuel pump / filter mount 19 (1.9)
Screw fixing control unit mount 19 3 (1.9 0.3)
Screws and nuts fixing turbocharger
tightening 46 (4.6)
Screw fixing thermostat assembly 22 2 (2.2 0.2)
Screws fixing water pump 22 2 (2.2 0.2)
Screws fixing fan mount to crankcase 105 5 (10.5 0.5)
Screws fixing starter motor 74 4 (7.4 0.4)
Screws fixing air heater 30 3 (3 0.3)
Capscrews fixing articulated rod 24.5 2.5 (2.4 0.2)
Capscrews fixing belt tensioner to cylinder block 26 3 (2.6 0.3)
Capscrews fixing idler pulley 50 5 (5 0.5)


TORQUE
PART
Nm kgm
Screws fixing alternator: M 10x1,5 l = 35 mm 30 3 (3 0.3)
M 10x1,5 l = 60 mm 44 4 (4.4 0.4)
Screws fixing air-conditioner compressor to the mount 24.5 2.5 (2.5 0.25)
Screws fixing guard 24.5 2.5 (2.5 0.25)
Filter clogging sensor fixing 55 5 (5.5 0.5)
Water / fuel temperature sensor fixing 35 (3.5)
Transmitter / thermometric switch fixing 25 (2.5)
Air temperature transmitter fixing 35 (3.5)
Pulse transmitter fixing 8 2 (0.8 0.2)
Fixing connections to injector 1.64 0.28 (0.164 0.02)

Figure 1
First phase:
FRONT SIDE pre-tightening
outside screws
30 Nm
60592
Second phase:
FRONT SIDE pre-tightening
inside screws
120 Nm
60593
Third phase:
closing inside
FRONT SIDE screws to angle
60
60593
Fourth phase:
closing inside
55
60593
Fifth phase:
closing outside
60
60594
DIAGRAM OF TIGHTENING SEQUENCE OF CRANKCASE BASE FIXING SCREWS

Figure 2
150678
Figure 3
171168
Figure 4
60582
DIAGRAM OF TIGHTENING SEQUENCE OF SCREWS AND NUTS FIXING TURBOCHARGER

ON EXHAUST MANIFOLD

Figure 5
171167
DIAGRAM OF TIGHTENING SEQUENCE OF HEAT EXCHANGER FIXING SCREWS
Figure 6
108830
DIAGRAM OF TIGHTENING SEQUENCE OF ENGINE OIL SUMP FIXING SCREWS
Figure 7
150677
DIAGRAM OF TIGHTENING SEQUENCE FOR SCREWS FIXING ROCKER COVER

Figure 8
149248
DIAGRAM OF TIGHTENING SEQUENCE OF SCREWS FIXING GEARBOX TO CRANKCASE
Figure 9
70567A
SCHEME OF THE TIGHTENING ORDER OF ROCKER ARMS SHAFTS FASTENING SCREWS

Figure 10
124509
DIAGRAM OF TIGHTENING SEQUENCE OF THERMOSTAT FIXING SCREWS
Figure 11
136522
DIAGRAM OF TIGHTENING SEQUENCE OF BLOW-BY CASE TO GEAR CASING FIXING SCREWS

Figure 12
151833
DIAGRAM OF TIGHTENING SEQUENCE OF THRUST PLATE TO CYLINDER HEAD FIXING SCREWS


F3BFE613 SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 8 - TOOLS F3BFE613

TOOLS
Rotary telescopic stand (range 2000 daN, torque 375 daNm)

99322230
99340053 Extractor for crankshaft front gasket
99340054 Extractor for crankshaft rear gasket
99340205 Percussion extractor
99342149 Extractor for injector-holder

TOOLS
99342155 Tool to extract injectors
99346250 Tool to install the crankshaft front gasket
99346260 Tool for fitting the rear sheath on the engine drive shaft
99348004 Universal extractor for 5 to 70 mm internal components

TOOLS
99360143 Easy puller for valve guide deassembly
99360180 Injector housing protecting plugs (6)
Pliers for assembling and disassembling piston split rings

99360184 (105-160 mm)
99360252 Tool to remove filters
Tool to take down-fit engine valves

99360259 (to be used with special plates)

TOOLS
Plate for take down-fit engine valves

99360263 (to be used with 99360259)
99360296 Tool to fit back valve guide (to be used with 99360143)
99360321 Tool to rotate engine flywheel (to be used with 99360325)
99360325 Spacer (to be used with 99360321)
99360329 Tool to install gasket on valve guide

TOOLS
Compression tool for checking the protrusion of cylinder liners

99360334 (to be used with 99370415-99395603 and special plates)
99360336 Spacer (to be used with 99360334)
Cylinder liner compression plate

99360338 (to be used with 99360334-99360336)
99360351 Tool to stop engine flywheel
Tool to take down and fit back camshaft bushes

99360499

TOOLS
99360500 Tool to lift crankshaft
99360553 Tool for assembling and installing rocker arm shaft
99360585 Swing hoist for engine disassembly assembly

99360603

99360605

TOOLS
99360612 Tool for positioning engine P.M.S.
99360613 Tool for timing of phonic wheel on timing gear
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners (to be used with specific rings)
99360728 Ring (135 mm) (to be used with 99360706)

TOOLS
99361036 Brackets fixing the engine to rotary stand 99322230
99365056 Tool for injector holder heading
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99390330 Valve guide sleeker
99390772 Tool for removing injector holding case deposits

TOOLS
Tool for threading injector holding cases to be extracted

99390804 (to be used with 99390805)
99390805 Guide bush (to be used with 99390804)
99394015 Guide bush (to be used with 99394041 or 99394043)
Cutter to rectify injector holder housing

99394041 (to be used with 99394015)
Reamer to rectify injector holder lower side

99394043 (to be used with 99394015)

TOOLS
Measuring pair for angular tightening with 1/2

99395216 and 3/4 square couplings
Gauge for defining the distance between the centres

99395219 of camshaft and transmission gear
99395603 Dial gauge (0 - 5 mm)
Centering ring of crankshaft front gasket cap

99396035

F3BFE613 APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F3BFE613

F3BFE613 APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX F3BFE613
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

TIER 4i C SERIES MALFUNCTION DIAGNOSIS 1
Part 3
Malfunction diagnosis
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PT - BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PT-BOX INSTRUCTIONS . . . . . . . . . . . . . . . . . 5
- Hardware installation . . . . . . . . . . . . . . . . . . . . 5
- Software installation . . . . . . . . . . . . . . . . . . . . . 7
- Software Interface . . . . . . . . . . . . . . . . . . . . . . 18
- Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- ECU diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Active diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 38
FAULT CODES (F2C) . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS FOR SYMPTOMS (F2C) . . . . . . . . 90
FAULT CODES (F3B) . . . . . . . . . . . . . . . . . . . . . 91
DIAGNOSIS FOR SYMPTOMS (F3B) . . . . . . . . . 131

2 MALFUNCTION DIAGNOSIS TIER 4i C SERIES

PREFACE Every time there is a breakdown claim and this breakdown is

A successful troubleshooting is carried out with the actually detected, it is necessary to proceed inquiring the
competence acquired by years of experience and attending electronic unit in one of the ways indicated and then proceed
training courses. with the diagnostic research making trials and tests in order to
When the user complains for bad efficiency or working have a picture of the working conditions and identify the root
anomaly, his indications must be kept into proper causes of the anomaly.
consideration using them to acquire any useful information to In case the electronic device is not providing any indication, it
focus the intervention. will be necessary to proceed relying on the experience,
Using FPT processing instruments, it is also possible to adopting traditional diagnosis procedures.
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input an
enquiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly
NOTE Any kind of operation on the electronic center unit

must be executed by qualified personnel, duly
authorized by FPT.
Any unauthorized tamper will involve decay of
after-sales service in warranty.

PT - BOX
PT - BOX is a test tool to be connected to a Personal Computer
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator -
5. Serial port indicator - 6. Error indicator - 7. CAN line indicator -
8. Line K indicator for automatic management
With the PT-BOX you can perform:

- Basic testing: central unit ID reading, failure memory reading, parameter reading, failure memory clearing and Flight Recorder
memory reading;
- Active testing: main component testing (actuators, contactors, etc..);
- Flight Recorder reading;
- ECU acknowledgement of replaced electronic components;
- 2nd level and PTO programming;
- Parameter acquisition during operation tests.

PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the 2. PT-DIAGNOSIS configuration
PT-DIAGNOSIS software so as not to any cause
injury to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecus and the PC.
on the screen. - Weight: 500 g;
- Dimension: 175x75x30mm;
General rules for use - Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed: - Thermal tolerance: 0-50C;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 2
complying with security regulations of the workshop;
- we strongly suggest that the PT-BOX modules be visibly
and uniquely identified (for example by using coloured
adhesive tape, labels with names, etc).
By only accepting the use disposal it is possible to

! access PT-DIAGNOSIS (the green tick icon
becomes active). 156133
1. Led indicators to display the activity of the

The diagnosis system consists of: communication lines K/L. - 2. The upper led display the
ECUs communication activity. - 3. The lower led indicators
- a PC (Panasonic / your PC + Microsoft Windows 2000 display the CAN lines activity. - 4. The three upper led
or Windows XP Professional); indicators show the activity of the K/L communication lines.
- 5. The lower led indicator (fault) shows the presence of
- an instrument used as interface between engines/vehicles errors on the K/L lines. - 6. The upper led indicator shows
and PC (PT-BOX tester); that the PT-BOX is power-supplied. - 7. When blinking the
- a SW program (PT-DIAGNOSIS) to process data. lower led indicator (run) shows that the PT-BOX module is
correctly working. - 8. Led indicators to display the USB
By combinating the above indicated components 2 different ports (upper led). - 9. Led indicators to display the serial
configuration are possible. ports (lower led).

Connect the pt-box module Pt-box - engine/vehicle connection

On the PT-BOX module there are the communication ports
for the connection to the PC and to the engine / vehicle. Figure 6
Communication ports for the connection to the PC

Figure 3
156138
- connect the module to the engine/vehicle by using the

specific connection cable.
156135
1. serial port - 2. USB port NOTE The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 4 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
Pt-box - pc connection
- External reader: DVD-ROM reader;
Figure 5
- Os: Microsoft WindowsTM XP Professional Service Pack
2 - Microsoft Windows 2000 Service Pack 4 plus -
Windows 2000-KB835732-x86-ENU.EXE (login with
administrator privileges);
- Browser: Internet Explorer 5.5.
Recommended
- Processor: 1 GHz Pentium IV - Centrino CPU;
- Hard disk space: 5 GB available;
- Ram: 512 MB;
- Display: 1024 x 768 high colour video adapter and
156137 monitor;
- Internet connection only needed for rss and pt-diagnosis
software update (eaus): high-speed e.g. ADSL;
- connect the USB cable (PT-BOX side marked) to the - External ports: 2 USB 2.0 connectors, Bluetooth;
PT-BOX module (remove the holding screws from the
PT-BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.

Software installation
Registration
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
The registration procedure is carried out on-line and it is
different according to the user type:
- OEM users
- Dealer users
NOTE For both configurations (PT-PLUS and

PT-DIAGNOSIS) the SW installation is the same.
- A fill-in form is displayed.
Registration>OEM users The activation code received will be requested the

! first time you run the PT-DIAGNOSIS software.
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
Registration form (OEM user)
For this reason:
- Check that the registration card has been delivered The Registration allows you to download the EVCA SYNC
together with the kit. WEB application which allows you to obtain the activation
code:
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
In the registration form:
1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
the identification data and the Network characteristics
areautomatically entered.
3. Enter the serial number of the PT-BOX instrument.

Figure 7
NOTE Before carrying out the registration we suggest to
install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application

To obtain the activation code it is necessary to install the
EVCA SYNC WEW application, after saving it on the desired
directory:
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module
4. Read the note in compliance with art. 13 of Italian
Legislative Degree 196 dated 30 June 2003 about the
processing of personal data Informative
5. Select the send key (only once!) wait
After sending a summary window is displayed waiting for the
end of the registration procedure.
1. Unzip the evcasyncweb1.2.6.zip (for example using

WinZip: www.winzip.com/downwz.htm).
2. Open the EVCASyncWeb1.2.6 and then
EVCASyncWeb15-09-10 (Rel1.2.6).
3. Run setup.exe and continue with the installation of the
guided application.
NOTE For further information about the installation of

EVCASyncWeb it is possible to read the detailed
guide EVCASyncWeb Setup.pdf in the directory
EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB
application. It will be used to obtain the activation code:
6. Select the print key for printing a summary report 4. At the end of the installation, the icon of the
(registration data and number of registered instrument). EVCASyncWeb application is displayed on the desktop
of the PC.
7. Select the link to download and then select the save key,
to save the application on the PC.

Running the EVCA SYNC WEB (OEM user) application
3. Enter the PT-BOX serial number of and the Customer

PIN.
4. To continue, select the confirm key.
1. Double click on the icon EVCASyncWeb application.

At the start up of the application choose the Internet
connection mode:
- by means of the Proxy Server;
it is necessary to enter the connection parameters; at the
end select the okey. It is possible to pre-set the
connection parameters: read the EVCASyncWeb
manual;
- without Proxy Server;
select the okey.
5. Enter the alpha code supplied with the Registration Card

(scrap the card).
The starting page EVCASyncWeb is displayed; some

functions are available (for more information read the manual
EVCASyncWeb).
2. Select the applications key for pc.

Summary of the selected choices (OEM user)

At the end of the activation procedure, the summary of the
selected choices is available. The following data are displayed:
Contract Activation (OEM User)

7. Select a contract type.
The contract types available for the OEM users are indicated
below:
- Fee (annually):
the duration of the contract is for one year, starting from - The type of selected contract.
the activation date of the contract. During this phase it is
- The list of instruments (PT/PB) associated to the contract
only possible to associate one instrument to the contract.
with the generated activation codes
- Token (to be deducted):
- The expire date of the contract (in case of yearly fee) or
it is the payment for a single download of an application;
residual credit (coins):
it is possible to associate to the contract to 4 instruments.
1. We suggest you to print and keep the summary data:
select the key print selections recap.
2. Show and download the list of the available
applications belonging to your profile (FPT
activation): select the applications download key.
The window containing the activation codes is displayed.

9. Print/copy the activation codes and keep them together
with the instruments they are associated to.
10. Select the okey to end.

Download the applications Registration>Dealer users

Before using the PT-DIAGNOSIS diagnosis system you must
register on the FPT web site.
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
Each option can be used to sort the list: to sort the list in
ascending/descending order according to a given key, select
the title of the corresponding column.
1. Select the application to be downloaded; the selected line
is highlighted in red.
2. Select the download the selected application key and follow
the system instructions.
3. Identify the path where the packets have been
downloaded.
4. At the end of the download install the packets (double
click) one by one.
3. Select Fiat Powertrain Technologies and then Partner Area.
NOTE The packets must be downloaded/installed one by

one.
4. Connect to the web site by selecting Click here.

5. Fill in the fields for the login procedure.
7. Go to the registration web page; select pt users registration

a fill-in form is displayed (on-line registration form).
NOTE For the new customers:
request username and password to
areapartner@fptpowertrain.com.
For the customers already registered:
use username and password received by e-mail.
Registration form (Dealer user)

The Registration allows you to download the EVCA SYNC
WEB application which allows you to obtain the activation
code.
In the registration form:

1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
6. Please follow the indicated instructions the identification data and the Network characteristics are
automatically entered.
After Sales>Various>Diagnostic Instruments>Diagnostic
Tools

3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (EAsy Update
Software).
7. Print the activation codes (print key) and keep them
together.
8. Select the link to download the EAUS application.
Installation of EAUS application (Dealer user)

The EAUS application is an update utility to automatically
download all SW Updates for all ECUs activated for FPT.
After having selected the link for downloading the EAUS
Figure 8 application, the system asks you to select the file or to directly
run it.
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module.
1. Select the run key:
5. Read the note in compliance with art. 13 of Italian the system automatically downloads first and then installs
Legislative Degree 196 dated 30 June 2003 about the the EAUS application; run the operation required by the
processing of personal data Informative. system and wait for the end of operation.

Connection
Figure 9
156138
1. Connect the PT-BOX module to the engine/vehicle using

the diagnosis cable.
2. Connect the PT-BOX module to the PC, using one of the
2. Select the end key to exit the installation. two USB cables provided with the module.
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! cable; therefore it must be connected to the
engine/vehicle to be able to work.
Figure 10
Run the EAUS (Dealer user) application
156140
3. Switch the PC on.
PT-BOX module USB driver set-up

(only for the PT-DIAGNOSIS configuration)
This operation is required only if the PC in use has never been
connected to an PT-BOX module:
1. It is now possible to download the update by using the

Automatic Update Function (tools>software update key).
1. Check that the PT-BOX module is correctly connected to
the PC via the USB cable.
2. The PC acknowledges the presence of a new hardware
component; press the cross button to continue.

5. Select the have disk> button to continue.

3. Automatically (Windows XP) the procedure starts to
set-up the driver; select the Install from a list or specific
location option; select the next> button to continue.
6. Enter the path:

ProgramFiles\EltracECI\Driver\PT-BOX.sys;
select the ok button.
4. Select the Dont search. I will choose the driver to install;

select the next> button to continue.
7. Select the next> button to continue.

4. The system asks you to enter the activation code received

from Field Service; select the tick button.
8. Driver set-up begins wait.

9. The procedure is completed; press the finish button.
5. Enter the activation code sent via Web.

6. Select the register button; a message confirms that
registration has taken place.
7. Select the cross button to close the Activation Code
window and go back to the PT-DIAGNOSIS screen.
10. The system informs that the new hardware has been
correctly installed; select the cross button to continue.
11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw +

PT-BOX module
The first time the PT-DIAGNOSIS Diagnosis System is used,

it is necessary to follow the procedure described below:
1. Make sure you possess the activation codes (Web
access).
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB/BT module.
3. Start the Panasonic PC.
8. Select the stop button and restart PT-DIAGNOSIS.
Now all the software functions are available.

Activating - new PT-BOX module

The activation procedure is necessary every time you want to
use an PT-BOX module that has not yet been paired to the
PT-DIAGNOSIS diagnosis system in use; follow the
operations described below:
6. Enter the activation code received from Field Service.

7. Select the register button; a message confirms that
registration has taken place.
8. Select the cross button to end activation.
9. Re-start the PT-DIAGNOSIS (E.A.SY. icon).
1. Make sure you have requested and obtained the
activating code for the PT-BOX module.
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB cable.
3. Start the PT-DIAGNOSIS software: double click on the
EASY icon (PT-DIAGNOSIS) placed on the desktop of
PC.
4. Select the tools>activations button.
5. Select the entry button.

Software Interface
The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear
and adaptable to various needs.
All windows follow the same design with additional features which depend on the specific working environments.
Each window presents three main areas to which specific functions are univocally associated:
- Keys Area
- Title Area
- Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys The Operative

area contains Keys area contains available
for accessing the system and function
operative list referred to the
environments and intervention area.
the functions to
which they are
associated.

