SM 667TA-CASE-NewHolland EN PDF

Copyright © New Holland
PROVEN PERFORMANCE PROVEN PERFORMANCE

REPAIR MANUAL FOR CNH U.K. ENGINES

667TA/EEG -- 667TA/EEC -- 667TA/EBF
667TA/EED -- 667TA/EBD
The following models are to integrate repair manuals:
NEW HOLLAND KOBELCO E265 -- E305
NEW HOLLAND D180 LGP -- D180 STD -- W170 -- W190
667TA/EEG -- 667TA/EEC 667TA/EBF -- 667TA/EED
667TA/EED -- 667TA/EBD
Every information, illustration and specification contained in the present manual is based on the most recent informa--
tion available at the time of printing.
NEW HOLLAND reserves the right, to modify the text at any time without prior communication.
NEW HOLLAND
PRINT No. 604.13.689
Edition -- May 2006
2 WE
MOTORI
2
IN--1
INTRODUCTION
TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no--
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357
FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:
Example:: T 1 -- 2 -- 3
Progressive page number for each group
Group number (if any)
Section number
S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing
SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.
This symbol regards safety.

! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2
INTRODUCTION
UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.
To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min--1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES
INDEX OF SECTIONS
Section 1 -- Diagnostics EW--1--1
Section 2 -- 667TA engine overhaul EW--2--1
Section 3 -- Recharging and start--up EW--3--1

4 WE
MOTORI
SECTION 1
DIAGNOSTICS
INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
CNH -- EST diagnostics tool . . . . . . . . . EW--1--4
Main engine operating anomalies . . . EW--1--5
INDICE
EW--1--3
DIAGNOSTICS
DIAGNOSTICS
FOREWORD
A good diagnosis is carried out with the competence With the use of computerised tools, it is also possible
acquired from years of experience and taking part in to establish a bi--directional communication with the
repair courses. central unit with which it is possible not only to decode
When a user complains about a bad efficiency or ope-- the error codes, but also to address the image in its
rating anomalies, his indications must be kept into memory to obtain those further necessary informa--
due account, taking from them those useful informa-- tion to go back to the anomaly origin.
tion that will be used to guide our intervention. Every time an inconvenience occurs and its existence
is detected, it is necessary to proceed with the elec--
After having detected the anomaly, it is advisable to tronic unit query through one of the pointed--out ways
carry out failure search operations by decoding self-- and then proceed with the diagnostic survey through
diagnosis data of the central electronic unit of theEDC tests and measures through which an outline of ope--
(Engine Diesel Control) system. rating conditions is obtained and the real anomaly
reasons are identified.
In case the electronic unit does not provide indica--
tions, one will have to proceed with one’s experience
by adopting traditional diagnostic modes.
EW--1--4
DIAGNOSTICS
CNH -- EST DIAGNOSTIC TOOL
88201
The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating para--
meters of electronic control components (control units, sensors etc.) and the check of flow--rates, pressures and
temperatures; it is further arranged for searching inconveniences and detect data for electronically--controlled
CNH engines.
Code Description Language

380060157 Italiano
380060158 French
380060159 English
380060160 German
CE EST diagnostic kit
380060161 Spanish
380060162 Holland
380060163 Danish
380060164 Portuguese
EW--1--5
DIAGNOSTICS
MAIN ENGINE OPERATING ANOMALIES
1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

2 -- Engine overheats; 7 -- Engine knocks irregularly;
3 -- Engine lacks power and works erratically; 8 -- Engine stops;
4 -- Engine exhaust smoke black or dark grey; 9 -- Excessive or insufficient oil pressure;
5 -- Engine exhaust smoke grey (verging on 10 -- Excessive fuel consumption;
white);
1 ENGINE WON’T START
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.
YES
Injectors efficient Check using a diagnostic tester.

NO Check o--ring seal.
Replace.
YES
The feeding circuit or injection pump does not Check and eliminate causes of infiltration.
show air penetration NO
(to be continued)
EW--1--6
DIAGNOSTICS
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water tank).
NO
YES
Prescribed compression ratio Overhaul the engine or make repairs only on

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

NO
YES
Pre--post heating system efficient Check using a diagnostic tester.

NO
YES
High pressure pump efficient Check using a diagnostic tester.

NO
2 ENGINE OVERHEATS
YES
Coolant level correct Check for leaks and restore the level.
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level.
NO
(to be continued)
EW--1--7
DIAGNOSTICS
Water pump in working order Overhaul or replace the unit.

NO
YES
Thermostat in working order Replace.

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

NO
YES
Cylinder head gasket in working order Replace.

NO
YES
Fan in working order Replace.

NO
EW--1--8
DIAGNOSTICS
3 ENGINE LACKS POWER AND WORKS

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

NO
YES
High pressure pump efficient Check using a diagnostic tester and replace if
NO necessary.
YES

NO Replace.
(to be continued)
EW--1--9
DIAGNOSTICS
Rail pressure relief valves efficient Disconnect fuel return pipe from rail and check
NO for leaks.
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.
YES
Prescribed compression ratio Check using a diagnostic tester.

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

NO
4 ENGINE EXHAUST SMOKE BLACK

OR DARK GREY
Air filter in working order Replace.

NO
YES

NO Replace.
YES
Prescribed compression ratio Check using a diagnostic tester.

NO
(to be continued)
EW--1--10
DIAGNOSTICS
High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO
ENGINE EXHAUST SMOKE GREY

5
(VERGING ON WHITE)

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

NO chamber; replace the cylinder head gasket or
overhaul the engine.
YES
High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO
6 ENGINE EXHAUST SMOKE LIGHT BLUE
Excessive oil consumption Check: oil vapour breather; cylinder compres--

NO
sion. Leaks into or out of turbocharger. Leaks
from valve guides
Overhaul cylinder head or engine if necessary.
EW--1--11
DIAGNOSTICS
7 ENGINE KNOCKS IRREGULARLY
Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect--
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.
NO
Knock detected in pistons Check the following items: play between the pis--
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.
NO
Knock detected in the cylinder head Check the following items: operation play be--
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
YES moreover, check for broken springs, for excess--
ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.
NO
Knock detected in injectors Check using a diagnostic tester.

YES Replace.
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.
EW--1--12
DIAGNOSTICS
8 ENGINE STOPS
Fuel tank filled Refuel and drain (if necessary).

NO
YES
Fuel filters in working order Replace.

NO
YES
Feeling circuit in working order Check the circuit and proceed as necessary.
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
NO arms.
YES
Intact valves Replace the valves.

NO
9 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE
Pressure control valve in working order Check and replace (if necessary).
NO
(to be continued)
EW--1--13
DIAGNOSTICS
Oil pump and delivery pipes both in working or-- Check and replace (if necessary).
der NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.
YES
Engine oil SAE viscosity conforming to stan-- Replace the engine oil with equivalent of ad--
dards NO equate viscosity.
10 EXCESSIVE FUEL CONSUMPTION
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.
YES
Air filter in working order Replace.

NO
YES

NO Replace.
EW--1--14
DIAGNOSTICS
NOTES
SECTION 2
ENGINE OVERHAUL
INDEX
Coding of source engines . . . . . . . . . . EW--2--4 High pressure electronic injection
Main engines features . . . . . . . . . . . . . . EW--2--5 system (Common rail) . . . . . . . . . . . . . . EW--2--38
General engines features . . . . . . . . . . . EW--2--6 EDC 7 operation . . . . . . . . . . . . . . . . . . . EW--2--39
Supply system . . . . . . . . . . . . . . . . . . . . . EW--2--40
Assembling play -- specifications . . . EW--2--8
Supply system diagram . . . . . . . . . . . . . EW--2--41
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--14 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--42
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15 Mechanical supply pump . . . . . . . . . . . . . EW--2--43
Graphic indications and symbols . . . EW--2--16 Normal operating condition . . . . . . . . . . . EW--2--43
667TA engines . . . . . . . . . . . . . . . . . . . . . EW--2--17 Output overpressure condition . . . . . . . . EW--2--43
Description of main mechanic Drain conditions . . . . . . . . . . . . . . . . . . . . . EW--2--44
engine components . . . . . . . . . . . . . . . . EW--2--18 High--pressure pump type CP3.3 . . . . . . EW--2--44
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--18 High pressure pump--inside structure . . EW--2--46
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Working principle . . . . . . . . . . . . . . . . . . . . EW--2--47
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--2--19
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--20 Boost gauge valve . . . . . . . . . . . . . . . . . EW--2--50
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Electro--injector . . . . . . . . . . . . . . . . . . . . EW--2--51
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--22 Electro--injector . . . . . . . . . . . . . . . . . . . . . EW--2--52
EGR exhaust gas recirculation system EW--2--22 Pressure limiter for fuel return . . . . . . EW--2--53
Internal EGR acting on the Location of the main electrical
exhaust valves . . . . . . . . . . . . . . . . . . . . . . EW--2--22 components . . . . . . . . . . . . . . . . . . . . . . . EW--2--54
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--23 EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--55
Cable on engine . . . . . . . . . . . . . . . . . . . . EW--2--56
Cylinder head engines: 667TA/EBF --
Injectors connector (A) . . . . . . . . . . . . . . . EW--2--57
667TA/EBD -- 667TA/EED . . . . . . . . . . . . EW--2--24
Sensors connector (C) . . . . . . . . . . . . . . . EW--2--57
Cylinder head engines: 667TA/EEG --
Crankshaft sensor . . . . . . . . . . . . . . . . . . . EW--2--58
667TA/EEC . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25
Timing sensor . . . . . . . . . . . . . . . . . . . . . . EW--2--58
Valves and valve seats . . . . . . . . . . . . . . . EW--2--26
Supercharging air pressure --
Valves and valve seats . . . . . . . . . . . . . . . EW--2--27 temperature sensor . . . . . . . . . . . . . . . . . . EW--2--59
Valve drive jumpers . . . . . . . . . . . . . . . . . . EW--2--27 Engine oil temperature--pressure sensor EW--2--59
Engine head grinder . . . . . . . . . . . . . . . . . EW--2--27 Fuel temperature and pressure sensor . EW--2--60
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--28 Electro--injectors . . . . . . . . . . . . . . . . . . . . EW--2--61
Auxiliary component drive . . . . . . . . . . . . EW--2--29 Pre--post heating resistance
and contactor . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Engine lubrification . . . . . . . . . . . . . . . . EW--2--30 Coolant temperature sensor . . . . . . . . . . EW--2--63
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--31 Fuel temperature sensor . . . . . . . . . . . . . EW--2--64
Oil pressure regulation valve . . . . . . . . . EW--2--31 High pressure pump -- pressure regulator EW--2--65
By--pass valve . . . . . . . . . . . . . . . . . . . . . . EW--2--31 Checking the fuel system . . . . . . . . . . . EW--2--66
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32 Description of tests and checks
Oil sump engines: 667TA/EEG --667TA/ that can be performed . . . . . . . . . . . . . . EW--2--66
EEC -- 667TA/EBF -- 667TA/EED . . . . . . EW--2--33 Necessary equipment . . . . . . . . . . . . . . . . EW--2--66
Low pressure supply test . . . . . . . . . . . . . EW--2--67
Oil sump engines: 667TA/EED --
667TA/EBD . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Low--Pressure Pump . . . . . . . . . . . . . . . . EW--2--68
Test on the pressure relief valve
Engine oil vapour recirculation . . . . . . . . EW--2--35
on the rail . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Engine cooling . . . . . . . . . . . . . . . . . . . . . EW--2--36 Test on fuel backflow from the return . . . EW--2--70
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Engines overhaul at the bench . . . . . . EW--2--72
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Disassembling the engine . . . . . . . . . . . . EW--2--72
INDEX
Repair operations . . . . . . . . . . . . . . . . . . EW--2--81 Connecting rod--piston coupling . . . . . . . EW--2--92

Cylinder unit . . . . . . . . . . . . . . . . . . . . . . . EW--2--81 Mounting the piston rings . . . . . . . . . . . . . EW--2--93
Checks and measurements . . . . . . . . . . . EW--2--81 Mounting the connecting rod/piston
Checking the eccentric lift and assemblies in the cylinder liners . . . . . . . EW--2--93
the pin alignment . . . . . . . . . . . . . . . . . . . . EW--2--81 Measuring the crankpin assembling play EW--2--94
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81 Checking piston protrusion . . . . . . . . . . . EW--2--95
Checking the surface supporting Distribution gearbox case . . . . . . . . . . . . EW--2--95
the head on the cylinder cluster . . . . . . . EW--2--83 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--2--96
Timing system . . . . . . . . . . . . . . . . . . . . . EW--2--83 Flywheel cover case . . . . . . . . . . . . . . . . . EW--2--96
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--83 Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--97
Replacing the bushings . . . . . . . . . . . . . . EW--2--84 Replacing the engine flywheel ring gear EW--2--97
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--84
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--101
Mounting the tappets -- Distributing shaft EW--2--84
Removing the valves . . . . . . . . . . . . . . . . EW--2--101
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--85
Checking the cylinder head water seal . EW--2--102
Measuring the journals and crankpins . . EW--2--85
Checking the cylinder head supporting
Replacing the oil pump drive gears . . . . EW--2--87
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--102
Measuring the journal assembling play . EW--2--87
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--103
Mounting the main bearings . . . . . . . . . . EW--2--87
Valve descaling, check and grinding . . . EW--2--103
Checking the drive shaft shoulder play . EW--2--88
Connecting rod--piston assembly . . . EW--2--88 Checking the play between
the valve stem, valve guide and
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--89
valve centring . . . . . . . . . . . . . . . . . . . . . . . EW--2--103
Measuring the piston diameter . . . . . . . . EW--2--89
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . EW--2--103
Conditions for correct pin/piston
matching . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--90 Valves seats . . . . . . . . . . . . . . . . . . . . . . . EW--2--104
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--90 Valve seat reconditioning -- replacement EW--2--104
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--2--90 Valve springs . . . . . . . . . . . . . . . . . . . . . . EW--2--105
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--91 Mounting the cylinder head . . . . . . . . . EW--2--106
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--91 Reattaching the cylinder head . . . . . . . . . EW--2--106
Checking the connecting rods . . . . . . . . . EW--2--92 Fitting injectors . . . . . . . . . . . . . . . . . . . . . . EW--2--107
Checking the torsion . . . . . . . . . . . . . . . . . EW--2--92 Rods and tappets . . . . . . . . . . . . . . . . . . EW--2--108
Checking the flexion . . . . . . . . . . . . . . . . . EW--2--92 Rocker arm assembly . . . . . . . . . . . . . . . . EW--2--108
Mounting the connecting rod--piston Tappet clearance adjustment . . . . . . . . . EW--2--109
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--92 Wiring support . . . . . . . . . . . . . . . . . . . . . . EW--2--111
EW--2--3
667TA ENGINE OVERHAUL
Figure 1 Figure 2
114201
114199
ENGINES: 667TA/EEG -- 667TA/EEC ENGINES: 667TA/EED -- 667TA/EBF
Figure 3
114200
ENGINES: 667TA/EED -- 667TA/EBD