To go from one environment to another
3. Select the Class and the System under test to which the
engine/ vehicle belongs; then press the navigation key (is
active - green) to continue.
1. The Start Window shows the family.
Start Window
- It is possible to select a new family or to choose a family
from the database;
- green identifies a pull-down menu.
4. The window Choose Activity appears; it is here possible

to choose from four lists.
Window Choose Activity
It is now possible to choose:
- diagnosis;
- test;
- programming;
- specific functions.
Navigation keys
2. Select the fami ly of the engine/vehicle under diagnosis; They allow you to go from one environment to another.
then press the navigation key (is active - green) to Enabled keys are displayed in green and disabled keys are
continue. displayed in grey.
Family Choice Window navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu;
- a paged list is used to display a large amount of navigation key forward enabled
information one page at a time; navigation tools are
available to navigate from page to page. navigation key back enabled
Database key
It allows you to access the Database

environment.
Browse key
To scroll long lists which cannot

be contained in a single window. ignition key
For the equipped engines, it allows you to operate engine

Detail of Keys area ignition directly via the diagnostic tool. Two positions (stop
In the Start Window the Keys area contains the Keys for and mar) and three states (enabled stop, disabled stop,
accessing the functions which are always available: enabled mar) are possible.
communication panel
It indicates that the communication with the ECU is active or
that the ECU is not present (no ecu).
The lower leds indicate the communication state of the
electronic system as shown below:
Square LEDs: two states (green/red); green indicates that
communication with the electronic system has been initialised;
if red indicates the communication has been interrupted.
Rectangular LEDs: blinking indicate that data exchange
between electronic system and diagnostic system is in
progress.
Utilities key
stop key
To quit PT-DIAGNOSIS application at any time.
engine/vehicle key
It allows you to return to the Family Choice Window.
utilities key
When selected the Key background will be yellow and allows
you to access a menu.
guide to diagnosis key

It allows you to access the environment Guide to Diagnosis
(only available for some ranges). It is available in the Electrical
Control Units environment.

Teleservices key
It allows you to access the remote connections services. Electronic control units key
Activations key
It allows you to access the Electronic Ecus environment.
It allows you to access the management function of the The key appears on a yellow background (default status,
activation codes. environment Electronic Control Units enabled) or on a grey
Select the measure unit key background (environment Electronic Control Units disabled).
If you want to work at the same time with more Ecus, select
It allows you to choose the measure unit system. the key environment electronic ecus>add ecu.
Electrical diagrams key

It refers to a CLASSES list for which an electrical diagram is
The Metric System (SI), the international standard one, is available. The key appears on a yellow background
based on the meter, kilogram and second. The British System (environment Electrical Diagrams enabled) or on a grey
(fps) is based on the foot, pound and second. background (environment Electrical Diagrams disabled).
Select language key To enter the Electrical Diagrams environment select the key
electrical diagrams area.
To change the language; restart the application to make the
setting operational.
Software update key Report key
It allows you to carry out the automatic update of the It allows you to access the Report environment.
PT-DIAGNOSIS software. The key appears on a yellow background (environment
Eci management key Report enabled) or on a grey background (environment
Report disabled). To access the Report environment select
It allows you to manage the connection (usb or Bluetooth) the report key.
PT-DIAGNOSIS - PT-BOX module.
On/Off-line key
It can be on-line or off-line.
The on-line key indicates that the PT-Diagnosis SW uses the
In the Start Window select the fami ly; by pressing the PT-BOX/PC module connection.
navigation key forward it is possible to access the next The off-line key indicates the PT-Diagnosis SW is working in
window. New icons appear in the Keys area for accessing simulated mode. To change the status select the key.
specific functions:

Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. engine mode l, CUSTOMER or NUMBER PLATE).
key delete search

It cancel the filter; it is active only after a search.
key order
It orders the list according to the selected ordering criterion.
key report
It gives access to the summary environment; enabled after
selecting an engine.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
2. The list of accepted engines is available.

They can be search by means of the following keys:
3. Select an engine from the list (the background is yellow);
- DATE it is possible:
- ENGINE MODEL - to analyse engine data (report button);
- CUSTOMER - to start again the diagnosis procedure on the engine
(navigation button forward);
- NUMBER PLATE
- to return to the start window (navigation button
back).

How to order the engines list 3. If required, enter the word or the code to be searched
and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive
select the cancel search key.
For the selection of a new engine see ECU Diagnosis.

!
1. Select the order key.

2. Select the order method.
- DATE
- ENGINE MODEL
- CUSTOMER
- NUMBER PLATE
Environment Report
How to search for an engine from the database
When the engine sheet of the engine under test has been
saved in the Report Environment, the engine has been
accepted.
You access the Report environment in the following ways:
1. Select the search key.

2. Select the search method.
- DATE
- from the Buttons area at any time by selecting the
- ENGINE MODEL corresponding button;
- CUSTOMER - from the DataBase environment by selecting the
required engine and the report button.
- NUMBER PLATE

Environment Report
DIAGNOSIS REPORT LIST

KEY:
summary of all performed
ENGINE DATA KEY: diagnosis operations
engine identification data;
the fields can be always
changed (with the
exception of the engine
model and the date) can be PROGRAMMING
always changed REPORT LIST KEY:
summary of all performed
programming operations
SAVE KEY: AUTOMATIC

it allows you to save the ACCEPTANCE KEY:
engine sheet (to accept it) (enabled only if the
communication is active)

Acceptance When you read or cancel the faults memory or carry out a
programming it is not possible to return directly to the window
The acceptance (sheet saving) is mandatory when important Family Choice; by selecting the engine button the following
operations are performed on the engine (read or cancel faults windows are displayed:
memory, programming).
1. Read or cancel the faults memory or carry out a 1. Before continuing it is necessary to save the data of the
programming and then select from the corresponding performed activity; select the tick icon; the Report
environment the report button; you enter the Report environment appears.
environment.
2. Enter data.
2. Enter data.
3. Save the sheet by selecting the save button.
3. Save the sheet by selecting the save button.

4. From the Buttons area select the button of the operation
you want to perform. It is now possible to return to the Family Choice window.

Automatic acceptance
From the Report environment it is also possible to accept the
engine automatically.
This operation is only possible if the communication

! with the system has been activated.
1. Read or cancel the faults memory or carry out a

programming and then select from the corresponding
environment the report button.
5. The automatic acceptance reads the following

information:
- Engine Model (engine type + engine serial number)
- PIC
- Engine type
- Engine Serial Number
6. At the select the save key.
2. You enter the Report environment. ECU diagnosis

3. Select the button automatic acceptance.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. By means of the automatic acceptance the system tries to
communicate with the engine ECU: confirm the displayed
message by pressing the tick icon; wait until the ECU is
ready.

3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
4. The present Repair Guide describes the diagnosis

environment and the specific functions to which it is
associated:
- Identification Code Reading
- Faults Memory Reading
- Parameters Reading
Identification code reading

3. Confirm the new message by pressing the tick icon.
1. To access the Read Identification environment select the

item Identification Code Reading from the Diagnosis list
and then press the navigation button forward.

Multitasking option
report key
PT-DIAGNOSIS introduces a very important news: it is
Shows the Diagnosis Report List (and allows you to print each
possible to associate more ECUs to the family of engine under
report).
test.
Add an ecu
print key
It is possible to interrupt the diagnosis with an ECU and to start
Prints the summary page of Identification Parameters. the procedure with another one.
4. Wait until the ECU is ready; the general information

about the electronic system under test is read:
- identification code
- HW version
- SW version 1. Select the button ecus area>add ecu; the Choose Vehicle
- production date window will appear, where you can select the desired
ECU.
-
Managing more ecus
After identification code reading it is possible to carry out
other activities (step 5) or to return to the window Choose It is possible to operate with two or more connected ECUs
engine (step 6). at the same time.
1. Select the button ecus area>desired ecu.

The activity remains interrupted for the not selected ECUs
and can be started again at any time.
Cancel an ecu
5. To access the other activities from the environment It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECUs.
buttons: choose an activity; the system automatically access
the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecus area>required ecu>cancel.
button ecus area>ecu under test>cancel.
2. Select the required ECU.

Ignition Key Button Modes - on line/off line Read faults memory

At the system start up the on/off button is on-line if the
PT-BOX module is activated and connected to the PC,
otherwise is disabled (off-line).
On line mode
The function Ignition Key is active; it can be managed in
automatic or manual mode; the ignition key screen appears
only after the selection of a function that requires it (e.g.
diagnosis functions).
In automatic mode all ignition key activations are managed by
the diagnosis instrument.
In manual mode all ignition key activations are managed by the
operator on the engine.
The automatic activation depends on the type of engine; make
sure the engine supports the function before selecting 1. To access the Read Faults Memory environment select the
automatic mode. item Faults Memory Reading from the list Diagnosis and
then press the navigation button forward.
1. After selecting the automatic mode a test procedure is

carried out.
2. Switch the ignition off. 2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation of
3. The engine chassis may move. the ignition key; select the required mode; the key button
The PT-DIAGNOSIS SW activates the ignition key and is disabled.
displays a screen page in which it asks to check the dashboard;
if it is turned on the diagnosis procedure can be continued;
otherwise the system asks for position of the key to ON in
manual mode.
Both in manual and in automatic mode:
1. Before ignition key activation a message is always
displayed: request (manual mode) or warning
(automatic).
2. When the ECU is cancelled a message indicates that it is
necessary to interrupt the communication and then to
confirm the operation.
3. The chosen mode remains until the engine under test is
changed.
Off line mode
The basis diagnosis is simulated and it is possible to read some
information about the electronic system under test.
3. Confirm the new message by pressing the tick icon.

cancel faults memory key

It cancels the faults selected in the list; it is possible to cancel
a fault at a time; the cancel operation will be effective when you
confirm it by pressing the tick icon displayed in the next
pop-up-window.
faults key
It allows you to access the Faults environment; it can be yellow
(the faults list is displayed) or gray (environment Faults
disabled).
4. Wait until the ECU is ready; the list and faults type
occurred during the working are displayed.
There are two types of failures:
- failures present during the reading procedure (red);
- intermittent failures not present during the reading
operation but which occurred at least once before
(black).
Detail of Buttons area of the Faults Memory area

New icons appear in the window Read Faults Memory for
accessing specific functions:
On line Mode
Faults Memory Reading Icons
environmental condi tions key

Active when the communication with the ECU has been
interrupted this is used to examine environmental conditions
when the failure occurred. It can be gray (default status) or
yellow (when selected).
repair guide key

Active when the communication with the ECU has been
interrupted it gives an analysis of the fault selected from the list;
On line Mode in particular other information (blink code, failure code and
Faults Memory Reading Icons fault mode) is available it can be gray (default status) or yellow
(when selected).
on key
The communication between the system and the ECU is report key
active: it performs again the Faults Reading; it updates the ECU
communication. It allows you to save the report of carried out operations see
Select the button to interrupt the reading. Report environment > button diagnosis report.
off key
The communication with the ECU has been interrupted. print key
Select the button to start again the electronic system reading. It allows you to print the displayed window.

Off line Mode 2. Select the button environmental conditions.

Faults Memory Reading Icons It examines the present environmental conditions at time of
the fault.
blink code search key
Appears only if the communication with the ECU interrupted
is (under OFF LINE Mode) recognize the fault where blink
code or required word appear.
To go from one function to another (faults, environmental
conditions, troubleshooting) select the corresponding button.
Operations like Read and Cancel Faults Memory are very
important: they are automatically stored and need the engine
acceptance.
How to get information about a fault

1. Interrupt the communication with the ECU (button
on/off) and select an item from the faults list: the fault is
described in the below blank area; in particular the
following information is available:
3. Select the repair guide button; the following information
is available:
- the blink code
- the failure code (DTC)
- the failure mode (FMI)
Appears a new icon, the measures key
measures key
The Measurements pop-up window opens with a list of

possible measurements and the relevant operating
suggestions.
- the fault
- the signal type
- the repetition type
The button faults appears on yellow background because it
is selected.

Parameters reading 3. The read parameters are shown and the values assumed
4. Select the groups key.
The groups key allows you to access the groups management
functions (see group Management).
Detail of parameters buttons area

New icons appears on the window Parameters Reading for
accessing specific functions:
1. To access the Parameters Reading environment select

the item Parameters Reading from the Diagnosis List and
then press the navigation button forward.
on key
The communication between the system and the ECU is
active: select the button to interrupt the reading.
off key
The communication with the ECU has been interrupted; select
the button to start again the electronic system reading.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
Pay close attention to the displayed messages and wait until
the ECU is ready.
parameters acquisition key

It allows to record the trend in time of the measurable
parameters.
report key
It allows you to save the report of carried out operations.
print key
It allows you to print the displayed window.

Groups Management 9. From the drop down menu (above on the left), select one
of the available parameter groups, excluding the
parameter you are changing.
10. On the left-hand list the parameters of the selected group
are shown; on the right-hand list the parameter of the
group you are changing are shown.
The parameters with a gray background on the left-hand list
are parameters that have already been added and can not be
selected.
5. The Groups window opens.

The pre-defined parameter groups are first displayed then
the customized ones; the pre-defined parameters
(measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and

confirm by pressing the right arrow key ( ).
12. To remove a parameter (from the right-hand list select it
and confirm by pressing the left hand arrow key ( ).
Select the save key to save and exit the groups management
environment.
Modify a parameters group

Create a new parameters group
6. Select create.
7. Enter the name of the group you want to create.
8. Confirm by selecting the green tick icon.
1. Select a customized parameters group.

2. Select modify; the window for parameters groups
management opens.
3. Select the group you want to change and continue with
step 9 (link).

Cancel a parameters group Window Store Parameter
2. Select the sample time by using the arrows on the

Sampling active area.
3. Select the duration of registration by using the arrows key
1. Select a group of customized parameters on the active area Duration.
2. Select delete; confirm or cancel the request.
Appendix parameter acquisition key
4. Select the key start/stop to start the registration (a new

window open Notes where you can add a comment).
5. Close the Notes window, the registration starts.
6. Wait for the end of registration procedure (it is also
possible to interrupt the registration, by using the stop
key).
1. Select the parameters acquisition key; the window Store

Parameter opens.
The key is only active under on line mode.
7. Select the archive key: the Archive window open showing
the list of available registration in the archive.
Parameters reading

Archive window
- To display tables (horizontal or vertical).
- To colour display the area indicated by the diagram.
- Print.
- To go back
Programming
The consultation can be started
To access the programming area of the ECU under test
proceed as follows:
1. From the Archive windows, select a registration; it is

possible:
- to cancel it (cancel key)
- to read data (report key)
- to show data (show key, opens the Data Reading
window)
- to print data (print key)
- to save data in text format (save as key)
- to go back (cross key)
Data Reading window
1. Select the Engine Family under diagnosis.

continue.
2. From the Archive window, select a registration and the

show key; the Data Reading window opens; it is possible:
- To select all parameters (fast selection key).
- Deselect all parameters (fast deselection key).
- To show the diagram with full-screen.
- Increase, reduce or to bring back to the original 3. Select the Class and the System under test to which the
display the time range (x-axle, seconds). engine belongs; select the forward navigation key
(enabled - green) to continue.

4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. programming verify the charge left in the
computers battery.
It is recommended to plug the PC in (connect it to
the engine/vehicle or to the mains supply).
Programming environment
It is possible to use specific functions, by selecting the
corresponding key:
6. Select the ignition key management (automatic/manual): - Data Reading

if the electronic system engine under test is fitted with this
function, select the automatic key. - Change the configuration
- PT-DIAGNOSIS shows the running activities. - Programming
- The ignition key ON is automatically activated. - PTO (only for the PT-DIAGNOSIS full version SW)
- The connection to the ECU starts.

The available function types are determined according to the Data Reading
type of ECU under test. The Keys area contains the buttons
for accessing the functions specific for the Programming This is used to view the data concerning the ECU and the
environment. respective programming state; tampering attempts are shown.
The following are indicated:

print key
- station type and number;
If enabled, select to print a report. - programming date;
- ECU software release.
cancel key
If enabled, select to re-establish a configuration.
navigation keys
If enabled, select to move between different environments.
cross key
If enabled, select to cancel an operation.

The system views the following data classes:
- supplying data;
- factory data (never updated);
- service data (updated after each programming
event).
scroll keys
If enabled, select to scroll the list step by step.
fast scroll keys

If enabled, select to scroll the list step by step.

Active diagnosis
It is possible to carry out an active diagnosis only in
To start the Active Diagnosis online mode. In case of error check the following
!
connections ECU/PT-BOX/PT-DIAGNOSIS.
1. Select the Engine Family under diagnosis.

continue.
5. Select the ignition key management (automatic/manual):
if the electronic system engine under test is fitted with
this function, select the automatic key.
- PT-DIAGNOSIS displays some information about
the activity in progress.
- The ignition key ON is automatically activated.
- The ECU connection starts.
6. Read the displayed messages and select the green tick

icon to continue.
3. Select the Class and the System under test to which the
engine belongs; select the forward navigation key (enabled
- green) to continue.
7. At the end the system permits access to the Active

Diagnosis environment; the components list is displayed,
on which tests can be carried out.
4. From the Test list select the option acti ve diagnosis;

select the forward navigation key (it is active, in green
displayed).

Active Diagnosis environment

The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list.
1. Select the component on which the test will be carried out.
2. Select the forward navigation key to continue and carry out the test.
Help key Components:

if selected it shows selectable list
information about
the electronic system
under test;
information about Browse key
the guide to the
diagnosis are not
provided.
Forward navigation
key
Back navigation key

It allows you to move one
step back; if selected at
this level it allows you to
exit the Active Diagnosis
environment.


Print P2D32C009 E
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NOTE The fault codes depend on the application, therefore some may never NOTE be displayed during diagnosis.
FAULT CODES (F2C)

Long Term Possible failure
DTC Description Dfp name MIL OBD System Power red Failure Reason of failure correction
1D9 ECU internal ADCMon Mil OFF non 0 Buffer overrun No intervention neces-
fault: Analog to sary
Digital conver-
sion failure
Short circuit in wiring or Check wiring or replace

in accelerator pedal. accelerator pedal.

112 Accelerator APP1 Mil OFF non 1) yes (technical) 0
because of
Pedal 1
Fid_CoEng_trqLim
Err
Idle switch defect or wir- Check wiring of idle
ing of idle switch broken switch pin_idlswt or re-
or accelerator pedal de- place accelerator pedal
fect
Ambient pressure Replace ECU (not neces-

sensor inside ECU is de- sary if never running in
fect. high altitude and if tur-
bocharger without VGT).

1EB Atmospheric APSCD Mil OFF non 0 fect. high altitude and if tur-
MALFUNCTION DIAGNOSIS
Pressure bocharger without VGT).
Sensor

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41
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42
113 Ac c e l e r a t o r AccPedPlausBrk Mil OFF non 0 Accelerator pedal and If driver caused the prob-
Pedal and brake pedal are activated lem, no intervention ne-
brake not together (could also be cessary, else check signal
plausible caused by driver pressing of accelerator pedal and
both pedals at same time). mechanical movement of
Accelerator pedal locked accelerator pedal.
or defect.
2F9 Too long time AirCtlRmpTOIv Mil OFF non 0 Defect in the EGR actuat- Check for errors of the
spent in trans- ors (EGR- and throttle EGR actuators (correct
ition mode valve). installation, wiring, elec-
RgnNrm trical connectors,
jammed actuator)
12D Gridheateral- AirHtStickOnIv Mil OFF non 0 Short circuit to ground of Check grid heater switch
ways switched grid heater. and replace it.
on
Short circuit of wiring to Check of wiring or re-

external source or inside place relay.
relay.

ground or inside relay. place relay.
12B Power stage ArHt1 Mil OFF non 0
air heater 1 ac-
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Print P2D32C009 E
tuator Broken or disconnected Check of wiring or re-

wiring or defective relay. place relay.
Print P2D32C009 E
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Sensor defective or short Check wiring or replace
circuit to external source sensor.

134 circuit to ground. sensor.
Boost pressure BPSCD Mil OFF non 0
sensor
Difference of ambient and Check ambient and

boost pressure is out of boost pressure sensor for
range. accuracy.
126 Battery voltage BattCD Mil OFF non 0 Alternator voltage gov- Replace alternator gov-
fault ernor defect ernor device or alternat-
or
Battery defect, alternator Replace battery or altern-

defect, wiring problems ator. Check ECU and wir-
(too high resistance) or ing.
ECU defect. Occurence
possible during cold start.
117 Brake signal BrkCD Mil OFF non 0 Error during actuated ped- Adjust switches sychron-
al: Switches not synchron- ously, check signal raw
ous or one switch is de- values (Amb. cond.) and
fective/disconnected. Er- wiring.
ror during inactive pedal:
One switch is stuck or
shortage to external
source is present.
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43
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44
39E Info torque BstPrtTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to turbo charger pro- due to this failure alone.
turbo charger tection.
If power reduction oc-
protection act-
curred due to actual de-
ive
fect, the failure triggering
the torque limitation
should also be in the fail-
ure memory.
Follow troubleshooting
of this root error.
Short circuit of wiring to Check of wiring.

external source.

ground.
124 Cold start CSLpCD Mil OFF non 0 Broken or disconnected Check of wiring or re-
lamp wiring or defective cold place cold start lamp.
start lamp.
Defective wiring or defect- Check of wiring or re-

ive cold start lamp. place cold start lamp.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
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circuit to external source. sensor.

131 Coolant tem- CTSCD Mil OFF non 0 circuit to ground. sensor.
perature
sensor Coolant temperature and Check coolant temperat-
oil temperature values are ure sensor and oil tem-
not plausible, system can- perature sensor
not discriminate which of
both sensor is wrong
232 Coolant tem- ClgAbsTst Mil OFF non 0 Extreme ambient condi- Ensure that engine was
perature tions. Or inaccurate sensor not running in extreme
sensor abso- (although sensor does not ambient conditions.
lute test exceed its signal range) or Check wiring and accur-
thermostat blocked open. acy of sensor, replace-
ment of sensor
132 Coolant tem- Clg_DynTst Mil OFF non 0 Extreme ambient condi- Ensure that engine was
sensor dynam- (although sensor does not ambient conditions.
ic test exceed its signal range) or Check wiring and accur-
ment of sensor. CHeck
thermostat.
24F Info: Induce- CoVehEmerStrt Mil OFF non 0 Only an Info-Failure signal- Check and repair failures
ment Engine ing that engine shut down which are activating in-
shut off active inducement is active. ducement procedure
14F Info torque CoVehPrflmAct Mil OFF non 0 A defect has occurred (in Check and repair the
limitation: In- the EDC or DCU) which faiures which triggered
ducement act- triggered a performance the performance limita-
Base - 11/2011
ive limitation required by legis- tion

lation.
45
Base - 11/2011
46
13C Ambient Tem- EATSCD Mil OFF non 0

perature Sensor defective or short Check wiring or replace
Sensor circuit to ground. sensor.
142 Running with EngMBackUp Mil OFF non 1) yes (technical) be- 0 Signal interrupted do to Check wiring, sensor in-
camshaft cause of wiring problem, defective stallation and proper
sensor only Fid_CoEng_trqLimE or incorrectly installed functioning of crankshaft
rr crankshaft speed sensor. sensor (evaluated raw
signals).
Signal interrupted do to Check wiring, sensor in-

wiring problem, defective stallation and proper
or incorrectly installed functioning of camshaft
camshaft phase sensor. phase sensor (evaluate
raw signals).
143 C a m s h a f t EngMCaS1 Mil OFF non 1) yes (technical) be- 0

sensor failure cause of
Fid_CoEng_trqLimE Signal interrupted do to Check wiring, sensor in-
rr wiring problem, defective stallation and proper
TIER 4i C SERIES
Print P2D32C009 E
raw signals).
Print P2D32C009 E
TIER 4i C SERIES
or incorrectly installed functioning of crankshaft
crankshaft speed sensor. sensor (evaluate raw sig-
nals).

141 C r a n k s h a f t EngMCrS1 Mil OFF non 1) yes (technical) be- 0 wiring problem, defective stallation and proper
sensor failure cause of or incorrectly installed functioning of crankshaft
Fid_CoEng_trqLimE crankshaft speed sensor. sensor (evaluate raw sig-
rr nals).
144 O f f s e t EngMOfsCaSCrS Mil OFF non 0 Signal interrupted do to Check wiring, sensor in-
between cam- wiring problem, defective stallations and proper
shaft and or incorrectly installed functioning of camshaft
cranksh. camshaft or crankshaft and crankshaft sensors
sensor. (evaluate raw signals).
64C Info torque EngPrtOvhtPrv Mil OFF non 0 Active power reduction No actions necessary
limitation: Ex- due to engine overheat due to this failure alone. If
haust overheat protection. power reduction oc-
protection act- curred due to actual de-
ive fect, the failure triggering
ure memory. Follow
Base - 11/2011
troubleshooting of this
root error.
47
Base - 11/2011
48
54C Info torque EngPrtOvrSpd Mil OFF non 0 Engine overspeed has oc- No reactions necessary
limitation: curred. only if this fault/informa-
Engine over- tion status reoccurs fre-
speed protec- quently. In this case check
tion active driving conditions of
vehicle, engine speed ac-
quisition and injection
system for quantity set-
point and actual value
during fault recognition,
check also for ECU er-
rors.
49E Info torque EngPrtTrqLim Mil OFF non 0 Active power reduction No actions necessary
limitation: gen- due to engine mechanics due to this failure alone. If
eric engine protection. power reduction oc-
ure memory. Follow
root error.
34D Performance EngPrtTrqNLim Mil OFF non 0 Active power reduction No actions necessary
limit active due due to engine mechanics due to this failure alone. If
to either stage protection by speed limita- power reduction oc-
tion. curred due to actual de-
ure memory. Follow
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Print P2D32C009 E
root error.
Print P2D32C009 E
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135 Fuel Temp. FTSCD Mil OFF non 0
Signal Sensor defective or short Check wiring or replace
circuit to ground. sensor.
Short circuit of wiring to Check of wiring, replace

external source or inside fuel filter heater.
fuel filter heater.

ground or inside fuel filter fuel filter heater.
heater.
149 Fuel filter heat- FlFCD_Htg Mil OFF non 0
ing output
High battery voltage, high Check of wiring or re-

ECU temperature and high place fuel filter heater, if
load or defective wiring or necessary replace ECU.
defective fuel filter heater.
11C Water in Fuel FlSys_WtDetIv Mil OFF non 0 Water separation tank of Switch off ignition and
fuel filter full or water level empty water tank of fuel
sensor of fuel filter defect- filter, check level sensor.
ive.
1AF D M 1 D C U FrmMngDM1SPN1I Mil OFF non 1) yes (OBD) be- 0 At least one of the DCU Check what SPN and
SPN1 message v cause of Fid_CoVe- error assigned to SPN1 corresponding DCU er-
hPrflm21OBD group has occured and is ror is active and perform
reported via CAN to the troubleshooting accord-
EDC. ing to DCU support.
Base - 11/2011

49
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50
3AF D M 1 D C U FrmMngDM1SPN3I Mil OFF non 0 At least one of the DCU Check what SPN and
SPN3 message v error assigned to SPN3 corresponding DCU er-
group has occured and is ror is active and perform
Disconnected cable in the Check wiring of NOx

wiring of the NOx sensor sensor and its proper
or defective NOx sensor. functioning. If necessary
replace NOx sensor.
Short circuit in the wiring Check wiring of NOx

of the NOx sensor or de- sensor and its proper
fective NOx sensor. functioning. If necessary
1A3 Nox signal of FrmMngNOxSensIv Mil OFF non 1) yes (OBD) be- 0 replace NOx sensor.
Nox Sensor cause of Fid_CoVe-
hPrflm11OBD
Strange driving cycle or in- Check installation (in-
proper installation of the cluding wiring) and func-
TIER 4i C SERIES
sensor, defective NOx tionality of sensor. If ne-
Print P2D32C009 E
sensor. cessary change NOx

sensor
Print P2D32C009 E
TIER 4i C SERIES
1A2 Nox signal of FrmMngNOxSensN Mil OFF non 0 CAN communication dis- Check for proper CAN
Nox Sensor OxIv turbed, defective or inac- communication and
curate NOx sensor. check accuracy and prop-
er functioning of NOx
sensor.
Failure due to engine Read out the DCU failure

switch off after a high load memory and perform
period, leading to high troubleshooting accord-
temperatur in exhaust sys- ing to DCU support.
tem. A defect occurred in
the urea dosing system
which can impair the cool-
ing of the urea dosing
valve.
1A8 Error / Protec- FrmMngSCR1ProtIv Mil OFF non 0
tion request
on urea valve
via SCR1
A defect occurred in the Read out the DCU failure
urea dosing system which memory and perform
can impair the cooling of troubleshooting accord-
the urea dosing valve. ing to DCU support.
1B4 Timeout for FrmMngTOBC2ED Mil OFF non 0 Defective CAN controller Check presence and cor-
BC2EDC1 C1Iv of Body Computer, under- rect connection of the
voltage of BC, missing BC, BC to the network,
CAN cable connecting the Check correct function-
BC is disconnected or ing of the BC CAN con-
broken. Short circuit in troller and its voltage sup-
wiring. ply. Check wiring.
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51
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52
1A5 M e s s a g e FrmMngTODM1DC Mil OFF non 1) yes (technical) be- 0 Defective CAN controller Check presence and cor-
D M 1 D C U UIv cause of of DCU, undervoltage of rect connection of the
timeout Fid_CoEng_trqLimE DCU, missing DCU, CAN DCU to the network,
rr cable connecting the DCU check correct functioning
is disconnected or broken. of the DCU CAN con-
2) yes (technical) be-
Short circuit in wiring. troller and its voltage sup-
cause of
ply. Check wiring.
Fid_CoEng_trqLimE
rr4
3) yes (OBD) be-
cause of Fid_CoVe-
hPrflm11OBD
1A4 Message Nox FrmMngTONOxSe Mil OFF non 1) yes (OBD) be- 0 Defective CAN controller Check presence and cor-
S e n s o r nsIv cause of Fid_CoVe- of NOx Sensor, under- rect connection of the
timeout hPrflm11OBD voltage of NOx Sensor, NOx Sensor to the net-
missing NOx Sensor, CAN work, Check correct
cable connecting the NOx functioning of the NOx
Sensor is disconnected or Sensor CAN controller
broken. Short circuit in and its voltage supply.
wiring. Check wiring.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
1A6 Message SCR1 FrmMngTOSCR1Iv Mil OFF non 1) yes (technical) be- 0 Defective CAN controller Check presence and cor-
timeout cause of of Dosing Control Unit , rect connection of the
Fid_CoEng_trqLimE undervoltage of DCU, DCU to the network,
rr missing DCU, CAN cable Check correct function-
connecting the DCU is dis- ing of the DCU CAN
connected or broken. controller and its voltage
cause of
Short circuit in wiring. supply. Check wiring.
Fid_CoEng_trqLimE
rr4
3) yes (OBD) be-
cause of Fid_CoVe-
hPrflm11OBD
cause of
Fid_CoEng_trqLimE
rr4
1B7 Timeout in FrmMngTxTO Mil OFF non 0 Disturbed CAN, incorrect Check CAN communica-
CAN send configuration of the CAN, tion, check CAN config-
messages EDC is disconnected from uration, ensure proper
the network, EDC CAN connection of the EDC
controller defective. to the network, replace
EDC.
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53
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54
1D1 ECU internal HWEMonCom Mil OFF non 0 Electric disturbances, in- Replace ECU if failure re-
fault: SPI bus ternal defect of the ECU mains present.
Fault leading to a SPI bus com-
munication error.
Wrong programming/- Try to flash the EDC cor-

flashing of the EDC, intern- rectly with a proper data-
al defect of the EDC. set, if defect persists: re-
place EDC.

1D2 ECU internal HWEMonEEPROM Mil OFF non 0 al defect of the EDC. set, if defect persists: re-
fault place EDC.

place EDC.
1D3 ECU internal HWEMonRcyLocke Mil OFF non 0 Electronic disturbances, Analyze what error
fault d various hardware defects triggered the recovery
(ECU internal) or configur- (Read out label
ation problems. HWEMon_numRecov-
ery and compare the
value with the according
table). If error occurs re-
peatedly, reprogram
TIER 4i C SERIES
Print P2D32C009 E
EDC. If error remains, re-

place EDC.
Print P2D32C009 E
TIER 4i C SERIES
2D3 ECU internal HWEMonRcySup- Mil OFF non 0 Electronic disturbances, Analyze what error
fault pressed various hardware defects triggered the recovery
ery and compare the
peatedly, reprogram
place EDC.
3D3 ECU internal HWEMonRcyVisible Mil OFF non 0 Electronic disturbances, Analyze what error
fault various hardware defects triggered the recovery
ery and compare the
peatedly, reprogram
place EDC
1E9 ECU internal HWEMonUMaxSup- Mil OFF non 0 Excessive voltage supply of Check the battery for
fault: Supply ply a CJ940 component: High correct voltage supply,
voltage CJ940 battery voltage, defective check wiring. If defect re-
upper limit wiring, internal defect of mains replace EDC (in-
the EDC. ternal defect).
1EA ECU internal HWEMonUMinSup- Mil OFF non 0 Insufficient voltage supply Check the battery for suf-
fault: Supply ply of a CJ940 component: ficient voltage supply,
voltage CJ940 Low battery voltage, de- check wiring. If defect re-
lower limit fective wiring, internal de- mains replace EDC (in-
fect of the EDC. ternal defect).
15B Info: High HpTst Mil OFF non 0 The High Pressure Test is Wait until the High Pres-
Base - 11/2011
pressure test requested via a diagnostic sure Test has terminated.

started by ser- tester.
vice tool
55
Base - 11/2011
56
Sensor possibly saturated If failure 1AE
with water droplets. IAHSCDStrDly also
stored in memory: pro-
ceed according that de-
scription. If failure
ACTIVE: run engine at
medium speed > 10 min,
if failure does NOT get
INACTIVE: check wiring
harness and replace
sensor if necessary. If fail-
ure not active AND ratio
active time / occur-
rence < 10 min/occur-
rence: no action needed.
2AE Info: humidity IAHSCD Mil OFF non 0 If failure not active AND
sensor poten- ratio active time / occur-
tially wet rence > 10 min/occur-
rence: possible short cir-
cuit: check wiring har-
ness or replace sensor, if
necessary.
Sensor defective or short Check wiring. Replace

circuit to ground. sensor if necessary.

circuit to external source. sensor if necessary.
1AE Humidity sig- IAHSCDStrtDly Mil OFF non 0

nal ratio failure Sensor defective or short Check wiring. Replace
TIER 4i C SERIES
Print P2D32C009 E

Print P2D32C009 E
TIER 4i C SERIES
133 Boost Temp. IATSCD Mil OFF non 0 Sensor defective or short Check wiring or replace
Signal circuit to ground. sensor.
1E2 Error state of ImmCtl Mil OFF non 0 1) Defective CAN or im- 1) Ensure correct CAN
Immobilizer mobilizer and new control functioning (timeout er-
(no fuel re- unit (here no PIN entry is rors), unlock fuel release
lease) possible) OR T15 was via a tester request, re-
toggled more than a calib- place immobilizer
ratable value OR number
2) Enter PIN code via ac-
of allowed incorrect PIN
celerator pedal or instru-
entries is exceeded.
ment cluster, ensure cor-
2) Defective CAN or im- rect CAN functioning
mobilizer OR wrong code (timeout errors), replace
AND code is kown by the immobilzer
EDC AND T15 has not
been toggeled excessively
Short circuit of high-side to Check the wiring or re-

battery or ground. place injector.
Short circuit of low-side to Check the wiring or re-

ground in injector cable. place injector.
171 Bank 1 specific InjVlvBnk1A Mil OFF non 0
errors - Short
circuit / not Depending on the pattern, Check the wiring and the
classifiable various reasons can cause injection signals, replace
the defect, internal ECU ECU.
problem.
Base - 11/2011
57
Base - 11/2011
58
172 Bank 1 specific InjVlvBnk1B Mil OFF non 0 Defect in wiring or inject- Check the wiring and in-
warnings - or. jector.
Open load



errors - Short
circuit / not
classifiable Depending on the pattern, Check the wiring and the
various reasons can cause injection signals, replace
problem.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
Open load
Clock error or irruption of Check the power supply

the power supply voltage. or replace ECU if prob-
lem reoccurs.
Defective ECU. Reset ECU. If no recov-

ery, replace ECU.
17C Chip-specific InjVlvChipA Mil OFF non 0 Internal failure of ECU or TESTMODE calibration
errors-->stop TESTMODE takes too wrong or replace ECU if
engine long. problem reoccurs.
Defective SPI-bus parti- Replace ECU if problem

cipant, timing problem due reoccurs (Send in ECU
to software bug. for investigation).

lem reoccurs.

ery, replace ECU.
27C Chip-specific InjVlvChipB Mil OFF non 0 Internal failure of ECU or TESTMODE calibration
Defective ECU. Replace ECU if problem

reoccurs (Send in ECU
for investigation).
Base - 11/2011
59
Base - 11/2011
60
Short circuit in wiring with Check the wiring or re-
external source. place injector.
Defective coil of injector. Check the wiring and re-

place injector.
161 Cylinder1 - InjVlvCyl1A Mil OFF non 0

Short circuit
Low/High
Depending on the pattern, Check the wiring and the
problems also possible.
167 Cylinder1 - InjVlvCyl1B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
Open load tion of wiring or inside in- place injector.
jector.


place injector.