EW--2--4
CODING OF SOURCE ENGINES
6 6 7 T A E D B +
Engine calibration
(power)
Compression ratio:
B = 16.5:1 > 130 kW
D = 17.5:1 ≤ 130 kW
E = 17.5:1 > 130 kW
Electronic injection
(common rail)
Intercooler
Turbocharged
67 = cylinder capacity
6 = no. of cylinders
EW--2--5
MAIN ENGINES FEATURES
A E265 E305 D180 LGP D180 STD W170 W190
B 667TA 667TA 667TA 667TA 667TA 667TA
C EEG EEC EBF EED EED EBD
E 6728 cm3
137 kW 148 kW 157 kW 145 kW 145 kW 169 kW

F 2100 rpm 2100 rpm 2000 rpm 2000 rpm 2000 rpm 2000 rpm
Net power at flywheel (ISO 14396)
G Direct injection
H (common rail)
T.A.A.
I
(Boosted by intercooler)
A Machine type
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6
GENERAL ENGINES FEATURES

667TA
Type
EEG EEC EBF EED EBD
Cycle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct
Number of cylinders 6 in--line
Bore mm 104
Stroke mm 132
Total displacement cm3 6728 cm3
Compression ratio --
Max. rating* kW 137 148 157 145 169

min --1 2100 2100 2000 2000 2000
Max. torque Nm (kgm) 710 810 952 860 1002

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

Type of turbocompressor: HOLSET HX35
Forced by means of gear pump.

LUBRICATION
pressure relief valve. oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
* Net power at flywheel (ISO 14396)
EW--2--7
667TA
Type
EEG EEC EBF EED EBD
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
FILLING
Total capacity
Ambra Mastergold HSP 1st filling: litres -- --
kg -- --
-- engine sump litres -- --

kg -- --
-- engine sump + filter litres 17 19

kg -- --
FEEDING high pressure

Bosch--type injection Common Rail
Pump setting
Start of delivery mm
Type of injector CRIN 1 CRIN 2
Injection sequence 1 -- 5 -- 3 -- 6 -- 2 -- 4
250 250 250

Injection pressure bar -- to to to
1600 1400 1600
EW--2--8
ASSEMBLING PLAY -- SPECIFICATIONS

667TA
Type
EEG EEC EBF EED EBD
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners ∅1 104.000 to 104.024
Pistons: supplied with standard

spares
Type
49.5
Measurement dimension X
103.759 to 103.777
Outer diameter ∅1
38.010 to 38.016
Pin seat ∅2
Piston -- cylinder liners 0.235 to 0.273
Piston diameter ∅1 0.4
Position of pistons
from crankcase X --
Gudgeon pin ∅3 37.994 to 38.000
Gudgeon pin--Pin seat 0.01 to 0.022
Type of piston X1* 2.705 to 2.735

Piston ring slots X2 2.420 to 2.440
X3 4.03 to 4.05
* measured on ∅ of 101 mm
S1*
2.560 to 2.605
Piston rings S2
2.350 to 2.380
S3
3.977 to 3.990
* measured 1.5 mm away from the ex-
ternal ∅
1 0.100 to 0.175
Piston rings – Slots 2 0.04 to 0.09
3 0.040 to 0.083
Piston rings 0.4

EW--2--9
667TA
Type
EEG EEC EBF EED EBD
Piston ring end opening in cylinder liner:

X1
0.3 to 0.4
X2
0.6 to 0.8
X3
0.3 to 0.55
Connecting rod small--end

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

meter
41.279 to 41.553
Outer ∅4
38.019 to 38.033
Inner ∅3
Connecting rod small--end bushing –

0.266 to 0.566
seat
Gudgeon pin – Bushing 0.019 to 0.039
Measurement dimension X --
Max. error on connecting rod axis pa-

rallelism = --
Journals ∅1 82.99 to 83.01

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

n. 1--7 ∅3 87.982 to 88.008
n. 2--3--4--5--6 87.977 to 88.013
EW--2--10
667TA
Type
EEG EEC EBF EED EBD
Half bearings -- journals:
n. 1--7 0.044 to 0.106
n. 2--3--4--5--6 0.041 to 0.103
Half bearings -- crankpins 0.039 to 0.111
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2

25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.095 to 0.265

EW--2--11
667TA
Type
EEG EEC EBF EED EBD
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head ∅1 7.042 to 7.062
Valves:
∅4 6.970 to 6.999
α 60° ± 0.25°
∅4 6.970 to 6.999
α 45° ± 0.25°
Valve stem and respective guide 0.043 to 0.092
Seat on head
for valve seat:
∅1 34.837 to 34.863
∅1 34.837 to 34.863
Valve seat outer diameter; inclination of

valve seats on cylinder head:
∅2
34.917 to 34.931
α
60°
∅2
34.917 to 34.931
α
45°
Hollow X 0.59 to 1.11
X 0.96 to 1.48
Between the valve 0.054 to 0.094

seat and the head
0.054 to 0.094
Valve seats --
EW--2--12
667TA
Type
EEG EEC EBF EED EBD
Valve spring height:
free spring H 47.75
under a load of:
339.8 N ± 19 N H1 35.33
741 N ± 39 N H2 25.2
Injector protrusion X not adjustable
Seats for distributing shaft bushings no.

7
59.222 to 59.248
Sedi albero distribuzione n.
54.089 to 54.139
1--2--3--4--5--6
Distributing shaft support

pins:
1⇒7 ∅ 53.995 to 54.045
External diameter of the bushing

for the camshaft with a load
of 3.3 kN ∅ 59.222 to 59.248
Bushing inner diameter ∅ 54.083 to 54.147
Bushing and seat in crankcase 0.113 to 0.165
Bushing and support pin 0.038 to 0.162

Eccentric working lift:
6.045
7.239
EW--2--13
667TA
Type
EEG EEC EBF EED EBD
∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030
∅2
Outer diameter of
tappet collar:
∅3
∅2 15.924 to 15.954
∅2 ∅3 15.960 to 15.970
Between the tappets and the seats 0.030 to 0.070
Tappets --
∅1
Rocker arm shaft ∅1 21.965 to 21.977
Rocker arms ∅2 22.001 to 22.0027

∅2
Between the rocker arm and the shaft 0.024 to 0.0377

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

EW--2--15
TOOLS
380000158 1--6 Nm dynamometric screw driver for calibrating injector solenoid valve connector check
nut (Common Rail)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket (except engines: 667TA/EBF -- 667TA/EED)
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel (except engines: 667TA/EBF -- 667TA/EED)
380000990 Engine flywheel retaining tool (except engines: 667TA/EEG -- 667TA/EEC)
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001099 Tool for extracting electric injectors (Common Rail)
EW--2--16
GRAPHIC INDICATIONS AND SYMBOLS
Detachment
Intake
Disconnect
Reattachment
Exhaust
Connect
Removing
Operation
Disassembling
Mounting
Assembling
ρ Compression ratio
Tolerance
Torque--tighten
Weight difference
Torque--tighten + angular value Dragging torque

α
Countersink Rotation
Adjustment Angle
Setting Angular value
Warning
! Preload
Note
Visual check
Revs number
Mounting position check
Measurement
Dimension to be measured Temperature
Check
Equipment bar
Pressure
Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer
Air bleed
EW--2--17
667TA ENGINES
Figure 4
114058
1. Turbocompressor -- 2. Automatic belt stretcher -- 3. Alternator -- 4. Fixed guide pulley --

5. Water pump -- 6. Damper flywhee -- 7. Oil sump -- 8. Electronic central unit --
9. High pressure pump with feed pump -- 10. Diesel oil filter -- 11. Common rail
EW--2--18
DESCRIPTION OF MAIN MECHANIC

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

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.
EW--2--20
Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cy-
chining. linder in which it is mounted.
- By a letter (on the connecting rod body) indica-
The connecting rod half bearings aremade of steel, ting the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.
Figure 7
84038
EW--2--21
Pistons
The combustion chamber is found on the piston The following reference data are engraved on the pi-
crown. The crown is cooled by the engine oil delive- ston crown:
red by the nozzle fitted to the crankcase. 1. Spare part number and design modification
Recesses, housing spring rings, are three; the 1st number
one is made of a cast iron insert. 2. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cy-
linder liner.
3. Date of manufacture;
4. Stamping indicating 1st recess insert testing.
Figure 8
86549
EW--2--22
Distributing shaft EGR EXHAUST GAS RECIRCULATION SY-

STEM
The distributing shaft rests on seven supports in the The exhaust gases can be partially conveyed back
crankcase. into the cylinders to lower the maximum values of the
The rear bearing is equipped with steel bushes combustion temperature that are responsible for the
coated with friction--resistant material that are fitted production of nitrogen oxides (NOx).
with interference. There are two drive cams per cylin- The exhaust gas recirculation system (EGR), lowe-
der. ring the combustion temperature by decreasing the
concentration of oxygen in the combustion chamber,
A. Intake valve control is therefore an effective system to control the emis-
B. Exhaust valve control sion of NOx.
The distributing shaft is controlled directly by the dri- Internal EGR acting on the exhaust valves
ve shaft by means of straight--tooth gears. The internal EGR system, thanks to an appropriate
exhaust cam design permits some of the exhaust ga-
ses to be reintroduced back into the engine cylinders.
This type of EGR, internal EGR is not provided with
any electronically controlled element: the system is
always on. Its configuration doesn’t need any additio-
nal elements such as control valves, pipes or heat ex-
changers.
The exhaust cam, besides the main lobe, has an ad-
Figure 9 ditional lobe (C) compared to the configuration wi-
thout EGR. During the intake stroke of the cylinder
under examination, this lobe permits briefly opening
the exhaust valve. In this way, recirculation is gene-
rated on the cylinder in the intake stroke due to the
greater pressure of the exhaust gases compared to
the intake gases.
70164
114501
EW--2--23
Valve control
Figure 10
003198t
1. Rocker arm -- 2. Arbour -- 3. Adjusting screw -- 4. Rod -- 5. Jumper -- 6. Lock cones -- 7. Cup --
8. Spring -- 9. Tappet -- 10. Distributing shaft
EW--2--24
Cylinder head engines: 667TA/EBF -- 667TA/EBD -- 667TA/EED

The seats of the following parts are obtained on the Moreover, the following components are inserted
cast--iron cylinder head: onthe heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injectors (6); - intake manifold (2) with seat for cold start air
- thermostat (5); heater (3).
Figure 11
114059
DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--25
Cylinder head engines: 667TA/EEG -- 667TA/EEC

The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder (8) head: the heads:
- inserted valve seats (10); - exhaust manifold (1) in two parts
- intake manifold (2) with seat for cold start air
- injectors (2); heater (3).
- thermostat (4); - support (7) with injector wiring harness (3).
Figure 12
114060
EW--2--26
Valves and valve seats

Figure 13
70319
1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side
Valve seats have following angles: Exhaust valves 2 have a distinctive notch at the cen-
- 45° (exhaust valves) tre of the head.
- 60° (intake valves)
Figure 14
70334
Figure 14 shows the oil seals mounted on valve

stems.
EW--2--27
Valves and valve seats

Le guide valvole non sono riportate
Figure 15
INTAKE EXHAUST 79457
Valve drive jumpers Jumpers must be positioned with marks (→) to-
When remounting the cylinder head, the orientation wards exhaust manifold.
of valve drive jumpers must be observed.
Figure 16
70345
1. Jumper -- 2. Rods
Engine head grinder A single thickness gasket is available as a spare
Cylinder head nominal thickness is 105 ± 0.25 mm part.
and maximum removal enabled by metal must not
exceed 0.13 mm.
Figure 17
70325
EW--2--28
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-
Figure 18 Figure 20
114086 86488
ENGINES: 667TA/EEG -- 667TA/EEC MOTORI: 667TA/EBF -- 667TA/EED
Figure 19
86454
MOTORI: 667TA/EED -- 667TA/EBD

EW--2--29
Auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft The belt is stretched by means of automatic belt
(5) to water pump (3) and to alternator (2). stretcher (1).
Figure 21
114061
1. Automatic belt stretcher -- 2. Alternator -- 3. Water pump -- 4. Poly--V belt -- 5. Drive shaft
EW--2--30
ENGINE LUBRIFICATION
Forced circulation lubrication is performed by the fol- gine crankcase, with oil filter adapter;
lowing components: - oil pressure control valve (1) built into the oil filter
- rotor--equipped oil pump (5), housed in the cran- adapter;
kcase front part, controlled by the straight tooth - by--pass valve (4) for clogged oil filter cut--off,
gear force--fitted on the drive shaft shank; built into the oil filter adapter;
- water / oil heat exchanger (3), housed in the en- - cartridge--type oil filter (2).
Figure 22
Pressure oil path

Oil return drop----type path
Oil introduction
114087
A. Engine oil sump: 667TA/EED -- 667TA/EBD

B. Engine oil sump: 667TA/EEG -- 667TA/EEC -- 667TA/EBF -- 667TA/EED
EW--2--31
Heat exchanger
Figure 23
114062
1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5*. Oil return to filter – 6*. Oil inflow from filter -- 7. Oil filter
* Only engines: 667TA/EEG -- 667TA/EEC
Oil pressure regulation valve By--pass valve

Figure 24 Figure 25
Flow
107419 70483
PRINCIPAL DATA FOR OIL PRESSURE Blow--by max:

REGULATION VALVE SPRING CHECKING 20 cm3/l’ with 0.83 bar pressure and 26.7 _C oil
Pressure regulating calibration at 100_C oil temper- temperature.
ature
-- minimum speed 1.2 bar;
-- maximum speed 3.8 bar.
EW--2--32
Oil pump
Figure 26
84052
Figure 27
70150
1. Drive shaft with oil pump drive gear

EW--2--33
Oil sump engines: 667TA/EEG -- 667TA/EEC -- 667TA/EBF -- 667TA/EED

The steel oil sump (1) is flexibly secured to the engine The C--section rubber gasket (2), fitted onto the oil
block by an aluminium plate (3), Figure 29. sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.
Figure 28
84054
Figure 29
84055
EW--2--34
Oil sump engines: 667TA/EED -- 667TA/EBD

The cast iron oil sump is secured to the engine block
by bolts with interposed flat washers.
Figure 30
003202t
003203t
EW--2--35
Engine oil vapour recirculation

In tappet cover, a pre--separator (1) is housed, the In blow--by system (3), vapours partially condense
shape and position of which determines an increase and come back into oil sump while the remaining part
in the speed of outgoing oil vapours while condensig is being recirculated as sucked through piping (2).
them partially. Condensed oil comes back into oil
sump while residual vapours are being conveyed,
collected and filtered in blow--by system (3).
Figure 31
Oil condensate
Oil vapours 000966t
1. Pre--separator -- 2. Sucking recirculation -- 3. Filter -- 4. Engine return

EW--2--36
ENGINE COOLING
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components: - thermostat, used to regulate coolant flow.
- heat exchanger, used to cool the lubricating oil
(lubrificatiion see);
Figure 32
Water coming out from thermostat
Water recirculating in engine
Water going into pump
86494
EW--2--37
WATER PUMP Thermostat

The water pump is housed in a seat obtained from the
crankcase and is controlled by means of a poly--V Figure 35
belt.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
Figure 33
79458
A = stroke start at 79.0 ÷ 83.0 °C;

B = stroke at 96 _C ≥ 7.5 mm.
84058
Figure 34
84059
EW--2--38
HIGH PRESSURE ELECTRONIC INJEC-

TION SYSTEM (COMMON RAIL)
Introduction
Extremely high injection pressures are necessary in than 152 kW, DSLA nozzles are fitted which work a
order to reduce PARTICULATE emissions. pressures up to 1450 bar.
The common rail system makes it possible to inject Description of system
fuel at pressures of up to 1450 -- 1600 bar, while the
injection precision obtained by electronic control of The injection system is composed of an electrical
the system serves to optimise operation of the en- part and a hydraulic part.
gine while limiting emissions and fuel consumption. Electrical system
For engines more powerful than 152 kW, the CRIN2 The electronic control unit monitors engine control
injectors have DLLA nozzles that work up to a pres- parameters by means of the various sensors on the
sure of 1600 bar, whilst for engines less powerful engine.
Figure 36
107851
1. Connection to Electro--injectors -- 2. Sensor monitoring temperature of engine’s cooling liquid --

3. Fuel pressure sensor cable -- 4. Sensor of engine’s oil temperature and pressure --
5. Driving shaft sensor -- 6. Electro--injector -- 7. Temperature and air pressure sensor --
8. Camshaft sensor -- 9. Fuel heater cable and fuel temperature sensor --
10. Pressure gauge cabling -- 11. EDC 7 gearbox.
EW--2--39
EDC 7 OPERATION Smoke control under acceleration

Engine preheating element control With intense load demands, in accordance with sig-
Pre--post heating is activated when even just one of nals received from the air inlet meter and the engine
the water, air or fuel temperature sensors detects a speed sensor, the control unit manages the pressure
temperature ≤ 5 °C. regulator and modulates the activation time of the
electro--injectors to prevent the emission of smoke
Phase recognition from the exhaust.
By means of signals transmitted by the camshaft and
crankshaft sensors, the cylinder into which fuel must After Run
be injected is determined at the time of starting. After the engine is stopped, the control unit micropro-
Injection control cessor saves various parameters to the EEPROM
On the basis of information transmitted by the sen- memory, including the faults log so that they will be
sors, the control unit administrates the pressure available the next time the engine is started.
regulator and modifies the pre--injection and main in- Control of working speed in normal operating
jection mode. conditions
On F4 engines pre--injection is activated at all engine
speeds. Each time work load varies, the control unit adjusts
torque so as to maintain the engine in maximum
Injection pressure closed loop control power conditions. If the load causes a reduction in
On the basis of the engine load, as determined by power, the control unit increases torque i.e. it in-
processing of data transmitted by the various sen- creases the amount of fuel injected in order to restore
sors, the control unit administrates the regulator to the engine to maximum power.
maintain injection pressure at constantly optimal va-
lues. Recovery strategies
Pilot and main injection advance control Recovery strategies are characterized by certain dif-
On the basis of signals transmitted by the various ferences as application varies, i.e.
sensors, the control unit determines the optimum in- - Control of fuel leaks
jection point on the basis of internal mapping. In the case of fuel supply problems, the system
Idle speed control controls the engine with suitable constant power
The control unit processes signals transmitted by the values obtained with a low number of revs and
various sensors and adjusts the quantity of fuel in- high torque values in order to inject the maximum
jected. quantity of fuel.
It also controls the pressure regulator and modulates
injection duration of the electro--injectors. - Control of pressure in the rail
Within specific limits, the control unit also monitors When the pressure in the rail exceeds safety va-
battery voltage. lues, the engine reduces power.
Overheating protection
- Synchronism problems
If the water temperature reaches 110 °C, the control In the case of synchronism problems, faulty rev
unit reduces engine performance. sensors, the system controls the engine by in-
When the temperature returns below 100 °C, the en- creasing the number of revs in order to improve
gine resumes normal operation, (in some applica- interpretation of the signals.
tions, the over boosting temperature is the reference
temperature). - Power restrictions as operating temperature in-
Maximum engine speed limiting creases
Depending on the application, the control unit mem- When the temperature of the supercharging air
ory can contain appropriate engine speed limits. rises above 88 °C, power reduction is started;
When the engine speed surpasses these limits the when a temperature of 120 °C is reached, per-
control unit activates power reduction strategies by formance is further reduced and is comparable to
controlling energization time of the electro--injectors. that of the same engine if it were aspirated.
In some applications the maximum limiting response
consists in stopping the engine. - Reduction of power as reference temperature
Cut Off varies
In normal operating conditions, the system
Fuel cut--off in release phases is managed by the knows the supercharging air, oil and water tem-
control unit with the following logical interventions: peratures.
- disactivation of the electro--injectors; If the temperature of the engine water is not avail-
able, the system takes the temperature of the oil
- reactivation of electro--injectors immediately
as reference and when this reaches the threshold
prior to arrival at idle speed;
of 103 °C, it starts to reduce the power available.
- control of fuel pressure regulator. On reaching 113 °C, power is reduced to 50%.
EW--2--40
SUPPLY SYSTEM
Figure 37
High pressure
Low pressure
Fuel outlet
108607
1. Electro--injector -- 2. Common rail -- 3. Pressure limiting device for fuel return -- 4. Common rail pressure
relief valve -- 5. Pre--filter mounted on the frame -- 6. High--pressure pump --
7. Mechanical vane pump -- 8. Fuel filter
The common rail system has a special pump that The low--pressure circuit is composed of the follo-
continually keeps the fuel at high pressure, irrespec- wing pipes:
tive of the phase and the cylinder that must receive
the injection and it accumulates it in a duct common - fuel pipe from fuel tank to prefilter;
to all the electro--injectors.
At the electro--injector inlet there is therefore always - pipes supplying the mechanical supply pump
fuel at the injection pressure calculated by the elec- through the heat exchanger of the control unit,
tronic control unit. the manual priming pump and the pre--filter;
When the solenoid valve of an electro--injector is
energized by the electronic control unit, fuel taken di- - pipes supplying the high pressure pump via the
rectly from the rail is injected into the relevant cylin- fuel filter.
der.
The fuel system is composed of a low--pressure cir- The fuel system is completed by the fuel outlet circuit
cuit and a high--pressure circuit. from the common rail, injectors and high--pressure
The high--pressure circuit is composed of the follo- pump cooling circuit.
wing pipes:
- pipe connecting the high--pressure pump outlet
to the common rail;
- pipes supplying the electro--injectors from the
common rail.
EW--2--41
SUPPLY SYSTEM DIAGRAM

Figure 38
OUTLET
INTAKE (LOW PRESSURE)
HIGH--PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
108608
1. High pressure pump -- 2. Relief valve on the high--pressure pump, 5 bar -- 3. Adjuster valve fitted on the
fuel return from the electro--injectors, 1.3 -- 2 bar -- 4. Over--pressure valve of the Common Rail -- 5. Com-
mon Rail -- 6. Pressure sensor -- 7. Electro--injector -- 8. Return pipe -- 9. Heat exchanger of the
control unit -- 10. Mechanical priming pump -- 11. Prefilter fitted on chassis -- 12. Fuel tank --
13. Mechanical fuel supply pump -- 14. Fuel filter -- 15. Pressure regulator -- 16. Backflow pipe from high--
pressure pump -- 17. By--pass valve -- 18. By--pass valve.
The pressure regulator, upstream from the high-- The relief valve (3) housed on the cylinder head, fit-
pressure pump, controls the flow of fuel needed in the ted on the electro--injector return, governs the flow of
low--pressure system. Then the high--pressure pump fuel returning from the electro--injectors at a pressure
correctly supplies the common rail. This solution, of 1,3 ÷ 2 bars.
pressurizing only the necessary fuel, improves ener- In parallel with the mechanical supply pump there are
gy efficiency and limits the heating of the fuel in the two by--pass valves.
system. The by--pass valve 18 makes it possible to have the
The relief valve (2) fitted on the high pressure pump fuel flow back from the mechanical pump outlet to its
serves the purpose of maintaining the pressure at the inlet, when the pressure at the fuel filter inlet exceeds
pressure regulator inlet at a constant level of five bars the permissible limit. The by--pass valve 17 makes it
regardless of the efficiency of the fuel filter and the possible to fill the supply system via the manual pri-
upstream system. ming pump (10).
Relief valve (2) operates to increase fuel flow in the
high pressure pump cooling circuit through pipe (16)
carrying fluid into and out of pipe (8).
EW--2--42
Fuel filter
It is placed on engine cylinder block in the circuit bet- Heater is activated if the fuel temperature is ≤ 0 °C
ween supply pump and high--pressure pump (CP3). and is heated till it reaches 5 °C. Fuel temperature,
signalled by the related sensor to EDC control unit 7,
The following are placed on the support: fuel tempe- allows a very accurate computation of fuel flow--rate
rature sensors and heater resistance. to be injected into the cylinders.
Figure 39
003206t
1. Fuel filter support -- 2. Heater connector -- 3. Electric fuel heater -- 4. Fuel filter -- 5. Fuel temperature
sensor -- A. High--pressure pump outlet fitting -- B. Fuel exhaust inlet fitting from Common Rail and cylinder
head (injectors) -- C. Exhaust fitting from high--pressure pump -- D. Inlet fitting from supply pump --
E. Fuel exhaust outlet fitting to tank.
EW--2--43
Mechanical supply pump

Normal operating condition
Geared pump, assembled in the rear part of the high-- Under normal operating conditions, the fuel flow insi-
pressure pump; its function is supplying the same. It de the mechanical pump is shown in the figure.
is controlled by the high--pressure pump shaft.
Figure 40
001237t
A. Fuel inlet from tank -- B. Fuel outlet to filter

1 -- 2. By--pass valves in closure position
Output overpressure condition The current pressure, overcoming the elastic resi-
The by--pass valve (1) triggers when an overpressu- stance of spring (1), communicates outlet with inlet
re is generated as output (B). through duct (2).
Figure 41
001238t
EW--2--44
Drain conditions
The by--pass valve (2) triggers when, with turned--off Under this situation, the by--pass valve (2) is opened,
engine, the supply system has to be filled in through due to the inlet pressure, and the fuel flows to outlet
the priming pump. (B).
Figure 42
001239t
High--pressure pump type CP3.3 On the read high--pressure pump side, the mechani-
Pump with 3 radial pumping elements controlled cal supply pump is assembled, controlled by the
through distribution gear, it does not need to be pha- high--pressure pump shaft.
sed--up.
Figure 43
001250t
1. Fuel outlet fitting to rail -- 2. High--pressure pump -- 3. Pressure regulator -- 4. Fuel inlet fitting
from filter -- 5. Fuel outlet fitting to filter support -- 6. Fuel inlet fitting from control unit heat exchanger --
7. Fuel outlet fitting from mechanical pump to filter -- 8. Mechanical supply pump.
IMPORTANT -- The high pressure pump unit -- feeding pump is not subject to overhaul , therefore it must not
be disassembled neither the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
EW--2--45
Figure 44
001967t
1. Mechanical supply pump -- 2. Fuel return from high--pressure pump -- 3. Delivery valve to Common Rail --
4. Single pumping element -- 5. By--pass valves on supply pump -- 6. Pump shaft -- 7. Fuel inlet from filter --
8. 5--bar limiting valve -- 9. Pressure regulator.
EW--2--46
High pressure pump--inside structure
Figure 45
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: with but is only translated in a circular movement
along a wider radius, with the resulting alternate
- a piston (5) actuated by a three--lobe element (2)
actuation of the three pumping elements;
floating on the pump shaft (6). The element (2),
being floating on a misaligned part of the shaft - cap intake valve (3);
(6), when the shaft rotates, does not rotate there- - ball delivery valve (4).
EW--2--47
Working principle
Figure 46
Sec. B-B
Sec. D-D 72597
1. Rail delivery outlet -- 2. Rail delivery valve -- 3. Pumping element -- 4. Pump shaft -- 5. Pumping element
supply duct -- 6. Pressure regulator supply duct -- 7. Pressure regulator
The pumping element (3) is orientated towards the PWM command received by the engine control mod-
pump’s camshaft (4). During the intake phase, the ule, stops the fuel flow to the pumping element.
pumping element is fed through the feeding line (5). During compression phase of the pumping element,
The quantity of fuel to flow to the pumping element the fuel achieves the level of pressure determining
is determined by the pressure regulating gauge (7). the opening of the by--pass valve to common rail (2),
The pressure regulating gauge, according to the feeding it through the exhaust unit (I).
EW--2--48
Figure 47 shows the fuel runs at low pressure inside The pressure gauge (5) determines the quantity of
the pump; the following elements are clearly visible: fuel to feed the pumping elements: the fuel in excess
the main feeding line to the pumping elements (4); flows through the exhaust gallery (9).
the feeding lines to the pumping elements (1--3--6),
The limiting valve to 5 bar, in addition to recovering
the duct lines run for the pump lubrication (2), the
fuel exhaust as a collector has also function to keep
pressure gauge (5), the flow limiting valve to 5 bar (8)
the pressure constant to 5 bar limit at gauge entry.
and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the
feeding and recovery lines.
Figure 47
Sec. C-C 72598
1. Pumping element inlet -- 2. Pump lubricating ducts -- 3. Pumping element inlet -- 4. Main pumping ele-
ments supplying duct -- 5. Pressure regulator -- 6. Pumping element inlet -- 7. Regulator exhaust duct --
8. 5--bar limiting valve -- 9. Fuel exhaust from regulator inlet.
Figure 48 shows the fuel flow under high pressure