Short circuit
Low/High Depending on the pattern, Check the wiring and the
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
jector.


place injector.
163 Cylinder3 - InjVlvCyl3A Mil OFF non

Short circuit 0
Low/High

jector.
Base - 11/2011
61
Base - 11/2011
62

place injector.
Short circuit
Low/High

the defect, internal ECU ECU
16A Cylinder4 - InjVlvCyl4B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
jector.


place injector.
Short circuit
Low/High
TIER 4i C SERIES
Print P2D32C009 E

Print P2D32C009 E
TIER 4i C SERIES
16B Cylinder5 - InjVlvCyl5B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
jector.


place injector.

Short circuit
16C Cylinder6 - InjVlvCyl6B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
jector.
16E M i n i m u m InjVlvNumMinInj Mil OFF non 0 See individual injector and See individual injector
number of in- injection-bank errors (In- and injection-bank errors
jectors to run jVlvCyl... and InjVlvBnk...) (InjVlvCyl... and In-
the engine was which have triggerd the jVlvBnk...) which have
not reached shut-off or error in the triggerd the shut-off or
component. error in the component.
Base - 11/2011
63
Base - 11/2011
64
215 fault path for MFLv_Irvrs Mil OFF non 0 Wrong manipulation of Check for correct func-
irreversible multi function lever, tioning of switches and
cruise control blocked or electrical de- buttons of the multi func-
shut off for fects in switches, defects in tion lever, check wiring
wiring (short circuits). for short circuits (if signal
is processed via digital in-
put pins of the EDC).
315 fault path for MFLv_Rvrs Mil OFF non 0 Wrong manipulation of Check for correct func-
reversible multi function lever, tioning of switches and
cruise control blocked or electrical de- buttons of the multi func-
shut off for fects in switches, defects in tion lever, check wiring
wiring (short circuits). for short circuits (if signal
is processed via digital in-
put pins of the EDC).
Short circuit of main relay Check the wiring and all

2 output to external components connected
source, defect in one of the to main relay 2, if defect
connected components or remains main relay inside
defective main relay 2. ECU could be defective,
replace ECU.
125 Main relay de- MRlyCD Mil OFF non 0

fect (for High Short circuit of main relay Check the wiring and all
press pump 2 output to ground, defect components connected
P340/for en- in one of the connected to main relay 2, if defect
gine brake de- components or defective remains main relay inside
c o mp r .v al v e main relay 2. ECU could be defective,
P342)) replace ECU.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
225 Interrupted af- MRlyCDAftRun Mil OFF non 0 The ECU is switched off by Inform driver about cor-
terrun main electrical switch in- rect vehicle shut off,
stead of terminal 15, de- check wiring, replace
fective main relay, wiring main relay.
problem.

replace ECU.
129 Main relay 3 MRlyCDMnRly3 Mil OFF non 0 Short circuit of main relay Check the wiring and all
(A/C compr./- 3 output to ground, defect components connected
fuel filter heat- in one of the connected to main relay 3, if defect
er) components or defective remains main relay inside
main relay 3. ECU could be defective,
replace ECU.
Find device which per- Check wiring, ensure cor-

forms signal range check rect connection of ex-
and search for electrical ternal switch and check
failures in the remote for electrical defects, re-
switch. place device if necessary.
Open wire or disconnec- Check wiring, ensure cor-

ted external switch (resist- rect connection of ex-
ances) device or short cir- ternal switch and check
cuit of wiring to ground. for electrical defects, re-
114 Multiple State MSSCD Mil OFF non 0 place device if necessary.
Switch
Find device which per- Ensure correct connec-

forms monitoring of re- tion of the external
mote switch and check switch device and check
connection and proper its proper functioning, re-
functioning of the remote place if necessary.
Base - 11/2011
switch.
65
Base - 11/2011
66
Broken or disconnected Check of wiring or re-
Defective wiring, ECU, Check wiring, ECU,

powerstage or metering power stage and meter-
159 Metering unit MeUnCDNoLoad Mil OFF non 0 unit. ing unit.
PWM-power-
stage
259 Short circuit to MeUnCDSCBat Mil OFF non 0 Short circuit of wiring to Check of wiring or re-
battery of external source or inside place relay.
metering unit relay.
output
359 Short circuit to MeUnCDSCGnd Mil OFF non 0 Short circuit of wiring to Check of wiring or re-
ground of ground or inside relay. place relay.
metering unit
output
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
128 Main relay MnRly1_SCB Mil OFF non 0 Short circuit of main relay Check the wiring and all
S C B a t t 1 output to external components connected
(Lambda H./- source, defect in one of the to main relay 1, if defect
Grid H./Bat- connected components or remains main relay inside
t.switch) defective main relay 1. ECU could be defective,
replace ECU.
228 Main relay MnRly1_SCG Mil OFF non 0 Short circuit of main relay Check the wiring and all
S C G N D 1 output to ground, defect components connected
(Lambda H./- in one of the connected to main relay 1, if defect
Grid H./Bat- components or defective remains main relay inside
t.switch) main relay 1. ECU could be defective,
replace ECU.
1D4 ECU internal Montr Mil OFF non 0 Defective monitoring If error exists only tem-
fault module or CPU (e.g. im- porary (i.e. injection re-
paired functioning of the occurs) error can be ig-
CPU clock) of the EDC. nored and error deleted
Disturbed SPI-Bus. in the fault memory. In
case of a permanent er-
ror the injection remains
blocked and the ECU has
to be replaced.
19F Multi signal de- NOxEstIv Mil OFF non 0 Application dependent: Determine what defect
fects in Implausible sensor signals has set the Fid and re-
EGSys_NOxE or defective sensors etc. solve the problem caus-
stIv ing this original defect.
Base - 11/2011
67
Base - 11/2011
68
29D Info torque NTCTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: en- due to engine break shut due to this failure alone. If
gine brake shut off event. powerreduction oc-
off active curred due to actual de-
ure memory. Follow
root error.
1B1 Busoff in CAN NetMngCANAOff Mil OFF non 0 Wrong configuration of Check timing configura-
A CAN timing (Prescaler, tion with hardware com-
synchronization jump patibility, check termina-
width, sampling, propaga- tion resistors and net-
tion and phase segments), work connection and
bad termination resistors, contacts. Short circuits to
defective network connec- external source, ground
tion and contacts or de- or CAN High to Low.
fective CAN controller Monitor CAN commu-
with erroneous messages. nication for erroneous
behaviour of a parti-
cipant.
1B2 Busoff in CAN NetMngCANBOff Mil OFF non 0 Wrong configuration of Check timing configura-
B CAN timing (Prescaler, tion with hardware com-
TIER 4i C SERIES
Print P2D32C009 E

cipant.
Print P2D32C009 E
TIER 4i C SERIES
1B3 Busoff in CAN NetMngCANCOff Mil OFF non 0 Wrong configuration of Check timing configura-
C CAN timing (Prescaler, tion with hardware com-
cipant.


Sensor defective, wiring Check wiring and sensor

138 Oil Pressure OPSCD Mil OFF non 0 interrupted
Sensor
Inaccurate oil pressure Check oil pressure

sensor or defect (e.g. sensor for accuracy and
blocked piping) in the oil check oil system.
system.
238 Oil Pressure OPSCD1 Mil OFF non 0 Inaccurate oil pressure Check oil pressure
too low sensor or defect (e.g. too sensor for accuracy and
low oil level, leakage) in the check oil system.
Base - 11/2011
oil system.
69
Base - 11/2011
70

13A Oil Temp. OTSCD Mil OFF non 0

Sensor
Inaccurate oil or coolant Check oil and coolant
temperature sensors or in- temperature sensor for
sufficient oil or coolant re- accuracy and check oil
circulation (low coolant and coolant system for
level etc.) proper functioning.
23A Oil Temperat- OTSCD1 Mil OFF non 0 Inaccurate oil temperature Check oil temperature
ureabovenor- sensor or defect (e.g. sensor for accuracy and
mal blockage, insufficient recir- check oil system.
culation) in the oil system
1E3 E n e r g i s i n g OvRMon Mil OFF non 0 Electronic disturbances, Check injection relevant
time exceeds requested torque increase application, if failure per-
limit of over- via tester, wrong applica- sists replace ECU.
run monitor. tion of injection relevant
parameters, defective
ECU.
1E4 Plausibility er- OvRMonSigA Mil OFF non 0 Electronic disturbances, in- If failure persists after
ror in engine ternal ECU problem. reinitialization replace
TIER 4i C SERIES
speed check ECU.
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
1FB error path of O x i C C D O x- Mil OFF non 0 Oxidation catayst not in- Check oxicat for pres-
oxidation cata- iNotPres stalled or damaged (major ence and damage, check
lyst not crack or blockage etc.), de- exhaust gas piping for
present fect in exhaust gas pipes, damages, ensure accur-
temperature sensors not acy of exhaust gas tem-
accurate or mounted in- perature sensor up- and
correctly. downstream of oxicat.
1FC defect ratio OxiCCDSensIntChg Mil OFF non 0 Temperature sensors of Check temperature
bet wee n oxicat interchanged, oxicat sensors for accuracy and
threshold lim- severely damaged, wrong correct installation, check
its layout of exhaust gas pipes, oxicat for damage, check
temperature sensors not exhaust gas piping for
accurate. correct layout.
3FA Regeneration P F l t L c k- Mil OFF non 0 Specific regeneration re- Check filter and state
demand num- HDNumRgn2 quest of 2 locked. variable of saturation
ber 2 model, look for sensor
errors. Check differential
Filter could be clogged or pressure for correct func-
estimation of saturation tioning and accuracy.
degree could be wrong
due to sensor errors which
could trigger too many
long regenerations. De-
fective differential pressure
sensor (zero offset, block-
age etc.).
Base - 11/2011
71
Base - 11/2011
72
age etc.).
non Defective rail pressure Check rail pressure

sensor or in Metering Unit sensor for plausible val-
control or pressure relief ues, check presence of
valve opening at at low other rail pressure con-
pressure. trol faults, check PRV
valve.
PRV does not open once Check functioning of the

the pressure limit is PRV.
reached: Mechanical de-
fect or wrong application
137 Rail pressure PRVMon Mil OFF 1) yes (technical) be- 0 parameter.
relief valve cause of
Fid_CoEng_trqLimE
rr_MAX (only for
MAX failure)
2) yes (technical) be- PRV does not open even Check functioning of the
cause of after pressure shock: Stuck PRV.
Fid_CoEng_trqLimE PRV or wrong application
parameter.
TIER 4i C SERIES
rr3_MAX (only for
Print P2D32C009 E
MAX failure)
Print P2D32C009 E
TIER 4i C SERIES
19D Info torque PrflmTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to the OBD perform-due to this failure alone. If
OBD/Induce- ance limiter because of in- power reduction oc-
ment torque hibited urea injection. curred due to actual de-
limitation act- fect, the failure triggering
ive the torque limitation
ure memory. Follow
root error.
69E Info torque QLimTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: fuel due to limiting fuel quant- due to this failure alone. If
quantity limita- ity. power reduction oc-
tion active curred due to actual de-
ure memory. Follow
root error.
Short circuit of wiring to Check wiring and proper

external source or defect- functioning of rail pres-
ive pressure sensor, rail sure sensor.
pressure overshoot.
136 Rail pressure RailCD Mil OFF non 0
sensor CP3
Short circuit of wiring to Check wiring and proper
ground or defective pres- functioning of rail pres-
Base - 11/2011
sure sensor. sure sensor.
73
Base - 11/2011
74
Rail pressure sensor inac- Ensure correct wiring
curate. and proper functioning of
rail pressure sensor, re-
place sensor.
236 Rail pressure RailCDOfsTst Mil OFF non 1) yes (technical) be- 0
sensor offset cause of Rail pressure sensor inac- Ensure correct wiring
monitoring Fid_CoEng_trqLimE curate. and proper functioning of
rr rail pressure sensor, re-
place sensor.
152 Fuel Rail pres- RailMeUn1 Mil OFF non 1) yes (technical) be- 0 High pressure side: Leak- Check for defects ac-
sure low with cause of age in high pressure sec- cording to reason of fail-
fuel high pres- Fid_CoEng_trqLimE tion, injection nozzle stuck ure list.
sure pump at rr in open position, worn
maximum flow high pressure pump, worn
injector, leaking pressure
cause of
relieve valve
Fid_CoEng_trqLimE
rr3 Low pressure side: Pres-
sure before gear pump too
low, gear pump output too
low (fuel filter clogged,
leakage in low pressure
side).
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
158 Setpoint of RailMeUn10 Mil OFF non 1) yes (technical) be- 0 High pressure system: Rail Check for defects ac-
fuel volume cause of pressure sensor inaccur- cording to reason of fail-
flow through Fid_CoEng_trqLimE ate, high pressure pump ure list.
metering unit rr defective.
is lower than
2) yes (technical) be- Low pressure system: Me-
calculated limit
cause of tering unit reflux too low,
Fid_CoEng_trqLimE fuel system leakage, meter-
rr3 ing unit jammed in closed
position.
153 Fuel high pres- RailMeUn2 Mil OFF non 1) yes (technical) be- 0 Metering unit stuck in Check for defects ac-
sure pump is at cause of open position, zero-deliv- cording to reason of fail-
minimum de- Fid_CoEng_trqLimE ery throttle clogged, ure list.
livery and the rr metering unit without
Rail pressure is power due to electricel er-
not reducing ror.
cause of
Fid_CoEng_trqLimE Low pressure side: Pres-
rr3 sure before gear pump too
high (e.g. by pressure re-
lieve valve), pressure after
zero-delivery throttle too
high.
154 Rail pressure RailMeUn3 Mil OFF non 0 High pressure side: Leak- Check for defects ac-
below minim- age in the high pressure cording to reason of fail-
um value section, injection nozzle ure list.
stuck in open position,
worn high pressure pump,
worn injector, leaking pres-
sure relieve valve.
Low pressure side: Pres-
sure before gear pump too
low or gear pump output
too low (clogged fuel filter,
leak on output side).
Base - 11/2011
75
Base - 11/2011
76
155 Rail pressure RailMeUn4 Mil OFF non 0 Metering unit stuck in Check for defects ac-
above maxim- open position, zero-deliv- cording to reason of fail-
um value ery throttle clogged, ure list.
metering unit without
power due to electricel er-
ror. Low pressure side:
Pressure before gear pump
too high (e.g. by pressure
relieve valve), pressure
after zero-delivery throttle
too high.
156 Rail pressure RailMeUn6 Mil OFF non 1) yes (technical) be- 0 Leakage in the high pres- Check for defects ac-
drop rate dur- cause of sure section, injection cording to reason of fail-
ing overrun Fid_CoEng_trqLimE nozzle stuck in open posi- ure list.
too high rr tion, worn high pressure
pump, worn injector, leak-
ing pressure relieve valve,
cause of
injector reflux too high.
Fid_CoEng_trqLimE
rr3
157 Setpoint of RailMeUn7 Mil OFF non 1) yes (technical) be- 0 High pressure system: Check for defects ac-
metering unit cause of Leakage in the high pres- cording to reason of fail-
in overrun Fid_CoEng_trqLimE sure section, injection ure list.
mode not rr nozzle stuck in open posi-
plausible tion, worn or defective
high pressure pump, worn
cause of
injector, leaking pressure
Fid_CoEng_trqLimE
relieve valve. Low pressure
rr3
system: Zero delivery is
not active in metering unit
(excessve leakage in
metering unit).
21D SCR Catalyst SCRCatAgeingIv Mil OFF non 0 Excessive ageing of SCR-- Replace catalyst and re-
TIER 4i C SERIES
Print P2D32C009 E
Thermal Age- Catatlyst. set EEPROM value of

ing Limit ex- catalyst ageing time via
ceeded tester.
Print P2D32C009 E
TIER 4i C SERIES
31D DCU State SCRCatDCUStateIv Mil OFF non 1) yes (OBD) be- 0 Defect or abnormal beha- Read out failure memory
Monitoring cause of Fid_CoVe- viour of urea dosing sys- of the DCU and perform
(not injecting) hPrflm12OBD tem. troubleshooting, check
behaviour of urea dosing
system closely.
71D NOx sensor SCRCatLambdaMon Mil OFF non 1) yes (OBD) be- 0 NOx sensor is outside the Check if NOx sensor is
p l a u s i b i l i t y Iv cause of Fid_CoVe- muffler (exhaust system). mounted correctly.
check hPrflm12OBD
2A2 NOx Sensor SCRCatNOxDrIv Mil OFF non 0 NOx sensor inaccurate or Check NOx sensor for
drift test defective, defect in wiring, correct functioning (dis-
urea injection valve or fuel mount sensor -> NOx
injector jammed open, ex- value should be 0 ppm
cessive urea deposits in ex- during driving), check
haust system, strange be- wiring of sensor, check
haviour of SCR catalyst. fuel injectors, check urea
dosing system for correct
dosing amount (perform
UDST and Dosing Valve
Check, check DCU error
memory for leakage fail-
ures), check SCR catalyst
for correct functioning,
check exhaust system for
excessive urea deposits.
Base - 11/2011
77
Base - 11/2011
78
21E Catalyst effi- SCRCatNOxLvl1Iv Mil OFF non 0 Measured catalyst effi- Check Reagent, if correct
ciency lower ciency lower than the es- concentration check
than first Nox timated (NH3 slip urea dosing system for
prediction present), inaccurate NOx correct dosing amount
threshold level measurement (value too (perform UDST and
high) downstream of cata- Dosing Valve Check,
lyst, incorrect NOx estim-check DCU error
ation (value too low) up- memory for leakage fail-
stream of catalyst, estim-ures), check accuracy of
ated catalyst efficiency too NOx-sensor and NOx--
high (due to inaccuracies in model (humidity, boost
the exhaust mass flow cal- pressure and temperat-
culation, the estimated ure) for plausible values,
NH3 storage, temperature check NOx-conversion
measurements up- and efficiency of catalyst,
downstream of the cata- check exhaust system for
lyst) or catalyst degrada- excessive urea deposits.
tion, excessive urea depos-
its in exhaust system, re-
agent with too low UREA
concentration (<<32%).
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
31E Catalyst effi- SCRCatNOxLvl2Iv Mil OFF non 1) yes (OBD) be- 0 Measured catalyst effi- Check Reagent, if correct
ciency lower cause of Fid_CoVe- ciency lower than the es- concentration check
than second hPrflm12OBD timated (NH3 slip urea dosing system for
Nox predic- present), inaccurate NOx correct dosing amount
tion threshold measurement (value too (perform UDST and
level high) downstream of cata- Dosing Valve Check,
3A2 Nox Sensor SCRCatNOxPlIv Mil OFF non 0 NOx sensor inaccurate or Check urea dosing sys-
plausibility test defective, defect in wiring, tem for correct dosing
inaccurate NOx estima- amount (perform UDST
tion, urea injection valve and Dosing Valve Check,
jammed open or excessive check DCU error
urea deposits in exhaust memory for leakage fail-
system, defective SCR ures), check NOx sensor
catalyst. for correct functioning,
check wiring of sensor,
check NOx estimation
(humidity, boost pres-
sure and temperature)
for plausible values, check
SCR catalyst for correct
functioning, check ex-
haust system for excess-
Base - 11/2011
ive urea deposits.
79
Base - 11/2011
80
Temperature sensor Check wiring and signal
downstream of catalyst is of temperature sensor.
inaccurate or defective, Ensure complete cool
defect in wiring (also check down of vehicle (>10
connectors). hours) without sun ex-
posure and and measure
all 3 sensors signals. If
temperature differences
are above 20C replace
defective sensor.
Temperature sensor up- Check wiring and signal
stream of catalyst is inac- of temperature sensor.
curate or defective, defect Ensure complete cool
in wiring (also check con- down of vehicle (>10
nectors). hours) without sun ex-
defective sensor.
Ambient temperature If the ambient temperat-
11F P l a u s i b i l i t y SCRCatPlausIv Mil OFF non 1) yes (OBD) be- 0 sensor or both upstream ure sensor is inaccurate it
check of cata- cause of Fid_CoVe- and downstream catalyst is likely that the urea
lyst system hPrflm12OBD temperature sensors are pump module (DTC
inaccurate, defect in wiring $E4) and urea tank tem-
(also check connectors). perature (DTC $E5) are
also reported implausible
by the DCU. Check wir-
ing and signal of temper-
ature sensors. Ensure
complete cool down of
vehicle (>10 hours)
without sun exposure
and and measure all 3
sensors signals. If temper-
ature differences are
above 20C replace the
sensors which seem im-
plausible.
Temperature sensor up- Check both sensor sig-
TIER 4i C SERIES
or downstream of the nals and their wiring, look
Print P2D32C009 E
catalyst or both are inac- for static implausibility,