running through the exhaust galleries of the pumping
elements.
Figure 48
Sec. A-A 72601
1. Fuel exhaust flue -- 2. Fuel exhaust gallery -- 3 Fuel exhaust flowing from pump with connector to high
pressure pipe for common rail
EW--2--49
Operation
The cylinder is filled through the cap intake valve only The pumping element piston goes back towards the
if the supply pressure is suitable to open the delivery bottom dead center and the remaining fuel is decom-
valves set on the pumping elements (about 2 bars). pressed.
The amount of fuel supplying the high--pressure When the pumping element chamber pressure be-
pump is metered by the pressure regulator, placed comes less than the supply pressure, the intake
on the low--pressure system; the pressure regulator valve is again opened and the cycle is repeated.
is controlled by the EDC7 control unit through a PWM
signal. The delivery valves must always be free in their
movements, free from impurities and oxidation.
When fuel is sent to a pumping element, the related
piston is moving downwards (suction stroke). When The rail delivery pressure is modulated between 250
the piston stroke is reversed, the intake valve closes and 1600 bars by the electronic control unit, through
and the remaining fuel in the pumping element the pressure regulator solenoid valve.
chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail. The pump is lubricated and cooled by the fuel.
The thereby--generated pressure makes the exhaust The radialjet pump disconnection – reconnection
valve open and the compressed fuel reaches the time on the engine is highly reduced in comparison
high--pressure circuit. with traditional injection pumps, because it does not
require setting.
The pumping element compresses the fuel till the top
dead center (delivery stroke) is reached. Afterwards, If the pipe between fuel filter and high--pressure
the pressure decreases till the exhaust valve is clo- pump is to be removed--refitted, be sure that hands
sed. and components are absolutely clean.
RAIL
Figure 49
108609
The rail volume is comparatively small to allow a abled by a calibrated hole being set downstream of
quick pressurisation at startup, at idle and in case of the high--pressure pump.
high flow--rates.
A fuel pressure sensor (1) is screwed to the rail. The
It anyway has enough volume as to minimise system signal sent by this sensor to the electronic control unit
spikes and the use of plenum chambers caused by is a feed--back information, depending on which the
injectors openings and closings and by the high-- rail pressure value is checked and, if necessary, cor-
pressure pump operation. This function is further en- rected.
EW--2--50
BOOST GAUGE VALVE

The boost valve (1750 bars) is assembled to the rail safety parameters. Then it provides mechanically
with the purpose to protect the system’s components gauging the pressure into rail to aprx. 800 bars.
in case of excessive increase of pressure within the
high pressure system. Pressure limiter. This way the valve enables working of the engine for
extended timing at limited performances, avoiding
The valve can be single--stage (as the one showed
the fuel’s overheating and preserving the exhaust
in the picture) or double--stage with double working
galleries.
limit (1750 bars and 800 bars).
In the second case, when the pressure within the If the above mentioned valve is activated, the engine
high pressure system reaches 1750 bars, the valve control module excludes by isolation the pressure
is activated as a single--stage one to exhaust the fuel gauge and records the errore code 8.4.
and consequently reduce the pressure until reaching The pump will flow the maximum delivery to the rail.
Figure 50
70502
1. Body – 2. Small piston – 3. Stop – 4. Spring – 5. Direct tank discharge – 6. Seat on rail
A Normally, the tapered piston end keeps closed B If the 1750 bar fuel pressure is exceeded in rail,
the discharge towards the tank. the small piston is displaced and the excess
pressure is discharged into the tank.
EW--2--51
ELECTRO--INJECTOR Injection start

The injector is similar as construction to the traditional Figure 52
ones, apart from the absence of plunger return
springs.
The injector can be deemed as composed of two
parts:
- actuator – spray nozzle composed of pressure
rod (1), plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and
pilot valve (5).
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position

15
Figure 51
15
70506
When coil (4) is energised, it makes shutter (6) move

upwards. The control volume (9) fuel flows towards
flow duct (12) making a pressure drop occur in control
volume (9). Simultaneously the fuel pressure into
pressure chamber (8) makes plunger (2) lift, with fol-
lowing fuel injection into the cylinder.
Injection end
70505
When coil (4) is de--energised, shutter (6) goes back
to its closing position, in order to re--create such a
force balance as to make plunger (2) go back to its
1. Pressure rod – 2. Plunger – 3. Nozzle – 4. Coil – closing position and end the injection.
5. Pilot valve – 6. Ball shutter – 7. Control area –
8. Pressure chamber – 9. Control volume –
10. Control duct – 11. Supply duct – 12. Control IMPORTANT -- The injector cannot be overhauled
fuel outlet – 13. Electric connection – 14. Spring – and therefore it must not be disassembled.
15. High--pressure fuel inlet.
EW--2--52
Electro--injector
The injectors are BOSCH CRIN 1 and CRIN 2, fitted
according to the power developed by the engine.
Injectors Jet Engines Pressures

CRIN 1 -- 667TA/EEG -- 667TA/EEC --
CRIN 2 DLLA 137 PV 3 667TA/EBF -- 667TA/EBD 250 ÷ 1600 bar
CRIN 2 DSLA 143 PV 3 667TA/EED 250 ÷ 1400 bar
Figure 53
108610
1. Jet
EW--2--53
PRESSURE LIMITER FOR FUEL RETURN
It is housed on the rear of the cylinder head, and ad- sure to the return fuel, the fuel vapours formation in-
justs the pressure of fuel returning from injectors at side injectors is avoided, optimising fuel spraying and
a pressure 1.3 and 2 bars. By guaranteeing this pres- combustion.
Figure 54
70507
A. To tank -- B. From injectors

EW--2--54
LOCATION OF THE MAIN ELECTRICAL COMPONENTS
Figure 55
108641
The engines are fully driven by the electronic engine The electrical and electronic components of the en-
control module, which is assembled directly to the gine are listed here following:
engine by means of a heat exchanger enabling its 1. Coolant temperature sensor.
cooling, utilising rubber buffers to reduce vibration
2. Electro--injector.
originated by the engine.
3. RAIL pressure sensor.
Through the engine control module it is possible to
4. Air temperature/pressure sensor.
verify the correct working of the engine. (See part
three of the hereby user’s guide specifically dedi- 5. Starter motor.
cated to diagnostic). 6. Timing sensor.
7. Solenoid valve for pressure regulator.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre--post heating.
EW--2--55
EDC7 ECU
Figure 56
01525t
A -- Connector to injectors; B -- Connector to chassis (Provide reference of the vehicle to which the engine
is assembled); C -- Connector to sensors
EW--2--56
Cable on engine
All the components described below refer to the en-
gine cable in question, therefore the connections to
the pins are a preliminary version, in other words at
the approval stage.
Figure 57
114296
1. Injectors for cylinders 1--2 -- 2 Injectors for cylinders 3--4 -- 3. Injectors for cylinders 5--6 -- 4. Engine rpm
sensor -- 5. Timing sensor -- 6. Engine oil pressure and temperature sensor -- 7. Fuel temperature sensor --
8. Coolant temperature sensor -- 9. Air temperature and pressure sensor -- 10. Rail temperature and pres-
sure sensor -- 11. Pressure regulator -- 12. Connector C EDC control unit (signal) -- 13. Connector A EDC
control unit (power).
EW--2--57
Injectors connector (A) Sensors connector (C)
ECU PIN FUNCTION ECU PIN FUNCTION

1 Cylinder 5 injector 1 --
7 -- 7 --
8 -- 8 --
9 Pressure regulator 9 Timing sensor
10 Pressure regulator 10 Timing sensor
Negative for rail temperature and pressure sen-
12 Cylinder 3 injector 12
sor
Positive for rail temperature and pressure sen-
sor
Signal from rail temperature and pressure sen-
sor
15 Cylinder 6 injector 15 Coolant temperature sensor
17 --
18 Signal from fuel temperature sensor
19 Engine rpm sensor
20 --
21 --
22 --
23 Engine rpm sensor
Negative for engine oil pressure and tempera-
24
ture sensor
Negative for air temperature and pressure sen-
25
sor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature sensor
29 --
30 --
31 --
Positive for engine oil pressure and tempera-
32
ture sensor
Positive for air temperature and pressure sen-
33
sor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
EW--2--58
Crankshaft sensor
This is an inductive sensor located at the front left on the crankshaft.
hand side of the engine. The crankshaft sensor pro- The crankshaft sensor is connected to the control
duces signals obtained from a magnetic flux field unit on pins 19C -- 23C. The sensor impedance is
closing through the openings in a phonic wheel fitted ∼900 Ω.
Figure 58
50319
Crankshaft sensor
Timing sensor electronic control unit as an injection phase signal.

This is an inductive sensor located at the rear left Although it is similar to the flywheel sensor, these two
hand side of the engine. The timing sensor generates devices are NOT interchangeable because of the dif-
signals obtained from a magnetic flux field closing ferent external shape.
through the holes in the timing gear on the camshaft. The timing sensor is connected to the control unit on
The signal generated by this sensor is utilized by the pins 9C -- 10C. The sensor impedance is ∼900 Ω.
Figure 59
50320
Timing sensor
3 2 1
50288
50342
Connector Wiring diagram
ECU pin
Ref
Ref. Description
Camshaft sensor Timing sensor
1 Signal 19C 10C
2 Signal 23C 9C
3 Schield
EW--2--59
Supercharging air pressure -- temperature

sensor
his component incorporates a temperature sensor The power supply is 5 volt
and a pressure sensor. Voltage at the sensor output is proportional to the de-
Mounted on the intake manifold, the sensor tected pressure or temperature.
measures the maximum flow rate of air supplied,
Pin 25C -- 36C Temperature
which serves to make an accurate calculation of the
Pin 33C -- 34C Pressure
quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins
25C -- 36C -- 33C -- 34C.
Engine oil temperature--pressure sensor The sensor is supplied with 5 Volts. The signal de-
This component is analogous to the air temperature-- tected is transmitted to the EDC control unit which,
pressure sensor. in turn, controls the relative device on the instrument
The engine oil temperature--pressure sensor is in- panel (gauge + low pressure warning light).
stalled on the engine oil filter support in a vertical The oil temperature is not displayed on any gauges
position. -- this value is used exclusively by the control unit.
This sensor measures the engine oil temperature
and pressure.
The sensor is connected to the control unit on pins Pin 24C -- 28C Temperature
24C -- 28C -- 32C -- 27C. Pin 32C -- 27C Pressure
Figure 60
50324 50344
Wiring diagram
ECU Pin
Ref
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power unit 32C 34C
4 Signal (pressure) 27C 34C
EW--2--60
Fuel temperature and pressure sensor
Mounted on one end of the rail, this sensor measures of the electrical injection command.
the internal fuel pressure and informs the control unit This sensor is connected to the control unit on pins
of the value (feedback). 12C -- 14C-- 13C.
The injection pressure value is used as a pressure The power supply is 5 Volt.
control feedback signal and to determine the duration
Figure 61
0051065t
Fuel pressure sensor connector
Ref. Description ECU Pin

1 Ground 12C
2 Signal 14C
3 Power supply 13C
EW--2--61
Electro--injectors
The electro--injectors are effectively N.O. solenoid connector A.

valves. The impedance of the coil of each injector is 0.56 --
Each injector is connected to the EDC control unit on 0.57 Ω.
Ref. Description ECU Pin

1 Cylinder 2 injector 11 A
2 Cylinder 2 injector 6A
CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Figure 62
50343
Figure 63
50349
EW--2--62
Pre--post heating resistance and contactor
The pre--post heating resistance is located on the in- heating operations. This resistance is powered by a
take manifold. contactor on the left hand side of the chassis.
The resistance serves to heat the air in pre / post The resistance impedance is approximately 0.5 Ω.
Figure 64
003215t
Resistance
Figure 65
002371t
A. Control contactor
The control contactor is connected to the control unit The contactor is tripped with water and/or fuel tem-
B connector. perature below 5 °C.
The contactor impedance is approximately 15 Ω.
WARNING -- Do not use flammable liquids or gases to help starting the engine.
These substances could easily catch fire once in contact with the resistance, causing very dangerous situa-
tions.
EW--2--63
Coolant temperature sensor
This is a variable resistance sensor able to read the an instrument panel gauge, if present.
coolant temperature in order to provide the control This sensor is connected to the control unit on pins
unit with an indication of the thermal status of the en- 15C -- 26C.
gine. The impedance of the coolant temperature sensor at
The same signal is utilized by the control unit to drive 20 °C is approximately 2.50 Ω.
Figure 66
107471
EW--2--64
Fuel temperature sensor
This sensor is identical to the coolant temperature The fuel temperature sensor is connected to the con-
sensor. trol unit on pins 35C -- 18C.
This sensor detects the fuel temperature to provide The sensor impedance at 20 °C is approximately
the control unit with a parameter defining the thermal 2.50 Ω.
status of the fuel.
Figure 67
0051140t
1. Fuel temperature sensor -- 2. Filter heating resistance
The ECU drives the filter heater contactor at fuel tem-

perature ≤ 5 °C.
Figure 68
107799 107798
Connector
ECU Pin
Ref
Ref. Description
Coolant Fuel
1 Ground 15C 35C
2 Temperature signal 26C 18C
EW--2--65
High pressure pump -- pressure regulator
Figure 69
000912t
A. Pressure regulator
The quantity of fuel supplied to the high pressure Delivery pressure to the rail is modulated between
pump is metered by the pressure regulator on the low 250 and 1450 bar by the electronic control unit by
pressure system; the pressure regulator is managed controlling the pressure regulator solenoid valve.
by the EDC7 control unit. - This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on
pins 9A -- 10A.
- The solenoid valve impedance is approximately
3.2 Ω..
EW--2--66
CHECKING THE FUEL SYSTEM
This section analyses the tests for correctly trouble- tion system correlated with error codes 8.x saved in
shooting and checking the fuel circuit and the com- the control unit, or not accompanied by any error
mon rail injection system. The stated procedure can code and the user notices a drop in performance. The
be used in the event of trouble with the engine injec- following table gives descriptions of error codes 8.x.
Error Description
8.1 -- Negative deviation of the fuel pressure (actual pressure higher than the objective pressure).
-- Positive deviation of the fuel pressure (actual pressure lower than the objective pressure).
-- Drop in fuel pressure with vehicle in motion (lack of diesel).
-- Drop in fuel pressure with vehicle in motion: downhill with throttle pedal released (lack of die-
sel).
-- Drop in fuel pressure with the engine idling (lack of diesel).
8.2 -- Fuel pressure sensor on rail.
8.4 -- Backflow valve control (opening the pressure relief valve DBV).
8.5 -- Fuel pressure in the rail too high.
-- Fuel pressure in the rail too low.
DESCRIPTION OF TESTS AND CHECKS Necessary equipment

THAT CAN BE PERFORMED Use an appropriate set as described in the figure.
The contemplated tests are:
- Low pressure supply test
- Test on the pressure relief valve on the rail
- Test on fuel backflow from the injector return
Figure 70
108599
1. Pressure gauge 1 (0 -- 15bar) and standard couplings -- 2. Pressure gauge 2 and standard couplings --
3. 2--litre container -- 4. Pressure gauge pipes -- 5. Graduated container of 100ml -- 6. Plug for rail --
7. Closed Voss coupling.
EW--2--67
Low pressure supply test
The figure shows a diagram describing the use of the

components available in the specific set.
Figure 71
108600
A. Fuel tank -- B. Prefilter -- C. Low--pressure pump -- D. Fuel delivery circuit --

E. Fuel filter -- F. High--pressure pump CP3.3 -- G. High--pressure circuit -- H. Common rail --
I. Fuel recirculation circuit -- L. Injectors -- M1. Pressure gauge 1 fuel filter inlet --
M2. Pressure gauge 2 fuel filter outlet -- N. External container.
Figure 72
108601
EW--2--68
Low--Pressure Pump
The function of the gear pump is to supply the high-- Under normal operating conditions, the flow of fuel in-
pressure pump CP3.3. It is driven by the shaft of the side the pump is as shown in the figure.
high--pressure pump and is fitted on its rear portion.
Figure 73
108602
On completing the fuel supply system and with the - On pressure gauge M1 it must be between 6 and
battery charged to 24.7V, the engine must start within 9 bar:
the 20 seconds of activation of the starter motor, -- if lower than 6 bar: replace the pump,
drawing fuel from the external container placed at -- if higher than 9 bar: replace the diesel filter.
most 1 metre lower than the engine. If the pump is not
- On pressure gauge M2 it must be greater than 5
able to draw up fuel in the stated time and therefore
bar:
start the engine, replace it.
-- if lower, replace the diesel filter,
-- if the trouble persists, check the seals of the
After starting the engine, check the pressure at 1500 couplings of the fuel filter support and of the
rpm: high--pressure pump inlet.
EW--2--69
Test on the pressure relief valve on the rail
Fitted at one end of the rail, its function is to protect

the system’s components if any malfunctioning
causes an excessive increase in the pressure of the
high--pressure system.
Figure 74
108603
Disconnect recirculation pipe (1) from the pressure tive even though a great amount of diesel flows out.
relief valve and plug with the Voss fitting in the ap- Whereas, if the valve seeps diesel without fault code
propriate set. No diesel must come out of the valve 8.4, then replace it.
at any engine speed. If the diagnosis system signals
fault code 8.4 ”Engine -- backflow valve control”, it With the overpressure sensor disconnected or with
means that the EDC control unit has recognised that a bundle of defective cables fault code 8.2 is gener-
the valve has opened after a significant change in the ated and the rail pressure is set to 710bar (measur-
pressure of the rail (greater than 1700bar). Since its able with the diagnosis instrument). Therefore the
opening is to be considered a consequence of the ab- trouble is to be found in the wiring and it is not necess-
normal increase in pressure, the valve is NOT defec- ary to replace the component.
IMPORTANT -- The experience acquired to date shows that the defectiveness is RARELY due to the sensor.
EW--2--70
Test on fuel backflow from the return
Permits establishing the operating status of the injec- quantity of fuel injected per cycle. In its turn, this is
tors. The engine speed and power are controlled converted into microseconds of injector opening ac-
through the injectors. The power required by the cording to the rail pressure.
user, through the accelerator, is converted into the
Figure 75
108604
Notes: (fault code 8.1) in the phase of acceleration and/or

The injectors may have problems of both a mechan- cold start trouble, make the following checks.
ical and an electrical nature; before proceeding with
the following analysis, it is wise to rule out the pres-
- Possible incorrect tightening of the nut (1) locking
ence of water in the tank and in the fuel prefilter.
the injector duct on the cylinder head. The pre-
When the EDC warning light comes on occasionally scribed torque setting is 50 ± 5 Nm.
Figure 76
108605
EW--2--71
- Proceed with the injector fuel backflow tests.

Remove the duct (1) from the cylinder head, plug
it (2) and fit on the coupled transparent pipe (3).
Figure 77
108606
Make sure first of all that the engine idling speed is flowing out in one minute from the coupling on the cyl-
as set in the factory. Check the quantities of fuel recir- inder head by means of a graduated container. Once
culation from the cylinder head. The conditions for you have ensured that recirculation exceeds 80ml
measuring the quantities of injector return fuel are: per minute, plug the rail outlet of one injector (4) at a
time, using the rail plugs in the set. The defective in-
- engine idling and without air compressor or air
jector is the one whose exclusion caused a signifi-
conditioner working;
cant reduction in recirculation. In addition, remember
- engine at temperature (> 50 °C). that when changing an injector it is necessary to
change the duct. After identifying the injectors / ducts
The quantity that flows out must be no greater than
with a high recirculation, check that the tightness of
80ml of diesel in one minute. Excessive recirculation
the ducts is as designed (50Nm ± 5) and tighten them
(more than 80ml of diesel a minute) could be caused
if they are loose and then check the recirculation va-
by:
lues again. If on the other hand the tightness is cor-
- incorrect coupling between one or more injectors rect, remove the pipe and check that the spherical
and the related ”needles”; end towards the injector is not out of shape; replace
it if it is and then check the recirculation value again.
- problem of internal leakage of the injector.
If the duct is not out of shape either, then replace the
To identify the defective injector, follow the method injector and duct because there must be a leak inside
described hereunder. Measure the quantity of fuel the injector. Check the recirculation value again.
EW--2--72
ENGINES OVERHAUL AT THE BENCH Figure 80

Disassembling the engine
- Exhaust the engine oil by removing plug from
sump.
Figure 78
86500
Disconnect fuel piping (1) from rail and from high--

pressure pump (5) and detach it removing securing
screws (2).
IMPORTANT -- When unlocking fitting (3) of piping

70125
(1), it is necessary, with a suitable wrench, to pre-
vent fitting (4) of high--pressure pump (5) from ro-
To apply to the engine block the brackets for faste- tating.
ning the engine to the overhaul stand, proceed as fol-
lows (working from the left side of the engine):
- use tool 380000985 to remove the fuel filter (5)
from the support (1);
- disconnect the low pressure fuel pipes (2 -- 3 -- 4)
From the right side:
from the support (1);
- remove the support (1) bracket from the engine Figure 81
block.
Figure 79
70126
70128
IMPORTANTE -- Press clamp (1), as shown in Fi- Remove the screws (2) and remove the oil pipe (3)
gure B, to disconnect the low p ressure fuel pipes from the supercharger pipe (1) and from the engine
(2 -- 3 -- 4, Figure 78) from the corresponding con- block.
nections. After disconnecting the pipe, reset the Remove the starter (5) from the flywheel housing (4).
clamp (1) in locking position (Figure A) to prevent Apply brackets 380000995 to engine block and use
distortions. them to secure the engine to the revolving stand
380000978.
EW--2--73
Figure 82
70129
1. Injector connections -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil
temperature and pressure sensor -- 5. Output shaft sensor -- 6. Injector -- 7. Air temperature/pressure sen-
sor -- 8. Timing sensor -- 9. Fuel heater and fuel temperature sensor -- 10. Pressure limiter -- 11. EDC7 ECU
Disconnect the engine cable by disconnecting the Figure 83 (Demonstration)

connectors: (1) from injector wiring (6); (7) air pressu-
re/ temperature sensor; (3) fuel pressure sensor; (11)
ECU; (10) high pressure pump sensor; (8) timing sen-
sor; (2) engine coolant temperature sensor on ther-
mostat; (5) engine speed sensor.
91576
Disconnect fromthe rail (2): the fuel pipe (4) accor-

ding to procedures described in Figure 79. Discon-
nect fuel pipes (5) from rail (2) and injector manifolds
(3).
Remove the screws (1) and disconnect the rail (2).
EW--2--74
Figure 84 Figure 86
74170 70132
Disconnect pipe (2) from fuel return pressure limiter Loosen tappet adjustment fastening nuts (1) and un-
(1), as shown in Figure 79. screw the adjusters. Remove the screws (2), remove
Remove the nut, loosen the retaining collar and dis- the rocker assembly (3), consisting of: bracket (6),
connect the oil vapour pipe (5). Remove bolts (3) and rockers (4), shafts (5) and remove jumpers (7) from
take off the blow--by filter (4). valves. Remove rods (8).
Remove nuts and remove the tappet cover including
the gasket.
Figure 85
Figure 87
86501
Remove nuts (7) and disconnect the electrical cables

from injectors (8). Remove screws (1) and disconnect
injector wiring support (2) including the gasket.
Remove screws (5), disconnect air pressure/tempe-
rature sensor (6). Remove nuts (3) and remove fuel 70133
manifolds (4).
Remove injector fastening screws. Use tool

IMPORTANT -- Disassembled fuel manifolds (4) 380001099 (1) to remove injectors (2) from the cylin-
must not be used again, but however replaced with der head.
other new ones.
EW--2--75
Figure 88 Figure 90
86504
Remove bolts (1) and disconnect exhaust manifold

114064 and heater air shroud (2). Remove the screws (4),
and take out the cover (3) and the thermostat set un-
derneath.
Remove shroud (5), if present, from turbocharger (1). Remove the cylinder head (6) fastening screws (5).
Disconnect oil piping (4) from heat exchanger / oil fil-
ter support.
IMPORTANT -- Pointed out external screws are
Remove nuts (2) and detach turbo--supercharger (1)
shorter.
from exhaust manifold (3).
Figure 91 (Demonstration)
Figure 89
70137
Hook brackets (1) with metal ropes and remove cylin-

der head (2) from block using hoist.
Figure 92
70511
Remove securing screws (1) and detach exhaust ma-

nifold in two sections (2--3) with related gaskets.
72498
Remove cylinder head gasket (1).

EW--2--76
Figure 93 Figure 96
114168
Release on the drive belt tensioner (2) and extract the
belt (3) from the belt pulleys from the water pump 70142
ones and from the belt rebound pulleys. Remove the screws (1) and disconnect the ECU (2)
Disassemble the belt tensioner (2). including the heat exchanger.
Loosen the screws fixing the alternator (1) to the sup-
port and disassemble it.
Figure 94 Figure 97
70145
108549
Use tool 380000985 to remove the oil filter (1). Remove the nut (1) and disconnect the timing sensor
Except 667TA/EEG--/EEC engines (2).
Remove bolts (2) and disconnect the alternator Remove the nuts (3) and disconnect the high pressu-
mount (3). re pump (4) including the feed pump (5).
Figure 95
Figure 98
70141
70146
Remove the screws (4) and disconnect the oil tempe-
rature/pressure sensor (3). Remove the screws (1)
and then remove: heat exchanger/oil filter support Fit tool 380000990 (2) to the flywheel housing (1) to
(2), intermediate plate (6) and relevant gaskets. stop flywheel (3) rotation. Loosen the screws (4).
Remove the oil level sensor (5).
EW--2--77
Figure 99 Figure 102
108548
00904t
Remove the screws (3) and disassemble the damp- Using the specific tie rod (3) of the tool 99363204 and
ing flywheel (2) and the pulley (1). the ancillary lever (4), remove the external holding
Figure 100 ring (2) from the front cover (1).
Figure 103
70149
108549
Remove the screws (1) and disconnect the water Remove the screws (1) and take out the front cover
pump (2). Remove the screw (3) and the roller (4). (2).
Remove the screw (3) and disconnect the engine
speed sensor (4). IMPORTANT -- Note the installation position of
bolts (1) because they are of different lengths.
Figure 101
Figure 104
00900t
Remove the ring sealing the engine’s driving shaft

from the front cover. Use the tool (4) to operate on the
front bar hold of the driving shaft. Through the steer- 70150
ing holes of the tool, perforate the inside holding ring
(1) with a straight way drill (diam. 3,5 mm) for the Remove screws (1) and take off gear oil pump.
depth of 5mm. Fix the tool to the ring tightening the
6 screws provided with the equipment. Then proceed IMPORTANT – Oil pump (2) cannot be overhau-
removing the ring (2) by tightening the screw (3). led..
EW--2--78
74775
70151 Only engines: 667TA/EEG -- /EEC -- /EBF -- /EED

Remove tool 380000990 (2). Remove the screws (2), disassemble the plate (3)
Remove screws (1), securing engine flywheel (3) to and disconnect the oil sump (1).
drive shaft (4).
Figure 109
Figure 106
70152
Screw two pins (2) of adequate length into drive shaft 86516
holes (3).
Take out engine flywheel (1) so that it can be harnes- Remove the screws (1 and 4) and disassemble the
sed by means of a hoist and placed into its own con- oil suction tube (5). Remove the screws (2) and dis-
tainer. assemble the stiffening plate (3).
Figure 107
Only engines: 667TA/EED -- /EBD

Figure 110
70153
Remove screws (2) and take off rear cover (1).
IMPORTANT -- Take note of themounting position 86505

of screws (1), due to the different size of the latter.
Put engine upside down, remove screws (2) and di-
Put engine upside down. sconnect oil sump (1) with underlying gasket.
EW--2--79
70158
Remove connecting rod cap (2) fastening screws (1),

then take off the caps.
86506
Remove the pistons (complete with connecting rods)
Remove screws (1) and (4) and dismantle oil suction from the crankcase upper part.
strainer (5).
Remove screws (2) and dismantle stiffening plate (3). IMPORTANT -- Half bearingsmust be kept in their
respective housings; in fact, if they have to be
Figure 112 used again, they must be mounted in the same po-
sition they had prior to being taken off.
Figure 115
70156
Remove screws (1) and take gear (3) off distributing

shaft (2). 70159
Remove screws (1) and take off bed caps (2).