curate, defect in wiring check for oil leakages, re-
(also check connectors), place one or both
oil leakage into exhaust sensors.
system.
Print P2D32C009 E
TIER 4i C SERIES
41D Poor reduct- SCRCatRdcAgQl Mil OFF non 0 Maybe a wrong fluid (e.g. Replace the fluid in the
ant agent (DEF Water) is in the Urea tank. Urea tank.
/ AdBlue) qual-
ity
4AA urea quality SCRCatWarnLvl1 Mil OFF non 1) yes (OBD) be- 0 Thisisnot a standalonefail- Check and repair leading
and urea warn- cause of Fid_CoVe- ure, this failure is triggered failure.
ing level 1 hPrflm21OBD by another failure via
Fid_SCRCatWarnLvl1_m
p.
7AD urea quality SCRCatWarnLvl10 Mil OFF non 0 Thisisnot a standalonefail- Check and repair leading
and urea warn- ure, this failure is triggered failure.
ing level 10 by another failure via
Fid_SCRCatWarnLvl10_
mp.
Base - 11/2011
81
Base - 11/2011
82
p.
6AA urea quality SCRCatWarnLvl3 Mil OFF non 0 Thisisnot a standalonefail- Check and repair leading
p.
p.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
2AD urea quality SCRCatWarnLvl5 Mil OFF non 1) yes (OBD) be- 0 Thisisnot a standalonefail- Check and repair leading
p.
p.
p.
p.
Base - 11/2011
83
Base - 11/2011
84
p.
59D Info torque SCRPrtTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: SCR due to excessive temper- due to this failure alone. If
injector over- atures in the SCR catalyst. power reduction oc-
heat protec- curred due to actual de-
tion active fect, the failure triggering
ure memory. Follow
root error.
Watch dog switch off path If failure reoccurs after

defect. ECU initialisation: replace
ECU.
Electronic disturbances, in- If failure remains after
ternal ECU problem. ECU initialisation: replace
1D5 ECU internal SOPTst Mil OFF non 1) yes (technical) be- 0 ECU.
fault: Redund- cause of
ant shutoff Fid_CoEng_trqLimE Electronic disturbances, in- If failure remains after
paths test rr ternal ECU problem. ECU initialisation: replace
failed ECU.
Excessive battery voltage, Check battery voltage,
defect in wiring harness, check wiring for correct
electrical failure in connec- voltage supply of the
ted sensors or in the EDC. sensor and the EDC.
If no anomaly is found in
wiring or connected
sensors replace EDC.
1E6 ECU sensor SSpMon1 Mil OFF non 1) yes (technical) be- 0
supply: 5V cause of Insufficient battery voltage, Check battery voltage,
supply voltage Fid_CoEng_trqLimE defect in wiring harness, check wiring for correct
electrical failure connected voltage supply of the
TIER 4i C SERIES
1 rr
Print P2D32C009 E
sensors or in the EDC. sensor and the EDC.

wiring or connected
Print P2D32C009 E
TIER 4i C SERIES
electrical failure of the voltage supply of the
EDC. sensor and the EDC.
wiring or connected
1E5 ECU sensor SSpMon12V Mil OFF non 0

supply: 12V Insufficient battery voltage, Check battery voltage,
supply voltage defect in wiring harness, check wiring for correct
wiring or connected
1E7 ECU sensor SSpMon2 Mil OFF non 1) yes (technical) be- 0 Excessive battery voltage, Check battery voltage,
supply: 5V cause of defect in wiring harness, check wiring for correct
supply voltage Fid_CoEng_trqLimE electrical failure in connec- voltage supply of the
2 rr ted sensors or in the EDC. sensor and the EDC.
wiring or connected
Insufficient battery voltage, Check battery voltage,
wiring or connected
Base - 11/2011
85
Base - 11/2011
86
wiring or connected
supply: 5V cause of Insufficient battery voltage, Check battery voltage,
supply voltage Fid_CoEng_trqLimE defect in wiring harness, check wiring for correct
3 rr electrical failure connected voltage supply of the
cause of If no anomaly is found in
Fid_CoEng_trqLimE wiring or connected
rr2 sensors replace EDC.
19E Info torque SmkTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to smoke limitation. due to this failure alone. If
smoke limita- power reduction oc-
ure memory. Follow
root error.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
1E1 Starter crank StrtCDHS Mil OFF non 1) yes (technical) be- 0 Short circuit of wiring to Check of wiring or re-
relay electrical cause of ground or inside relay. place relay.
failure (High Fid_CoEng_trqLimE
Side power rr
stage)
2E1 Starter crank StrtCDLS Mil OFF non 1) yes (technical) be- 0 Short circuit of wiring to Check wiring or replace
relay electrical cause of external source or inside relay.
failure (Low Fid_CoEng_trqLimE relay.
Side power rr
stage)

external source.

ground or inside system diagnostic lamp.
lamp

123 Power stage SysLamp Mil OFF non 0 wiring or defective dia- place diagnostic lamp.
for system gnostic lamp.
lamp
High battery voltage, high Check load and output,
ECU temperature and high check wiring, replace dia-
load OR defective wiring, gnostic lamp or ECU.
diagnostic lamp or ECU.
Base - 11/2011
87
Base - 11/2011
88
119 No key T15CD Mil OFF non 0 Due to a short circuit in Check wiring for correct
Switched input the ignition switch the installation and for short
(terminal 15) EDC is switched on, al- circuits.
signals detec- though T15 has not been
ted activated.
11A Terminal50al- T50CD Mil OFF non 0 Permanent T50 high signal Check wiring and look for
ways pressed at digital input due to wir- electrical defects.
ing problem or short cir-
cuit.
1D6 ECU internal TPUMon Mil OFF non 0 Electronic disturbances, If failure persists: Replace
fault: deviation wrong TPU timebase. ECU.
between TPU
and system
time
Wrong application of con- Check for correct applic-

version factors for speed ation values, check SPS
calculation, defective SPS, and replace it if necessary.
real overspeed.
hardware related record- Check and replace

ing error (TPU) of the VSS vehicle speed sensor
or SPS
111 Fault path 1 for VSSCD1 Mil OFF non 0
vehicle Speed
sensing
Vehicle speed sensor miss- Check for correct applic-
ing or disconnected. ation values, check SPS
TIER 4i C SERIES
Wrong application of con- and replace it if necessary.
Print P2D32C009 E
version factors for speed

calculation, defective SPS.
Print P2D32C009 E
TIER 4i C SERIES
Defect in the tachometer Check tachometer for
speed signal acquisition or broken components and
wrong configuration of the correct functioning, clean
device. components or replace
tachometer if necessary.

311 Fault path 3 for VSSCD3 Mil OFF non 0 tachometer if necessary.
vehicle Speed
signal from ta-
chometer

tachometer if necessary.
See general remarks. See general remarks.

1D7 Dataset vari- VarMngCodDs Mil OFF non 0
ant coding See general remarks. See general remarks.
1D8 ECU internal WdCom Mil OFF non 0 Disturbed SPI-Bus. If ECU functions cor-
fault: Supervi- rectly after recovery only
sion of SPI-- temporary SPI error oc-
handler Flag curred and fault memory
can be deleted and error
ignored. If permanent SPI
error is present and the
ECU does not leave boot
block --> Replace ECU.
Base - 11/2011
89
Base - 11/2011
90
DIAGNOSIS FOR SYMPTOMS (F2C)
Signalled Possible Related Recommended
Anomaly Possible Cause Anomalies Tests or Measures Remarks
The engine will stop or Fuel pre-filter clogged
wont start.
After the new vehicle has Reversed tank suction / return pipes. The engine is fed by the return pipe,
been delivered, the engine the suction of which in the tank is
will stop after a short opera- lower.When the pipe sucks no
tion time. The tank holds a more, the engine will stop.
lot of fuel; all the rest is O.K.
Reduced power / difficult Injection system / the engine operates Overheating Engine test: cylinder efficiency test.
engine maneuverability. with one cylinder failing:
- injector seizure.
Fuel consumption increase. Air filter clogging with no signal from Smoke Check the cabling, connections
the warning light on the instrument and component.
board.
The engine does not reach The boosting pressure sensor provides Smoke
the other speedsunder load too high values, which, in any case, fall
conditions. within the range
The driver feels that the en- Impaired hydraulic performance of an Engine test: check up
gine is not working correctly injector.
like it did before.
The engine will stop or Presence of air in the fuel supply circuit. It might even not switch off; it might Bleed air.
wont start again. have operation oscillations, or start,
yet with difficulty and after making
TIER 4i C SERIES
manyattempts.
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
NOTE The fault codes depend on the application, therefore some may never NOTE be displayed during diagnosis.
FAULT CODES (F3B)

1D9 ECU internal ADCMon Mil OFF non Buffer overrun No intervention neces-
fault: Analog to sary
Digital conver- 0
sion failure


112 Ac c e l e r a t o r APP1 Mil OFF non 0 in accelerator pedal. accelerator pedal.
Pedal 1
Idle switch defect or wir- Check wiring of idle
ing of idle switch broken switch pin_idlswt or re-
or accelerator pedal de- place accelerator pedal
fect

1EB Atmospheric APSCD Mil OFF non 0 bocharger without VGT).
Pressure
Sensor
113 Ac c e l e r a t o r A c- Mil OFF non 0 Accelerator pedal and If driver caused the prob-
Pedal and cPedPlausBrk brake pedal are activated lem, no intervention ne-
brake not together (could also be cessary, else check signal
plausible caused by driver press- of accelerator pedal and
ing both pedals at same mechanical movement of
time). Accelerator pedal accelerator pedal.
Base - 11/2011
locked or defect.
91
Base - 11/2011
92
2F9 Too long time AirCtlRmpTOIv Mil OFF non 0 Defect in the EGR actuat- Check for errors of the
spent in trans- ors (EGR- and throttle EGR actuators (correct
ition mode valve). installation, wiring, elec-
RgnNrm trical connectors,
jammed actuator)
12D Gridheateral- AirHtStickOnIv Mil OFF non 0 Short circuit to ground of Check grid heater switch
ways switched grid heater. and replace it.
on

external source or inside place relay.
relay.

12B Power stage ArHt1 Mil OFF non 0 ground or inside relay. place relay.
air heater 1 ac-
tuator
151 Cyl.1 specific BIPCyl1 Mil OFF non 1) yes (technical) be- 0 Hydraulic instabilities in Check fuel system, check
errors cause of fuel system, bad transition resistances in contacts
Fid_CoEng_trqLimE resistances in contacts, and cable harness, re-
rr cable harness or defective place injector valve.
injection valve (bad re-
sponse times, fouling caus-
ing valve to jam, short cir-
cuit of some coils --> not
detected by power stage).
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
Base - 11/2011
93
Base - 11/2011
94
detected by power stage)

circuit to external source sensor.

134 Boost pressure BPSCD Mil OFF non 1) yes (technical) be- 0
sensor cause of
Fid_CoEng_trqLimE
rr
Difference of ambient and Check ambient and
2) yes (technical) be- boost pressure is out of boost pressure sensor for
TIER 4i C SERIES
cause of range. accuracy.
Print P2D32C009 E
Fid_CoEng_trqLimE
rr3
Print P2D32C009 E
TIER 4i C SERIES
Alternator voltage gov- Replace alternator gov-
ernor defect ernor device or alternat-
or
Battery defect, alternator Replace battery or altern-

126 Battery voltage BattCD Mil OFF non 0 defect, wiring problems ator. Check ECU and wir-
fault (too high resistance) or ing.
ECU defect. Occurence
possible during cold start.
117 Brake signal BrkCD Mil OFF non 0 Error during actuated ped- Adjust switches sychron-
al: Switches not synchron- ously, check signal raw
ous or one switch is de- values (Amb. cond.) and
fective/disconnected. Er- wiring.
ror during inactive pedal:
One switch is stuck or
shortage to external
source is present.
39E Info torque BstPrtTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to turbo charger pro- due to this failure alone.
turbo charger tection.
If power reduction oc-
protection act-
curred due to actual de-
ive
ure memory.
Follow troubleshooting
of this root error.
Base - 11/2011
95
Base - 11/2011
96

131 Coolant tem- CTSCD Mil OFF non 0

perature Coolant temperature and Check coolant temperat-
sensor oil temperature values are ure sensor and oil tem-
not plausible, system can- perature sensor
not discriminate which of
both sensor is wrong
232 Coolant tem- ClgAbsTst Mil OFF non 0 Extreme ambient condi- Ensure that engine was
sensor abso- (although sensor does not ambient conditions.
lute test exceed its signal range) or Check wiring and accur-
ment of sensor
132 Coolant tem- Clg_DynTst Mil OFF non 0 Extreme ambient condi- Ensure that engine was
sensor dynam- (although sensor does not ambient conditions.
ic test exceed its signal range) or Check wiring and accur-
ment of sensor. CHeck
thermostat.
24F Info: Induce- CoVehEmerStrt Mil OFF non 0 Only an Info-Failure signal- Check and repair failures
ment Engine ing that engine shut down which are activating in-
shut off active inducement is active. ducement procedure
14F Info torque CoVehPrflmAct Mil OFF non 0 A defect has occurred (in Check and repair the
limitation: In- the EDC or DCU) which faiures which triggered
TIER 4i C SERIES
ducement act- triggered a performance the performance limita-
Print P2D32C009 E
ive limitation required by legis- tion

lation.
Print P2D32C009 E
TIER 4i C SERIES
13C Ambient Tem- EATSCD Mil OFF non 0
perature Sensor defective or short Check wiring or replace
Sensor circuit to ground. sensor.
142 Running with EngMBackUp Mil OFF non 1) yes (technical) be- 0 Signal interrupted do to Check wiring, sensor in-
camshaft cause of wiring problem, defective stallation and proper
sensor only Fid_CoEng_trqLimE or incorrectly installed functioning of crankshaft
rr crankshaft speed sensor. sensor (evaluated raw
signals).

raw signals).
143 C a m s h a f t EngMCaS1 Mil OFF non 1) yes (technical) be- 0 Signal interrupted do to Check wiring, sensor in-
sensor failure cause of wiring problem, defective stallation and proper
Fid_CoEng_trqLimE or incorrectly installed functioning of camshaft
rr camshaft phase sensor. phase sensor (evaluate
raw signals).

or incorrectly installed functioning of crankshaft
crankshaft speed sensor. sensor (evaluate raw sig-
nals).
141 C r a n k s h a f t EngMCrS1 Mil OFF non 1) yes (technical) be- 0 Signal interrupted do to Check wiring, sensor in-
sensor failure cause of wiring problem, defective stallation and proper
Fid_CoEng_trqLimE or incorrectly installed functioning of crankshaft
rr crankshaft speed sensor. sensor (evaluate raw sig-
nals).
144 O f f s e t EngMOfsCaSCrS Mil OFF non 0 Signal interrupted do to Check wiring, sensor in-
between cam- wiring problem, defective stallations and proper
shaft and or incorrectly installed functioning of camshaft
cranksh. camshaft or crankshaft and crankshaft sensors
Base - 11/2011
sensor. (evaluate raw signals).
97
Base - 11/2011
98
64C Info torque EngPrtOvhtPrv Mil OFF non 0 Active power reduction No actions necessary
limitation: Ex- due to engine overheat due to this failure alone. If
haust overheat protection. power reduction oc-
ure memory. Follow
root error.
54C Info torque EngPrtOvrSpd Mil OFF non 0 Engine overspeed has oc- No reactions necessary
limitation: curred. only if this fault/informa-
Engine over- tion status reoccurs fre-
speed protec- quently. In this case check
tion active driving conditions of
vehicle, engine speed ac-
quisition and injection
system for quantity set-
point and actual value
during fault recognition,
check also for ECU er-
rors.
49E Info torque EngPrtTrqLim Mil OFF non 0 Active power reduction No actions necessary
limitation: gen- due to engine mechanics due to this failure alone. If
eric engine protection. power reduction oc-
ure memory. Follow
root error.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
34D Performance EngPrtTrqNLim Mil OFF non 0 Active power reduction No actions necessary
limit active due due to engine mechanics due to this failure alone. If
to either stage protection by speed limita- power reduction oc-
tion. curred due to actual de-
ure memory. Follow
root error.
135 Fuel Temp. FTSCD Mil OFF non 0 Sensor defective or short Check wiring or replace
Signal circuit to external source. sensor.


external source or inside fuel filter heater.
fuel filter heater.

ground or inside fuel filter fuel filter heater.
heater.
149 Fuel filter heat- FlFCD_Htg Mil OFF non 0
ing output
High battery voltage, high Check of wiring or re-
ECU temperature and high place fuel filter heater, if
load or defective wiring or necessary replace ECU.
defective fuel filter heater.
11C Water in Fuel FlSys_WtDetIv Mil OFF non 0 Water separation tank of Switch off ignition and
fuel filter full or water level empty water tank of fuel
sensor of fuel filter defect- filter, check level sensor.
Base - 11/2011
ive.
99
Base - 11/2011
100
3AF D M 1 D C U FrmMngDM1SPN3I Mil OFF non 0 At least one of the DCU Check what SPN and
SPN3 message v error assigned to SPN3 corresponding DCU er-
group has occured and is ror is active and perform
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
1A3 Nox signal of FrmMngNOxSensIv Mil OFF non 1) yes (OBD) be- 0 Disconnected cable in the Check wiring of NOx
Nox Sensor cause of Fid_CoVe- wiring of the NOx sensor sensor and its proper
hPrflm11OBD or defective NOx sensor. functioning. If necessary
replace NOx sensor.
Short circuit in the wiring Check wiring of NOx

of the NOx sensor or de- sensor and its proper
fective NOx sensor. functioning. If necessary
replace NOx sensor.
Strange driving cycle or in- Check installation (in-

proper installation of the cluding wiring) and func-
sensor, defective NOx tionality of sensor. If ne-
sensor. cessary change NOx sen-
sor.
1A2 Nox signal of FrmMngNOxSensN Mil OFF non 0 CAN communication dis- Check for proper CAN
Nox Sensor OxIv turbed, defective or inac- communication and
curate NOx sensor. check accuracy and prop-
er functioning of NOx
sensor.
Failure due to engine Read out the DCU failure

switch off after a high load memory and perform
period, leading to high troubleshooting accord-
temperatur in exhaust sys- ing to DCU support.
tem. A defect occurred in
the urea dosing system
1A8 Error / Protec- FrmMngSCR1ProtIv Mil OFF non 0 which can impair the cool-
tion request ing of the urea dosing
on urea valve valve.
via SCR1
A defect occurred in the Read out the DCU failure
urea dosing system which memory and perform
can impair the cooling of troubleshooting accord-
Base - 11/2011
the urea dosing valve. ing to DCU support.
101
Base - 11/2011
102
1A5 M e s s a g e FrmMngTODM1DC Mil OFF non 1) yes (technical) be- 0 Defective CAN controller Check presence and cor-
D M 1 D C U UIv cause of of DCU, undervoltage of rect connection of the
timeout Fid_CoEng_trqLimE DCU, missing DCU, CAN DCU to the network,
rr cable connecting the DCU check correct functioning
is disconnected or broken. of the DCU CAN con-
Short circuit in wiring. troller and its voltage sup-
cause of
ply. Check wiring.
Fid_CoEng_trqLimE
rr4
3) yes (OBD) be-
cause of Fid_CoVe-
hPrflm11OBD
1A4 Message Nox FrmMngTONOxSe Mil OFF non 1) yes (OBD) be- 0 Defective CAN controller Check presence and cor-
S e n s o r nsIv cause of Fid_CoVe- of NOx Sensor, under- rect connection of the
timeout hPrflm11OBD voltage of NOx Sensor, NOx Sensor to the net-
missing NOx Sensor, CAN work, Check correct
cable connecting the NOx functioning of the NOx
Sensor is disconnected or Sensor CAN controller
TIER 4i C SERIES
broken. Short circuit in and its voltage supply.
Print P2D32C009 E
wiring. Check wiring.