Figure 113
Figure 116
70157 70160
The penultimate bed cap (1) and its respective sup-
Remove screws (2) and take off timing gear case (1). port have half bearing (2) provided with shoulder.
IMPORTANT -- Take note of themounting position
of lower and upper half bearings; in fact, if they ha-
IMPORTANT -- Take note of themounting position ve to be used again, they must be mounted in the
of screws (2), due to the different size of the latter. same position they had prior to being taken off.
EW--2--80
70164
84086
Remove drive shaft (2) from crankcase by means of Carefully remove distributing shaft (1) from the engi-
tool 380000992 (1) and a hoist. ne crankcase.
Figure 118
70162
Take off main half bearings (1).

Remove screws (2) and take off oil nozzles (3).
70163
Remove screws (1) and take off distributing shaft (3)

70165
retaining plate (2).
Remove tappets (1) from the engine crankcase.
IMPORTANT -- Take note of plate (2) mounting
position.
EW--2--81
REPAIR OPERATIONS Checking the eccentric lift and the pin align-
CYLINDER UNIT ment
Checks and measurements Place the shaft on back centres and check, bymeans
Figure 122 of a centesimal comparator placed on themiddle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.582 mm (for ex-
haust eccentrics) and 6.045 mm (for intake eccen-
trics). If different values are found, replace the shaft.
Figure 124
70166
After the engine has been dismantled, clean the cran-
kcase--cylinder cluster thoroughly. Use proper rings
to move the cylinder cluster. Check the crankcase ca-
refully for cracks. Check the condition of working
caps. They must be replaced if they arerusty or their
sealing properties are in doubt. Inspect the cylinder
liner surfaces; they must not show traces of seizing,
scoring, out--of--roundness, taper and excessive
wear. The check of cylinder liner inner diameter (in or- 70171
der to measure the amount of out--of--roundness, ta-
per and wear) is carried out by means of bore gauge
(1) equipped with a comparator previously reset on Check the diameter of distributing shaft support pins
the ring gauge (2) of the cylinder liner diameter. (2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
IMPORTANT -- If no ring gauge is available, use BUSHINGS

amicrometer to perform reset.
Figure 125
Figure 123
70167
Measurements must be taken for each single cylin-
der, at three different heights of the liner and on two 70172
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on The distributing shaft bushings (2) must be force--fit-
the latter plane and during the first measurement. ted into their respective seats.
When detecting out--of--roundness, taper or wear, the The inner surfaces must show no traces of seizing or
cylinder liners must be bored and refaced. Cylinder li- wear.
ner reconditioning must be performed with regard to Use bore gauge (3) to measure the diameter of front
the spare piston diameter increased by 0.5 mm of the and rear bushings (2) and of distributing shaft inter-
rated value, and to the prescribed assembling play. mediate seats (1).
Measurements must be taken on two axes perpendi-
cular to each other.
EW--2--82
Figure 126
sec. A--A
107268
MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushing
EW--2--83
Figure 127 Checking the surface supporting the head on

the cylinder cluster
Figure 128
84088
Verify that the head supporting plane on the cylinder
cluster does not show deformations. This check can
be carried out by taking off dowels (4) by means of a
gauged rule (2) and thickness gauge (3). After detec-
ting the deformed areas, flatten the supporting surfa-
ce by means of a grinder. The flatness error must not
be greater than 0.075 mm.
80585
IMPORTANT -- In case of reconditioning, all the li- IMPORTANT -- Crankcase flattening may be car-
nersmust bemachined to the same increase (0.5 ried out only after making sure, when the repair
mm). work has been completed, that the protrusion of
the piston fromthe cylinder liner is not greater than
Check the main bearing seats as follows: the specified value.
- mount the bed caps on the supports without bea- Check the condition of cylinder cluster working caps
rings; (1); they must be replaced if they are rusty or their
- tighten the fastening screws to the specified tor- sealing properties are in doubt.
que; After flattening, restore the cylinder liner countersink,
as shown in Figure 127.
- check, by means of an adequate internal compa-
rator, that the seat diameter is the same as the
specified value. TIMING SYSTEM
If a greater value is found, replace the crankcase. Distributing shaft
Figure 129
84089
MAIN FEATURES OF DISTRIBUTING SHAFT

The features described given below refer to the normal diameter of pins
The shaft support pin and eccentric surfaces must be of seizing and scoring, it is advisable to replace the
perfectly smooth; if, on the contrary, they show traces shaft and its respective bushings.
EW--2--84
Replacing the bushings Mounting the tappets Distributing shaft

70176
Lubricate tappets (1) and fit them to their respective

70174 seats of the crankcase.
When replacing bush (1) use drift 380000991 (2) and Figure 133
handle 380000999 (3) to remove and refit.
IMPORTANT -- On refitting, bush (1) must be

aligned so that the lubrication holes are aligned
with the holes on the engine block seat.
70164
Tappets Lubricate the distributing shaft support bushings and

mount distributing shaft (1) taking care not to damage
Figure 131 the bushings or supporting seats.
Figure 134
70238
86507
MAIN FEATURES OF TAPPETS AND THEIR Place distributing shaft (3) retaining plate (1) with the
RESPECTIVE SEATS ON THE CRANKCASE slotted hole facing the crankcase upper side and the
stamping facing the operator, then fasten screws (2)
to the specified torque.
EW--2--85
Figure 135 DRIVE SHAFT

Measuring the journals and crankpins
Figure 137
70179
Check the distributing shaft end play (1). 70182
It must result of 0,23 ÷ 0,13 mm. If traces of excessive seizing, scoring or out--of--
roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to grin-
Figure 136 ding pins (2), measure the journals by means of a mi-
crometer (1) so as to determine the amount (diame-
ter) by which the pins have to be reduced.
IMPORTANT -- It is advisable to write down the

measured values on a table.
See Figure 138.
Reduction classes are 0.250 and 0.500 mm.
IMPORTANT -- Journals and crankpins must al-

ways be ground to the same reduction class. The
reduction carried out on journals and crankpins
70180
must be marked with a special stamping made on
the side of crank arm 1. For reduced crankpins,
use letter M. For reduced journals, use letter B.
Mount nozzles (2) and tighten fastening screws (1) to
For reduced crankpins and journals, use letters
the specified torque.
MB.
Figure 138
70514
DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING

VALUES MUST BE WRITTEN DOWN
EW--2--86
Figure 139
84091
MAIN TOLERANCES OF DRIVE SHAFT

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

CRITICAL ©
IMPORTANT
SECONDARY
Figure 140
BEARINGS ON BEARINGS ON FIRST

TIMING SIDE TIMING SIDE BEARING ON
UPPER SIDE
84275
EW--2--87
Replacing the oil pump drive gears Measuring the journal assembling play
84092
Mount drive shaft (1).

Check the play between the drive shaft journals and
70184
their respective bearings by following the procedure
below:
Figure 144
Verify that the teeth of gear (1) are not damaged or
worn; otherwise, proceed with removal by means of
a suitable extractor (3) foce--fitted on drive shaft (2).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature of
160 ± 10% °C and force--fitted onto the drive shaft by
putting the key in between.
Mounting the main bearings

Figure 142
70186
- clean thoroughly the parts and eliminate traces (if

any) of oil;
- place a piece of gauged wire (3) (parallel to the
longitudinal axis) on drive shaft pins (4);
- mount caps (1), complete with half bearings (2),
on their respective supports.
Figure 145
70185
IMPORTANT -- If main bearings do not need repla-

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

their inner diameter by 0.250 -- 0.500 mm.
IMPORTANT -- No matching operation must be

carried out on bearings.
70187
Clean thoroughly the main half bearings (1) provided Fasten pre--lubricated screws (1) by tightening them
with lubrication holes, then fit them to their seats. in three subsequent phases.
The penultimate main half bearing (1) is provided with - 1st phase with a torque wrench at 50 ± 6 Nm.
shoulder half rings.
- 2nd phase with a torque wrench at 80 ± 6 Nm.
EW--2--88
Figure 146 Checking the drive shaft shoulder play

Figure 148
α
70188
- 3rd phase with tool 380001001 (1) placed as

70190
shown in the figure: tighten screws (2) further to
an angle of 90° ± 5°. The shoulder play is checked by placing a magnetic
comparator (2) on drive shaft (3) as shown in the figu-
re: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
Figure 147
CONNECTING ROD--PISTON ASSEMBLY
Figure 149
70189
- take the caps off the supports.

70191
The play between the main bearings and their respec-
tive pins can be measured by comparing the width ta-
ken on by gauged wire (2) at the point where it is flatte-
ned most, with the scale graduation shown on gauged PARTS MAKING UP THE
wire envelope (1). CONNECTING ROD -- PISTON ASSEMBLY
1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston
The numbers shown on the scale indicate themat- rings -- 5. Screws -- 6. Half bearings --
ching play (mm). 7. Connecting rod -- 8. Bushing
If the measured play is different from the specified
one, replace half bearings and repeat the check; once IMPORTANT -- Pistons are supplied as spares in-
the prescribed play has been obtained, lubricate main creased by 0.4 mm.
bearings and mount the supports definitely by tighte-
ning the fastening screws as described above.
EW--2--89
Figure 150 Pistons

Measuring the piston diameter
Figure 152
32613
32615
Taking piston rings (1) off piston (2) by means of pliers
380000986 (3). Measuring the piston diameter (1) by means of a mi-
crometer (2) to determine the assembling play.
Figure 151
IMPORTANT -- The diameter must be measured
49.5 mm far from the piston skirt base.
Figure 153
32614
The piston rings (2) retaining the piston pin (1) are re-
moved by means of a mark scraper (3). 70192
The play between the piston and the cylinder liner can
also be measured by means of a thickness gauge (1)
as shown in the figure.
Figure 154
X = 0,6 ± 0,15
114088
MAIN DATA ABOUT PISTON, PINS AND SPRING RINGS*

* Dimension is taken on 101 mm diameter
EW--2--90
Gudgeon pins Figure 158

Figure 155
32620
18857
Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 2nd and 3rd slot and the re-
spective seats on piston (2).
Conditions for correct pin/piston matching
Figure 156
Figure 159
32619
Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 157
41104
SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the two trapezoidal
cross--sectioned seal ring, the play between the slot
and the ring itself must be measured as follows; allow
piston (1) to protrude from the crankcase so that ring
(2) at issue comes out of about half from cylinder liner
16552
(3).
In this position, check, by means of a thickness gau-
Check the thickness of seal rings (2) by means of a ge, the play (X) between the ring and the slot: it must
micrometer (1). correspond to the specified value.
EW--2--91
Y Year of manufacture
D Day of manufacture
H Weight class
70194
Measuring the play between the ends of piston rings

(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).
Connecting rods
Figure 161
114314
IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted.
In case of replacement, it is therefore necessa-
ry to number the new connecting rod with the
same number as the replaced one.
- By a letter (on the connecting rod body) which
indicates the weight class of the factory--as-
sembled connecting rod:
-- V, 1560 to 1600 (marked in yellow);
-- W, 1601 to 1640 (marked in green);
-- X, 1641 to 1680 (marked in blue);
Replacement rods are supplied class W and mar-
86498 ked in green *.
MAIN DATA OF CONNECTING ROD, GUDGEON Material removal is not permitted.
PIN BUSHING AND HALF BEARINGS
* Dimension of inner diameter to be obtained after Bushings
driving into the connecting rod small--end and re-
facing by means of a reamer. Verify that the bushing in the connecting rod small--
end is not loosened and does not show traces of sco-
** This dimension cannot be measured in a free sta- ring or seizing. Otherwise, replace it.
te.
Removing and reassembling are carried out with the
same suitable beater.
IMPORTANT -- The connecting rod--connecting
rod cap matching surfaces are knurled to ensure When driving, take the greatest care that the holes al-
better match. lowing oil to flow onto the bushing and the connecting
Therefore, it is recommended not to remove rod small--end correspond to each other. Use a rea-
knurls. mer to reface the bushing so as to obtain the required
diameter.
EW--2--92
Checking the connecting rods Checking the flexion

61695
61696
Check connecting rod flexion (5) by comparing two
Check the centrelines of connecting rods (1) are par- points C and D of pin (3) on the vertical plane of the
allel using proper device (5) as follows: connecting rod axis.
- mount connecting rod (1) on tool (5) spindle, then Place comparator (2) vertical support (1) so that the
secure it by means of screw (4); comparator rests on pin (3) at point C.
Swing the connecting rod to and fro, looking for the hi-
- place spindle (3) on V--shaped block squares by ghest position of the pin; under such condition, set
putting connecting rod (1) on stop bar (2). comparator (2) to zero.
Move the spindle with connecting rod (5) and repeat
the highest point check on opposite side (D) of pin (3).
Checking the torsion The difference between points C and D must not be
greater than 0.08 mm.
Figure 164 Mounting the connecting rod--piston assembly
Connecting rod--piston coupling
Figure 166
86550
61694 The following reference data are engraved on the pi-
Check connecting rod torsion (5) by comparing two ston crown:
points (A and B) of pin (3) on the horizontal plane of 1. Spare part number and design modification num-
the connecting rod axis. ber;
Place comparator (2) support (1) so that the compara- 2. Inscription (facing the crankcase front side) indi-
tor is preloaded by ∼ 0,5 mm on pin (3) at point A, then cating the mounting sign of the piston in the cylin-
set comparator (2) to zero. Move spindle (4) with con- der liner.
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A 3. Date of manufacture;
and B must not be greater than 0.08 mm. 4. Stamping indicating 1st recess insert testing.
EW--2--93
Figure 167 IMPORTANT -- Spare piston rings are supplied in

the following dimensions:
-- standard, marked with yellow paint;
-- increased by 0.4 mm, marked with yellow/green
paint;
Figure 170
86551
Connect piston (2) to connecting rod (4) by means of

pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers stam-
ped on connecting rod (4) can be seen as shown in
the figure.
Figure 168
70200
Mount half bearings (1) both on the connecting rod

and the cap.
IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same or-
der and positions they had prior to being taken off.
No matching operation must be carried out on half
bearings.
72705 Mounting the connecting rod/piston assem-

blies in the cylinder liners
Insert pin (1) fastening piston rings (2).
Figure 171
Mounting the piston rings
Figure 169
70201
Lubricate thoroughly the pistons, including the piston

32613 rings and the cylinder liner inside.
Use pliers 380000986 (3) to fit piston rings (1) on pi- Use band 380000994 (2) to mount the connecting
ston (2). The rings must be mounted with the writing rod--piston assemblies (1) into the cylinder liners;
“TOP” facing upwards; moreover, the ring apertures moreover, verify that:
must be turned in such a way that they are offset to - the number of each connecting rod corresponds
each other by 120°. to the cap matching number.
EW--2--94
70204
70202 - Tighten screws (1) (previously lubricated with en-
SCHEME FOR MOUNTING THE CONNECTING gine oil) to the specified torque by means of a tor-
ROD----PISTON ASSEMBLY INTO THE TUNNEL que wrench (2);
- the piston ring apertures are offset to each other
by 120°; Figure 175
- all the connecting rod/piston assemblies weigh
the same; α
- the writing stamped on the piston crown faces the
crankcase front side, or the notch obtained on the
piston skirt corresponds to the position of oil noz-
zles.
Measuring the crankpin assembling play
Figure 173 70205
- Apply tool 380000304 (1) on the compass

wrench, then tighten screws (2) further in acriss--
cross sequence.
Figure 176
70203
The play can be measured by following the procedure

below:
- clean thoroughly the parts and eliminate any tra- 70206
ce of oil;
- Take off the cap and calculate the existing play by
- place a piece of gauged wire (2) on drive shaft comparing the width of gauged wire (1) with the
pins (1); scale graduation shown on the wire envelope (2).
- mount the connecting rod caps (3) with their re-
spective half bearings (4).
EW--2--95
Figure 177 Distribution gearbox case

Figure 179
70207
If the measured play is different from the specified 70209
one, replace half bearings and repeat the check. SCHEME FOR SEALANT LOCTITE 5205
Once the specified play has been obtained, lubricate APPLICATION AREA
the connecting rod half bearings and mount them de-
finitely by tightening the connecting rod cap fastening Clean thoroughly distribution gearbox case (1) and
screws as described. the engine crankcase.
Cleaning the surface to be sealed is necessary and
IMPORTANT -- Prior to mounting the connecting unavoidable in order to ensure optimum seal.
rod cap fastening screws definitely, verify that the Apply sealant Loctite 5205 on the case so as to make
diameter of the same (as measured at the middle a bead with a diameter of a few millimetres. The bead
of the thread length) is not smaller than 0.1 mm of must be smooth (no lumps) and free from air bubbles,
the diameter measured at about 10 mm from the thin areas or gaps.
screw end. Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
Check manually that connecting rods (1) run axially both sides of the joint and obstruct lubricant flowing
on the drive shaft pins, and that the end play of the passages.
same (as measured by means of a thickness gauge After completing sealant application, the joints must
(2)) is 0.10 to 0.33 mm. be mounted immediately (within 10 -- 20 minutes).
Figure 180
Checking piston protrusion
Figure 178
70210
SCHEME FOR REAR GEARBOX CASE
FASTENING SCREW TIGHTENING SEQUENCE
70208 Reconnect box (1) to engine block. Screw securing
After the connecting rod--piston assemblies have be- screws in the position found out on dismounting and
en mounted, check, by means of comparator lock screws at tightening torques below indicated ac-
380001004 (1) equipped with base 380001000 (2), cording to the order shown in figure.
the protrusion of pistons (3) at the top dead centre re- Screws M12 65 ÷ 89 Nm
lative to the crankcase upper plane. Screws M8 20 ÷ 28 Nm
Screws M10 42 ÷ 52 Nm
It must result of 0.28 -- 0.52 mm.
EW--2--96
Valve timing Flywheel cover case

70211
70214
Mark, with a felt--tip pen, the tooth of drive gear (1)
mounted on drive shaft (2), the side surface of which SCHEME FOR SEALANT LOCTITE 5205
bears a stamped notch (→) for timing. APPLICATION AREA
Clean thoroughly the attaching surfaces of flywheel ca-
Figure 182 se (1) and distribution gearbox case.
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant Loctite 5205 on the case (1) so as to ma-
ke a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from air
bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing pas-
sages.
After completing sealant application, the joints must be
mounted immediately (within 10 -- 20 minutes).
70212
Turn drive shaft (4) and distributing shaft (2) in such Figure 185
a direction that whenmounting driven gear (1) on the
distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Figure 183
70216
SCHEME FOR FLYWHEEL COVER CASE

FASTENING SCREW TIGHTENING SEQUENCE
Reconnect box (1) to engine block, screw securing
screws in the position found out on dismounting and
70213 thighten them at torque below indicated according to
the order shown in figure.
Tighten gear (2) fastening screws (1) to distributing Screws M12 75 ÷ 95 Nm
shaft (3), then fasten them to the specified torque. Screws M10 44 ÷ 53 Nm
EW--2--97
70152
Screw down two pins (2) of adequate length into the
70216
shaft holes (3), then remove the engine flywheel (1)
by means of suitable harnesses and a hoist.
Apply part (5) of tool 380000983 on drive shaft rear
Figure 189
shank (6), secure it by means of screws (4) and for-
ce--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
ENGINE FLYWHEEL
Figure 187
70218
Apply tool 380000990 (2, except for 667TA/EEG --
667TA/EEC engines) to the flywheel cover case (1)
to stop engine flywheel (3) rotation.
Tighten screws (4) fastening engine flywheel (3) to
the drive shaft.
Figure 190
114066
A engines: 667TA/EEG -- 667TA/EEC

B engines: 667TA/EBF -- 667TA/EED
C engines: 667TA/EED -- 667TA/EBD
Replacing the engine flywheel ring gear 70219
Check the condition of ring gear (2) teeth. If breaks or Tighten engine flywheel (2) fastening screws (1) in
excessive tooth wear is found, remove the ring gear two separate phases:
from the engine flywheel (1, Figure 187) by using a - 1st phase: tighten to a torque of 30 ± 4 Nm by
normal beater, then mount the new gear ring after means of a torque wrench;
previously heating it to 150 °C for 15′ to 20′; the coun- - 2nd phase: angle--tighten to 60° ± 5°.
tersink made on the gear ring inner diameter must fa-
ce the engine flywheel. IMPORTANT -- Angle tightening is carried out by
means of tool 380000304.
EW--2--98
70220 70223
Mount oil pump (1). Take seal ring (2) off front cover (1), clean thoroughly
Screw down fastening screws (2) and tighten them to the attaching surface and apply sealant Loctite 5205
the specified torque. onto the same.
Figure 192
Figure 195
70221 70224
Apply a new seal ring (2) onto water pump (1). Clean thoroughly the surface of front cover (2) atta-
ching base, then mount front cover.
Fasten screws (1) and tighten them to the specified
torque.
Figure 196
Figure 193
70225
Apply part (5) of tool 380000983 on drive shaft front

70222
shank (6), secure it by means of screws (4) and for-
ce--fit the new seal ring (3) onto the same. Position
Mount water pump (1). part (1) on part (5), then screw nut (2) to fully mount
Fasten screws (2) and tighten them to the specified- seal ring (3) in front cover (7).
torque.
EW--2--99
Only engines: 667TA/EED -- /EBD Figure 200

Figure 197
Set the gasket (1) on the oil sump (2).

86506
Mount plate (3) and strainer (5), then screw down fa- Figure 201
stening screws (1--2--4) and tighten them to the speci-
fied torque.
Figure 198
74775
Fit the oil sump (1) and apply the plate (3) to it.
Tighten the screws (2) to the specified torque.
86505
Mount oil sump (1) and apply plate (3) on the same. Figure 202
torque.
Only engines: 667TA/EEG -- /EEC -- /EBF -- /EED α
Figure 199
70363
Key phonic wheel (1) and hub (2) on drive shaft.

Screw securing screws (3) and tighten them in two
steps.
- 1st step, tightening with a dynamometric wrench
at 50 ± 5 Nm torque.
- 2nd step, locking with 90° angle.
IMPORTANT -- Angle tightening is carried out by

means of tool 380001001 (4).
108553 Mount damper flywheel (5) and pulley (6).
Fit the plate (1), the oil pick up tube (2) and tighten the Screw securing screws (7) and tighten them at 68 ±
fastening screws (3) to the specified torque. 7 Nm torque.
EW--2--100
70230 70232
Mount a new seal ring on rpm sensor (3). Lubricate the sealing ring (2) with engine oil and set
Fit rpm sensor (3) in front cover (1) and tighten screw it on the oil filter (3).
(2) for securing at prescribed torque. Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3)
by 3/4 turn (except for 667TA/EEG -- 667TA/EEC en-
gines).
Apply a new sealing ring on the oil temperature/pres-
sure sensor (4) and fit it on the support (1).
Fit a new sealing ring (6) in the engine block seat.
Figure 206
Figure 204
70234
Position the alternator support (1) so that pins (3 and

4) are set against the engine block.
70231
Mount the following items on the crankcase: a new

gasket (1), heat exchanger (2), a new gasket (3), and
oil filter support (4).
torque.
EW--2--101
Figure 207 CYLINDER HEAD

Removing the valves
Figure 210
114170
Reconnect alternator (1) and tighten the bolts to the
specified torque.
Reconnect automatic tensioner (4) and tighten bolt
(3) to the specified torque. 70319
Turn the automatic belt tensioner (4) to fit the belt (2) Intake (1) and exhaust (2) valves have heads with the
on pulleys and guide rollers. same diameter.
Figure 208 The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
IMPORTANT -- Should cylinder head valves be not

replaced, number them before removing in order
to refit them in the same position.
A = intake side -- S = exhaust side
70145
Refit the high pressure pump (5) including the feed
pump (6) and tighten the nuts (3) to the specified tor- Figure 211
que. Fit the support (4) with a new sealing ring, the ti-
ming sensor (2) with a new sealing ring and tighten
the relevant fastening nut (1) to the specified torque.
Figure 209
70321
Valves can be removed by means of tool 380000987

70320
(1) by pressing slightly on collar (3) so that lock cones
Refit the ECU (3) including the heat exchanger to the (2) can be removed by compressing springs (4).
engine block and tighten the screws (2) to the speci- Then remove collar (3) and springs (4).
fied torque.
Repeat the operation on all valves.
IMPORTANT -- Replace support elastic elements Turn the head upside down and remove the valves
(1). (5).
EW--2--102
Figure 212 Checking the cylinder head supporting surface

Figure 214
70322
Remove the sealing rings (1 and 2) from the relevant

valve guides. 70324
The plane of the supporting surface of head (1) to cy-

IMPORTANT -- Sealing rings (1) for intake valves linder cluster is checked by means of a ruler (2) and
are yellow. a thickness gauge (3).
Sealing rings (2) for exhaust valves are green. The deformation found on the entire length of the cy-
linder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
Checking the cylinder head water seal
Figure 213
Figure 215
70323
Check the water seal by means of suitable equip-

ment.
Use a pump to feed water heated to ∼90 °C at a pres-
sure of 2 to 3 bar.
70325
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassem- The rated thickness A of the cylinder head is 105 ±
bling/ assembling operations. 0,25 mm; maximum allowed metal removal must not
exceed thickness B by 0.13 mm.
IMPORTANT -- Prior to mounting the caps, apply
wate--repellent sealant on the sealing surface of
the same. IMPORTANT -- After reconditioning, check valve
hollow and recondition, if necessary, the valve
seats to obtain the prescribed hollow.
If leaks are detected from the cylinder head, the latter
must be replaced.
EW--2--103
VALVES Checking the play between the valve stem, val-

Figure 216 ve guide and valve centring
EXAUST INTAKE Figure 219
VALVE VALVE
70326
MAIN DATA OF INTAKE AND EXHAUST VALVES 70327
Valve descaling, check and grinding

Check can be made by means of a magnetic compa-
Figure 217 rator (1) placed as shown. Assembling play must be
equal to 0.039 to 0.079 mm.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
VALVE GUIDE
18625
Figure 220
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns.
Reface, if necessary, the valve seats by means of
grinder 380000975, by removing as less material as
possible.
Figure 218
INTAKE EXHAUST
79457
18882
Use a bore gauge to measure the valve guide inner
Use a micrometer (2) to measure valve stem (1), diameter, which must be equal to the value shown in
which must be equal to 7.96 to 7.98. the figure.
EW--2--104
VALVES SEATS
Valve seat reconditioning -- replacement
Figure 221
70330
Check valve seats (2). If slight burns or scoring are

found, proceed with reconditioning by means of the
proper tool (1) according to the inclination values
shown in Figure 222.
Figure 222
INTAKE EXHAUST
107283
MAIN DATA ABOUT VALVE SEATS ON CYLINDER HEAD

EW--2--105
Figure 223
EXHAUST INTAKE
70332
MEAN FEATURES VALVE SEAT
If the valve seats cannot be restored by simply recon- Heat the cylinder head to 80 to 100 °C, then mount
ditioning them, they can be replaced with spare parts. the new valve seats (previously cooled) onto the
By using the same tool (1, Figure 221) and taking ca- head by means of a suitable beater.
re not to indent the cylinder head, remove as much Recondition the valve seats by means of tool
material as possible from the valve seats until the lat- 380000975, according to the values shown in
ter can be taken off the cylinder head by means of a Figure 222.
punch.
VALVE SPRINGS
Figure 225
Figure 224
50676
MAIN DATA FOR INTAKE AND EXHAUST VALVE

SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of the proper tool. Compare the elastic strain
70333 and load data with those relative to the new springs
shown in the table below.
After the reconditioning operations, verify, by means
of base 380001000 (2) and comparator 380001004
(1), that valve hollow (3) corresponds to the specified
value. Height Under a load of
mm N
H 47.75 Free
H1 35.33 P 339.8 ± 9 N
H2 25.2 P2 741 ± 39 N
EW--2--106
MOUNTING THE CYLINDER HEAD Reattaching the cylinder head

70334
70335
Lubricate the valve stem (1) and insert into the re-
spective valve guide according to the position marked Verify that the cylinder head attaching plane and the
upon disassembling. crankcase attaching plane are both clean.
Mount seal rings (2 and 3) onto the valve guide. Do not spoil the cylinder head gasket.
IMPORTANT -- Seal rings (2) for aspiration valves Arrange gasket (1) for cylinder head with writing
are yellow: seal rings (3) for exhaust valves are “TOP” (1) towards head.
green. The arrow shows where gasket shim is inserted.
IMPORTANT -- Prior to reusing the cylinder head

fastening screws, verify that they do not show tra-
ces of wear or deformations; otherwise, replace
them.
Figure 227
Figure 229
70336
77032 Mount cylinder head (1), screw screws (2) and tigh-
ten them in three successive steps, following order
and modalities indicated in next figure.
Position spring (4) and upper collar (3) on the cylinder
head: use tool 380000987 (1) to compress spring (4) IMPORTANT -- Angle tightening is carried out by
and link the parts to the valve by means of lock cones means of tool 380001001 (3).
(2).
EW--2--107
70476
Scheme of cylinder head fastening screw tightening

sequence:
- 1st phase: pre--fastening by means of a torque
wrench:
• screw 12x1,75x130 ( ) 35 ± 5 Nm
s 70339
• screw 12x1,75x150 ( ) 55 ± 5 Nm
- 2nd phase: angle tightening: 90° ± 5° Fit injectors (1) on the cylinder head seats, directed
- 3rd phase: angle tightening: 90° ± 5° so that the fuel inlet hole (2) is facing the fuel manifold
seat (3) side.
A = Front side
Figure 233
Fitting injectors
Figure 231
70338 70133
Use tool 380001099 (1) to fit the injector (2) into its
Fit a new sealing ring (2) lubricated with vaseline and seat.
a new sealing washer (3) on injector (1). Screw injector fastening screws without tightening
them.
EW--2--108
Figure 234 RODS AND TAPPETS

Figure 236
32655
Rocker control rods shall not be distorted; the ball
seats in touch with the rocker adjusting screw and
70341 with tappets (arrows) shall not show seizing or wear;
otherwise replace them. Intake and exhaust valve
Fit a new sealing ring (3) lubricated with vaseline on control rods are identical and are therefore interchan-
the fuel manifold (2) and fit it into the cylinder head geable.
seat so that the positioning ball (5) is coinciding with
the relevant housing (4).
Rocker arm assembly
Figure 237
IMPORTANT -- Disassembled fuel manifolds (2)
must not be used again, but however replaced with
other new ones.
Screw the fastening nuts (2, Figure 235) without loc-

king them.
IMPORTANTE -- During this operation, the injector

(1) shall be moved so that the manifold (2) is pro-
perly inserted into the fuel inlet hole (2,
Figure 232).
70343
PARTS MAKING UP THE ROCKER ARM
Figure 235 ASSEMBLY:
1. Screws -- 2. Support -- 3. Arbour -- 4. Rocker arm
Figure 238
70342
Use the dynamometric wrench to tighten gradually 70344

and alternately the injector fastening screws (1) to 8.5 MAIN DATA OF ARBOUR--ROCKER ARM
± 0.8 Nm torque.
Check that shaft/rocker coupling surfaces are not
Tighten the fuel manifold (3) fastening nuts (2) to 50 showing excessive wear or damages.
Nm torque.
EW--2--109
Figure 239 Tappet clearance adjustment

Figure 241
70345 70520
Fit the rods (2). Adjust clearance between rockers and valves using
Position jumpers (1) on valves with marks (→) facing setscrew wrench (1), box wrench (3) and feeler gau-
the exhaust manifold. ge (2).
Working clearance shall be as follows:
-- intake valves: 0,25 ± 0,05 mm
-- exhaust valves: 0,51 ± 0,05 mm
IMPORTANT -- Due to the additional lobe for the

INTERNAL E.G.R., it is not possible to use the
valve clearance adjustment procedure that re-
quires adjusting the clearance of all the valves by
positioning the crankshaft 2 times only.
Each cylinder must be checked by taking it to the
T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
Figure 240 cylinder in question.
70346
Check that tappet adjusters (1) are loosen to prevent

their balking on the rods (2, Figure 239) when refitting
the rocker assembly.
Then refit the rocker assembly consisting of: bracket
(5), rockers (3), shafts (4) and secure themto the cy-
linder head by tightening the fastening screws (2) to
36 Nm torque.
EW--2--110
74762
Connect new fuel pipes (1) to rail (3) and injector ma-
nifolds (2).
IMPORTANT -- When removed, pipes (1) shall al-
ways be replaced.
Figure 245
s
114067
Apply LOCTITE 5999 to the contact surfaces of in-

take manifold (1) and fit the manifold and heater to
the cylinder head.
Screw in bolts (2) and tighten to the specified torque.
Fit air intake (3) with a new gasket (5) and tighten
bolts (4) to the specified torque.
The figure shows the air intake for 667TA/EEG --
99226
667TA/EEC engines.
IMPORTANT -- Pipe (7) connections shall be tigh-
tened to 20 Nm torque, using the proper wrench (5)
and the dynamometric wrench 380000158 (4).
Connect the fuel pipe (3) to the rail (2) following the pro-
Figure 243
cedure shown in the following figure.
Figure 246
70126
Press the clamp (1) in arrow direction (Figure B) and
74761 connect the pipe to the rail (2, Figure 245), reset the
Fit the rail (2) and tighten the screws (1) to the speci- clamp to the initial locking position “A”.
fied torque, connect the ground cable (3) to the intake
manifold (4) and tighten the fastening nut (5) to the IMPORTANT -- Check proper fuel pipe connec-
specified torque. tion.
EW--2--111
Wiring support Figure 250

Figure 247
72501
Check electrical cable (5) conditions, replace if dama- 72502

ged by cutting the support (2) clamps and removing
the screws (5) that secure it to connections (3). Fit a new gasket (2) on the tappet cover (1).
Fit a new gasket (1) on the support (2).
Figure 251
Figure 248
72511
Fit the tappet cover (1) and tighten the nuts (2) to the
specified torque.
70353
Fit the wiring support (2) and tighten the screws (1)
to the specified torque. Figure 252
Figure 249
114068
Re--attach exhaust manifold (3) with new gaskets.

Screw securing screws (6) and tighten them at the re-
quired torque.
Re--attach turbo--supercharger (1) to exhaust collec-
70354
tor (3) with a new gasket and tighten securing nuts (2)
at the required torque.
Connect the electrical cables (1) to the injectors (3) Connect piping (5) to turbo--supercharger (1) support
and use the dynamometric wrench 380000158 (4) to (7).
tighten the fastening nuts (2) to the specified torque. Connect oil piping (4) toheat exchanger support.
EW--2--112
114069 70126
Connect the air duct (2) to the turbosupercharger (3) Press the clamp (1) in arrow direction (Figure B) and
and lock it by clamp (1). connect the pipe.
Reset the clamp to the initial locking position A.
IMPORTANT -- Check proper fuel pipe connec-

tion.
Figure 254
6
2 5
4
3
74170
Insert the blow--by filter (4) tightening the screws.

Connect the pipeline (6) and fix the oil vapour recover
pipe through the clamp (5); lock up the nut fixing it to
the upper edge.
Connect the pipeline (2) to the pressure-- limiter (1).
EW--2--113
Figure 256
70129
1. Connections for electro--injectors -- 2. Engine cooling liquid temperature sensor -- 3. Fuel pressure sensor
-- 4. Engine oil temperature and pressure sensor -- 5. Drive shaft sensor -- 6. Electro--injector -- 7. Air tempe-
rature and pressure sensor -- 8. Distribution phase sensor -- 9. Fuel heater and fuel temperature sensor --
10. Pressure regulator -- 11. Control unit
Re--attach engine cable by connecting electro--injec- Apply rocker lever 380000216 to engine lifting hooks,
tors (6) wiring connectors (1); (7) air pressure/tempe- hook the rocker lever to hoist and detach engine from
rature sensor; (3) rail pressure sensor; (11) control rotating stand. Disassemble brackets 380000995.
unit; (10) high--pressure pump sensor; (8) distribution
phase sensor; (2) engine cooling liquid temperature
sensor on thermostat; (5) engine revolutions sensor.
EW--2--114
70125
70128
Screw manually the fuel filter to the support (1), screw
Complete engine refitting as follows: the filter by 3/4 turn, connect the pipes (2--3--4) to the
Form the right side: relevant support connections (1) as shown in the fol-
lowing figure.
Refit the starter (5) to the flywheel housing (4) and
tighten the fastening nuts to the specified torque.
Fit the oil pipe (3) with a new sealing ring into the engi-
ne block and secure it to the turbosupercharger (1) by
the screws (2) tightened to the specified torque.
70362 70126
Refit the bracket (2) including the fuel filter support (1) Press the clamp (1) as shown in figure B.
to the engine block, tighten the screws (3) to the spe- After disconnecting the pipe, reset the clamp (1) to
cified torque. the initial locking position A, to prevent deformations.
When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.
SECTION 3
RECHARGING AND START--UP
INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--3--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--6
Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--6
BOSCH 24 V -- 4 kW . . . . . . . . . . . . . . . . EW--3--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--3--7
ISKRA 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--3--5
INDICE
EW--3--3
RECHARGING AND STRAT--UP
STARTER MOTOR
BOSCH -- 24 V -- 4 kW -- For engines: 667TA/EEG

667TA/EEC
ISKRA -- For engines: 667TA/EBF
667TA/EED
Quick diagnosis
Fault Possible causes Remedy
Dragging torque insufficient 1. Batteries run down Restore

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

EW--3--5
ISKRA 24 V -- 4 kW
Fork mesh type, driven by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
Figura 5 Figura 6
114183 114184

EW--3--6
ALTERNATOR
BOSCH NCBI 28 V 35--70 A -- For engines: 667TA/EEG

667TA/EEC
Quick diagnosis
Fault Possible causes Remedy
No recharge 1. Interruption of recharge circuit Check the recharge circuit con--

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

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

minals and cable terminals of
batteries, starter motor and al--
ternator
2. Voltage regulator not in wor-- Replace the component
king order
3. Earth fault Check earth connections
EW--3--7
Bosch NCBI 28 V 35--70 A

Thre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.
Direction of rotation (control side) clockwise
Current delivered at 6.000 min--1 ≥ 55A
Rated voltage 28,5V
Figura 7 Figura 9
84270 84271
Figura 8 Figura 10
84272 84274
CHARACTERISTIC CURVES CHARACTERISTIC CURVES

OF CURRENT DELIVERY OF VOLTAGE REGULATOR
EW--3--8

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Copyright © New Holland

PROVEN PERFORMANCE PROVEN PERFORMANCE

REPAIR MANUAL FOR CNH U.K. ENGINES

667TA/EEG -- 667TA/EEC 667TA/EBF -- 667TA/EED

Progressive page number for each group

Group number (if any)

This symbol regards safety.

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

Section 2 -- 667TA engine overhaul EW--2--1

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

CNH -- EST DIAGNOSTIC TOOL

Code Description Language

MAIN ENGINE OPERATING ANOMALIES

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

1 ENGINE WON’T START

Injectors efficient Check using a diagnostic tester.

Prescribed compression ratio Overhaul the engine or make repairs only on

Fuel filters in working order Replace.

Pre--post heating system efficient Check using a diagnostic tester.

High pressure pump efficient Check using a diagnostic tester.

Water pump in working order Overhaul or replace the unit.

Thermostat in working order Replace.

Valve timing correct Check and perform correct timing.

Cylinder head gasket in working order Replace.

Fan in working order Replace.

3 ENGINE LACKS POWER AND WORKS

Thermostat in working order Replace.

Injectors efficient Check using a diagnostic tester.

Prescribed compression ratio Check using a diagnostic tester.

Turbocharger in working order Repair or replace the unit.

4 ENGINE EXHAUST SMOKE BLACK

Air filter in working order Replace.

Injectors efficient Check using a diagnostic tester.

Prescribed compression ratio Check using a diagnostic tester.

ENGINE EXHAUST SMOKE GREY

Injectors efficient Check using a diagnostic tester.

Coolant level correct Possible flow of coolant into the combustion

6 ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption Check: oil vapour breather; cylinder compres--

7 ENGINE KNOCKS IRREGULARLY

Knock detected in injectors Check using a diagnostic tester.

Fuel tank filled Refuel and drain (if necessary).

Fuel filters in working order Replace.

Intact valves Replace the valves.

9 EXCESSIVE OR INSUFFICIENT OIL

10 EXCESSIVE FUEL CONSUMPTION

Air filter in working order Replace.

Injectors efficient Check using a diagnostic tester.

Repair operations . . . . . . . . . . . . . . . . . . EW--2--81 Connecting rod--piston coupling . . . . . . . EW--2--92

667TA ENGINE OVERHAUL

ENGINES: 667TA/EEG -- 667TA/EEC ENGINES: 667TA/EED -- 667TA/EBF

ENGINES: 667TA/EED -- 667TA/EBD

667TA ENGINE OVERHAUL

CODING OF SOURCE ENGINES

667TA ENGINE OVERHAUL

MAIN ENGINES FEATURES

A E265 E305 D180 LGP D180 STD W170 W190

B 667TA 667TA 667TA 667TA 667TA 667TA

C EEG EEC EBF EED EED EBD

137 kW 148 kW 157 kW 145 kW 145 kW 169 kW

667TA ENGINE OVERHAUL

GENERAL ENGINES FEATURES

Cycle 4--stroke diesel engine