Print P2D32C009 E
TIER 4i C SERIES
cause of
Fid_CoEng_trqLimE
rr4
3) yes (OBD) be-
cause of Fid_CoVe-
hPrflm11OBD
cause of
Fid_CoEng_trqLimE
rr4
1B7 Timeout in FrmMngTxTO Mil OFF non 0 Disturbed CAN, incorrect Check CAN communica-
CAN send configuration of the CAN, tion, check CAN config-
messages EDC is disconnected from uration, ensure proper
the network, EDC CAN connection of the EDC
controller defective. to the network, replace
EDC.
1D1 ECU internal HWEMonCom Mil OFF non 0 Electric disturbances, in- Replace ECU if failure re-
fault: SPI bus ternal defect of the ECU mains present.
Fault leading to a SPI bus com-
Base - 11/2011
munication error.
103
Base - 11/2011
104
place EDC.

1D2 ECU internal HWEMonEEPROM Mil OFF non 0 al defect of the EDC. set, if defect persists: re-
fault place EDC.

place EDC.
1D3 ECU internal HWEMonRcyLocke Mil OFF non 0 Electronic disturbances, Analyze what error
fault d various hardware defects triggered the recovery
ery and compare the
peatedly, reprogram
place EDC.
2D3 ECU internal HWEMonRcySup- Mil OFF non 0 Electronic disturbances, Analyze what error
fault pressed various hardware defects triggered the recovery
ery and compare the
TIER 4i C SERIES
Print P2D32C009 E
peatedly, reprogram
place EDC.
Print P2D32C009 E
TIER 4i C SERIES
3D3 ECU internal HWEMonRcyVisible Mil OFF non 0 Electronic disturbances, Analyze what error
fault various hardware defects triggered the recovery
ery and compare the
peatedly, reprogram
place EDC
1E9 ECU internal HWEMonUMaxSup- Mil OFF non 0 Excessive voltage supply of Check the battery for
fault: Supply ply a CJ940 component: High correct voltage supply,
voltage CJ940 battery voltage, defective check wiring. If defect re-
upper limit wiring, internal defect of mains replace EDC (in-
the EDC. ternal defect).
1EA ECU internal HWEMonUMinSup- Mil OFF non 0 Insufficient voltage supply Check the battery for suf-
fault: Supply ply of a CJ940 component: ficient voltage supply,
voltage CJ940 Low battery voltage, de- check wiring. If defect re-
lower limit fective wiring, internal de- mains replace EDC (in-
fect of the EDC. ternal defect).
Base - 11/2011
105
Base - 11/2011
106
Sensor possibly saturated If failure 1AE
with water droplets. IAHSCDStrDly also
stored in memory: pro-
ceed according that de-
scription. If failure
ACTIVE: run engine at
medium speed > 10 min,
if failure does NOT get
INACTIVE: check wiring
harness and replace
sensor if necessary. If fail-
ure not active AND ratio
active time / occur-
rence < 10 min/occur-
2AE Info: humidity IAHSCD Mil OFF non 0 rence: no action needed.
sensor poten- If failure not active AND
tially wet ratio active time / occur-
rence > 10 min/occur-
rence: possible short cir-
cuit: check wiring har-
ness or replace sensor, if
necessary.


circuit to external source. sensor if necessary.
1AE Humidity sig- IAHSCDStrtDly Mil OFF non 0
nal ratio failure Sensor defective or short Check wiring. Replace

TIER 4i C SERIES
133 Boost Temp. IATSCD Mil OFF non 0
Print P2D32C009 E
Signal Sensor defective or short Check wiring or replace

Print P2D32C009 E
TIER 4i C SERIES
1E2 Error state of ImmCtl Mil OFF non 0 1) Defective CAN or im- 1) Ensure correct CAN
Immobilizer mobilizer and new control functioning (timeout er-
(no fuel re- unit (here no PIN entry is rors), unlock fuel release
lease) possible) OR T15 was via a tester request, re-
toggled more than a calib- place immobilizer
ratable value OR number
2) Enter PIN code via ac-
of allowed incorrect PIN
celerator pedal or instru-
entries is exceeded.
ment cluster, ensure cor-
2) Defective CAN or im- rect CAN functioning
mobilizer OR wrong code (timeout errors), replace
AND code is kown by the immobilzer
EDC AND T15 has not
been toggeled excessively



errors - Short
circuit / not
classifiable Depending on the pattern, Check the wiring and the
problem.
Open load
Base - 11/2011
107
Base - 11/2011
108
173 Bank 2 specific InjVlvBnk2A Mil OFF non 0 Short circuit of high-side to Check the wiring or re-
errors - Short battery or ground. place injector.
circuit / not
classifiable Short circuit of low-side to Check the wiring or re-

problem.
Open load

lem reoccurs.

ery, replace ECU.
17C Chip-specific InjVlvChipA Mil OFF non 0 Internal failure of ECU or TESTMODE calibration
Defective SPI-bus parti- Replace ECU if problem
TIER 4i C SERIES
cipant, timing problem due reoccurs (Send in ECU
Print P2D32C009 E
to software bug. for investigation).

Print P2D32C009 E
TIER 4i C SERIES
lem reoccurs.

ery, replace ECU.
27C Chip-specific InjVlvChipB Mil OFF non 0 Internal failure of ECU or TESTMODE calibration
Defective ECU. Replace ECU if problem

reoccurs (Send in ECU
for investigation).
161 Cylinder1 - InjVlvCyl1A Mil OFF non 0 Short circuit in wiring with Check the wiring or re-
Short circuit external source. place injector.
Low/High Defective coil of injector. Check the wiring and re-
place injector.

jector.

place injector.
162 Cylinder2 - InjVlvCyl2A Mil OFF non 0 Depending on the pattern, Check the wiring and the
Short circuit various reasons can cause injection signals, replace
Low/High the defect, internal ECU ECU.
Base - 11/2011

jector.
109
Base - 11/2011
110

place injector.
Short circuit
Low/High
jector.


place injector.
Short circuit
the defect, internal ECU ECU
16A Cylinder4 - InjVlvCyl4B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
TIER 4i C SERIES
Print P2D32C009 E
jector.
Print P2D32C009 E
TIER 4i C SERIES

place injector.

Short circuit Depending on the pattern, Check the wiring and the
Low/High various reasons can cause injection signals, replace
16B Cylinder5 - InjVlvCyl5B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
jector.


place injector.
166 Cylinder6 - InjVlvCyl6A Mil OFF non 0 Depending on the pattern, Check the wiring and the
Short circuit various reasons can cause injection signals, replace
Low/High the defect, internal ECU ECU.
16C Cylinder6 - InjVlvCyl6B Mil OFF non 0 Broken wire or disconnec- Check the wiring or re-
jector.
16E M i n i m u m InjVlvNumMinInj Mil OFF non 0 See individual injector and See individual injector
number of in- injection-bank errors (In- and injection-bank errors
jectors to run jVlvCyl... and InjVlvBnk...) (InjVlvCyl... and In-
the engine was which have triggerd the jVlvBnk...) which have
not reached shut-off or error in the triggerd the shut-off or
Base - 11/2011
component. error in the component.
111
Base - 11/2011
112
NIMA codes not pro- Try to flash the EDC cor-
grammed correctly, wrong rectly (including
programming/flashing of EEPROM initialization)
the EDC (initialization of with correct NIMA
EEPROM), internal defect codes and a proper data-
of the EDC. set, if defect persists: re-
place EDC.
17F Error on InjVlvQntAdj Mil OFF non 0

quantity ad-
justment val-
ues Invalid NIMA code has Try to flash the EDC cor-
been programmed. rectly with correct NIMA
codes and a proper data-
set.

replace ECU.
125 Main relay de- MRlyCD Mil OFF non 0 Short circuit of main relay Check the wiring and all
fect (for High 2 output to ground, defect components connected
press pump in one of the connected to main relay 2, if defect
P340/for en- components or defective remains main relay inside
gine brake de- main relay 2. ECU could be defective,
c o mp r .v al v e replace ECU.
P342))
225 Interrupted af- MRlyCDAftRun Mil OFF non 0 The ECU is switched off by Inform driver about cor-
terrun main electrical switch in- rect vehicle shut off,
stead of terminal 15, de- check wiring, replace
fective main relay, wiring main relay.
TIER 4i C SERIES
Print P2D32C009 E
problem.
Print P2D32C009 E
TIER 4i C SERIES
replace ECU.
129 Main relay 3 MRlyCDMnRly3 Mil OFF non 0

(A/C compr./-
fuel filter heat- Short circuit of main relay Check the wiring and all
er) 3 output to ground, defect components connected
in one of the connected to main relay 3, if defect
components or defective remains main relay inside
main relay 3. ECU could be defective,
replace ECU.
128 Main relay MnRly1_SCB Mil OFF non 0 Short circuit of main relay Check the wiring and all
S C B a t t 1 output to external components connected
(Lambda H./- source, defect in one of the to main relay 1, if defect
Grid H./Bat- connected components or remains main relay inside
t.switch) defective main relay 1. ECU could be defective,
replace ECU.
228 Main relay MnRly1_SCG Mil OFF non 0 Short circuit of main relay Check the wiring and all
S C G N D 1 output to ground, defect components connected
(Lambda H./- in one of the connected to main relay 1, if defect
Grid H./Bat- components or defective remains main relay inside
t.switch) main relay 1. ECU could be defective,
replace ECU.
Base - 11/2011
113
Base - 11/2011
114
1D4 ECU internal Montr Mil OFF non 0 Defective monitoring If error exists only tem-
fault module or CPU (e.g. im- porary (i.e. injection re-
paired functioning of the occurs) error can be ig-
CPU clock) of the EDC. nored and error deleted
Disturbed SPI-Bus. in the fault memory. In
case of a permanent er-
ror the injection remains
blocked and the ECU has
to be replaced.
19F Multi signal de- NOxEstIv Mil OFF non 0 Application dependent: Determine what defect
fects in Implausible sensor signals has set the Fid and re-
EGSys_NOxE or defective sensors etc. solve the problem caus-
stIv ing this original defect.
29D Info torque NTCTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: en- due to engine break shut due to this failure alone. If
gine brake shut off event. powerreduction oc-
off active curred due to actual de-
ure memory. Follow
root error.
1B1 Busoff in CAN NetMngCANAOff Mil OFF non 0 Wrong configuration of Check timing configura-
A CAN timing (Prescaler, tion with hardware com-
TIER 4i C SERIES
Print P2D32C009 E
cipant.
Print P2D32C009 E
TIER 4i C SERIES
1B2 Busoff in CAN NetMngCANBOff Mil OFF non 0 Wrong configuration of Check timing configura-
B CAN timing (Prescaler, tion with hardware com-
cipant.
1B3 Busoff in CAN NetMngCANCOff Mil OFF non 0 Wrong configuration of Check timing configura-
C CAN timing (Prescaler, tion with hardware com-
cipant.


138 Oil Pressure OPSCD Mil OFF non 0 Sensor defective, wiring Check wiring and sensor
Sensor interrupted
Inaccurate oil pressure Check oil pressure

Base - 11/2011
sensor or defect (e.g. sensor for accuracy and

blocked piping) in the oil check oil system.
115
system.
Base - 11/2011
116
238 Oil Pressure OPSCD1 Mil OFF non 0 Inaccurate oil pressure Check oil pressure
too low sensor or defect (e.g. too sensor for accuracy and
low oil level, leakage...) in check oil system.
the oil system.


13A Oil Temp. OTSCD Mil OFF non 0

Sensor Inaccurate oil or coolant Check oil and coolant
temperature sensors or in- temperature sensor for
sufficient oil or coolant re- accuracy and check oil
circulation (low coolant and coolant system for
level etc.) proper functioning.
23A Oil Temperat- OTSCD1 Mil OFF non 0 Inaccurate oil temperature Check oil temperature
ureabovenor- sensor or defect (e.g. sensor for accuracy and
mal blockage, insufficient recir- check oil system.
culation) in the oil system
1E3 E n e r g i s i n g OvRMon Mil OFF non 0 Electronic disturbances, Check injection relevant
time exceeds requested torque increase application, if failure per-
limit of over- via tester, wrong applica- sists replace ECU.
run monitor. tion of injection relevant
parameters, defective
ECU.
1E4 Plausibility er- OvRMonSigA Mil OFF non 0 Electronic disturbances, in- If failure persists after
TIER 4i C SERIES
ror in engine ternal ECU problem. reinitialization replace
Print P2D32C009 E
speed check ECU.

Print P2D32C009 E
TIER 4i C SERIES
1FB error path of O x i C C D O x- Mil OFF non 0 Oxidation catayst not in- Check oxicat for pres-
oxidation cata- iNotPres stalled or damaged (major ence and damage, check
lyst not crack or blockage etc.), de- exhaust gas piping for
present fect in exhaust gas pipes, damages, ensure accur-
temperature sensors not acy of exhaust gas tem-
accurate or mounted in- perature sensor up- and
correctly. downstream of oxicat.
1FC defect ratio OxiCCDSensIntChg Mil OFF non 0 Temperature sensors of Check temperature
bet wee n oxicat interchanged, oxicat sensors for accuracy and
threshold lim- severely damaged, wrong correct installation, check
its layout of exhaust gas pipes, oxicat for damage, check
temperature sensors not exhaust gas piping for
accurate. correct layout.
age etc.).
Base - 11/2011
117
Base - 11/2011
118
age etc.).
19D Info torque PrflmTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to the OBD perform-due to this failure alone. If
OBD/Induce- ance limiter because of in- power reduction oc-
ment torque hibited urea injection. curred due to actual de-
limitation act- fect, the failure triggering
ive the torque limitation
ure memory. Follow
root error.
69E Info torque QLimTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: fuel due to limiting fuel quant- due to this failure alone. If
quantity limita- ity. power reduction oc-
ure memory. Follow
root error.
21D SCR Catalyst SCRCatAgeingIv Mil OFF non 0 Excessive ageing of SCR-- Replace catalyst and re-
TIER 4i C SERIES
Thermal Age- Catatlyst. set EEPROM value of
Print P2D32C009 E
ing Limit ex- catalyst ageing time via

ceeded tester.
Print P2D32C009 E
TIER 4i C SERIES
31D DCU State SCRCatDCUStateIv Mil OFF non 1) yes (OBD) be- 0 Defect or abnormal beha- Read out failure memory
Monitoring cause of Fid_CoVe- viour of urea dosing sys- of the DCU and perform
(not injecting) hPrflm12OBD tem. troubleshooting, check
behaviour of urea dosing
system closely.
71D NOx sensor SCRCatLambdaMon Mil OFF non 1) yes (OBD) be- 0 NOx sensor is outside the Check if NOx sensor is
p l a u s i b i l i t y Iv cause of Fid_CoVe- muffler (exhaust system). mounted correctly.
check hPrflm12OBD
2A2 NOx Sensor SCRCatNOxDrIv Mil OFF non 0 NOx sensor inaccurate or Check NOx sensor for
drift test defective, defect in wiring, correct functioning (dis-
urea injection valve or fuel mount sensor -> NOx
injector jammed open, ex- value should be 0 ppm
cessive urea deposits in ex- during driving), check
haust system, strange be- wiring of sensor, check
haviour of SCR catalyst. fuel injectors, check urea
dosing system for correct
dosing amount (perform
UDST and Dosing Valve
Check, check DCU error
memory for leakage fail-
ures), check SCR catalyst
for correct functioning,
check exhaust system for
excessive urea deposits.
Base - 11/2011
119
Base - 11/2011
120
21E Catalyst effi- SCRCatNOxLvl1Iv Mil OFF non 0 Measured catalyst effi- Check Reagent, if correct
ciency lower ciency lower than the es- concentration check
than first Nox timated (NH3 slip urea dosing system for
prediction present), inaccurate NOx correct dosing amount
threshold level measurement (value too (perform UDST and
high) downstream of cata- Dosing Valve Check,
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
31E Catalyst effi- SCRCatNOxLvl2Iv Mil OFF non 1) yes (OBD) be- 0 Measured catalyst effi- Check Reagent, if correct
ciency lower cause of Fid_CoVe- ciency lower than the es- concentration check
than second hPrflm12OBD timated (NH3 slip urea dosing system for
Nox predic- present), inaccurate NOx correct dosing amount
tion threshold measurement (value too (perform UDST and
level high) downstream of cata- Dosing Valve Check,
Base - 11/2011
121
Base - 11/2011
122
3A2 Nox Sensor SCRCatNOxPlIv Mil OFF non 0 NOx sensor inaccurate or Check urea dosing sys-
plausibility test defective, defect in wiring, tem for correct dosing
inaccurate NOx estima- amount (perform UDST
tion, urea injection valve and Dosing Valve Check,
jammed open or excessive check DCU error
urea deposits in exhaust memory for leakage fail-
system, defective SCR ures), check NOx sensor
catalyst. for correct functioning,
check wiring of sensor,
check NOx estimation
(humidity, boost pres-
sure and temperature)
for plausible values, check
SCR catalyst for correct
functioning, check ex-
haust system for excess-
ive urea deposits.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
Temperature sensor Check wiring and signal
downstream of catalyst is of temperature sensor.
inaccurate or defective, Ensure complete cool
defect in wiring (also check down of vehicle (>10
connectors). hours) without sun ex-
defective sensor.
Temperature sensor up- Check wiring and signal

stream of catalyst is inac- of temperature sensor.
curate or defective, defect Ensure complete cool
in wiring (also check con- down of vehicle (>10
nectors). hours) without sun ex-
defective sensor.
Ambient temperature If the ambient temperat-
sensor or both upstream ure sensor is inaccurate it
11F P l a u s i b i l i t y SCRCatPlausIv Mil OFF non 1) yes (OBD) be- 0 and downstream catalyst is likely that the urea
check of cata- cause of Fid_CoVe- temperature sensors are pump module (DTC
lyst system hPrflm12OBD inaccurate, defect in wiring $E4) and urea tank tem-
(also check connectors). perature (DTC $E5) are
also reported implausible
by the DCU. Check wir-
ing and signal of temper-
ature sensors. Ensure
complete cool down of
vehicle (>10 hours)
without sun exposure
and and measure all 3
sensors signals. If temper-
ature differences are
above 20C replace the
sensors which seem im-
plausible.
Temperature sensor up- Check both sensor sig-
or downstream of the nals and their wiring, look
catalyst or both are inac- for static implausibility,
curate, defect in wiring check for oil leakages, re-
(also check connectors), place one or both
Base - 11/2011
oil leakage into exhaust sensors.

system.
123
Base - 11/2011
124
41D Poor reduct- SCRCatRdcAgQl Mil OFF non 0 Maybe a wrong fluid (e.g. Replace the fluid in the
ant agent (DEF Water) is in the Urea tank. Urea tank.
/ AdBlue) qual-
ity
p.
Fid_SCRCatWarnLvl10_
mp.
p.
6AA urea quality SCRCatWarnLvl3 Mil OFF non 0 Thisisnot a standalonefail- Check and repair leading
p.
p.
TIER 4i C SERIES
Print P2D32C009 E
p.
Print P2D32C009 E
TIER 4i C SERIES
p.
p.
p.
p.
59D Info torque SCRPrtTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: SCR due to excessive temper- due to this failure alone. If
injector over- atures in the SCR catalyst. power reduction oc-
heat protec- curred due to actual de-
tion active fect, the failure triggering
ure memory. Follow
Base - 11/2011
root error.
125
Base - 11/2011
126
Watch dog switch off path If failure reoccurs after
defect. ECU initialisation: replace
ECU.
Electronic disturbances, in- If failure remains after

ECU.
1D5 ECU internal SOPTst Mil OFF non 1) yes (technical) be- 0
fault: Redund- cause of
ant shutoff Fid_CoEng_trqLimE
paths test rr
failed Electronic disturbances, in- If failure remains after
ECU.

wiring or connected
supply: 5V cause of
Insufficient battery voltage, Check battery voltage,
supply voltage Fid_CoEng_trqLimE
1 rr
wiring or connected
TIER 4i C SERIES
Print P2D32C009 E

Print P2D32C009 E
TIER 4i C SERIES
wiring or connected
1E5 ECU sensor SSpMon12V Mil OFF non 0

wiring or connected

wiring or connected
1E7 ECU sensor SSpMon2 Mil OFF non 0
2 electrical failure connected voltage supply of the
wiring or connected
Base - 11/2011
127
Base - 11/2011
128
wiring or connected
1E8 ECU sensor SSpMon3 Mil OFF non 1) yes (technical) be- 0 Insufficient battery voltage, Check battery voltage,
supply: 5V cause of defect in wiring harness, check wiring for correct
supply voltage Fid_CoEng_trqLimE electrical failure connected voltage supply of the
3 rr sensors or in the EDC. sensor and the EDC.
wiring or connected
19E Info torque SmkTrqLim Mil OFF non 0 Active power redcution No actions necessary
limitation: due to smoke limitation. due to this failure alone. If
smoke limita- power reduction oc-
ure memory. Follow
root error.
1E1 Starter crank StrtCDHS Mil OFF non 1) yes (technical) be- 0 Short circuit of wiring to Check of wiring or re-
relay electrical cause of ground or inside relay. place relay.
failure (High Fid_CoEng_trqLimE
Side power rr
stage)
2E1 Starter crank StrtCDLS Mil OFF non 1) yes (technical) be- 0 Short circuit of wiring to Check wiring or replace
relay electrical cause of external source or inside relay.
TIER 4i C SERIES
failure (Low Fid_CoEng_trqLimE relay.
Print P2D32C009 E
Side power rr
stage)
Print P2D32C009 E
TIER 4i C SERIES
external source.

ground or inside system diagnostic lamp.
lamp

wiring or defective dia- place diagnostic lamp.
123 Power stage SysLamp Mil OFF non 0 gnostic lamp.
for system
lamp
High battery voltage, high Check load and output,

ECU temperature and high check wiring, replace dia-
load OR defective wiring, gnostic lamp or ECU.
diagnostic lamp or ECU.
119 No key T15CD Mil OFF non 0 Due to a short circuit in Check wiring for correct
Switched input the ignition switch the installation and for short
(terminal 15) EDC is switched on, al- circuits.
signals detec- though T15 has not been
ted activated.
11A Terminal50al- T50CD Mil OFF non 0 Permanent T50 high signal Check wiring and look for
ways pressed at digital input due to wir- electrical defects.
ing problem or short cir-
cuit.
Base - 11/2011
129
Base - 11/2011
130
1D6 ECU internal TPUMon Mil OFF non 0 Electronic disturbances, If failure persists: Replace
fault: deviation wrong TPU timebase. ECU.
between TPU
and system
time
211 Fault path 2 for VSSCD2 Mil OFF non 0 Defective or incorrect Check speed measuring
vehicle Speed functioning speed measur- device for proper func-
sensing ing device, see CAN mes- tioning and for its CAN
sage Cruise control / Ve- configuration.
hicle speed (RxCCVS)
See general remarks. See general remarks.
1D7 Dataset vari- VarMngCodDs Mil OFF non 0

ant coding See general remarks. See general remarks.
1D8 ECU internal WdCom Mil OFF non 0 Disturbed SPI-Bus. If ECU functions cor-
fault: Supervi- rectly after recovery only
sion of SPI-- temporary SPI error oc-
handler Flag curred and fault memory
can be deleted and error
ignored. If permanent SPI
error is present and the
ECU does not leave boot
block --> Replace ECU.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
DIAGNOSIS FOR SYMPTOMS (F3B)
Signalled Possible Possible Related Recommended
Anomaly Cause Anomalies Tests or Measures Remarks
The battery goes flat quickly. Pre-heating resistor powered Local overheating.
continuously.
The engine will stop or wont start. Fuel pre-filter clogged.
Difficult start when the engine is The 3.5 bar valve on fuel return
either hot or cold. is stuck open.
Slight overheating. Either 0.3 bar tank return valve

or return piping clogged.
After the new vehicle has been Reversed tank suction / return The engine is fed by the
delivered, the engine will stop after pipes. return pipe, the suction of
a short operation time.The tank which in the tank is lower.
holds a lot of fuel; all the rest is O.K. When the pipe sucks no
more, the engine will stop.
Reduced power / difficult engine Injection system / the engine Overheating Engine test: cylinder efficiency test. If the
maneuverability. operates with one cylinder trouble is not related to electric
failing: components (Blink code 5.x), the rocker
- injector plunger seizure; arm holder shaft needs be disassembled.
- valve rocker arm seizure. Check the rocker arm roller and bushing
as well as the respective cam.
Fuel consumption increase. Air filter clogging with no signal Smoke. Check the cabling, connections and
from the warning light on the component.
instrument board.
Base - 11/2011
131
Base - 11/2011
132
Signalled Possible Possible Related Recommended
Anomaly Cause Anomalies Tests or Measures Remarks
The engine does not reach the The boosting pressure sensor Smoke.
other speeds under load provides too high values, which, in
conditions. any case, fall within the range.
The driver feels that the engine is Impaired hydraulic performance of Engine test: check-up Replace the injector of the
not working correctly like it did an injector. cylinder in which Modus de-
before. tects lower performance le-
vels (compared with the
others) only after verifying
that the control rocker arm
adjustment is correct.
The driver feels that the engine is Wrong adjustment of an injector Engine test: check up. Perform correct adjustment,
not working correctly like it did control rocker arm. then repeat the engine test.
before.
The engine operates with five Plunger seizure. Possible overheating. Engine test: cylinder efficiency. Replace the injector of the
cylinders; noise (knock). cylinder in which the diag-
nosis instrument detects
lower performance levels
(compared with the others).
Replace the injector of the cylinder Wrong adjustment of the injector Possible mechanic damage to the Engine test: cylinder efficiency. Replace the injector of the
in which the diagnosis instrument control rocker arm (excessive areas surrounding the injector. cylinder in which the diag-
detects lower performance levels travel) with impact on the plunger nosis instrument detects
(compared with the others). on the nozzle. lower performance levels
(compared with the others).
The engine will stop or wont start Presence of air in the fuel supply It might even not switch off; it Bleed air.
TIER 4i C SERIES
again. circuit. might have operation oscillations,
Print P2D32C009 E
or start, yet with difficulty and after

making many attempts.
TIER 4i C SERIES DENOX SYSTEM 1
Part 4
Denox System
Page
DENOX 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3
- General Information . . . . . . . . . . . . . . . . . . . . 3
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Ad Blue fluid level gauge control . . . . . . . . . . . 5
- Pump module . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . . 5
- SCR pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Exhaust gas temperature sensor . . . . . . . . . . . 6
- Humidity detecting sensor . . . . . . . . . . . . . . . . 7
- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . . . 8
- Pin out DCU 15 D2-2 . . . . . . . . . . . . . . . . . . . 9
- WABCO water shut-off valve . . . . . . . . . . . . . 12
MAINTENANCE PLANNING . . . . . . . . . . . . . . 13
- Filters in Tier4 DEF/Ad Blue circuit with

DeNOx-2 dosing system . . . . . . . . . . . . . . . . . 13
- UDS Control unit (Urea Dosing System) . . . . 15

2 DENOX SYSTEM TIER 4i C SERIES

DeNOx 2 SYSTEM
General Information
To limit the nitrogen oxide exhaust gas values (NOx) within the limits required, with low fuel consumption, the vehicles have been
equipped with a post-treatment system for these substances contained in the exhaust gas, which is essentially an electronically
controlled oxidative catalyst.
Using the Selective Catalytic Reduction (SCR) process, the system transforms the nitrogen oxide (NOx) into inert compounds:
free nitrogen (N2) and water vapour (H2O).
The SCR process is based on a series of chemical reactions that, due to the reaction of ammonia with the oxygen in the exhaust
gas, lead to the reduction of nitrogen oxides (NOx) contained in the exhaust gas.
The system essentially comprises:
- a tank (4) of reagent solution (water - urea: Ad Blue) with a level indicator;
- a pump module (1);
- a mixing and injection module (7);
- a catalytic converter;
- two temperature sensors (9 and 11) at the exhaust gas inlet and outlet to the catalytic converter;
- a humidity sensor fitted on the engine air intake pipe downstream of the air filter.
The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (1), which
according to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity
in the incoming air, adjusts the flow rate of the Ad Blue solution to be put into the system.
The pump module (1) picks up the reagent solution from the tank (4) and sends it under pressure to the mixing and injection mod-
ule (7) to be injected into the exhaust pipe upstream of the catalytic converter.
The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature,
the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2).
Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature required
by the process.
The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where
the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into free
nitrogen (N2) and water vapour (H2O).

Figure 1
148514
1. Pump module - 2. Tank level sensor - 3. tank temperature sensor - 4. Ad Blue tank - 5. Prefilter - 6. return flow valve -
7. Dosing module - 8. MV2 - 9. Exhaust gas temperature sensor - 10. Catalyst - 11. Exhaust gas temperature sensor -
12. NOx detection sensor - 13. Ad Blue pressure sensor - 14. Filter - 15. Diaphgram pump - 16. Reverting valve -
17. Ad Blue temperature sensor

Tank Pump module

Figure 2 Figure 4
148510
1. DCU control unit connector - 2. Pressure compensattion

3. Ad Blue solution infeed - 4. Prefilter -
5. Ad Blue solution outlet -
169835
6. Ad Blue return pipe from dosing module -
The tank with the level indicator command (1) contains the 7. Ad Blue l tank return - 8. Filter
reducing substance necessary for the SCR process, comprising The SCR system is electronically managed by the DCU
a solution of 35% urea and water, known as Ad Blue. (Dosing Control Unit) incorporated in the pump module,
which according to the number of engine revs, the torque
delivered, the exhaust temperature, the amount of nitrogen
oxides and humidity in the incoming air, adjusts the flow rate
of the Ad Blue solution to be put into the system.
Dosing module
Figure 5
Ad Blue fluid level gauge control
Figure 3
108129
1. Ad Blue infeed - 2. Electrical connection -

3. Ad Blue outlet
Has the job of dosing the Ad Blue solution to be sent into the
exhaust pipe upstream of the catalytic converter.
SCR pipes
116181
NOTE The SCR pipe harnesses complete with the VOSS

1. Ad Blue fluid intake pipe - 2. Ad Blue fluid return pipe - are only available for production. In case of repair
3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor - operations, for the replacement of each component
5. Outlet pipe for hot engine coolant fluid - 6. Float - (cooling water pipes, AdBlue pipes, fittings,
7. AdBlue liquid heating coil (only versions equipped with corrugated pipes, sectioning plates etc.) refer to the
08277 optional) - 8. AdBlue breather supplied spare Accessories.

Exhaust gas temperature sensor

Figure 6
102303
Figure 7
102304
FUNCTIONAL WIRING DIAGRAM

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

Humidity detecting sensor

Figure 8
102311
1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply.

This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of humidity
found in sucked air, to determine the calculation of nitric oxide emissions.
Figure 9
102312
ELECTRIC BLOCK DIAGRAM

1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter

Nitric oxide sensor
Figure 10
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare

This sensor has the function to communicate the dosing of AdBlue liquid (Urea) and the catalyst conditions to the control unit.

Pin out DCU 15 D2-2
Figure 11
UDS
DCU15
113576
Pin No Abbrev Name

1 V_V_BAT+R Battery + via main relay (output)
2 V_V_BAT+R Battery + via main relay (output)
3 V_V_BAT+ Battery plus
4 V_V_BAT+ Battery plus
5 B_D_CANH1 Controller Area Network 1 (high)
6 B_D_CANL1 Controller Area Network 1 (low)
7 B_D_CANH2 Controller Area Network 2 (high)
8 B_D_CANL1 Controller Area Network 2 (low)
9 dnc do not connect
10 O_S_CLH Compensation line heating
11 O_S_RAMV Reduction agent metering valve
12 O_V_RAMV Reduction agent metering valve supply (BAT+ )
14 G_G_BAT- Battery minus
15 G_G_BAT- Battery minus
17 G_R_CATTSPRE Catalyst temperature sensor ground (upstream)
18 I_A_RALS Reduction agent level sensor signal
19 G_R_RALS Reduction agent level sensor ground/Reduction agent tank temperature sensor ground

Pin No Abbrev Name

21 O_S_SVS Service soon available
22 O_S_HH1 Hose heating 1 (Suction line heating)
23 O_S_RATH Reduction agent tank heating
24 I_S_T15 Terminal 15 (switched BAT+)
25 G_R_CATTSPOST Post-catalyst temperature sensor ground (downstream)
26 I_A_CATTSPOST Post-catalyst temperature sensor signal (downstream)
28 I_A_CATTSPRE Catalyst temperature sensor signal (upstream)
29 I_A_TRATS Reduction agent tank temperature sensor signal
30 V_V_5VRALS Reduction agent level sensor supply
31 B_D_ISOK ISO-K interface
32 O_S_HH3 Hose heating 3 (Pressure line heating)
34 O_S_HH4 Hose heating 4 (Back flow to supply module line heating)
35 O_S_HH2 Hose heating 2 (Back flow to tank line heating)

Figure 12
148515

WABCO water shut-off valve The N/C valve enables the tank and Ad Blue pipe to be heated
with the engine coolant.
Figure 13
The NTC temperature sensor controls the diverter valve
which, depending on the temperature, opens or closes the
flow of hot engine coolant in the heater coil.
170130
1. Water inlet - 2. Connector - 3. Water outlet.
Figure 14
170129
1. Coolant from crankcase / air compressor - 2. ECU DCU signal - 3. WABCO shut-off valve -
4. Return to water pump inlet - 5. AdBlue tank - 6. Supply module - 7. Dosing module.
Heating is switched off when all temperatures exceed the following thresholds:
- DEF tank temperature: +16C;
- Supply module temperature: +10C;
- Ambient temperature: -4C
Thresholds for entering normal heating mode:
- DEF tank temperature: +15 C;
- Supply module temperature: +8 C;
- Ambient temperature: -5 C.

MAINTENANCE PLANNING
DEF/Ad Blue system test with Pt-Box Every 150000 km
Filters in Tier4 DEF/Ad Blue circuit with DeNOx-2 dosing system
FILTER TYPE FILTER LOCATION MAINTENANCE

Tank mesh Coarse DEF/Ad Blue tank Cleaning if needed
Filter in DEF/Ad Blue supply line (Voss) 100 m Tank to supply module Cleaning at every oil change
interval
Supply module prefilter Coarse Supply module No maintenance to be
performed
Supply module filter (Bosch) 10 m Supply module Before 1800 working hours
or before 2 years
100 m Dosing module inlet No maintenance to be
performed
Dosing module prefilters 100 m Dosing module outlet No maintenance to be
performed
NOTE The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.


Print P2D32C009 E
TIER 4i C SERIES
UDS Control unit (Urea Dosing System)
Failing Type of Possible Checks to be Measuring Values to
DTC FMI component Failure Visible failure Cause Repair action performed conditions be detected Remarks
0015 TEMPERA- The system is not in- Sensor with Check that the parameter
(21) TURE SENSOR jecting Ad-Blue. open circuit or temperature value is plau-
AFTER CATA- short cir- sible.Check the connec-
LYST cuit.Connec- tions and the sensor. Re-
tions inside place the sensor if the
pump module connections are OK. if the
damaged. error is still present, re-
place the pump module
0017 SENSOR Availablefor futureimple-

(23) VOLTAGE 1 mentation
(5V INTERNAL;
FOR ADBLUE
LEVEL SEN-
SOR)
0018 SENSOR Availablefor futureimple-

(24) VOLTAGE 2 mentation
(5V INTERNAL;
FOR ADBLUE
AND AIR
PRESSURE
SENSORS)
0019 ADBLUE PRES- The system is not in- Sensor with Replace pump module.
(25) SURE SENSOR jecting Ad-Blue. open circuit or
IN BOX (ELEC- short cir-
TRICAL AND cuit.Connec-
PLAUSIBILITY) tions inside
pump module
damaged.
0041 DIAGNOSTIC Diagnostics led does Possible con- Check wiring of Cluster
(65) LAMP not light up. nection and pin 12 used to turn on the
wiring error of OBD led. If the reading is
DENOX SYSTEM
diagnostics led 0V the fault is with its in-
or defective ternal wiring. This error
led. can occur if the Ad-Blue
injection function has
Base - 11/2011
been reactivated.
15
Base - 11/2011
16
DENOX SYSTEM
0057 REVERTING Cooling system may Flow manage- Replace pump module.
(87) VALVE ELEC- not be opera- ment valve faul-
TRICALLY ting.Possible reduc- ty.Pump module
tion in power internal fault.
0058 DOSING Cluster system Pressure greater Run UDST test and then If the prob-
(88) VALVE pressure raise/drop than 5 bar due to metering valve test. Check lem persists,
BLOCKED message. valve jammed the connection with the contact the
open. Pressure junction connector market THD
less than 5 bar (ST67):connector pin 1 to with the re-
due to valve DCU pin 12connector pin sults of your
jammed clo- 2 to DCU pin 11 tests.
sed.Metering
module electri-
cal or mechan-
ical fault.Electri-
cal/mechanical
error with
consequent ex-
cess NOx in ex-
haust pipe.
0059 DOSING Cluster system Pressure greater Run UDST test and then If the prob-
(89) VALVE pressure raise/drop than 5 bar due to metering valve test. Check lem persists,
BLOCKED message. valve jammed the connection with the contact the
open. Pressure junction connector market THD
less than 5 bar (ST67):connector pin 1 to with the re-
due to valve DCU pin 12connector pin sults of your
jammed closed. 2 to DCU pin 11 tests.
Metering mod-
ule electrical or
mechanical fault.
Electrical/me-
chanical error
with consequent
excess NOx in
TIER 4i C SERIES
exhaust pipe.
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
006A HEATER OF Slight power reduc- Possible short-- Replace the filter heater.
(106) FILTERBOX tion circuit or open
circuit in filter
heaterPossible
problem in wir-
ing or inside
pump module.
0073 TEMPERA- No reaction per- Temperature Check the plausibility of the

(115) TURE AFTER ceivable by the driv- sensor before temperature read using the
CATALYST erAd-Blue may not catalytic con- gauge (with engine cold
TOO LOW be injected. verter not in- and comparing with envi-
stalled correctly ronmental tempera-
(or installed after ture).Warm up the engine
the catalytic and check the reading.If the
converter). sensor setting is incorrect,
replace the sensor. Other-
wise check whether the
Dataset must be corrected.
0074 ADBLUE Warning light on. Insufficient Ad-- Check the Ad-Blue level
(116) PRESSURE Ad-Blue not in- Blue in tank. manually.Find out if pump is
TOO LOW jected. Pump operating turning.Carry out the
AT SYSTEM incorrectly. Pos- UDST test.
START sible Ad-Blue
leak or filter
blocked. Ad--
Blue pressure
DENOX SYSTEM
sensor faulty.
Base - 11/2011
17
Base - 11/2011
18
DENOX SYSTEM
009D NOx SEN- Fault light ON. Check for Ad-- Check for Ad-Blue in Nox sensor
(157) SOR Blue in tank. tank.Check that the pump operational
MEASURES Possible level module is functioning cor- characteris-
TOO HIGH sensor fai- rectly with a UDST test. tics:Vmin 14
Nox lure.Possible Check the wiring and con- V; Vstandard
Nox sensor fai- nection of the junction 28.5 V;
lure.Prefilters connector (ST67) with the Power Vmax
blocked. Possi- pump module (pins 32 V;Power
ble pump modu- 12/11).Check the resis- Imean0.6 A;
le fault. CAN line tance and operation of the Power Ipeak
problems. electro-injector. Check 12 A; Maxi-
operation of catalytic con- mum power
verter and whether its filter 20 W. If the
elements are free of block- problem re-
age. (Do not use abrasive gards the
materials or detergents to sensor, re-
clean the system.)Check place it,
that the Nox sensor on the check its
catalytic converter (85144) operation
is functioning correctly.If and if the
the voltage exceeds the problem per-
maximum value, the sensor sists, contact
stops working. Functional- the market
ity is restored when the THD with
voltage drops back to with- the results of
in the prescribed limits.The your tests.
sensor is also protected
against reverse supply con-
nection.Check the connec-
tion between the sensor
and the ECU (sensor pin 3
- CAN L ECU pin 6) (sen-
sor pin 4 - CAN ECU pin
5).
00A1 CAN RE- Some parameter CAN line inter- Check CAN line connec-
TIER 4i C SERIES
(161) CEIVE FRAME values may be re- ruptedProblems tion.
Print P2D32C009 E
E2SCR placed. in ECM control

unit.
Print P2D32C009 E
TIER 4i C SERIES
00A2 CAN RE- Some parameter CAN line inter- Check CAN line connec-
(162) CEIVE FRAME values may be re- ruptedProblems tion.
E2SCR EX- placed. in ECM control
TENDED unit.
00AC ADBLUE Available for future imple-
(172) QUALITY mentation
SENSOR RE
LATED ER-
RORS CAN
00AD CAN RE- Available for future imple-
(173) CEIVE FRAME mentation
TIME/DATE
00C3 CAN EEC3 Some parameter CAN line inter- Check CAN line connec-
(195) MESSAGE values may be re- ruptedProblems tion.
placed. in ECM control
unit.
00C4 CAN EGF1 Some parameter CAN line inter- Check CAN line connec-
unit.
00C6 CAN Some parameter CAN line inter- Check CAN line connec-
(198) EC1BAM values may be re- ruptedProblems tion.
MESSAGE placed. in ECM control
unit.
00C8 CAN ERC1 Some parameter CAN line inter- Check CAN line connec-
unit.
DENOX SYSTEM
00C9 CAN BUS Some parameter CAN line inter- Check CAN line connec-
(201) OFF values may be re- ruptedProblems tion.
unit.
Base - 11/2011
19
Base - 11/2011
20
DENOX SYSTEM
00CA LOAD Fault light ON. Check for Ad-- Check for Ad-Blue in Nox sensor
(202) POINT Blue in tank. tank.Check that the pump operational
EVALU- Possible level module is functioning cor- characteris-
ATION sensor fai- rectly with a UDST test. tics:Vmin 14
lure.Possible Check the wiring and con- V; Vstandard
Nox sensor fai- nection of the junction 28.5 V;
blocked. Poss- pump module (pins 32 V;Power
ible pump mod- 12/11).Check the resis- Imean0.6 A;
ule fault. CAN tance and operation of the Power Ipeak
line problems. electro-injector. Check 12 A; Maxi-
5).
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
00CB LOAD Fault light ON. Check for Ad-- Check for Ad-Blue in Nox sensor
(203) POINT Blue in tank. tank.Check that the pump operational
EVALU- Possible level module is functioning cor- characteris-
ATION sensor fai- rectly with a UDST test. tics:Vmin 14
ABOVE/BE- lure.Possible Check the wiring and con- V; Vstandard
LOVE LIMIT Nox sensor fai- nection of the junction 28.5 V;
blocked. Poss- pump module (pins 32 V;Power
ible pump mod- 12/11).Check the resis- Imean0.6 A;
ule fault. CAN tance and operation of the Power Ipeak
line problems. electro-injecto 12 A; Maxi-
mum power
20 W. If the
problem re-
gards the
sensor, re-
place it,
check its
operation
and if the
problem per-
sists, contact
the market
THD with
the results of
your tests.
00CC ENVIRON- Some parameter CAN line inter- Check CAN line connec-
(204) MENT PRES- values may be re- ruptedProblems tion.
SURE VALU- placed. in ECM control
ATION unit.
DENOX SYSTEM
Base - 11/2011
21
Base - 11/2011
22
DENOX SYSTEM
00D1 EEPROM / No reaction per- Internal fault or Reprogram the control unit
(209) CHECKSUM ceivable by the control unit da- with the dataset already
FAILURES driver taset incorrect present or with an updated
(incomplete or dataset if already pres-
obsolete). ent.Replace the control
unit if the problem persists.
00D2 IGNITION No fault perceived Wiring or con- Check the connection.

(210) ON SIG- by thedriver.After-- tact K15 (key
NAL K15 Run not carried out. 15) faulty.
00D3 MAIN RELAY No fault perceived Wiring or con- Check connection of +15
(211) OPENS TOO by thedriver.After-- tact K15 (key key contact; Check the
EARLY / TOO Run not carried out. 15) faulty.Main Main Relay, wiring and the
LATE relay may be control unit dataset ver-
faulty or stuck. sion.Replace the control
unit if the problem persists.
00D4 EXCESSIVE System not working Ad-Blue tem- Check the Ad-Blue tank
(212) AD-BLUE perature excess- heater;Check the other
TEMPERA- ive inside pump heater and replace the con-
TURE IN module or tank. trol unit if the problem is in-
PUMP MOD- ternal to the pump module.
ULE DURING
AFTERRUNG
TIER 4i C SERIES
(EMERG-
Print P2D32C009 E
ENCY SHUT
OFF)
Print P2D32C009 E
TIER 4i C SERIES
00E1 PLAUSIBILITY Slight power reduc- Sensor may be Check for an updated Da-
(225) OF DOWN- tion faulty.Possible taset for the vehicle in
STREAM mechanical question.Replace sensor if
CATALYST problem (e.g. necessary
TEMPERA- sensor discon-
TURE SEN- nected from
SOR (AFTER catalytic con-
SCR CATA- verter).
LYST)
00E4 AD-BLUE No reaction per- Temperature Use a diagnostic tester to

(228) BOX TEM- ceivable by the driv- sensorfaulty.Ad-- ensure the difference be-
PERATURE erATTENTION: Blue may be tween TEMPERATURE OF
SENSOR Ad-Blue could frozen in the AD-BLUE IN BOX and
PLAUSIBILITY freeze in the tank in tank. TEMPERATURE OF AD--
ERROR (DY- winter. BLUE IN TANK is less than
NAMIC / 10 C.
STATIC)
DENOX SYSTEM
Base - 11/2011
23
Base - 11/2011
24
DENOX SYSTEM
00E5 AD-BLUE No reaction per- Temperature Check the tank tempera- Check and
(229) TANK TEM- ceivable by the driv- sensorfaulty.Ad-- ture sensor, wiring and con- correct any
PERATURE erATTENTION: Blue may be nectors.Replace sensor if fault with
SENSOR Ad-Blue could frozen in the necessary DTC: 32
PLAUSIBILITY freeze in the tank in tank. (Tempera-
ERROR (DY- winter. ture sensor in
NAMIC / tank).
STATIC)
00E6 ADBLUE No fault perceived Incorrect oper- Run UDST test. Check the If the prob-
(230) TANK TEM- by the driver. ation of the tank operation of the tank tem- lem persists,
PERATURE temperature perature sensor: pins 2 and contact the
NOT PLAUS- sensor or incor- 3 at 25C - 1 K?or on con- market THD
IBLE WITH rect operation nector ST68:pins 2 and 3 at with the re-
PUMP MOD- of sensor T2 in- 25C - 1 K?Check the Ad-- sults of your
ULE TEM- side the meter- Blue temperature in the tests.
PERATURE ing module. In- box by reading the para-
correct oper- meters with the diagnosis
ation of the en- instrument.Check the con-
gine water cir- nection of the circulation
culation sole- solenoid valve and Ad-Blue
noid valve for tank heating (78267): sole-
heating the Ad-- noid valve pin 1 to DCU pin
Blue tank. 1 solenoid valve pin 2 to
DCU pin 23Check that,
when operating, there is
voltage across pins 1 and 2;
if it reads 0V the fault is in
the internal wiring.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
00E8 COOLANT System not working Cooling valve Replace pump module.
(232) CONTROL (inside pump)
VALVE not working.
MECHAN-
ICALLY
(COMMIS-
SIONING)
00EA PRESSURE Power reduction- Pipe between Check the pipes in ques-
(234) LINE Ad-Blue not in- pump module tion.Replace the pump
BLOCKED jected. and dosing valve module if necessary.
blocked.Dosing
valve may be
stuck.
DENOX SYSTEM
Base - 11/2011
25
Base - 11/2011
26
DENOX SYSTEM
00EB AD-BLUE Slight power reduc- Ad-Blue tank or Fill the Ad-Blue tank and
(235) LOW LEVEL tion level sensor not check the level sensor if
calibrated (or necessary.
float stuck).
00EC LOW AD-- System not wor- Ad-Blue tank or Fill the Ad-Blue tank and
(236) BLUE LEVEL: kingPossible reduc- level sensor not check the level sensor if
EMPY AD-- tion in power calibrated (or necessary.
BLUE TANK float stuck).
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
00F0 NOx Fault light ON. Check for Ad-- Check for Ad-Blue in Nox sensor
(240) EMISSIONS Blue in tank. tank.Check that the pump operational
THRESHOLD Possible level module is functioning cor- characteris-
EXCEEDED sensor fai- rectly with a UDST test. tics:Vmin 14
DUE TO lure.Possible Check the wiring and con- V; Vstandard
GROUP Nox sensor fai- nection of the junction 28.5 V;
FAULTS:AD-- lure.Prefilters connector (ST67) with the Power Vmax
BLUE INJEC- blocked. Poss- pump module (pins 32 V;Power
TION ible pump mod- 12/11).Check the resis- Imean0.6 A;
GROUP ule fault. CAN tance and operation of the Power Ipeak
(Long Term line problems. electro-injector. Check 12 A; Maxi-
Fault) operation of catalytic con- mum power
5).
DENOX SYSTEM
Base - 11/2011
27
Base - 11/2011
28
DENOX SYSTEM
00F2 NOx Fault light ON. Catalytic con- Check quality of Ad-Blue Nox sensor
(242) EMISSIONS verter malfunc- and diesel, and whether operational
THRESHOLD tion. Nox there are blockages at the characteris-
EXCEEDED emissions metering module. Check tics:Vmin 14
DUE TO threshold ex- operation of turbine and V; Vstandard
GROUP ceeded. CAN whether catalytic con- 28.5 V;
FAULTS: line problem re- verter filter elements are Power Vmax
CATALYST garding trans- free of blockage. Check 32 V;Power
TEMPERA- mission of signal that the Nox sensor on the Imean0.6 A;
TURE (Long detected by sen- catalytic converter (85143) Power Ipeak
Term Fault) sor to engine is functioning correctly. 12 A; Maxi-
ECU for catalytic Check the connection be- mum power
converter tem- tween the sensor and the 20 W. If the
perature con- ECU (sensor pin 3 - CAN L problem re-
trol. Possible ECU pin 6) (sensor pin 4 - gards the
sensor failure. CAN ECU pin 5).If the volt- sensor, re-
age exceeds the maximum place it,
value, the Nox sensor stops check its
working.Functionality is re- operation
stored when the voltage and if the
drops back to within the problem per-
prescribed limits. The sen- sists, contact
sor is also protected against the market
reverse supply connection. THD with
the results of
your tests.
TIER 4i C SERIES
Print P2D32C009 E
Print P2D32C009 E
TIER 4i C SERIES
00F3 NOx Fault light ON. Nox sensor mal- Check for Ad-Blue in If the prob-
(243) EMISSIONS function. Check tank.Check that the pump lem regards
THRESHOLD for Ad-Blue in module is functioning cor- the sensor,
EXCEEDED tank. Possible rectly with a UDST test. replace it,
DUE TO pump module Check the wiring and con- check its
GROUP fault. Possible nection of the junction operation
FAULTS: metering mod- connector (ST67) with the and if the
HIGH NOx ule fault and pump module (pins problem per-
VALUE (Long consequentviol- 12/11).Check the resis- sists, contact
Term Fault) ation of Nox tance and operation of the the market
emissions electro-injector. Check THD with
threshold. Poss- operation of catalytic con- the results of
ible fault regard- verter and whether its filter your tests.
ing catalytic con- elements are free of block-
verter malfunc- age. (Do not use abrasive
tion. CAN line materials or detergents to
problems. clean the system.)Check
that the Nox sensor on the
catalytic converter (85144)
is functioning correctly.If
the voltage exceeds the
maximum value, the sensor
stops working. Functional-
ity is restored when the
voltage drops back to with-
in the prescribed limits.The
5).
DENOX SYSTEM
Base - 11/2011
29
Base - 11/2011
30
DENOX SYSTEM
00F4 NOx Fault light ON. Check for Ad-- Check for Ad-Blue in Nox sensor
(244) EMISSIONS Blue in tank. tank.Check that the pump operational
THRESHOLD Possible level module is functioning cor- characteris-
EXCEEDED sensor fai- rectly with a UDST test. tics:Vmin 14
DUE TO lure.Possible Check the wiring and con- V; Vstandard
GROUP Nox sensor fai- nection of the junction 28.5 V;
FAULTS: lure.Prefilters connector (ST67) with the Power Vmax
LOW AD-- blocked. Poss- pump module (pins 32 V;Power
BLUE LEVEL ible pump mod- 12/11).Check the resis- Imean0.6 A;
(Long Term ule fault. CAN tance and operation of the Power Ipeak
Fault) line problems. electro-injector. Check 12 A; Maxi-
5).
TIER 4i C SERIES
Print P2D32C009 E

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Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

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

If issues on this publication differ from what is actually noticed

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

Print P2D32C009 E Base - 11/2011

Base - 11/2011 Print P2D32C009 E

PREFACE TO USERS GUIDELINE MANUAL . . 3

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

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32C009 E Base - 11/2011

Base - 11/2011 Print P2D32C009 E

PREFACE TO USERS GUIDELINE MANUAL

Danger for persons

Danger of serious damage for the assembly

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

1 1 = Seat of small end bush

Print P2D32C009 E Base - 11/2011

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - 11/2011 Print P2D32C009 E

Print P2D32C009 E Base - 11/2011

Base - 11/2011 Print P2D32C009 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32C009 E Base - 11/2011

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

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

Base - 11/2011 Print P2D32C009 E

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32C009 E Base - 11/2011

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Basic edition referred to When month - year update

Base - 11/2011 Print P2D32C009 E

Main engines diagrams 2

Removal and installation of main engine components 5

Safety prescriptions Appendix

Print P2D32C009 E Base - 11/2011

Base - 11/2011 Print P2D32C009 E

MAPPING BETWEEN TECHNICAL AND COMMERCIAL CODING

Technical Code Commercial Code

Print P2D32C009 E Base - 11/2011

Section Description Page Date of revision

Base - 11/2011 Print P2D32C009 E

VIEWS OF THE ENGINE . . . . . . . . . . . . . . . . . . 3

Print P2D32C009 E Base - 11/2011

Base - 11/2011 Print P2D32C009 E

VIEWS OF THE ENGINE

LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

Print P2D32C009 E Base - 11/2011

FRONT HAND SIDE VIEW